Service ManualType GCM05

DC Intertrip Relay

Service ManualType GCM05

DC Intertrip Relay

HANDLING OF ELECTRONIC EQUIPMENTA person's normal movements can easily generate electrostatic potentials of several thousand volts.Discharge of these voltages into semiconductor devices when handling electronic circuits can causeserious damage, which often may not be immediately apparent but the reliability of the circuit will havebeen reduced.

When housed in the case, the electronic circuits of ALSTOM products will meet the claimed electrostaticdischarge level, without damage. Do not expose them to the risk of damage by withdrawing modulesunnecessarily.

Each module incorporates the highest practicable protection for its semiconductor devices. However, if itbecomes necessary to withdraw a module, the following precautions should be taken to preserve the highreliability and long life for which the equipment has been designed and manufactured.

1. Before removing a printed circuit board (PCB), ensure that your electrostatic potential is reduced bytouching earth for a few seconds, (the case is plastic and may not be at the same potential as thePCB). After removal of a PCB regularly touch the case earth connection to minimise the build up ofelectrostatic potential.

2. Handle the module by its front-plate, frame, or edges of the printed circuit board.Avoid touching the electronic components, printed circuit track or connectors.

3. Do not pass the module to any person without first ensuring that you are both at the sameelectrostatic potential. Shaking hands achieves equipotential.

4. Place the module on an antistatic surface, or on a conducting surface which is at the samepotential as yourself.

5. Store or transport the module in a conductive bag.

More information on safe working procedures for all electronic equipment can be found in BS 5783 andIEC 60147-0F.

If you are making measurements on the internal electronic circuitry of an equipment in service, it ispreferable that you are earthed to the case with a conductive wrist strap. Wrist straps should have aresistance to ground between 500k – 10MΩ . If a wrist strap is not available, you should maintainregular contact with the case to prevent the build up of static. Instrumentation which may be used formaking measurements should be earthed to the case whenever possible.

ALSTOM strongly recommends that detailed investigations on the electronic circuitry, or modificationwork, should be carried out in a Special Handling Area such as described in BS 5783 or IEC 60147-0F.

4

This manual should be read in conjunction with Publication R6139.

CONTENTS

SAFETY SECTION 5

1. HANDLING AND INSTALLATION 9

1.1 General considerations 9

2. TECHNICAL DATA 10

3. COMMISSIONING 13

3.1 Electrostatic discharges (ESD) 133.2 Inspection 133.3 Wiring 133.4 Earthing 133.5 Insulation 133.6 Calibration 133.7 Tests 143.8 Control board adjustments (information only) 15

4. MAINTENANCE 16

4.1 Visual inspection 164.2 Functional checks 16

5. PROBLEM ANALYSIS 16

5.1 Intertrip send signal not received by the remote end relay 165.2 Operation of the intertrip faulty relay (supervision relay) 16

6. COMMISSIONING AND TEST RECORD 19

REPAIR FORM 21

5

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 toensure that products are properly installed and handled in order to maintain them ina safe condition. It is assumed that everyone who will be associated with theequipment 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 theproduct documentation, is given below.

Caution: refer to product documentation Caution: risk of electric shock

Protective/safety *earth terminal

Functional *earth terminal.Note: this symbol may also be used for a protective/safety earth terminal if that terminal is part of aterminal block or sub-assembly eg. power supply.

*Note: The term earth used throughout the product documentation is the directequivalent of the North American term ground.

Installing, Commissioning and ServicingEquipment connections

Personnel undertaking installation, commissioning or servicing work on thisequipment should be aware of the correct working procedures to ensure safety.The product documentation should be consulted before installing, commissioning orservicing the equipment.

Terminals exposed during installation, commissioning and maintenance may presenta hazardous voltage unless the equipment is electrically isolated.

If there is unlocked access to the rear of the equipment, care should be taken by allpersonnel to avoid electric shock or energy hazards.

Voltage and current connections should be made using insulated crimp terminationsto ensure that terminal block insulation requirements are maintained for safety.To ensure that wires are correctly terminated, the correct crimp terminal and tool forthe wire size should be used.

6

Before energising the equipment it must be earthed using the protective earthterminal, or the appropriate termination of the supply plug in the case of plugconnected equipment. Omitting or disconnecting the equipment earth may cause asafety hazard.

The recommended minimum earth wire size is 2.5 mm2, unless otherwise stated inthe 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)

Equipment operating conditions

The equipment should be operated within the specified electrical and environmentallimits.

Current transformer circuits

Do not open the secondary circuit of a live CT since the high voltage producedmay be lethal to personnel and could damage insulation.

External resistors

Where external resistors are fitted to relays, these may present a risk of electric shockor burns, if touched.

Battery replacement

Where internal batteries are fitted they should be replaced with the recommendedtype and be installed with the correct polarity, to avoid possible damage to theequipment.

Insulation and dielectric strength testing

Insulation testing may leave capacitors charged up to a hazardous voltage. At theend of each part of the test, the voltage should be gradually reduced to zero, todischarge capacitors, before the test leads are disconnected.

Insertion of modules and pcb cards

These must not be inserted into or withdrawn from equipment whilst it is energised,since this may result in damage.

Fibre optic communication

Where fibre optic communication devices are fitted, these should not be vieweddirectly. Optical power meters should be used to determine the operation or signallevel of the device.

7

Older ProductsElectrical adjustments

Equipments which require direct physical adjustments to their operating mechanism tochange current or voltage settings, should have the electrical power removed beforemaking the change, to avoid any risk of electric shock.

Mechanical adjustments

The electrical power to the relay contacts should be removed before checking anymechanical settings, to avoid any risk of electric shock.

Draw out case relays

Removal of the cover on equipment incorporating electromechanical operatingelements, 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 theequipment 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 beforeinsertion or removal, to avoid potentially lethal voltages.

Decommissioning and Disposal

Decommissioning: The auxiliary supply circuit in the relay may includecapacitors across the supply or to earth. To avoid electricshock or energy hazards, after completely isolating thesupplies to the relay (both poles of any dc supply), thecapacitors should be safely discharged via the externalterminals prior to decommissioning.

Disposal: It is recommended that incineration and disposal to watercourses is avoided. The product should be disposed of in asafe manner. Any products containing batteries should havethem removed before disposal, taking precautions to avoidshort circuits. Particular regulations within the country ofoperation,may apply to the disposal of lithium batteries.

8

Technical SpecificationsProtective fuse rating

The recommended maximum rating of the external protective fuse for this equipmentis 16A, Red Spot type or equivalent, unless otherwise stated in the technical datasection of the product documentation.

Insulation class: IEC 61010-1:1990/A2: 1995 This equipment requires aClass I protective (safety) earthEN 61010-1: 1993/A2: 1995 connection to ensure userClass I safety.

Installation IEC 61010-1:1990/A2: 1995 Distribution level, fixedCategory Category III installation. Equipment in(Overvoltage): EN 61010-1: 1993/A2: 1995 this category is qualification

Category III tested at 5kV peak, 1.2/50µs,500Ω, 0.5J, between all supplycircuits and earth and alsobetween independent circuits.

Environment: IEC 61010-1:1990/A2: 1995 Compliance is demonstrated byPollution degree 2 reference to generic safetyEN 61010-1: 1993/A2: 1995 standards.Pollution degree 2

Product safety: 73/23/EEC Compliance with the EuropeanCommission Low VoltageDirective.

EN 61010-1: 1993/A2: 1995 Compliance is demonstratedEN 60950: 1992/A11:1997 by reference to generic safety

standards.

9

Section 1. HANDLING AND INSTALLATION

1.1 General considerations

Protective relays, although generally of robust construction, require careful treatmentprior to installation and a wise selection of site. By observing a few simple rules thepossibility of premature failure is eliminated and a high degree of performance canbe expected.

The relays are dispatched individually, in cartons specifically designed to protectthem from damage.

Relays should be examined immediately they are received to ensure that no damagehas been sustained in transit. If damage due to rough handling is evident, a claimshould be made to the transport company concerned immediately, and the nearestALSTOM agent should be promptly notified.

Care must be taken when unpacking and installing the relays so that none of theparts are damaged, and must at all times be handled by skilled persons only.

Relays should be examined for any wedges, clamps, or rubber bands necessary tosecure moving parts to prevent damage during transit and these should be removedafter installation and before commissioning.

If relays are not installed upon receipt, they should be stored in a place free from dustand moisture in their original cartons, and where de-humidifier bags have beenincluded in the packing they should be retained. The action of the de-humidifiercrystals will be impaired if the bag has been exposed to ambient conditions, andmay be restored by gently heating the bag for about an hour, prior to replacing it inthe carton.

Dust which collects on a carton may, on subsequent unpacking, find its way into therelay; in damp conditions the carton and packing may become impregnated withmoisture and the de-humidifying agent will lose its efficiency.

Storage temperature –20°C to +60°C.

The installation should be clean, dry and reasonably free from dust and excessivevibration. The site should preferably be well illuminated to facilitate inspection.

An outline diagram is normally supplied showing panel mounting and hole centres.For individually mounted relays these dimensions will also be found in thePublication.

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Section 2. TECHNICAL DATA

Auxiliary supply voltage (Vx) 24/125V dc

Voltage ranges (selectable) 20V to 50V dc

50V to 150V dc

Operating mode Master Slave Intertrip Send

DC/DC converter operating frequency 3kHz (max) 400Hz 11kHz (max)

Output volts to pilot * 24Vdc <15Vdc 150Vdc(adjustable)

Power consumption <6W <5W <10W

* Total ac ripple voltage typically 160mV r.m.s. in all operating modes.

Input Terminals 4/5 Terminals 4/6

Pickup ≤20V dc ≤50V dc

Drop off ≥10V dc ≥25V dc

Max volts 50V dc 150V dc

Pilot receive Intertrip receive Pilot/relay faulty

Pilot pickup volts <80V dc <20V dc

Pilot drop-off volts >60V dc >15V dc

Output contacts

Intertrip receive 4 normally open or 3 normallyopen and one normally closed

Pilot/relay faulty supervision 2 normally closed

Contact Ratings

Current Make and CarryContinuously Break

ac 1100VA with maxima Resistive 1100VA inductiveof 10A and 250V 825VA with maxima

of 10A and 250V

dc 240VA with maxima Resistive 240VA inductiveof 10A and 125V 120VA with maxima

of 10A and 125V

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Indications Power – green LED

Intertrip send – red LED

Intertrip receive – red LED

Pilot wire isolation 15kV rms. for 1 minute, between thepilot 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 dc7000Ω ac 50Hz16000Ω ac >300Hz

Intertrip time Voltage = 150 VoltsTypical values based on Send Relay Pilot

Pilot cable details 2 ended 3 ended 4 endedscheme scheme scheme

0 ohms 60ms 66ms 70ms

1,000 ohms 1µF 65ms 68ms 73ms

2,000 ohms 2 µF 67ms 72ms 79ms

System reset time 2 seconds from completion of trip send

Dielectric withstandIEC 60255-5: 1977 2kV rms for 1 minute between all

terminals and earth.

2kV rms for 1 minute between allindependent circuits, with terminals oneach independent circuit connectedtogether.

1kV rms for 1 minute across normallyopen contacts.

High voltage impulse

IEC 60255-5: 1977 Three positive and three negativeimpulses of 5kV peak, 1.2/50µs 0.5Jbetween all terminals of the same circuit(except output contacts), betweenindependent circuits, and between allterminals connected together and caseearth.

High frequency disturbanceIEC 60255-22-1: 1988 Class III 2.5kV peak between independent circuits

and independent circuits and earth.

1.0kV peak across terminals of the samecircuit (except metallic contacts).

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Insulation resistanceIEC 60255-5: 1977 >100MΩ at 500V

Electrostatic dischargeIEC 60255-22-2: 1996 Class III 8kV discharge in air with cover in place

6kV contact discharge with coverremoved

Fast transientIEC 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 rangeOperating range –5 °C to +50°C

Storage and transit –20°C to +60°C

Vibration

IEC 60255-21-1: 1988 Response class 1

HumidityIEC 60068-2-3: 1969 56 days at 93% RH and +40°C

Enclosure protectionIEC 60529: 1989 IP20 (finger protected)

Weight 2.5Kg

Mounting Supplied as projection mounted, howeverthe unit can be flush mounted by simplyrelocating the mounting brackets. Theunit must be mounted so that the terminalblock is not at the top.

Dimensions Overall dimensions

Length 230mm

Width 162mm

Height 100mm

EMC compliance89/336/EEC Compliance with the European

Commission Directive on EMC is claimedvia the Technical Construction File route

EN 50081-2: 1994 Generic standards were used to establishEN 50082-2: 1995 conformity

Product safety:73/23/EEC Compliance with the European

Commission Low VoltageDirective.

EN 61010-1: 1993/A2: 1995 Compliance is demonstratedEN 60950: 1992/A11:1997 by reference to generic safety

standards.

13

Section 3. COMMISSIONING

Before carrying out any work on the equipment the user should familiarise himselfwith the contents of the Safety Section. Particular attention should be given to the pilotwire 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 componentsand electrical connections. Full precautions are described inside the front cover of thispublication.

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 ratinginformation 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 sendinput), 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 notexceeding 500V. Accessible terminals of the same circuit should first be strappedtogether. Deliberate circuit earthing links removed for the tests, must subsequently bereplaced.

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 tooperate, the first requirement is to select one relay to “Master” mode and theremaining relays as “Slave”.

For multiple ended schemes, it is suggested the relay chosen to be master be as closeas possible to the centre of the pilots, and that approximately equal numbers of“Slaves” be connected either side of the master.

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The “Master” unit injects a supervision voltage of approximately 24V dc onto thepilots. 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 pilotshort circuits depending on position along the cable, but will not detect pilot opencircuits 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 adequatefor most applications, however this voltage may have to be adjusted on site due tovariations in the pilot impedance, sub-station battery level and the number ofconnected units. Once set however, each relay will regulate for a given loadimpedance. In setting the threshold level for trip conditions, it is necessary to considerthat to ensure the fastest possible system operating time, the intertrip send voltagelevel should be as high as possible, keeping within the design limitations of theproduct.

This setting can be performed in one of two ways:–

1) Initiate a trip output onto the pilot by applying the appropriate voltage toterminals 4 & 5 or 4 & 6. Adjust potentiometer VR1 whilst measuring the voltageoutput directly at that relay’s pilot terminals. Adjustment range is greater than165V, depending on those factors stated in the above paragraph.This adjustment in turn sets the “low” range voltage ie. supervision voltage, whenthe 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 thatrelay’s pilot terminals, the level is measured at the remote end and, the sendingends 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 unequalimpedance’s between the ends. Therefore, the voltage level received at one endwould be different from that received at another. In this situation, the mostpractical solution is, to adjust the sending end for the correct voltage beingmeasured 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.

3.7.1.1 Check the intertrip receive threshold

Slowly increase the pilot voltage and note the level at which the trip receive relayenergizes (should be between 60V to 80V).

Check the “Receive” LED is on.

3.7.1.2 Check the operation of the intertrip faulty supervision relay

Decrease the pilot voltage until the intertrip faulty supervision relay de-energizes andnote the voltage (should be below 20V).

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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 twoended 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 settimer.

– 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 voltagelevel, 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 whensending 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 potentiometeris adjusted, the relay must be reset as thresholds will have changed.

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Section 4. MAINTENANCE

Periodic maintenance is not necessary. However, periodic inspection and functionalchecks are recommended.

4.1 Visual inspection

Isolate all supplies, remove the lid screws and remove the lid. Inspect the printedcircuit board for any sign of loose components or connections.

Your attention is drawn to the fact that the relay can be damaged by electrostaticcharges. The PCB should not be touched unless electrostatic charge precautions havebeen taken.

The output relays are very simple but robust and rarely malfunction. Unless incorrectoperation is observed or damage has occurred, units should be left undisturbed.

4.2 Functional checks

The following periodic functional tests should be carried out, refer also to section 6.

The operation of the LED’s, supervision and output relays should be checked duringthese functional tests.

– Set all relays in the scheme to “Slave”.

– Place an adjustable dc source across the pilot pair. Adjust the level to where thetrip receive relay activates (should be between 60V–80V) and note this level inthe test certificate. When this test is performed, the Trip receive indication on therelay should be illuminated and cannot be cleared whilst the Trip conditionremains.

– Now decrease the applied dc level and ensure that the internal intertrip faultysupervision relay drops out below 20V dc. Should everything stated above beobserved, then this check can be deemed to have “Passed”. If not, then furtherinvestigation is necessary.

Section 5. PROBLEM ANALYSIS

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 formore information.

5.2 Operation of the intertrip faulty relay (supervision relay)

Check integrity of the pilot circuit ie.

– Open circuit pilot wires

– Cross-over of the pilot wires

– Short circuit pilots wires

Check one relay in the scheme is set to “Master”.

17

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19

Commissioning Engineer Customer Witness

Date Date

Section 6. COMMISSIONING AND TEST RECORD

Site Circuit

Model No Serial No

Rating Diagram

Auxiliary Voltage

Have all relevant safety instructions been followed?

Master/Slave switch setting located inside the case (Master/Slave)

Switch all relays in scheme to “Slave” during test.

Observing relevant safety instructions for pilot wires,connect a variable dc voltage across the pilot terminals,

Apply the auxiliary supply and check the “Power” LED indication

Check the intertrip receive threshold

– Slowly increase the pilot voltage and note the level atwhich the trip receive relay energises (should be between60V and 80V). Volts

– Check the “Receive” LED is on.

Check the operation of the intertrip faulty supervision relay

– Decrease the pilot voltage until the intertrip faultysupervision relay de-energizes and note the voltage(should be below 20V). Volts

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 4note the pilot voltage (should be between 120V and160V) Volts

– Check the “Send” LED is on.

Remarks: _________________________________________________________________

_________________________________________________________________________

_________________________________________________________________________

20

21

continued overleaf

REPAIR FORM

Please complete this form and return it to ALSTOM T&D Protection & Control Ltd with theequipment to be repaired. This form may also be used in the case of application queries.

ALSTOM T&D Protection & Control LtdSt. Leonards WorksStaffordST17 4LX,England

For: After Sales Service Department

Customer Ref: ___________________________ Model No: _____________________

Contract Ref: ___________________________ Serial No: _____________________

Date: ___________________________

1. What parameters were in use at the time the fault occurred?

AC volts _____________ Main VT/Test set

DC volts _____________ Battery/Power supply

AC current _____________ Main CT/Test set

Frequency _____________

2. Which type of test was being used? ____________________________________________

3. Were all the external components fitted where required? Yes/No(Delete as appropriate.)

4. List the relay settings being used

____________________________________________________________________________

____________________________________________________________________________

____________________________________________________________________________

5. What did you expect to happen?

____________________________________________________________________________

____________________________________________________________________________

____________________________________________________________________________

____________________________________________________________________________

______________________________________ _______________________________________Signature Title

______________________________________ _______________________________________Name (in capitals) Company name

6. What did happen?

____________________________________________________________________________

____________________________________________________________________________

____________________________________________________________________________

____________________________________________________________________________

7. When did the fault occur?

Instant Yes/No Intermittent Yes/No

Time delayed Yes/No (Delete as appropriate).

By how long? ___________

8. What indications if any did the relay show?

____________________________________________________________________________

____________________________________________________________________________

____________________________________________________________________________

9. Was there any visual damage?

____________________________________________________________________________

____________________________________________________________________________

____________________________________________________________________________

10. Any other remarks which may be useful:

____________________________________________________________________________

____________________________________________________________________________

____________________________________________________________________________

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 EnglandTel: 44 (0) 1785 223251 Fax: 44 (0) 1785 212232 Email: enquiries@pcs.alstom.co.uk Internet: www.alstom.com

©1999 ALSTOM T&D Protection & Control Ltd

Our policy is one of continuous product development and the right is reserved to supply equipment which may vary from that described.

Publication R8139B Printed in England.