R8139B GCM05
R8139B GCM05
R8139B GCM05
Type GCM05
DC Intertrip Relay
Service Manual
Type GCM05
DC Intertrip Relay
SAFETY SECTION 5
3. COMMISSIONING 13
3.1 Electrostatic discharges (ESD) 13
3.2 Inspection 13
3.3 Wiring 13
3.4 Earthing 13
3.5 Insulation 13
3.6 Calibration 13
3.7 Tests 14
3.8 Control board adjustments (information only) 15
4. MAINTENANCE 16
4.1 Visual inspection 16
4.2 Functional checks 16
5. PROBLEM ANALYSIS 16
5.1 Intertrip send signal not received by the remote end relay 16
5.2 Operation of the intertrip faulty relay (supervision relay) 16
6. COMMISSIONING AND TEST RECORD 19
REPAIR FORM 21
4
SAFETY SECTION
This Safety Section should be read before commencing any work on the equipment.
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.
Explanation of symbols and labels
The meaning of symbols and labels which may be used on the equipment or in the
product documentation, is given below.
*Note: The term earth used throughout the product documentation is the direct
equivalent of the North American term ground.
5
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 2.5 mm2, 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)
6
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 electric 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.
7
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.
8
Section 1. HANDLING AND INSTALLATION
9
Section 2. TECHNICAL DATA
Output contacts
Intertrip receive 4 normally open or 3 normally
open and one normally closed
Pilot/relay faulty supervision 2 normally closed
Contact Ratings
Current Make and Carry
Continuously Break
ac 1100VA with maxima Resistive 1100VA inductive
of 10A and 250V 825VA with maxima
of 10A and 250V
dc 240VA with maxima Resistive 240VA inductive
of 10A and 125V 120VA with maxima
of 10A and 125V
10
Indications Power – green LED
Intertrip send – red LED
Intertrip receive – red LED
Pilot wire isolation 15kV rms. for 1 minute, between the
pilot wire and other circuits and earth
AC noise immunity Up to 400V rms. at 50Hz for 3s
(300Ω source impedance)
Impedance presented to pilots 22KΩ dc
7000Ω ac 50Hz
16000Ω ac >300Hz
Intertrip time Voltage = 150 Volts
Typical values based on Send Relay Pilot
11
Insulation resistance
IEC 60255-5: 1977 >100MΩ at 500V
Electrostatic discharge
IEC 60255-22-2: 1996 Class III 8kV discharge in air with cover in place
6kV contact discharge with cover
removed
Fast transient
IEC 60255-22-4 (1992) Class III 2kV, 5kHz applied directly to auxiliary
supply.
2kV, 5kHz applied directly to all inputs.
Mechanical rating Relay will perform >50,000 operations
Temperature range
Operating range –5 °C to +50°C
Storage and transit –20°C to +60°C
Vibration
IEC 60255-21-1: 1988 Response class 1
Humidity
IEC 60068-2-3: 1969 56 days at 93% RH and +40°C
Enclosure protection
IEC 60529: 1989 IP20 (finger protected)
Weight 2.5Kg
Mounting Supplied as projection mounted, however
the unit can be flush mounted by simply
relocating the mounting brackets. The
unit must be mounted so that the terminal
block is not at the top.
Dimensions Overall dimensions
Length 230mm
Width 162mm
Height 100mm
EMC compliance
89/336/EEC Compliance with the European
Commission Directive on EMC is claimed
via the Technical Construction File route
EN 50081-2: 1994 Generic standards were used to establish
EN 50082-2: 1995 conformity
Product safety:
73/23/EEC Compliance with the European
Commission Low Voltage
Directive.
12
Section 3. COMMISSIONING
Before carrying out any work on the equipment the user should familiarise himself
with the contents of the Safety Section. Particular attention should be given to the pilot
wire circuits statement.
3.1 Electrostatic discharges (ESD)
The relay uses components which are sensitive to electrostatic discharges.
When handling the module, care should be taken to avoid contact with components
and electrical connections. Full precautions are described inside the front cover of this
publication.
3.2 Inspection
Carefully examine the module to see that no damage has occurred during transit.
Check that the relay serial number on the module, the model number and rating
information are correct.
Carefully remove any elastic bands/packing fitted for transportation purposes.
3.3 Wiring
Check that the external wiring is correct to the relevant relay or scheme diagram.
The relay connection diagram appears on the label.
Particular attention should be paid to the correct wiring.
Warning: Do not exceed 50V on terminal number 5 (20–50V intertrip send
input), otherwise damage will occur to the internal electronic circuitry.
3.4 Earthing
The relay should be connected to the substation earth via terminal 3.
3.5 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 500V. Accessible terminals of the same circuit should first be strapped
together. Deliberate circuit earthing links removed for the tests, must subsequently be
replaced.
3.6 Calibration
Care must be observed that the correct voltages are applied to the relay.
3.6.1 Master/Slave switch setting
When the required relays have been installed within the scheme for which they are to
operate, the first requirement is to select one relay to “Master” mode and the
remaining relays as “Slave”.
For multiple ended schemes, it is suggested the relay chosen to be master be as close
as possible to the centre of the pilots, and that approximately equal numbers of
“Slaves” be connected either side of the master.
13
The “Master” unit injects a supervision voltage of approximately 24V dc onto the
pilots. Short, crossed or open circuits of the pilots will cause each of the remote
“Slave” units’ supervision contacts to close. The Master unit may detect some pilot
short circuits depending on position along the cable, but will not detect pilot open
circuits due to the supervision voltage it is injecting.
3.6.2 Intertrip send voltage level calibration
The intertrip send voltage level is factory set at 150V. This setting should be adequate
for most applications, however this voltage may have to be adjusted on site due to
variations in the pilot impedance, sub-station battery level and the number of
connected units. Once set however, each relay will regulate for a given load
impedance. In setting the threshold level for trip conditions, it is necessary to consider
that to ensure the fastest possible system operating time, the intertrip send voltage
level should be as high as possible, keeping within the design limitations of the
product.
This setting can be performed in one of two ways:–
1) Initiate a trip output onto the pilot by applying the appropriate voltage to
terminals 4 & 5 or 4 & 6. Adjust potentiometer VR1 whilst measuring the voltage
output directly at that relay’s pilot terminals. Adjustment range is greater than
165V, depending on those factors stated in the above paragraph.
This adjustment in turn sets the “low” range voltage ie. supervision voltage, when
the relay is set in “Master”.
Note: Output voltage on pilots when relay is set in “Slave” is independent of the
“Trip” level adjustment.
2) As above however, instead of measuring the “Trip” output voltage directly at that
relay’s pilot terminals, the level is measured at the remote end and, the sending
ends level adjustment is set for a given remote voltage.
This procedure is somewhat more difficult when more than two ends are used.
It would be normal that a scheme consisting of ‘N’ ends would consist of unequal
impedance’s between the ends. Therefore, the voltage level received at one end
would be different from that received at another. In this situation, the most
practical solution is, to adjust the sending end for the correct voltage being
measured at the most distant end to that from the sending end.
3.7 Tests
3.7.1 Operational checks
Connect a variable dc voltage across the pilot terminals.
14
3.7.1.3 Check the intertrip send voltage level
Initiate an intertrip send by either:
– Applying between 20V–50V to terminals 5 and 4 or
– Applying between 50V–150V to terminals 6 and 4
Note: The pilot voltage (should be between 120V–160V)
Check the “Send” LED is on.
3.7.2 Functional tests
3.7.2.1 Initiate an intertrip send from the local end:–
– Check local end send LED indication
– Check remote end receive LED indication
– Check remote end I/trip receive contact operation
3.7.2.2 Initiate an intertrip send from the remote end:–
– Check remote end send LED indication
– Check local end receive LED indication
– Check local end I/trip receive contact operation
3.7.2.3 Intertrip operation timing check:–
This test can be carried out at one end only if required. A timing check for a two
ended scheme is described below:–
Connect the circuit as shown in figure 2.
– A double pole switch is used to initiate a local intertrip send and start the test set
timer.
– The remote intertrip receive contact operates the MVTT 14 timer.
– The MVTT 14 timer (expired) initiates a remote intertrip send.
– The local intertrip receive contact stops the test timer.
Operating time = (total time – timer setting) / 2
The operating time can be adjusted if required by adjusting the intertrip send voltage
level, refer to section 3.6.2.
3.8 Control board adjustments (information only)
VR1 – Adjusts the voltage on the pilots when in the “Master” mode or when
sending a trip signal.
VR2 – Adjusts the threshold for the supervision relay.
VR3 – Adjusts the threshold for the receive relay.
VR4 – Adjusts the mark space of the local oscillator.
Note: Adjustment of VR4 also affects the setting of VR2 and VR3. If this potentiometer
is adjusted, the relay must be reset as thresholds will have changed.
15
Section 4. MAINTENANCE
– Place an adjustable dc source across the pilot pair. Adjust the level to where the
trip receive relay activates (should be between 60V–80V) and note this level in
the test certificate. When this test is performed, the Trip receive indication on the
relay should be illuminated and cannot be cleared whilst the Trip condition
remains.
– Now decrease the applied dc level and ensure that the internal intertrip faulty
supervision relay drops out below 20V dc. Should everything stated above be
observed, then this check can be deemed to have “Passed”. If not, then further
investigation is necessary.
5.1 Intertrip send signal not received by the remote end relay
The intertrip send voltage level may have to be adjusted. Refer to section 3.6.2 for
more information.
5.2 Operation of the intertrip faulty relay (supervision relay)
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Pilot cable To additional
remote units
Master Slave
+ – + –
Warning – Do not exceed 50V on pin 5 Warning – Do not exceed 50V on pin 5
Power Intertrip Intertrip receive Alarm Power Intertrip Intertrip receive Alarm
supply send supply send
20 50 20 50
17
0 / / 0 / /
20-150V 50 150 20-150V 50 150
+ – – + + + – – + +
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18
Master Slave
+ – + –
Warning – Do not exceed 50V on pin5 Warning – Do not exceed 50V on pin5
Power Intertrip Intertrip receive Alarm Power Intertrip Intertrip receive Alarm
supply send supply send
20 50 20 50
0 / / 0 / /
20-150V 50 150 20-150V 50 150
+ – – + + + – – + +
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18
18
Relay faulty alarm Pilot/relay faulty/alarm
– –
MVTT 14
+ +
1 3
MVTT 14
13 14
–
Stop test set timer
21 3 seconds
Site Circuit
Model No Serial No
Rating Diagram
Auxiliary Voltage
Remarks: _________________________________________________________________
_________________________________________________________________________
_________________________________________________________________________
Date Date
19
20
REPAIR FORM
Please complete this form and return it to ALSTOM T&D Protection & Control Ltd with the
equipment to be repaired. This form may also be used in the case of application queries.
continued overleaf
21
✁
6. What did happen?
____________________________________________________________________________
____________________________________________________________________________
____________________________________________________________________________
____________________________________________________________________________
______________________________________ _______________________________________
Signature Title
______________________________________ _______________________________________
Name (in capitals) Company name
✁
A L S T O M T & D P r o t e c t i o n & C o n t r o l L t d St Leonards Works, Stafford, ST17 4LX England
Tel: 44 (0) 1785 223251 Fax: 44 (0) 1785 212232 Email: [email protected] Internet: www.alstom.com