ABB KLF Instruction Leaflet

Page 1
ABB Power T&D Company Inc.
Power Automation and Protection Division Coral Springs, FL 33065
Type KLF
Instruction Leaflet
41-748.21C
Effective: January 1997 Supersedes I.L. 41-748.21B, Dated December 1993
( | ) Denotes Changed Since Previous Issue
CAUTION
!
Before putting protective relays into ser­vice, make sure that all moving parts oper­ate freely, inspect the contacts to see that they are clean and close properly, and oper­ate the relay to check the settings and elec­trical connections.
1. APPLICATION
These relays have been specially designed and tested to establish their suitability for Class 1E applications in accordance with the ABB Power T&D Company program for Class 1E Qulification Testing ad detailed in bulletin STR-1. Materials have been selected and tested to insure that the relays will perform their intended functions for their design life when operated in a normal environment as defined by ANSI standards when exposed to
radiation levels up to 104 rads, and when subjected to seismic events producing a Shock Response Spectrum within the limits of the relay rating.
“Class 1E” is the safety classification of the elec­tronic equipment and systems in nuclear power generating stations that are essential to emergency shutdown of the reactor, containment isolation, cooling the reactor, and heat removal from the con­tainment and reactor, or otherwise are essential in preventing significant release of radioactive mate­rial to the environment.
The KLF relay is a single-phase relay connected to the ac side of a synchronous machine and contains three units connected so that the operation of two units sounds an alarm warning the operator of a low excitation condition, and the additional opera-
Loss-of-Field Relay
(For Class 1E Application)
tion of the third unit sets up the trip circuit. The relay can be applied without modification to all types of synchronous machines, such as turbo gen­erators, water wheel generators or motors.
The KLF relay is designed for use with 3-phase 3­wire voltage supply and may use wye or delta-con­nected voltage transformers. The type KLF-1 relay may be used to increase security during inadvert­ent loss-of-potential (such as due to a blown poten­tial fuse).
2. CONSTRUCTION
The relay consists of two (2) air-gap transformers (compensators), two tapped auto-transformers, one reactor, one cylinder-type distance IT, direc­tional unit with adjustable reactor, an under-voltage unit with adjustable resistor, telephone relay with solid state time delay circuit, and an ICS indicating contactor switch.
2.1 Compensator
The compensators, which are designated TA and TC, are two (2) winding air-gap transformers (Fig-
ure 2). The primary or current winding of the
long-reach compensator TA has seven taps which terminate at the tap block. They are marked 2.4,
3.16, 4.35, 5.93, 8.3, 11.5, 15.8. The primary wind­ing of the short-reach compensator TC also has
seven taps which terminate at this tap block. They are marked 0.0, 0.91, 1.27, 1.82, 2.55, 3.64, 5.1. Voltage is induced in the secondary which is pro­portional to the primary tap and current magnitude. This proportionality is established by the cross sec­tional area of the laminated steel core, the length of an air gap which is located in the center of the coil, and the tightness of the laminations. All of these factors which influence the secondary voltage pro­portionality have been precisely set at the factory.
All possible contingencies which may arise during installation, operation or maintenance, and all details and variations of this equipment do not purport to be covered by these instructions. If further information is desired by purchaser regarding this particular installation, operation or maintenance of this equipment, the local ABB Power T&D Company Inc. representative should be contacted.
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41-748.21C
Front View Rear View
Figure 1. Type KLF Relay
The clamps which hold the laminations should not be disturbed by either tightening or loosening the clamp screws.
The secondary winding is connected in series with the relay terminal voltage. Thus voltage, which is proportional to the line current, is added vectorially to the relay terminal voltage.
2.2Auto-Transformer
The auto-transformer has three taps on its main winding, S, which are numbered 1, 2, and 3 on the tap block. A tertiary winding M has four taps which may be connected additively or subtractively to inversely modify the setting by any value from -15 to +15 percent in steps of 3 percent.
2
The sign of M is negative when the R lead is above the L lead. M is positive when L is in a tap location which is above the tap location of the R lead. The M setting is determined by the sum of per unit val­ues between the R and L lead. The actual per unit values which appear on the tap plate between taps are 0,.03,.06, and.06.
The auto-transformer makes it possible to expand the basic ranges of the long and the short reach
compensators by a multiplier of . Any relay
S
-------------­1 M±
ohm setting can be made within±1.5 percent from
2.08 ohms to 56 ohms for the long-reach and from.79 ohms to 18 ohms for the short-reach.
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Sub 1 185A181
Figure 2. Compensator Construction
2.3 Impedance Tripping Unit
The distance unit is a four pole induction cylinder type unit. The operating torque of the unit is pro­portional to the product of the voltage quantities applied to the unit and the sine of the phase angle between the applied voltages. The direction of the torque depends on the impedance phasor seen by the relay with respect to its characteristic circle.
Mechanically, the cylinder unit is composed of four basic components: A die-cast aluminum frame, and electromagnet, a moving element assembly, and a molded bridge. The frame serves as a mounting structure for the magnetic core. The magnetic core which houses the lower pin bearing is secured by the frame by a locking nut. The bear­ing can be replaced, if necessary, without having to remove the magnetic core from the frame.
The electromagnet has two sets of two series con­nected coils mounted diametrically opposite one another to excite each set of poles. Locating pins on the electromagnet are used to accurately posi­tion the lower pin bearing, which is mounted on the frame, with respect to the upper pin bearing, which is threaded into the bridge. The electromagnet is secured to the frame by four mounting screws.
The moving element assembly consists of a spiral spring, contact carrying number, and an aluminum cylinder assembled to a molded hub which holds the shaft. The hub to which the moving-contact
41-748.21C
arm is clamped has a wedge and cam construc­tion, to provide low-bounce contact action. A casual inspection of the assembly might lead one to think that the contact arm bracket does not clamp on the hub as tightly as it should. However, this adjustment is accurately made at the factory and is locked in place with a lock nut and should not be changed. Optimum contact action is obtained when a force of 4 to 10 grams pressure applied to the face of the moving contact will make the arm slip from the condition of reset to the point where the clamp projection begins to ride up on the wedge. The free travel can vary between 15° to
20°. The shaft has removable top and bottom jewel
bearings. The shaft rides between the bottom pin bearing and the upper pin bearing with the cylinder rotating in an air-gap formed by the electromagnet and the magnetic core. The stops are an integral part of the bridge.
The bridge is secured to the electromagnet and frame by two mounting screws. In addition to hold­ing the upper pin bearing, the bridge is used for mounting the adjustable stationary contact hous­ing. This stationary contact has .002 to .006 inch follow which is set at the factory by means of the adjusting screw. After the adjustment is made the screw is sealed in position with a material which flows around the threads and then solidifies. The stationary contact housing is held in position by a spring type clamp The spring adjuster is located on the underside of the bridge and is attached to the moving contact arm by a spiral spring. The spring adjuster is also held in place by a spring type clamp.
When contacts close, the electrical connection is made through the stationary contact housing clamp, to the moving contact, through the spiral spring and out to the spring adjuster clamp.
2.4 Directional Unit
The directional unit is an induction cylinder unit operating on the interaction between the polarizing circuit flux and the operating circuit flux.
Mechanically, the directional unit is composed of the same basic components as the distance unit: a die-cast aluminum frame, an electromagnet, a moving element assembly, and a molded bridge.
The electromagnet has two series-connected polarizing coils mounted diametrically opposite one another; two series-connected operating coils
3
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41-748.21C
* Sub 4 3531A58
Figure 3. Internal Schematic of Type KLF Relay in FT-41 Case
*Denotes Change
mounted diametrically opposite one another; two magnetic adjusting plugs; upper and lower adjusting plug clips, and two locating pins. The locating pins are used to accurately position the lower pin bearing, which is threaded into the bridge. The electromagnet is secured to the frame by four mounting screws.
The moving element assembly consists of a spiral spring, contact carrying mem­ber, and an aluminum cylinder assem­bled to a molded hub which holds the shaft. The shaft has removable top and bottom jewel bearings. The shaft rides between the bottom pin bearing and the upper pin bearing with the cylinder rotat­ing in an air gap formed by the electro­magnet and the magnetic core.
The bridge is secured to the electromag­net and frame by two mounting screws. In addition to holding the upper pin bear­ing, the bridge is used for mounting the adjustable stationary contact housing. The stationary contact housing is held in position by a spring-type clamp. The spring adjuster is located on the under­side of the bridge and is attached to the moving contact arm by a spiral spring. The spring adjuster is also held in place by a spring type clamp.
2.5 Undervoltage Unit
The voltage unit is an induction-cylinder unit.
Mechanically, the voltage unit is com­posed, like the directional unit, of four components: A die-cast aluminum frame, and electromagnet, a moving element assembly, and a molded bridge.
The electromagnet has two pairs of volt­age coils. Each pair of diametrically opposed coils is connected in series. In addition one pair is in series with an adjustable resistor. These sets are in
Sub 4 3533A29
parallel as shown in Figure 3. The adjustable resistor serves not only to shift the phase angle of the one flux with
Figure 4. KLF Time Delay Schematic
respect to the other to produce torque, but it also provides a pickup adjustment.
4
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41-748.21C
Sub 3 1487B21
Figure 5. External Schematic of Type KLF Relay
Otherwise the undervoltage unit is similar in its construction to the directional unit.
2.6 Solid State Time Delay Circuit
The telephone relay (x) is energized through a solid state time delay circuit (TD) as shown in Fig-
ure 3. The solid state time delay circuit shown in Figure 4 consists basically of an adjustable inte-
grating RC circuit with quick reset. The RC circuit is adjusted to provide the voltage level to trigger the SCR through a multi-layer silicon switch. The SCR in turn energizes the relay.
2.7 Indicating Contactor Switch Unit (ICS)
The dc indicating contactor switch is a small clap­per-type device. A magnetic armature, to which leaf-spring mounted contacts are attached, is attracted to the magnetic core upon energization of the switch. When the switch closes, the moving contacts bridge two stationary contacts, complet­ing the trip circuit. Also during this operation two fingers on the armature deflect a spring located on the front of the switch, which allows the operation indicator target to drop. The target is reset from the outside of the case by a push rod located at the bottom of the cover. The front spring, in addition to holding the target, provides restraint for the arma­ture and thus controls the pickup of the switch.
3. OPERATION
The relay is connected and applied to the system as shown if Figure 5. The directional unit closes its contacts for lagging VAR flow into the machine. Its zero torque line has been set at -13° from the
R-axis. Its primary function is to prevent operation of the relay during external faults. The impedance unit closes its contacts when, as a result of reduc­tion in excitation, the impedance of the machine as viewed from its terminals is less than a predeter­mined value. The operation of both impedance and directional units energize the time delay circuit which operates the X unit after .4 ±.05 seconds.
The operation of impedance, directional and X unit sounds an alarm, and the additional operation of the under voltage unit trips the machine. This time delay is to insure positive contact coordination under all possible operating conditions. During a seismic event which exposes the relay to a ZPA level of 5.7g, the operate time of the X unit may vary from .25 second to 1.25 seconds due to bounce induced in the Z and the D contacts. Dur­ing normal conditions, all contacts are open.
3.1 Principle of Distance Unit Operation
The distance unit is an induction cylinder unit hav­ing directional characteristics. Operation depends on the phase relationship between magnetic fluxes in the poles of the electromagnet.
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41-748.21C
Sub 2 185A331
Figure 7. Effect of Compensator Voltages
(ZC is positive)
One set of opposite poles, designated as the oper­ating poles are energized by voltage V1Tmodified
by a voltage derived from the long reach compen­sator TA. The other set of poles (polarizing) are
energized by the same voltage V1T except modi­fied by a voltage derived from the short reach com-
pensator TC. The flux in the polarizing pole is so adjusted that the unit closes its contacts whenever
flux in the operating set of poles leads the flux in the polarizing set.
The voltage V1T is equal to:
V120.5 V
+ 1.5 V
==
1T
23
1N
(1)V
As shown in Figure 5, one-half of V23, voltage is physically derived in the relay at midtap of a reac-
tor connected across voltage V23. Reach of the distance unit is determined by com-
pensators TA and TC as modified by auto-trans­former settings. Compensators TA and TC are designed so the their mutual impedances ZA and ZC have known and adjustable values as described below under “CHARACTERISTICS” and
SETTING CALCULATIONS”. The mutual imped- ance of a compensator is defined here as the ratio of secondary induced voltage to primary current and is equal to T. Each secondary compensator voltage is in series with the voltage V1T. Compen-
sator voltages are equal to 1.5 I1 ZAfor long reach compensator and 1.5 I1 ZC for short reach com­pensator, where I, is the relay current.
Figure 6 shows how the compensation voltages
1.5 I1 ZA and 1.5 I1 ZC influence the R-X circle. Notice that ZA independently determines the “long reach”, while ZC independently determines the “short reach”. With the reversing links in the nor-
mal position (+ZC) the circle includes the origin; with the opposite link position (-ZC) the circle misses the origin. The following paragraphs
explain this compensator action. Referring to Figure 5 notice that resistor RB and
capacitor CB cause the polarizing voltage to be shifted 90° in the leading direction. Thus, when the current is zero, polarizing voltage V
leads the
POL
operating voltage VOP by 90° and of sufficient magnitude to operate the relay. This means the
apparent impedance is along the X axis. Notice in Figure 7(b) that the ZA compensation reverses the
operating voltage phase position. The relay bal­ances when this voltage is zero. Note also this bal­ance is unaffected by the ZC compensation, since
this compensation merely increases the size of V
.
POL
Sub 2
185A182
Figure 6. R-X Diagram Characteristics with various
ZC - Compensator Settings.
6
For lagging current conditions notice Figure 7(c) illustrates how V
is reversed by the ZC com-
POL
pensation. In this case the ZA compensation has no effect of the balance point. This explains why
the reach point is fixed independently by ZC. Figure 7 assumes that ZC is positive (circle
includes origin). If the current coil link is reversed,
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41-748.21C
the compensation becomes +1.5 IZC. In Figure 7(b) this change would result in V
POL
being
reduced rather than increased by the compensa­tion. As the current increases V
will finally be
POL
reversed establishing restraining torque. Thus, the current need not reverse in order to obtain a “short reach” balance point. Instead the apparent imped­ance need only move towards the origin in the - X circle region to find the balance point. Therefore the circle does not include the origin with a reversed link position.
4. CHARACTERISTICS
The type KLF relay is available in one range.
4.1 Distance Unit
The distance unit can be set to have characteristic circles that pass through origin, include it, or exclude it, as shown in Figure 6.
The ZAand ZC values are determined by compen­sator settings and modified by auto-transformer
settings, S, L, and R. The impedance settings in ohms reach can be made for any value from 2.08 to 56 ohms for ZA, and from 0.79 ohm to 18 ohms
for ZC in steps of 3 percent. The taps are marked as follows:
T
-------------------------------------------------------------------------------------
2.4 3.16 4.35 5.93 8.3 11.5 15.8,,,,,,
-------------------------------------------------------------------------------------
0.0 0.91 1.27 1.82 2.55 3.64 5.1,,,,,, ,()
S
ASC
----------------------
123,,
---------------------------------------------------------------------------------
values between taps .03, .06, .06±
A
T
C
MAMC,()
age. This voltage is equal to 1.5 V1N voltage. The contacts can be adjusted to close over the range of
65 to 85 percent of normal system voltage. The dropout ratio of the unit is 98 percent or higher.
4.4 Trip Circuit
The main contacts will safely close 30 amperes at 250 volts dc and the seal-in contacts of the indicat­ing contactor switch will safely carry this current long enough to trip a circuit breaker.
4.5 Trip Circuit Constant
Indicating Contactor Switch (ICS)
0.2 ampere rating
1.0 ampere rating
2.0 ampere rating
8.5 ohm dc resistance .37 ohms dc resistance .1 ohm dc resistance
4.6 Burden
Current
5 amps, 60 Hz
T
& T
A
C
Settings VA
MAX.
MIN.
Phase AB
S
= SC VA
A
1 2 3
18.0
14.4
13.9
Rating Watts + Rated
125 250
18.6
3.8
POTENTIAL
120 VOLTS, 60 Hz
Angle
of LAG
°
2
31° 39°
dc Circuit
Angle
of LAG
°
77 51°
Phase BC
Angle VA of LAG
2.6
5.9
6.6
12° 38° 42°
3.9
7.8
4.2 Directional Unit
The KLF relay is designed for potential polarization with an internal phase shifter, so that maximum torque occurs when the operating current leads the polarizing voltage by approximately 13 degrees. The minimum pickup has been set by the spring tension to be approximately 1 volt and 5 amperes at maximum torque angle.
4.3 Undervoltage Unit
The undervoltage unit is designed to close its con­tacts when the voltage is lower than the set value. The undervoltage unit is energized with V1T-volt-
4.7 Thermal Ratings
Potential: 132 volts (L-L) continuous Current: 8 amperes continuous
200 amperes for 1 second
5. SETTING CALCULATIONS
5.1 General Setting Recommendations
The KLF relay may be applied as a single-zone device, or two relays may be used to provide two-zone protection. The single-zone setting may be fully offset (Zone 1) or may include the origin (Zone 2). The two-zone application would require a
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41-748.21C
Zone 1 KLF and a Zone 2 KLF, approximately equivalent to two-zone step-distance line protec­tion. A generalized external schematic, which is applicable to either Zone 1 or Zone 2 relays is shown in Figure 10. The recommended settings and relative advantages of these varioi4us config­urations are summarized on Table 1.
The single-zone and two-zone setting recommen­dations are modified when two or more machines are bussed at the machine terminals. The voltage and time delay considerations are treated in detail in other sections of this leaflet. The recommended settings are outlined in Table 2.
5.2 Zone 2 Setting Calculations (Distance Unit)
Set the distance unit to operate before the steady-state stability limit is exceeded. Also, to allow maximum output without an alarm, set the distance unit to allow the machine to operate at maximum hydrogen pressure and 0.95 per unit voltage (lowest voltage for which the capability curve machine cannot be realized without exceed­ing the steady-state stability limit, set the distance unit to operate before the steady-state limit is exceeded. Capability curves similar to Figure 8 are obtained from the generator manufacturer.
To determine the desired setting convert the capa­bility curve Figure 8 of the impedance curve Figure
Since the angle remains the same, the impedance plot conversion is:
Z1.4 33.6°, as shown in Figure 9.=
After plotting the steady-state stability limit and the machine capability curves on the R-X diagram, plot the relay circle between the stability limit and the capability curve. (Note in Figure 9 that the relay circle cannot be plotted within the 60# -VT = 0.95
curve, since the machine is beyond the steady-state stability limit for these conditions.) This plot defines the desired reach ZA and radius
R of the relay circle. Then use the following proce­dure to select tap settings.
Z
base
---------------------------------­kva()R
1000 kv()2R
C
V
ohms=
(2)
where
Z
= one per unit primary ohms/
base
as seen from the relay.
kv = rated phase-to-phase voltage
of the machine.
kVA = rated kVA of the machine. R
R
= the current transformer ratio.
C
= the potential transformer ratio.
V
9 by calculating , where VT is the per unit
|VT2|
--------------------­KVA()
C
terminal voltage and (KVA)c is the per unit output. The angle of each point on the impedance curve
(from the horizontal) is the same angle as the cor­responding point on the capability curve.
For example, from Figure 8, an output of 0.6 per unit KW on 30# hydrogen pressure curve is -0.4 per unit reactive KVA. Therefore,
KVA()
C
0.6()20.4–()
+=
2
= 0.715 per unit
0.4
and,
θTan 1

33.6°==
----------

0.6
Converting to the impedance curve:
2
V
Z
T
==
--------------------­KVA()
C
1.0
-------------
0.715
2
= 1.4 per unit
The actual settings, ZA and ZC, are:
ZA=(ZA per unit) x (Z ZC=(ZC per unit) x (Z
= (ZR - ZA) x (Z
base
) (3)
base
)
base
) (4)
Where R = radius of circle in per unit.
The tap-plate settings are made according
to equations:
ZAor Z
()
C
=
TS
-------------­1 M±
(5)
where:
T = compensator tap value. S = auto-transformer primary tap value. M = auto-transformer secondary tap
value. (M is a per unit value determined by taking the sum
of the values between the L and the R leads. The sign is positive when L is above R and acts to
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41-748.21C
2
lower the Z setting. The sign is negative when R is above L and acts to raise the Z setting).
The following procedure should be followed to obtain an optimum setting of the relay:
1. Select the lowest tap S which give a prod-
uct of 18.6SA greater than desired ZA and a prod­uct of 6SC greater than desired Z
C
2. Select a value of M that will most nearly
make it equal to:
TS
M
------- ­Z
1.=
If the sign is negative, then the M taps are con­nected with the R lead above the L lead to raise the setting.
5.3 Sample Calculations
Assume that a KLF relay is to be applied to the fol­lowing machine:
3-phase, 60 hertz, 3600 rpm, 18 kV, rated at 0.9 pf, 183,500 KVA at 45#H2.
RC= 1400/1 RV= 150/1
Step 3:
TAS
-------------­Z
A
M
A
1
15.8 2×
-------------------
27.6
1– 1.145 1 +.145=====
Set M = +.15. Place R lead in 0, L lead in upper .06. The relay setting is now:
ActualZ
TAS
--------------
A
1 M±
A
15.8 2×
-------------------
1 0.15+
31.6
----------
1.15
27.5== ==
This is 99.7% of the desired setting. To set ZC= 3.29 ohms:
Step 1: The lowest tap SC for 6SC greater than
3.29 is SC = 1. Set SC = 1
Step 2: TC nearest to
329,
----------- -
1
3.29 is 3.64=
Set TC in 3.64 tap.
Step 3:
M
TCS
C
---------------
C
Z
C
1
3.64 1×
-------------------
3.29
1 1.107 1 +.107== ==
If the recommended setting from Figure 9 is used: ZA per unit = 1.68
ZC per unit = 2R - ZA = 2 x 0.94 - 1.68 = 0.20 (The relay circle in Figure 9 was obtained by trial
and error using a compass to get the desired radius and offset.)
(1)
2
× 1400×
16.48== =
se
1000 kv()
----------------------------- -
()R
kva
V
R
1000 18()
c
------------------------------------------------- -
183 500 150×,
(2)
Z
Z
A
per unit()Z
A
base
(1.68 ) 16.48()27.6===
(3)
Z
Z
C
per unit()Z
C
()0.20()16.45()3.29Ω===
base
To set ZA= 27.6 Step 1: The lowest tap SA for 18.6 SA greater
than ZA = 27.6 is 2. Set SA in tap 2.
Step 2: TA nearest to = 13.8 is TA= 15.8
27.6
----------
2
Set TA in 15.8 tap
Hence, the nearest MC value is + .12. Now set R lead in 0.03 tap and L lead in the upper .06 tap.
(Since MC has plus sign lead L must be over R.)
T
S
Then, , or
Z
C
C
----------------------
1M
+()
3.64 1×
C
-------------------
1 0.12+
C
3.25===
98.8% of the desired value.
5.4 Undervoltage Unit
A. The undervoltage unit is usually set to a value
corresponding to the minimum safe system volt­age for stability. This voltage depends on many factors, but is usually between 70 and 80 percent of normal system voltage. The undervoltage unit is set at the factory for 77% of normal system voltage, or 92 V
(equivalent to 80 volts on the
L-L
undervoltage unit). In cases where each genera­tor is equipped with its own transformer (unit connected system) the standard factory setting is usually satisfactory for the undervoltage unit.
B. In applications where multiple units are con-
nected to the same bus, loss of field of one unit may not depress the bus voltage to the point where the undervoltage unit will operate if it has the standard setting. The following recommenda-
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41-748.21C
TABLE 1
RECOMMENDED SETTINGS FOR KLF RELAY
ZONE 1 (ALONE) ZONE 2 (ALONE) BOTH ZONE 1 AND 2
IMPEDANCE SETTING
VOLTAGE SETTING
TD-1
TD-2
ADVANTAGES
See Figure 11 See Figure 12 See Figures 11 & 12
(a) Contact shorted or (b) Set at 80% for
security
1/4 to 1 sec
(1 sec preferred)
Not required for (a) above. For (b) above use 1 Min.
Less sensitive to stable system swings
1) More sensitive to
2) Can operate on
3) Provide alarm
80%
1/4 to 1 sec
(1 sec preferred)
1 Min.
LOF condition
partial LOF
features for manual operation
Zone 1 voltage contact shorted with Zone 2 set at 80%
Zone 1 timer = 1/4 sec Zone 2 timer = 1 sec
1 Min
(1) Same as (1), (2)
and (3) at left.
(2) Provides back-up
protection
SPECIAL SETTINGS FOR MULTI MACHINES BUSSED AT MACHINE TERMINALS
IMPEDANCE SETTING
VOLTAGE SETTING
TD-1
TD-2
TABLE 2
ZONE 1 (ALONE) ZONE 2 (ALONE) BOTH ZONE 1 AND 2
See Figure 11 See Figure 12 See Figures 11 & 12
(a) Contact shorted or (b) Set at 87% for
security
1/4 to 1 sec
(1 sec preferred)
Not required for
(a) above. For (b) above use 10 sec
for cond. cooled, 25 sec for conv. cooled
10 sec for cond. cooled. 25 sec for conv. cooled.
87%
1/4 to 1 sec
(1 sec preferred)
Zone 1 voltage contact shorted with Zone 2 set at 87%
Zone 1 timer = 1/4 sec Zone 2 timer = 1 sec
10 sec for cond. cooled. 25 sec for conv. cooled.
10
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41-748.21C
tions should be considered:
1. For cross-compound turbine generator appli­cations, the dropout voltage (i.e., the voltage at which the back contact of the undervolt­age unit closes) of the undervoltage unit should be set for 87% of normal voltage (equivalent to 90 volts on the undervoltage unit).
2. For waterwheel generator applications, with multiple machine tied to a common bus, the dropout voltage of the undervoltage unit should be set at 87%.
3. For all applications where the alarm function is not to be used the undervoltage unit con­tact should be jumped (shorted).
4. For industrial applications, with two or more generators on the same bus, the undervolt­age unit contact should be jumped (shorted) and the alarm circuit not used.
5. For small Synchronous condenser and large motor applications, the undervoltage unit contact should, in general, be jumped (shorted), and the alarm circuit not used. In special cases the machine may be treated as in 2, above, where knowledge exists of expected undervoltage level.
6. For gas turbine units, with high generator impedance, the undervoltage unit may not operate. For these applications the under­voltage contacts should be short circuited.
C. The desired undervoltage unit setting is com-
puted by: Setting = VIT = 1.5 V
IN
where VINis phase-to-neutral voltage.
NOTE: An electrical check of this particular
setting is outlined in this instruction leaflet, under the heading “Acceptance Check”.
5.5 Time Delay Considerations
It may be conservatively stated that the rotor struc­ture and stator heating, as a result of a shorted field can be tolerated for 10 seconds on a conduc­tor-cooled machine and 25 seconds for a conven­tional machine. This time may be as low as 5 seconds for an open field (as opposed to a field closed through a field discharge resistor or an
exciter armature) and as high as one minute where the concern is protection of an adjacent tandem compound unit against partial loss-of-excitation in the faulted machine.
In view of the above considerations, it is often desirable to use an external timer in conjunction with the KLF Relay. The following examples are applications where an external timer would be desirable:
1. Cross-compound units, with undervoltage unit setting of 90 volts, should use an exter­nal timer to assure tripping before thermal damage can result. The timer is energized at the alarm output and should be set for 10 seconds for a cross-compound conductor cooled machine. For a conventionally cooled cross-compound machine, the external timer should be set for 25 seconds.
As an alternative to this, the KLF with shorted undervoltage contacts may be applied and the alarm feature not used. With this arrangement, tripping takes place after the 0.4 second time delay provided by the X unit in KLF relay.
2. Machines connected to a common high volt­age bus may be protected against loss of voltage due to loss-of-excitation in an adja­cent machine by using a one minute timer driven by the alarm output of the loss-of-field relay.
3. In some critical applications 2 zone loss-offield protection may be desirable. In this case, the Zone 1 KLF impedance circle should be small and fully offset in the nega­tive reactance region. The long-reach should be set equal to synchronous reactance, Xd. The short-reach should be set equal to one-half transient reactance, XD1/2. The trip circuit should trip directly, with no time delay. The alarm circuit should operate a timer which may be set from 0.4 - 1.0 seconds, depending on user preference. If the condi­tion persists, this timer permits tripping.
The second-zone KLF may be set with a larger impedance characteristic and will detect partial loss-of-field conditions. A typi­cal setting would be to just allow the machine to operate at maximum hydrogen pressure
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41-748.21C
and 9.5 per unit voltage. If a low voltage con­dition occurs, it is recommended that tripping be accomplished through a timer set for 0.6 second. Added to the X unit operate time of
0.4 second, this gives an overall time of 1.0 second. If the voltage is maintained, then the alarm circuit should start a “last-ditch” timer. This timer may be set anywhere from 10 sec­onds to one minute depending on machine type and user preference.
5.6 Performance During Reduced Frequency
During major system break-ups, it is possible that the generators may be called upon to operate at reduced frequency for long periods of time. During this condition the loss-of-field relay should be secure and not over-trip for load conditions. The KLF relay has a favorable characteristic during this condition, since its tripping characteristic becomes more secure during reduced frequencies, as shown in Figure 13.
6. SETTING THE RELAY
The type KLF relay requires a setting for each of the two compensators TA and TC, for each of the
two auto-transformers, primaries SA and SC, and for the undervoltage unit.
6.1 Compensator (TA and TC)
Each set of compensator taps terminates in inserts which are grouped on a socket and form approxi­mately three quarters of a circle around a center insert which is the common connection for all the taps. Electrical connections between common insert and tap inserts are made with a link that is held in place with two connectors screws, one in the common and one in the tap.
A compensator tap setting is made by loosening the connector screw in the center. Remove the connector screw in the tap end of the link, swing the link around until it is in position over the insert for the desired tap setting, replace the connector screw to bind the link to this insert, and retighten the connector screw in the center. Since the link and connector screws carry operating current, be sure that the screws are turned to bind snugly.
Compensator TC requires an additional setting for including or excluding the origin of R-X diagram
from the distance unit characteristic. If the desired characteristic is similar to that shown on Figure 6b, the links should be set vertically in the + TC arrow
direction. If a characteristic similar to that shown in Figure 6c is desired, set links horizontally in the ­TC arrow direction.
6.2 Auto-Transformer Primary (SA and SC)
Primary tap connections are made through a single lead for each transformer. The lead comes out of the tap plate through a small hole located just below the taps and is held in place on the proper tap by a connector screw.
An S setting is made by removing the connector screw, placing the connector in position over the insert of the desired setting, replacing and tighten­ing the connector screw. The connector should never make electrical contact with more than one tap at a time.
6.3 Auto-Transformer Secondary (MA and MC)
Secondary tap connections are made through two leads identified as L and R for each transformer. These leads comes out of the tap plate each through a small hole, one on each side of the verti­cal row of M tap inserts. The lead connectors are held in place on the proper tap by connector screws.
Values for which an M setting can be made are from -.15 to +.15 in steps of .03. The value of a setting is the sum of the numbers that are crossed when going from the R lead position to the L lead position. The sign of the M value is determined by which lead is in the higher position on the tap plate. The sign is positive (+) if the L lead is higher and negative (-) if the R lead is higher.
Z M L Lead R Lead
0.87 TS
0.89 TS
0.92 TS
0.94 TS
0.97 TS TS
1.03 TS
1.06 TS
1.1 TS
1.14 TS
1.18 TS
+.15 +.12 +.09 +.06 +.03
0
-.03
-.06
-.09
-.12
-.15
Upper .06 Upper .06 Lower .06 Upper .06
.03
0 0
Lower .06
0
.03
0
0
.03
0
Lower .06
0 0
.03 Upper .06 Lower .06 Upper .06 Upper .06
An M setting may be made in the following man­ner: Remove the connector screws so that the L and R leads are free. Determine from the following table the desired M value and tap positions. Nei­ther lead connector should make electrical contact with more than one tap at a time.
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41-748.21C
6.4 Undervoltage Unit
The voltage unit is calibrated to close its contact when the applied voltage is reduced to 80 volts. The voltage unit can be set to close its contacts from 70 volts to 90 volts by adjusting the resistor located next to the directional unit (to the left of the upper operating unit). The spiral spring is not dis­turbed when making any setting other than the cal­ibrated setting of 80 volts.
The undervoltage unit range of 70 to 90 volts is equivalent to 80 to 104 V
(or 67% to 87% nor-
L-L
mal system voltage). This is because the voltage on the unit is equal to 1.5 times V
L-N
.
6.5 Directional Setting
There is no setting to be made on the directional unit.
6.6 Indicating Contactor Switch (ICS)
No setting is required on the ICS.
7. INSTALLATION
The relays should be mounted on switchboard panels or their equivalent in a location free from dirt, moisture, excessive vibration, and heat. Mount the relay vertically by means of the four mounting holes on the flange for semi-flush mount­ing or by means of the rear mounting stud or studs for projection mounting. Either a mounting stud or the mounting screws may be utilized for grounding the relay. The electrical connections may be made directly to the terminals by means of screws for steel panel mounting of the terminal studs fur­nished with the relay for thick panel mounting. The terminal studs may be easily removed or inserted by locking two nuts on the stud and then turning the proper nut with a wrench.
For detailed FT Case information refer to I.L. 41-076.
8. ADJUSTMENTS AND MAINTENANCE
The proper adjustments to insure correct operation of this relay have been made at the factory. Upon receipt of the relay, no customer adjustments, other than those covered under “SETTINGS,” should be required.
8.1 Performance Check
The following check is recommended to insure that the relay is in proper working order: Relay should be energized for at least one hour.
A. Distance Unit (Z)
1. Connect the relay as shown in Figure 14 with the switch in position 2 and the trip circuit deenergized.
2. Make the following tap settings: TA= 11.5 TC= 2.55
SA=2 SC=1 MA= -.03 MC= -.09
TC link in middle block should be set for +T direction.
This setting corresponds to ZA = 23.7, ZC = 2.80 Adjust the phase shifter for 90° current lagging
the voltage.
3. With the terminal voltage at 80 volts, increase current until contacts just close. This current should be within ±3% of 2.25 amps (2.32 - 2.18 amps). This value corre­sponds to 1.5 ZA setting since the voltage as applied to terminals 4 and 5 is equivalent to
1.5 VIN voltage, or
V
Z
--------- -
A
I
1N
1
80
1
× 23.7== =
------ -
--------- -
1.5
2.25
4. Adjust phase shifter for 90° current leading the voltage.
5. With the terminal voltage at 80 volts increase current until contacts just close. This current should be within ±3% of 19.0 amps. (19.6 -
18.4 amps.) This value corresponds 1.5Z setting for the same reason as explained above.
5. Contact Gap The gap between the stationary contact and
moving contact with the relay in deenergized position should be approximately.040”.
B. Directional Unit Circuit (D)
1. Connect the relay as shown in Figure 14 with the switch in position 1 and the trip circuit deenergized.
2. With a terminal voltage of 1 volt and 5 amperes applied, turn the phase shifter to 13° (current leads voltage). The contacts should be closed. This is the maximum torque position.
3. Raise the voltage to 120 volts and vary the phase shifter to obtain the two angles where
C
C
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41-748.21C
the moving contact just makes with the left hand contact. These two angles (where torque reverses) should be where the current leads the voltage by 283° and 103°, ± 4°.
4. Contact Gap The gap between the stationary contact and
moving contact with the relay in deenergized position should be approximately.020”.
C. Undervoltage Circuit
1. Connect the relay as shown in Figure 14 with switch in position 2 and the trip circuit deen­ergized.
2. Decrease the voltage until the contacts close to the left. This value should be 80 ± 3% volts.
D. Reactor Check Apply 120 volts ac across terminals 6 and 7. Mea-
sure voltage from terminal 6 to 4 and 7 to 4. These voltages should be equal to each other within ± 1volt.
E. Solid State Time Delay Circuit
Then release the contacts and observe that they open positively.
All contacts should be checked and cleaned if nec­essary. A contact burnisher Number 182A836H01 is recommended for this purpose. The use of abra­sive material for cleaning contacts is not recom­mended, because of the danger of embedding small particles in the face of the soft silver and thus impairing the contact.
8.3 Repair Calibration
Relay should be energized for at least one hour. A. Auto-transformer check
Auto-transformers may be checked for turns ratio and polarity by applying ac voltage to terminals 4 and 5 and following the procedure below.
1. Set SA and SC on tap number 3. Set the “R” leads of MA and MC all on 0.0 and discon­nect the “L” leads. Adjust the voltage for 90 volts. Measure voltage from terminal 5 to the tap #1 of SA. It should be 30 voltages (± 1). From terminal 5 to tap #2 of SA should be 60 volts. The same procedure should be fol­lowed for taps #1 and #2 of SC.
Block the contacts of the Z unit closed. Apply 125 volts dc with positive at terminal 10 and negative at terminal 3. Manually close the contacts of the D unit. Using oscilloscope measure the time delay by observing the voltage block waveform between the relay terminal 3 (-) and terminal 1 (+). Operate time should be 0.4 ± .05 second.
F. Indicating Contactor Switch (ICS) Close the main relay contacts and pass sufficient
dc current through the trip circuit to close the con­tacts of the ICS. This value of current should not be greater than the particular ICS nameplate rat­ing. The indicator target should drop freely.
Repeat above except pass 85% of ICS nameplate rating current. Contacts should not pickup and tar­get should not drop.
8.2 Routine Maintenance
All relays should be inspected periodically. They should receive a “Performance Check” at least once every year or at such other time intervals as may be dictated by experience to be suitable to the particular application. A minimum suggest check on the relay system is to close the contacts manu­ally so that the breaker trips and the target drops.
2. Set SA and SC on 1 and adjust the voltage at the relay terminals for 100 volts. Measure voltage drop from terminals 5 to each of the MA and MC taps. This voltage should be equal to 100 (± 1) plus the sum of values between R and tap being measured. Exam­ple 100 (1 + .03 +.06) = 109 volts
Transformers that have an output different from nominal by more than 1.0 volt probably have been damaged and should be replaced.
B. Distance Unit (Middle Unit) Calibration
Make the following tap plate settings. TA = 15.8; TC = 5.1 SA = SC = 1 Make MA= MC = -.15 settings: “L” lead should be connected to the “O” insert. “R” lead should be connected to the upper “.06”
insert. (-.03-.06 - .06 = -.15 between L & R) For the most accurate calibration preheat relay
for at least an hour by energizing terminals 5, 6,
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41-748.21C
& 7 with 120 volts, 3 phase. The links in the middle tap block should be set
for the +TC direction.
1. Contact Gap Adjustment The spring type pressure clamp holding the stationary contact in position should not be loosened to make the necessary gap adjust­ments.
With moving contact in the opened position, i.e., against right stop on bridge, screw in stationary contact until both contacts just make (use neon light for indication). Then screw the stationary contact away from the moving contact 1 of .040”.
1
turn for a contact gap
/
3
2. Sensitivity Adjustment Using the connections of Figure 14 apply 10 volts ac 90° lagging, to terminals 4 and 5 pass .420 amperes through current circuit (terminals 9 and 8). The spiral spring is to be adjusted such that the contacts will just close. Deenergize the relay. The moving contact should return to open position against the right hand stop.
C. Impedance characteristic Check
1. Maximum Torque Angle Adjust resistor RB (mounted on the back of
the relay) to measure 8800 ohms. Applying 100 volts ac to terminals 5 and 4 and pass­ing 5.2 amperes, through the current circuit turn the phase shifter until the moving con­tact opens. Turn the phase shifter back (few degrees) until contacts close. Note degrees. Continue to turn the phase shifter until con­tact closes again. Note degrees. The maxi­mum torque angle should be (± 3°) computed as follows:
Degrees to Close Contacts at Left +
Degrees to Close Contacts at Right
-------------------------------------------------------------------------------------
2
Adjust resistor RB until the correct maxi­mum-torque angle is obtained.
2. Impedance Check a. Adjust voltage to be 90 volts.
For current lagging 90° the impedance unit should close its contacts at 3.12 –
3.35 amp. Reverse current leads, the impedance
unit should close its contacts at 9.7 – 10.3 amperes.
b. Reverse the links in the middle tap block
to -TC position. Apply current of 10 amps. The contacts should stay open. Reverse current leads to original position. The con­tacts should open when current is increased above 9.7 – 10.3 amperes.
Set links back to +TC position. Change S
A
and SC to setting “2”. Keeping voltage at 90 volts, 90° lagging, check pick-up cur­rent. It should be 1.56 – 1.68 amperes. Now set the phase shifter so that voltage leads the current by 90°. Impedance unit should trip now at 4.85 – 5.15 amperes.
c. Set TA = 11.5, TC = 2.55, SA = 2, SC = 1,
MA = -.03 MC = -.09. Set voltage at 90 volts leading the current by 90°. Imped­ance unit should trip at 2.61 – 2.45 amp. Reverse current leads. Pickup should be
20.8 –22.1 amp. Change SA, SC = 3. Check pickup. It
should be 6.95 – 7.35 amps. Reverse cur­rent leads. Pick-up should now be 1.74 –
1.63 amps.
D. Directional Unit (Top Unit)
1. Contact Gap Adjustment The spring type pressure clamp holding the
stationary contact in position should not be loosened to make the necessary gap adjust­ments.
With moving contact in the open position, i.e., against right stop bridge, screw in sta­tionary contact until both contacts just make. Then screw the stationary contact away from
90°=
the moving contact 3/4 of one turn for a con­tact gap of .022”.
2. Sensitivity Adjustment With reactor X having its core screwed out
by about 1/8 inch apply 1.00 volt to terminals 6 and 7. Observing polarities as per sche­matic, and 5 amperes current leading the voltage by 13°, the spiral spring is to be
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41-748.21C
adjusted such that the contacts will just close. The adjustment of the spring is accomplished by rotating the spring adjuster which is located on the underside of the bridge. The spring adjuster has a notched periphery so that a tool may be used to rotate it. The spring type clamp holding the spring adjuster should not be loosened prior to rotating the spring adjuster.
3. Plug adjustment for Reversing of Spurious Torques
a. Set TC = 0.0. Connect a heavy current
lead from TA center link to terminal 8. b. Short circuit terminals 6 and 7. c. Screw in both plugs as far as possible
prior to starting the adjustment. d. Apply 80 amps only momentarily, and the
directional unit need not be cooled during
initial rough adjustment. But, the direc-
tional unit should be cool when final
adjustment is made. e. When relay contact closes to the left,
screw out the right hand plug until spuri-
ous torque is reversed. f. When plug adjustment is completed check
to see that there is no closing torque when
relay is energized with 40 amps and volt-
age terminals 6 and 7 short-circuited.
4. Maximum Torque Angle Check With 120 volts and 5 amperes applied, vary
the phase shifter to obtain the two angles where the moving contacts just close. These two angles (where torque reverses) should be where the current leads the voltage by 283° ±4 and 103° ± 1. Readjust the reactor Xd if necessary.
E. Undervoltage Unit (Lower Unit)
NOTE: The moving contact is in closed posi-
tion to the left when deenergized.
1. Contact Gap Adjustments
the moving contact (use neon light for indica­tion) and then continue for one more com­plete turn.
b. R.H. (Normally Open) Contact Adjustment
With moving contact arm against the left hand stationary contact, screw the right hand stationary contact until it just touches the moving contact. Then back the right hand contact out two-thirds of one turn to give
0.020 inch contact gap.
2. Sensitivity Adjustment a. Apply voltage to terminals 4 and 5. With the
adjustable resistor, which is located at the upper left hand corner, set for maximum resistance (2500 ohms) adjust the spring so that contacts make (to the left) at 70 volts. The contacts should open when unit is ener­gized with 71 or more volts.
b. Relay is shipped with 80 volts setting. This is
accomplished by lowering resistance value until contacts make at 80 volts and open when unit is energized with 81 or more volts. The spring should not be used for this set­ting.
F. Solid State Time Delay Circuit
Refer to Figure 4 for the following test. a. Connect a jumper between the “D” contacts
(top unit) and connect a switch between the D-contact and relay terminal 10.
b. Connect a scope probe, common and exter-
nal trigger to relay terminals 1, 3 and contact “D” respectively.
c. Connect a rated dc power supply between
relay terminals 10 (+) and 3 (-).
d. Turn on the dc power supply and then turn
on the switch. The voltage at terminal 1 should jump from 0 to the rated voltage after a time delay of 0.4± 10% seconds. A trimpot on the PC board can be adjusted to obtain the desired time delay from 0.3 to 0.5 sec­onds.
a. L.H. (Normally Closed) Contact Adjustment
With the moving contact arm in the closed position, against left hand side of bridge, screw the left-hand contact in to just touch
16
G. Indicating Contactor Switch (ICS) Initially adjust unit on pedestal so that armature
fingers do not touch the yoke in the reset position. This can be done by loosening the mounting screw
Page 17
41-748.21C
in the molded pedestal and moving the ICS in the downward direction.
1. Contact Wipe. Adjust the stationary contacts so that both stationary contacts make with the moving contacts simultaneously and wipe 1/64” to 3/64” when the armature is against the core.
2. Target. Manually raise the moving contacts and check to see that the target drops at the same time as the contacts make or up to 1/16” ahead. The cover may be removed and the tab holding the target reformed slightly if necessary. However, care should be exercised so that the target will not drop with a slight jar.
3. Pickup. Unit should pickup at 98% of rating and not pickup at 85% of rating. If necessary the cover leaf springs may be adjusted. To lower the pickup current use a tweezer or similar tool and squeeze each leaf spring approximately equal by applying the tweezer between the leaf spring and the front surface of the cover at the bottom of the lower win­dow.
If the pickup is low, the front cover must be removed and the leaf springs bent outward equally.
2. Disconnect the L-leads of sections MA and M
C
3. Pass 10 amperes ac current in terminal 9 and out of terminal 8.
4. Measure the compensator voltage with an accurate high resistance voltmeter (5000 ohms/volt).
5. Compensator A-voltage should be checked between lead L
and terminal 5.
A
For TA = 15.8 the voltage measured should be 23.7 volts (±3%).
6. Compensator C voltage should be checked between lead LC and the fixed terminal on the resistor which is mounted in the rear.
For TC = 5.1, the voltage should be 76.5 volts (±3%).
7. For all other taps the compensator voltage is
1.5IT (±3%). Where I = relay current
T = tap setting
H. Compensator Check Accuracy of the mutual impedance T of the com-
pensators is set within very close tolerances at fac­tory and should not change under normal conditions. The mutual impedance of the compen­sators can be checked with accurate instruments by the procedure outlined below:
1. Set TA on the 15.8 tap TC on the 5.1 tap
9. RENEWAL PARTS
Repair work can be done and the relay recertified most satisfactorily at the factory. However, inter­changeable parts can be furnished to the custom­ers who are equipped for doing repair work. When ordering parts, always give the complete name­plate data. Note that replacement parts are not “certified” and repair work done outside the factory can not be certified by ABB.
17
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41-748.21C
18
Sub 2 185A183
Figure 8. Typical Machine Capability Curves
Page 19
41-748.21C
Sub 2 185A184
Figure 9. Typical Machine Capability Curves and Sample KLF Relay Setting
19
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41-748.21C
3
Figure 10. Generalized External Schematic
Su 35
20
Sub 1 3491A03
Figure 11. Zone 1 Impedance Characteristic
Page 21
+X
-X
R
DIRECTIONAL ELEMENT STEADY STATE STABILITY LIMIT ZONE 2 RELAY
MACHINE CAPABILITY CURVE MEL
(MAX. H2 PRESSURE)
Figure 12. Zone 2 Impedance Characteristic
41-748.21C
Sub 1 3491A03
NOTE - FOR 50 HZ RELAY ALL FREQUENCY
VALUES SHOULD BE MULTIPLIED BY
A FACTOR OF 0.8333
X
50 HERTZ
55 HERTZ
R
Figure 13. KLF Frequency Response for Impedance Unit
60 HERTZ
68 HERTZ
Sub 2 3491A08
21
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41-748.21C
22
Sub 2 1487B22
Figure 14. Diagram of Test Connections for KLF Relay
Page 23
41-748.21C
Figure 15. Outline and Drilling Plan for the Type KLF Relay in the FT-41 Case
Sub 4 3519A70
23
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