Technical Bulletin

M Series

Modular Rack Mount Protection Relay Cases Features

Suitable for 19 inch, 4U high rack mounting Suitable for flush panel mounting M4 screw terminations Stud termination possible Range of ring lugs available Simple screw (M4) mounting from front of panel (Supplied) Semi-projection mounting kits available 4U, 6U, 8U high 19 rack mounting frames available 4U, 6U, 8U high 19 flush mounting frames available Size 2 with 28 terminals Size 4 with 28 or 56 terminals Size 2, 4 & 8 blanking plates CT shorting switches available Sealable front cover IP5X category 2 dust protected and IP4X for solid ingress to IEC60529. Rugged metal construction with black powder coat matt finish

Application
The M Series has been specifically designed to meet the demanding & varied requirements for protection relay applications in power utility sub-station environments. The standard 4U high 19inch rack mounting modular configuration simplifies panel design & installation. Mounting points & overall panel dimensions meet international standards such that the cases may be interchanged with other similar types available on the market. Optional CT shorting switches, blanking plates & 19 rack mount frames are also available. Blanking plates may be specially fabricated with cut outs & labeling to suit control switches, fuses, pilot lamps etc. The M Series case range supercedes the previous D & E Series models.

Description

Made in Australia

The M Series range of protection relay enclosures has been designed with flexibility in mind. Only three versions are required to meet a wide range of applications. Both the size 2 & size 4 case are suitable for either flush panel mounting or 19 inch 4U high rack mounting. The design utilizes a draw out chassis for ease of installation & maintenance. M4 screw terminals are provided with optional CT shorting switches. The M Series cases are of metal construction for durability & screening from radiated electrical noise. Select from three versions as follows:

2M28-S 4M28-S 4M56-S

Size 2 Size 4 Size 4

28 terminals 28 terminals 56 terminals

1/8 width 4U high 1/4 width 4U high 1/4 width 4U high

Cases of different sizes may be mixed on the same rack up to the full width (19 inch) maximum. e.g. 4 x size 2 + 2 x size 4 would fill one 4U high 19 inch rack row. Alternatively the cases may be flush or projection mounted in either orientation (Vertical or horizontal) as necessitated by the panel design.

Reduced Case Length Versions

From August 2005 the M Series case range was reduced in length by 18mm to 217mm. This is indicated in the product case drawings by the -S code (For example 2M28-S indicates a short case version). Refer to the specific product Technical Bulletins to determine the case length. When purchasing replacement modules it is important to check the case length required. This can be done by quoting the old module serial number to the factory.

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2M28 Series Case Details

290-406-151 290-407-153 205-103-003 Relay mounting screw kit (4 screws) M4 terminal screw kit with captive lock washers (14 pieces per kit) Earth screw (1 piece) Supplied Supplied Supplied

Size 2 draw out case with 28 screw terminals Suitable for flush panel & rack mounting

2 Holes at

3.7

1 3 5 7 9 11 13 15 17 19 21 23 25 27

2 4 6 8 10 12 14 16 18 20 22 24 26 28

217 235 2M28 Long case version for some models

Size 2M28-S draw out case Drawing units: mm

Push button position indicative only Not supplied unless specified

Suits flush panel mounting & 4U high 19 inch rack frame

15

Figure 1: 2M28 Case dimensions

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4M28 Series Case Details

290-406-151 290-407-154 205-103-003 Relay mounting screw kit (4 screws) M4 terminal screw kit with captive lock washers (14 pieces per kit) Earth screw (1 piece) Supplied Supplied Supplied

Size 4 draw out case with 28 screw terminals Suitable for flush panel & rack mounting

4 Holes at 3.7 1 3 5 7 9 11 13 15 17 19 21 23 25 27 2 4 6 8 10 12 14 16 18 20 22 24 26 28

217 235 4M28 Long case version for some models

Size 4M28-S draw out case Drawing units: mm

Push button position indicative only Not supplied unless specified

Suits flush panel mounting & 4U high 19 inch rack frame

15

Figure 2: 4M28 Case dimensions

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4M56 Series Case Details

290-406-151 290-407-155 205-103-003 Relay mounting screw kit (4 screws) M4 terminal screw kit with captive lock washers (14 pieces per kit) Earth screw (1 piece) Supplied Supplied Supplied

Size 4 draw out case with 56 screw terminals Suitable for flush panel & rack mounting

4 Holes at 3.7

1 3 5 7 9 11 13 15 17 19 21 23 25 27

30 32 34 36 38 40 42 44 46 48 50 52 54 56

217 235 4M56 Long case version for some models

Size 4M56-S draw out case Drawing units: mm

Push button position indicative only Not supplied unless specified

Suits flush panel mounting & 4U high 19 inch rack frame

15

Figure 3: 4M56 Case dimensions

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Technical Data
AUTOMATIC CT SHORTING To avoid open circuiting external CTs when a relay module is draw out from the case, CT shorting switches are fitted. These have the effect of shorting the adjacent odd & even terminal pair before the connection to the relay module is broken during the draw out operation. CURRENT RATINGS CT terminals: Other terminals: VOLTAGE RATINGS All circuits & terminals: 20A 400A 10A 200A continuous 1s continuous 1s

NORMAL SERVICE CONDITION

CT circuits routed through relay module CT(s)

600V AC continuous 350V DC continuous

AUXILIARY INSULATION WITHSTAND In accordance IEC 255-5: 2KV RMS between all terminals & all terminals & frame. 1.2/50 5KV impulse between all terminals & all terminals & frame. IP RATING IP5X category 2 dust protected and IP4X for solid ingress to IEC60529.

Relay module fully inserted Circuit isolating bar engaged Equipment side CT circuits routed through relay module CT

CASE EARTH CONNECTIONS Case bonding to earth is critical for electrical ensure safety & EMI / EMC standards compliance. An electrical connection from earth to the case is achieved using a dedicated earth terminal located at the rear top of the case. A hex screw suitable for ring lugs & a star washer is provided as depicted in figure 5.

REMOVAL OF RELAY MODULE

Automatic shorting of CT(s)
CT shorting bar engaged

Circuit isolating bar disengaged

Figure 5: Case earth terminal detail Some electronic relays are also fitted with an additional earth stud which is mounted on an earth bracket that is fitted between the case earth & terminal 2. This is useful for marshalling multiple earth connections such as arc fault sensor screen cable earths & is depicted in figure 6.

Relay module CT terminals remain in touch until automatic CT shorting engaged (Make before break circuit function)

Heavy duty CT terminals & shorting switches may be specified between any adjacent odd & even terminal pair. Figure 4: CT Shorting switch function

Figure 6: Earth stud detail

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Termination Ring Lugs

TERMINATION RING LUGS Reliable electrical connection to M Series cases is achieved using M4 screws & ring lug terminals as depicted in figure 7. DAVICO RING LUGS WITH 90 DEGREE PRE-FORM Davico ring lug terminals are supplied with a 90 degree pre-bend as depicted in figure 9 so that they fit the M Series terminal block without pre-forming. Termination of wires ranging in size from 2 2 0.25mm up to 2.6mm is possible using an appropriate ring lug terminal selected from Table 1. These ring lugs are not suitable with stud terminals.

Figure 7: Typical flat ring terminal lugs RING LUGS DIMENSIONS Refer to Table 1 & 2 below for ring lug dimensional guidelines.

Figure 9: Davico lug with 90 degree pre-form RING LUGS WITHOUT 90 DEGREE PRE-FORM Ring lugs are available from various suppliers in a wide range of 2 sizes & configurations. Termination of wires ranging from 0.5mm 2 up to 6mm is possible using a ring lug terminal or equivalent selected from Table 2. Common flat lugs do not have the 90 degree pre-bend depicted in figure 9. In order to fit these lugs into the M Series terminal block, an angle must be pre-formed as depicted in figure 10.
Multi strand wire

Figure 8: Ring terminal lug dimensions Refer tables 1 & 2 STUD TERMINALS The stud terminal mounting kit is suitable for the following situations: Where more than two wire terminations per point are required Where large profile lugs are to be used Refer to the M Series Case Accessories section describing M4 studs & figure 13 for details. Table 1. Davico 90 Degree Pre-bend Termination Ring Lug Part Numbers RMS Terminal Kit (100 per kit) 290-407-163 290-407-164 Typical Size - mm Lug Description A Davico lug - 90 deg RED Davico lug - 90 deg BLUE 21.3 22.3 B 8.0 8.5 C 0.7 0.8 E 4.3 4.3

Hand bend operation

Insert insulated multi strand wire into flat ring lug & crimp using suitable tool

Form 90 degree bend with radius >1mm M4 screw with lock washer One lug per terminal

M4 screw with lock washer Two lugs per terminal

Figure 10: Flat lug 90 degree pre-form & screw fitting detail

Farnell Coding Description DVR1-4-90 DVR2-4-90 Cat. No. 1712571 1712572

Wire Size Range 0.25-1.6mm 1.0-2.6mm

2

Wires per Screw (Max) 2 2

Table 2. Utilux or Equivalent Termination Ring Lug Part Numbers RMS Terminal Kit (100 per kit) 290-407-165 290-407-166 290-407-167 290-407-168 290-407-169 290-407-170 Typical Size - mm A Supergrip lug RED * Supergrip lug BLUE * Supergrip lug YELLOW * Standard grip lug RED * Standard grip lug BLUE * Standard grip lug YELLOW * 21.3 22.3 23.2 21.3 22.3 23.2 B 8.0 8.5 7.2 8.0 8.5 7.2 C 0.7 0.8 1.0 0.7 0.8 1.0 E 4.3 4.3 4.3 4.3 4.3 4.3 Utilux Coding Description RRSGM4L BRSGM4L YRSGM4S RRM4L BRM4L YRM4S Cat. No. H4214 H4223 H4230 H4114 H4123 H4130 Wire Size Range 0.5-1.5mm 1.5-2.5mm 2.5-6.0mm 0.5-1.5mm 1.5-2.5mm 2.5-6.0mm
2 2 2 2 2 2

Description - Colour

Wires per Screw 2 2 1 2 2 1 Stud 3+ 3+ 3+ 3+ 3+ 3+

NOTE: * Utilux lugs specified are supplied flat & must be pre-formed to ~90 degrees before insertion into the M Series terminal block.

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M Series Case Accessories

ACCESSORIES The following accessories are available separately: 4M801K1 4M802K1 4M803K1 4M804K1 4M806K1 4M808K1 290-406-151 290-407-153 290-407-154 290-407-158 205-103-003 Size 1 4U Blanking Plate Size 2 4U Blanking Plate Size 3 4U Blanking Plate Size 4 4U Blanking Plate Size 6 4U Blanking Plate Size 8 4U Blanking Plate 177 x 25 177 x 51 177 x 77 177 x 103 177 x 155 177 x 206 mm mm mm mm mm mm TERMINATION SCREWS M4 Screws An M4 screw kit is supplied as standard with each M Series case. Additional M4 screw kits may be purchased separately. M4 screws are suitable for use with the recommended ring lugs as per tables 1 & 2.

Relay mounting screw kit (4 screws) M4 terminal screw kit with captive lock washers (14 pieces per kit) Stud terminal kit (28 terminals per kit) Earth bar to suit M Series Cases mounted in a 19 inch rack mount frame (4M800K1) Earth screw (1 piece)

CASE MOUNTING SCREWS An M4 self threading screw kit is supplied as standard with each M Series case.

Figure 12: M4 terminal screws with captive lock washers M4 Studs An M4 stud kit is available as an option. This kit consists of 28 studs complete with insulating sleeves to allow M4 studs are suitable for use with the recommended ring lugs as per table 1 & larger profile lugs that will not fit directly into the M Series terminal block.

Figure 11: Case mounting screws

Figure 13: Stud terminal Maximum Torque Setting The maximum torque setting that should be applied to either M4 screws or M4 studs is 2.0 Nm. 1.8 Nm is recommended.

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Sub Rack Frames

STANDARD VERSIONS AVAILABLE 4M800K1 4U High rack mount frame 4M800K6 4U High flush panel mount frame 4M800K9 6U High rack mount frame 4M800K10 6U High flush panel mount frame 4M800K7 2 x 4U High rack mount frame 4M800K8 2 x 4U High flush panel mount frame 19 INCH SUB RACK MOUNTING FRAMES Sub rack frames are constructed from powder coated mild steel & aluminium bar. The result is a very sturdy yet cost effective solution for mounting 4U & 6U modular cases in 19 inch cabinets or for flush mounting on panels or doors. Pre-drilled holes in the aluminium cross bars are designed for use with M4 self threading screws supplied with RMS relays or available separately.

Pre-drilled holes to suit M4 self threading screws provided with m Series cases

4U

4U high 19 inch rack mounting frame P/N 4M800K1

4U high panel mount sub rack frame P/N 4M800K6

4M800K6 panel cut out details

Figure 14: Rack mount frames

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Semi Projection Mounting

Semi projection mount kits are available in six (6) standard sizes for the size 2M and size 4M cases as follows:. SEMI PROJECTION MOUNT KITS Semi projection mount kits are available for the size 2M & 4M case. + Each kit consists of: 1 x semi projection mount top spacer (Acetal) 1 x semi projection mount bottom spacer (Acetal) 2 x black powder coated aluminium side panels Mounting screws Size 2 Case 4M820K1 4M820K2 4M820K3 4M820K4 4M820K5 4M820K6 50mm projection 75mm projection 100mm projection 125mm projection 150mm projection 200mm projection Size 4 Case 4M821K1 4M821K2 4M821K3 4M821K4 4M821K5 4M821K6 50mm projection 75mm projection 100mm projection 125mm projection 150mm projection 200mm projection

Size 6 Case 4M822K1 4M822K2 4M822K3 4M822K4 4M822K5 4M822K6 50mm projection 75mm projection 100mm projection 125mm projection 150mm projection 200mm projection

Size 8 Case 4M823K1 4M823K2 4M823K3 4M823K4 4M823K5 4M823K6 50mm projection 75mm projection 100mm projection 125mm projection 150mm projection 200mm projection

Semi Projection off panel

Figure 15: Semi projection mount kit details & panel cut outs

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Order Codes
M SERIES CASE PACKING DETAILS Relays built in the M Series case system are shipped in custom packaging suitable for air, sea or land freight. Each relay is individually packaged complete with Product/Test Manual, Terminal Screw Kit, Mounting Screw Kit & CD if applicable. The package consists of two recyclable foam moldings to secure & protect the relay from shock during transit. A two ply custom cardboard box is used to house the relay / foam module. A thermal label is attached to this box detailing the product type, customer, order & serial number information. Depending on the number of relays in a consignment these boxs may be shipped individually or packed into a larger carton. For bulk shipments these cartons are palletized. SIZE 2 CASE PACKAGING DIMENSIONS Individual shipping box FC0100 1 x size 2 shipping box: Generate the required order code as follows: e.g. 2M28-S-2 Order Code 1 2 3

M
1 2 4 M 2 28 56 CASE SIZE Size 2 Size 4

-S-

M SERIES CASE NUMBER OF TERMINALS 28 Terminals 56 Terminals SHORT CASE VERSION CASE CONFIGURATION * Element only One element per case Two elements per case Three elements per case Four elements per case

240 x 230 x 85mm

Multiple shipping cartons FC0113 6 x size 2 shipping boxes: 480 x 370 x 310mm FC0114 14 x size 2 shipping boxes: 480 x 370 x 620mm SIZE 4 CASE PACKAGING DIMENSIONS Individual shipping box FC0101 1 x size 4 shipping box:

S 3 1 2 3 4

340 x 230 x 140mm

Multiple shipping cartons FC0113 4 x size 4 shipping boxes: 480 x 370 x 310mm FC0114 8 x size 4 shipping boxes: 480 x 370 x 620mm TYPICAL PALLET SIZES (Add 15Kg for pallet) FC0113 shipping cartons 2L x 3W x 2H 960 x 1,110 x 610 mm 12 x relay cartons per pallet FC0114 shipping cartons 2L x 3W x 2H 960 x 1,110 x 1,240 mm 12 x relay cartons per pallet WEIGHTS OF INDIVIDUAL SHIPPING BOXES Case Size 2 No. of elements per case * 1 2 1 2 3 4 1 1 Nominal weight Kg 2.5 3.0 3.5 3.7 4.0 4.5 3.5 4.0

Note: * Auxiliary & tripping relays only

6 8 Note: *

This relates to auxiliary & tripping relays where multiple relay elements may be specified per relay case which affects the final weight.

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Australian Content
Unless otherwise stated the product(s) quoted are manufactured by RMS at our production facility in Melbourne Australia. Approximately 60% of our sales volume is derived from equipment manufactured in house with a local content close to 80%. Imported components such as semi-conductors are sourced from local suppliers & preference is given for reasonable stock holding to support our build requirements.

Design References
The products & components produced by RMS are based on many years of field experience since Relays Pty Ltd was formed in 1955. A large population of equipment is in service throughout Australia, New Zealand, South Africa, The Middle East & South East Asia attesting to this fact. Specific product & customer reference sites may be provided on application.

Quality Assurance
RMS holds NCSI (NATA Certification Services International), registration number 6869 for the certification of a quality assurance system to AS/NZS ISO9001-2008. Quality plans for all products involve 100% inspection and testing carried out before despatch. Further details on specific test plans, quality policy & procedures may be found in section A4 of the RMS product catalogue.

Product Warranty
All utility grade protection & auxiliary relay products, unless otherwise stated, are warranted for a period of 24 months from shipment for materials & labour on a return to factory basis. Repair of products damaged through poor application or circumstances outside the product ratings will be carried out at the customers expense.

Product Packaging
Protection relays are supplied in secure individual packing cardboard boxes with moulded styrene inserts suitable for recycling. Each product & packing box is labeled with the product part number, customer name & order details.

Standard Conditions of Sale

Unless otherwise agreed RMS Standard Terms & Conditions (QF 907) shall apply to all sales. These are available on request or from our web site.

Relay Monitoring Systems Pty Ltd

6 Anzed Court, Mulgrave, Victoria 3170, AUSTRALIA Tel: +61 3 8544 1200 Fax: +61 3 8544 1201 Email: [email protected] Web: www.rmspl.com.au

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R e l a y

M o n i t o r i n g

S y s t e m s

P t y

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