Areva MFAC
Areva MFAC
Areva MFAC
Service Manual
R8007F
3. 4. 5.
More information on safe working procedures for all electronic equipment can be found in BS5783 and IEC 60147-0F. If you are making measurements on the internal electronic circuitry of an equipment in service, it is preferable that you are earthed to the case with a conductive wrist strap. Wrist straps should have a resistance to ground between 500k 10M ohms. If a wrist strap is not available you should maintain regular contact with the case to prevent the build up of static. Instrumentation which may be used for making measurements should be earthed to the case whenever possible. AREVA T&D strongly recommends that detailed investigations on the electronic circuitry, or modification work, should be carried out in a Special Handling Area such as described in BS5783 or IEC 60147-0F.
TYPES:
MFAC 14 MFAC 34
CONTENTS
SAFETY SECTION 1. 1.1 1.2 1.3 1.4 2. 2.1 2.2 3. 4. 4.1 4.2 4.3 5. 5.1 5.2 6. 7. INSTALLATION General Unpacking Storage Site COMMISSIONING Description of relay, calculation of setting and commissioning preliminaries Instructions to ensure that the relay can be commissioned at the specific settings for the application MAINTENANCE MECHANICAL SETTINGS General Contact settings Mechanical flag settings PROBLEM ANALYSIS Failure to operate Output contacts not changing state SPARES COMMISSIONING TEST RECORD REPAIR FORM 5 9 9 9 9 9 10 10 12 18 18 18 18 18 19 19 19 20 21 23
CONTENT
1.
1.1 1.2
SAFETY SECTION
Health and safety Explanation of symbols and labels
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3 3
2. 3.
3.1 3.2 3.3 3.4 3.5 3.6
3 4
4 4 4 4 4 5
4. 5. 6.
5 5 6
1.
SAFETY SECTION
This Safety Section should be read before commencing any work on the equipment.
1.1
Health and safety The information in the Safety Section of the product documentation is intended to ensure that products are properly installed and handled in order to maintain them in a safe condition. It is assumed that everyone who will be associated with the equipment will be familiar with the contents of the Safety Section.
1.2
Explanation of symbols and labels The meaning of symbols and labels may be used on the equipment or in the product documentation, is given below.
Functional *earth terminal Note: This symbol may also be used for a protective/safety earth terminal if that terminal is part of a terminal block or sub-assembly e.g. power supply.
*NOTE: THE TERM EARTH USED THROUGHOUT THE PRODUCT DOCUMENTATION IS THE DIRECT EQUIVALENT OF THE NORTH AMERICAN TERM GROUND.
2.
Voltage and current connections should be made using insulated crimp terminations to ensure that terminal block insulation requirements are maintained for safety. To ensure that wires are correctly terminated, the correct crimp terminal and tool for the wire size should be used. Before energising the equipment it must be earthed using the protective earth terminal, or the appropriate termination of the supply plug in the case of plug connected equipment. Omitting or disconnecting the equipment earth may cause a safety hazard. The recommended minimum earth wire size is 2.5mm2, unless otherwise stated in the technical data section of the product documentation. Before energising the equipment, the following should be checked: Voltage rating and polarity; CT circuit rating and integrity of connections; Protective fuse rating; Integrity of earth connection (where applicable) Remove front plate plastic film protection Remove insulating strip from battery compartment
3.
3.1
Current transformer circuits Do not open the secondary circuit of a live CT since the high level voltage produced may be lethal to personnel and could damage insulation.
3.2
External resistors Where external resistors are fitted to relays, these may present a risk of electric shock or burns, if touched.
3.3
Battery replacement Where internal batteries are fitted they should be replaced with the recommended type and be installed with the correct polarity, to avoid possible damage to the equipment.
3.4
Insulation and dielectric strength testing Insulation testing may leave capacitors charged up to a hazardous voltage. At the end of each part of the test, the voltage should be gradually reduced to zero, to discharge capacitors, before the test leads are disconnected.
3.5
Insertion of modules and pcb cards These must not be inserted into or withdrawn from equipment whist it is energised since this may result in damage.
3.6
Fibre optic communication Where fibre optic communication devices are fitted, these should not be viewed directly. Optical power meters should be used to determine the operation or signal level of the device.
4.
OLDER PRODUCTS
Electrical adjustments Equipments which require direct physical adjustments to their operating mechanism to change current or voltage settings, should have the electrical power removed before making the change, to avoid any risk of electrical shock. Mechanical adjustments The electrical power to the relay contacts should be removed before checking any mechanical settings, to avoid any risk of electric shock. Draw out case relays Removal of the cover on equipment incorporating electromechanical operating elements, may expose hazardous live parts such as relay contacts. Insertion and withdrawal of extender cards When using an extender card, this should not be inserted or withdrawn from the equipment whilst it is energised. This is to avoid possible shock or damage hazards. Hazardous live voltages may be accessible on the extender card. Insertion and withdrawal of heavy current test plugs When using a heavy current test plug, CT shorting links must be in place before insertion or removal, to avoid potentially lethal voltages.
5.
6.
TECHNICAL SPECIFICATIONS
Protective fuse rating The recommended maximum rating of the external protective fuse for this equipment is 16A, Red Spot type or equivalent, unless otherwise stated in the technical data section of the product documentation.
Insulation class: IEC 601010-1 : 1990/A2 : 2001 Class I EN 61010-1: 2001 Class I IEC 601010-1 : 1990/A2 : 1995 Category III EN 61010-1: 2001 Category III This equipment requires a protective (safety) earth connection to ensure user safety. Distribution level, fixed insulation. Equipment in this category is qualification tested at 5kV peak, 1.2/50s, 500, 0.5J, between all supply circuits and earth and also between independent circuits.
Environment:
IEC 601010-1 : 1990/A2 : 1995 Pollution degree 2 EN 61010-1: 2001 Pollution degree 2
Product Safety:
72/23/EEC
Compliance with the European Commission Low Voltage Directive. Compliance is demonstrated by reference to generic safety standards.
Section 1.
1.1
INSTALLATION
General Protective relays, although generally of robust construction, require careful treatment prior to installation and a wise selection of site. By observing a few simple rules the possiblity of premature failure is eliminated and a high degree of performance can be expected. The relays are either despatched individually or as part of a panel/rack mounted assembly in cartons specifically designed to protect them from damage. Relays should be examined immediately they are received to ensure that no damage has been sustained in transit. If damage due to rough handling is evident, a claim should be made immediately to the transport company concerned and the nearest AREVA T&D representative should be promptly notified. Relays which are supplied unmounted and not intended for immediate installation should be returned to their protective polythene bags.
1.2
Unpacking Care must be taken when unpacking and installing the relays so that none of the parts are damaged or their settings altered and must at all times be handled by skilled persons only. Relays should be examined for any wedges, clamps, or rubber bands necessary to secure moving parts to prevent damage during transit and these should be removed after installation and before commissioning. Relays which have been removed from their cases should not be left in situations where they are exposed to dust or damp. This particularly applies to installations which are being carried out at the same time as constructional work.
1.3
Storage If relays are not installed immediately upon receipt they should be stored in a place free from dust and moisture in their original cartons and where de-humidifier bags have been included in the packing they should be retained. The action of the dehumidifier crystals will be impaired if the bag has been exposed to damp ambient conditions and may be restored by gently heating the bag for about an hour, prior to replacing it in the carton. Dust which collects on a carton may, on subsequent unpacking, find its way into the relay; in damp conditions the carton and packing may become impregnated with moisture and the de-humidifying agent will lose its efficiency. The storage temperature range is 25 and +70C.
1.4
Site The installation should be clean, dry and reasonably free from dust and excessive vibration. The site should preferably be well illuminated to facilitate inspection. An outline diagram is normally supplied showing panel cut-outs and hole centres. For individually mounted relays these dimensions will also be found in Publication R6008. Publication R7012 is a Parts Catalogue and Assembly Instructions. This document will be useful when individual relays are to be assembled as a composite rack or panel mounted assembly.
Publication R6001 is a leaflet on the modular integrated drawout system of protective relays. Publication R6014 is a list of recommended suppliers for the pre-insulated connectors.
Section 2.
2.1 2.1.1
COMMISSIONING
Description of relay, calculation of setting and commissioning preliminaries Description of MFAC 14/MFAC 34 This is a voltage operated relay having seven equally spaced settings of 15185 volts, 25175 volts, 25375 volts or 100400 volts which may be selected by means of a plug bridge. The relays may be used for any type of high impedance circulating current protection.
2.1.2
List of abbreviations. IE IF IFM IP IR ISH N n RCT RL RR RSH VF = Current transformer exciting current at relay setting voltage (referred to the CT secondary current) = Maximum value of primary through fault current for which protection must remain stable. = Maximum value of primary fault current for internal fault. = Primary current for operation of protection. = Relay operating current. = Current in shunt resistor at relay setting VR. = Turns ratio of current transformer. = No. of current transformers in parallel with relay. = Secondary resistance of current transformer. = Lead resistance between furthest current transformer and relay connection point. = Relay impedance. = Value of shunt resistor. = The theoretical voltage which would be produced across the relay circuit under internal fault condition. VF = IFM (RCT + 2RL + RR) N = Knee point voltage of current transformer. = Peak voltage across relay circuit under maximum internal fault conditions. = Minimum setting voltage. (calculated) = Relay setting voltage.
VK VP VS VR 2.1.3
Calculation of relay setting. The minimum setting voltage to ensure stability is VS IF (RCT + 2RL) N
The relay plug setting voltage VR must be set to the nearest tap above VS.
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The minimum knee point voltage must be VK 2VR The operating current of the relay is 38mA, irrespective of tap selected, excluding the current drawn by the external metrosil. When a standard metrosil is included with the relay, the relay operating current including the metrosil is given in the table below. It must be appreciated that metrosils have large tolerances and these figures are given for guidance only. a) Low range relay (5V steps) 15 Setting voltage VR 38 Relay current IR(mA) (including metrosil, C = 450) b) Low range relay Setting voltage VR 25 Relay current IR(mA) 19 (including metrosil, C = 450) c) High range relay Setting voltage VR 25 Relay current IR(mA) 19 (including metrosil, C = 900) d) 100400V version Setting voltage VR 100 150 200 250 300 350 400 Setting voltage IR(mA) 19 19 20 20 23 27 36 (including metrosil, C = 1100) The primary current for operation is given by IP = N (IR + nIE) If the resultant value of IP is too low it may be increased by the addition of a shunt resistor RSH to give a current of ISH = VR RSH The new increased value of primary current IP = N (IR + nIE + ISH) External metrosils. Each FAC relay is applied with an external metrosil which must be wired across the relay circuit. This provides a shunt circuit for high internal fault currents and prevents a high voltage being developed across the CT and relay circuits. 2.1.4 Commissioning preliminaries. Inspection. Carefully examine the module and case to see that no damage has occurred during transit. Check that the relay serial number on the module, case and cover are identical, and that the model number and rating information are correct. Carefully remove any elastic bands/packing fitted for transportation purposes. Carefully actuate the armature of each unit in turn with a small screwdriver/probe. Note that immediately after the point where any normally open contacts just make 11 75 19 125 175 225 275 325 20 22 24 31 44 50 19 75 20 100 125 150 175 23 27 36 53 50 38 75 39 100 125 150 175 185 42 46 55 72 81
there is a small further movement of the armature. This ensures that contact follow through and wiping action is present. On units fitted with hand reset flag indicators, check the flag is free to fall before, or just as, any normally open contacts touch. Check that the external wiring is correct to the relevant relay diagram or scheme diagram. The relay diagram number appears inside the case. Particular attention should be paid to the correct wiring and value of any external resistors indicated on the wiring diagram/relay rating information. Note that shorting switches shown on the relay diagram are fitted internally across the relevant case terminals and close when the module is withdrawn. It is essential that such switches are fitted across all CT circuits. If a test block type MMLG is provided, the connections should be checked to the scheme diagram, particularly that the supply connections are to the live side of the test block (coloured orange) and with terminals allocated with odd numbers (1, 3, 5, 7, etc.). Earthing. Ensure that the case earthing connection above the rear terminal block, is used to connect the relay to a local earth bar. Insulation. The relay, and its associated wiring, may be insulation tested between: a) all electrically isolated circuits b) all circuits and earth An electronic or brushless insulation tester should be used, having a dc voltage not exceeding 1000V. Accessible terminals of the same circuit should first be strapped together. Deliberate circuit earthing links, removed for the tests, must subsequently be replaced. Terminal allocation. Terminals of the relay are normally allocated as below, but reference should always be made to the relevant diagram. a) Single pole relays Normally open contacts 1, 3 and 2, 4. AC current input 27, 28. An alternative version of the relay has additional normally open contacts connected to 5, 7 and 6, 8. b) Triple pole relays Normally open contacts 1, 3 and 2, 4. The contacts are normally connected in parallel for the three phases but a version of the relay having contacts brought out separately is available. AC current inputs - 23, 24 : 25, 26 : 27, 28. 2.2 Instructions to ensure that the relay can be commissioned at the specific settings for the application It is only necessary to check the relay at the setting on which it is to be used. The relay must not be used at any setting other than that for which the setting has been calculated. 12
2.2.1
Test equipment required 1 Secondary injection test equipment capable of providing an ac voltage supply of up to at least 120% of the relay setting. 1 Multifinger test plug type MMLB 01 for use with test block type MMLG if fitted. 1 Miniature split plug type MMLB 03 to fit relay plug bridge. 3 Calibrated multimeters 010 amp ac, 0400 volt ac. 1 Set primary injection testing equipment.
2.2.2
General If the relay is wired through an MMLG test block it is recommended that all secondary injection tests should be carried out using this block. Ensure that the main system current transformers are shorted before isolating the relay from the current transformers in preparation for secondary injection tests. DANGER: DO NOT OPEN CIRCUIT THE SECONDARY CIRCUIT OF A CURRENT TRANSFORMER SINCE THE HIGH VOLTAGE PRODUCED MAY BE LETHAL AND COULD DAMAGE INSULATION. When type MMLG test block facilities are installed, it is important that the sockets in the type MMLB 01 test plug, which correspond to the current transformer secondary windings, are LINKED BEFORE THE TEST PLUG IS INSERTED INTO THE TEST BLOCK. Similarly, a MMLB 02 single finger test plug must be terminated with an ammeter BEFORE IT IS INSERTED to monitor CT secondary currents. It is assumed that the initial preliminary checks have been carried out.
2.2.3
Relay CT shorting switches With the relay removed from its case, check electrically that the CT shorting switch is closed.
2.2.4
Secondary injection testing Connect the circuit as shown in Figure 1 and ensure that the current transformer primary is open circuit and that if any earthing connections are fitted, they do not short out the primaries of any current transformers. Increase the voltage until the relay just operates. Note the current in the relay (this can be done using the miniature split plug inserted into the appropriate position of the plug bridge connected to an ammeter). It should be approximately 38mA at setting. Note also the voltage at which the relay operates which should correspond to the setting VR of the relay with a tolerance of 10%. The total secondary current for operation will be given on ammeter A1. This test should be repeated for each pole of the relay. Drop off/Pick up ratio. Check that this ratio is greater than 50%.
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2.2.5
Primary injection testing It is essential that primary injection testing is carried out to prove the correct polarity of current transformers. Before commencing any primary injection testing it is essential to ensure that the circuit is dead, isolated from the remainder of the system and that only those earth connections associated with the primary test equipment are in position.
2.2.6
Primary fault setting The primary fault setting of any balanced scheme can be checked using the circuit shown in Figure 2. The primary current is injected into each current transformer in turn and increased until the relay operates. The voltage at which the relay operates should be within 10% of the relay setting voltage VR. The primary current for operation and relay current should be noted. In the case of machine protection similar tests must be carried out by injecting first into each current transformer in turn to determine the primary fault setting. For large machines the machine itself can be used to provide the fault current to check the primary fault setting as shown in Figure 5. The machine should be run up to speed with no excitation. The excitation should then be increased until the relays have all operated. The primary current, relay current and relay voltage should be noted as each relay operates.
2.2.7
Through fault stability With any form of unbalanced protection it is necessary to check that the current transformers are correctly connected. For this purpose with a restricted earth fault scheme the circuit shown in Figure 3 may be used. During this test it is necessary to measure the spill current in the relay circuit and short out the relay and stabilising resistor (if fitted). The current is increased up to as near full load as possible and the spill current noted. The spill current should be very low, only a few milliamps if the connections are correct. A high reading (twice the injected current, referred through the current transformer ratio) indicates that one of the current transformers is reversed. Injection should be carried out through each phase to netural. Where primary injection is not practicable in the case of restricted earth fault protection on a transformer it may be possible to check stability by means of back energising the transformer from a low voltage (415V) supply as shown in Figure 4. In the case of machine protection, similar stability tests must be carried out by injecting into one and out of another current transformer connected on the same phase. For large machines, the machine itself can be used to provide the fault current, but the short circuit must now be fitted as shown in Figure 6. The machine should be run up to normal speed and the excitation increased until the primary current is approximately full load, when the spill current should be checked. All other types of balanced protection should be tested in a similar manner. At the conclusion of the tests ensure that all connections are correctly restored and any shorting connections removed.
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Relay A2 Stabilising resistor (if fitted) A1 Ammeter (in plug bridge circuit) Metrosil
Figure 1 Secondary injection of relay to check secondary operating current, setting voltage and relay operating current.
A1
15
A1
A B C
Temporary connections
Metrosil
A1
A B C LV supply
Figure 4 Stability check on restricted earth fault scheme by back energising with a low voltage supply.
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Generator
Isolating links A B C
87
87
87
Figure 5 Testing sensitivity of generator differential protection using generator to supply primary current.
A B C
A2
A2
A2
87
87
87
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Section 3.
MAINTENANCE
Periodic maintenance is not necessary. However, periodic inspection and test is recommended. This should be carried out every l2 months or more often if the relay is operated frequently or is mounted in poor environmental conditions. 3.1 Repeat secondary injection tests 2.2.4 to prove operation, with emphasis on contact wear and condition. Mechanical settings may be checked against those shown in Section 4.
Section 4.
4.1
MECHANICAL SETTINGS
General Armature gap measurements should be made with the top of the feeler gauge level with the centre line of the core. Contact pressures are measured with a gramme gauge at the contact tips. In general contact gaps and follow through are defined by quoting an armature gap at which the tips should be just closed or just open. The relay contact state is always defined with the relay in the unenergised position, unless otherwise specified on the appropriate circuit diagram.
4.1.1 4.1.2
With the armature closed the clearance between the back of the armature and the back stop should be 0.003"/0.008". Nominal armature gap open: 0.060" for all types. Set screw in armature so that armature gap when closed is approximately 0.005"/0.010".
4.2 4.2.1
Contact settings Normal duty make contacts With the armature closed onto a 0.011" feeler gauge the make contacts should be closed, but should be open using a 0.013" feeler gauge. Contact settings Force to just close the make contacts Force to just lift the fixed contact off its support Nominal contact gap 0.060"/0.080" 2 contacts (MFAC 34) 20/25 grams 15/20 grams 4 contacts (MFAC 14) 15/20 grams 20/25 grams
4.3 4.3.1
Mechanical flag settings Settings for self reset units MFAC l4/34 With the armature closed on to a 0.013" feeler gauge the flag should be free to fall, but should not fall using an 0.018" feeler gauge. Adjustment is made to the catch spring on the flag.
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Section 5.
5.1
PROBLEM ANALYSIS
Failure to operate Check diagram for correct input connections. Check tap voltage; this is marked above or below the plug bridge on the front of the module. Note: with the plug removed the relay setting goes to the highest tap value. Measure the input current at VS, this should be 38mA (excluding the metrosil). Flag spring may be jammed between armature and core face, preventing armature closure. Check internal wiring for damage. Check choke continuity - resistance 240 ohms 15%. Check resistor values - remove pcb from module and fold down to gain access to board. Setting range 15185 Adjustable resistor Capacitor Relay coil Setting range 25175 25327 Adjustable resistor RV1 Capacitor Relay coil Setting range 100400 Resistors on PCB ZJ0038 R1 R3 R5R6 R7R8 680 680 150 01000 3.3F 190 R9 120
Resistors on PCB ZJ0038 R1 R6 1.3K 2.4K 510 C1 1.7F 5% 50Hz, 1.18F 5% 60Hz. 560 15% Resistors on PCB ZJ0038 R1R6 2.7K R9 3.9K
5.2
Output contacts not changing state Check output terminals with reference to appropriate diagram. Operating pushrods not in position Internal wiring damaged Contamination of contacts Contacts should be cleaned with the burnishing tool supplied in the relay tool kits. On no account should knives, files or abrasive materials be used. Check mechanical settings as per Section 4.
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Section 6.
SPARES
When ordering spares, quote the full relay model number and any component reference numbers, or briefly describe the parts required. Should the need arise for the equipment to be returned to AREVA T&D for repair, then the form at the back of this manual should be completed and sent with the equipment together with a copy of any commissioning test results.
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Section 7.
High Impedance Differential Relay Type MFAC Date Station Relay Model No. Setting range Setting voltage Type of ext. metrosil Circuit. Serial No. CT ratio Relay setting Shunt resistor ohms (if fitted) Calculated primary operating current Test results
2.2.3 2.2.4
Relay CT shorting switch Secondary voltage to operate relay. Phase A B C Total current (A1) Relay current (A2) PU volts DO volts
2.2.6
Primary current to operate relay Phase A B C N Primary current (A1) Relay current (A2) Relay voltage
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2.2.7
Stability check by primary injection Restricted earth fault Phases AN BN CN Primary current (A1) Spill current (A2)
Circulating current between two or more sets of current transformers. Phases A1A2 B1B2 C1C2 Where more than two sets of current transformers are involved, injection should be carried out between set 1 and each other set in turn. Primary current (A1) Spill current (A2)
Commissioning Engineer
Customer Witness
Date 22
Date
REPAIR FORM
Please complete this form and return it to AREVA T&D with the equipment to be repaired. This form may also be used in the case of application queries. AREVA T&D St. Leonards Works Stafford ST17 4LX England For : After Sales Service Department
___________________ ___________________
1. What parameters were in use at the time the fault occurred? AC Volts DC Volts AC current Frequency ___________________ ___________________ ___________________ ___________________ Main VT/Test set Battery/Power supply Main CT/Test set
2. Which type of test was being used? 3. Were all the external components fitted where required? (Delete as appropriate) 4. List the relay settings being used Yes / No
continued overleaf
7. When did the fault occur? Instant Time delayed By how long? Yes / No Yes / No ___________________ Intermittent (Delete as appropriate) Yes / No
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Publication: R8007F
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