DEMA Relay Company
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DEMA Role San. ve Tic. A.Ş.
Ataturk Cad., Zumrutevler Filiz Sk., No.: 11, 34852, Maltepe, Istanbul, Turkey.
WEB: www.demarelay.com
Phone +90 (216) 352 77 34
Fax +90 (216) 442 17 95
e-mail: dema@demarelay.com
DEMA LTR-400
Lockout Relay
Quick Guide
www.demarelay.com
TG - 120.A, vEN.2009.01
DEMA proudly presents the users and modern networks a solid alternative for lockout duties with LTR-
400; with the state-of-art physical and functional technology for use in LV, MV or HV facilities; and
provides the users numerous assembly, commissioning, operating and servicing advantages as well as
the lowest total cost of ownership.
DEMA LTR-400 is the enhanced sequel to DEMA LTR010 model, featuring several electrical,
mechanical and dimensional improvements, and have been presented to service under the guarantee of
ISO9001:2000 Quality Assurance System.
The general specifications of LTR-400 are listed below to create a common sense for the product.
▪
Safe mechanical lockout mechanism with mechanical resetting to ensure secure locking and
unlocking of circuit breaker reclose,
▪
4 SPDT (single-pole / double-throw) auxiliary contacts,
▪
Mechanical indicator operating independently from the supply continuity,
▪
Operation without removing cover, thanks to IP52 button integrated on the cover,
▪
Precision manufacturing,
▪
Draw-out system that enables rapid unit replacement,
▪
Unbreakable protective earth circuit continuity,
▪
New generation casing with IP52 front side protection, IP20 rear side protection,
▪
Expert technical crew and matc
hless customer support. □
LTR-400
– General Specifications
Insulation Class
2 kV / 50 Hz / 1 min
Operating Temperature
-
5ºC to +40ºC
Storage Temperature
-
5ºC to +70ºC
Max. Storage Duration
3 years indoors in original box.
LTR-400
– Output Features
Output Contacts
4 SPDT (change-over) contacts.
Opening Time for Normally Closed Contacts
8 ms
Closing Time for Normally Open Contacts
13 ms
LTR-400 Contact Characteristics
Current carrying capacity
10 A
rms
Max. switching current
10 A
rms
Max. switching voltage
250 V
AC
Max. switching current at: 110 V
AC
, cosφ = 0.4 inductive.
10 A
rms
on each pole.
Max. switching current at: 110 V
AC
, cosφ = 1.0 resistive.
10 A
rms
on each pole.
LTR-400 - Power Features
Supply Voltage
110 V
AC
Operational Supply Voltage Range
+%10 U
r-aux
/ -%20 U
r-aux
Standby Power Consumption
No consumption.
Maximum Power Consumption, excl. external devices.
12.7 VA .
LTR-400 - Physical Properties
Case Type
DRC 96
– S2
Degree of Protection for Front Side
IP 52
Degree of Protection for Rear Side & Terminals
IP 20
Mounting
Flush
Main Unit
Withdrawable
Package Information
Gross Weight: 2.30 kg
Contents: Please check the following items upon arrival:
▪
LTR-400 Lockout Relay,1 piece.
▪
Connecting Elements Set, 4 x (custom screws, nuts and washers).
▪
LTR-400 Lockout Relay Quick Guide (this document).
Unit Label Information
Unit label is shown at the
picture below, and gives the following information:
Producer Logo
DEMA
Product Name
LTR-400
Product Description
Lockout Relay
Product Serial Number
L.123456
Outputs
4 x SPDT
Auxiliary Power Supply
110 VAC
□
Flush mounting requires processing of the panel
– the cut-out drawing needed for this can be found on
this document. The dimensions on the drawing are determined taking standard electrostatic coating
thickness into consideration, therefore, can be directly applied to bare metal sheet.
Mounting of the relay case on the prepared panel is done as described below.
1.
Open the relay cover, preferably drive out the internal unit for easier mounting. If the internal unit is
drawn out, take all precautions against dusting and damaging of the unit.
2.
Place the case into the cut-out.
3.
Use the supplied 4 sets of M4 custom screws, standard M4 nuts and washers to fix the case onto
the panel. Drive the screws from the front first, then tighten the nuts on the washers from the
backside of the panel.
4.
Make sure that the supplied custom screws are used for mounting. Using any other screws may
result in sealing failure and loss of protection degree of the cover!
5.
Make sure that all 4 mounting holes are screwed and tightened. Fixing the case from lesser points
may result in mechanical stresses and bending on the case construction due to possible
deformations on the panel. Such inappropriate applications may harden driving the internal unit
into or out of the case.
6.
Always use torque drivers when working with the relay. Apply (0.69-0.82) Nm torque when
tightening the nuts.
Inserting the internal unit and mounting the cover are done as described below.
1.
Rotate the lock handle to provide an approximate angle of 90
° between the handle and the internal
unit. Drive the internal unit into the case until the unit fits well, the press the lock button to lock the
unit in place. This will ensure healthy and robust electrical connection between the internal unit and
the case.
2.
Place the bottom part of the cover into its place on the case first, then close the cover on the case.
Make sure the cover fits in its place and the sealing is provided between the cover and the case.
Tighten the mounting element integrated on the cover.
0.20 Nm torque is sufficient to provide IP52 protection when tightening the mounting element on the
cover. Never apply torque values higher than 0.29 Nm! This may damage the mounting elements and
may lead the cover out of service! □
Cabling Schema
LTR-400 Lockout Relay circuit diagram is provided on the backside of this document.
Cabling Material
Cabling material selection is of great importance for all secondary systems. The principles listed below
are to be followed to build a robust system.
Cabling with thin & multi-wire cables:
▪
Never make a connection without applying ferrules to wire ends!
▪
Use 8 mm wire end ferrules for all block terminals, which are labeled with numbers from 10 to 44.
Using ferrules longer than 8 mm may reduce the dielectric withstand capability of the wiring!
▪
Provide solid earthing of the relay with low resistance earth grid. Use ring cable connectors for
connections to relay earthing bolt. Make the earthing connection directly to earth. Never earth the
device indirectly or over high resistances!
WARNING! Solid earthing is one of the fundamental actions to provide minimum safety
requirements. Before commissioning any electrical system, make sure that earthing process is
done correctly according to the relevant standards!
▪
Use appropriate tools for crimping the ferrules. Preferably use crimping tools with trapeze cross-
section crimping type.
▪
Use appropriate tools for stripping the cables. Preferably use stripping tools with adjustable
stripping lengths. Apply the instructions of the ferrule manufacturer when stripping.
▪
Use appropriate tools for removing the outer coat of multi-core cables, if applicable. Preferably use
cables with fillers and blades with adjustable cutting depths. Apply the instructions of the cable
manufacturer.
▪
Use torque screwdrivers to tighten the terminal bolts. Apply (0.56 - 0.69) Nm torque to the bolts
–
torque application lower than 0.69 Nm may lead to open circuits or high contact resistances, while
excessive torque application may damage the terminals!
▪
Use non-flammable, standards compliant cables.
▪
Determine the wire cross-sections according to relevant standards and engineering principles.
Cabling with single wire cables
Cabling with single wire cables is not recommended for secondary systems. Mechanical aging risks,
increasing contact resistance over time, and poor flexibility are the leading cons of single
wire cables. If
cabling with single wire cables is essential, check all connections with great care and apply routine
checking procedures to prevent failures. □
LTR-400 Lockout Relays are delivered as all necessary adjustments and tests made, and there are no
setting options for the relay, therefore, there are no actions that are needed to be taken by the user prior
to commissioning. □
Use the procedure below to commission each LTR-400 unit after the mounting and cabling actions are
taken. The procedure of commissioning LTR-400 is examined below; note that some parts of the
procedure are not related to the unit, thus are not explained thoroughly - so take professional help for
these steps, if needed. Use appropriate devices during the tests to build and erect a healthy lockout
system!
▪
Auxiliary Supply Check
Auxiliary supply cabling and auxiliary power supply functionality tests.
▪
Function Tests
Feed terminals
no’s 43 and 44 by appropriate auxiliary voltage and check to see
each of the auxiliary contacts works as expected from terminal numbered from 10 to 42. Check
that the devices to be controlled by the lockout relay (e.g. the circuit breaker) receives the signal
from the unit. Test the system to make sure that LTR-400 locks out and can be unlocked normally.
▪
Finalization
Energizing the primary circuit / Taking each related component under normal service
conditions.□
Stand-by State
After the successful commissioning of LTR-400, normal standby conditions are reached; this condition is
kept as long as system components operate correctly and there are no operating signals to the terminals
no’s 43 and 44 of LTR-400.
Activated state with outputs locked out
When the auxiliary supply terminals of
no’s 43 and 44 are fed by a master device (e.g. a protection
relay), LTR-400 reacts as follows:
•
The 4 auxiliary relays with SPDT (single-pole double-throw) construction operate to change-over
their circuits. The normally-open contacts (e.g. 11 and 12) close and the normally-closed contacts
(e.g. 10 and 11) open.
•
The change-over contacts are locked out on their operated state by means of a mechanical lock.
This means that the normally-open contacts (e.g. 11 and 12) will remain closed and the normally-
closed contacts (e.g. 10 and 11) will remain open regardless of the supply continuity to the
auxiliary supply terminals of
no’s 43 and 44; until the unit is reset.
Unlocking / resetting the LTR-400 unit and returning to stand-by state
Once the operation is acknowledged by the operator and appropriate actions on the whole system is
taken (e.g. repairing of a defect on the primary power circuit), it is required that the lockout unit is reset
by means of the mechanical resetting button on the front side of the relay, before the circuit breaker
being controlled by the LTR-400 unit is reclosed. Note that, if the circuit breaker is attempted to be
closed before the LTR-400 unit is unlocked / reset, the circuit breaker will be tripped by the LTR-400 unit
immediately.
□
Under normal service conditions, no testing or maintenance action is required for LTR-400. If an LTR-
400 unit somehow becomes unstable or out of service under a paranormal condition; testing,
maintenance or reparation of the unit may become essential.
Apply the procedure at the “Commissioning LTR-400” section, and check to diagnose the following
possible causes of irregularities:
•
Check and see that the cabling of the unit is healthy.
•
Check the availability of auxiliary supply voltage.
•
Check and see that the auxiliary supply system operates correctly and supplies the unit within the
specified supply voltage range.
•
Check to see that;
o
The master circuits that are controlling the supply of LTR-400 units (e.g. protection
relays) are healthy and operating correctly.
o
The receiver circuits of external devices (e.g. circuit breakers) are healthy and
operating correctly.
If no diagnosis for the reason of malfunction can be spotted, contact DEMA Relay Company for further
assistance and advanced diagnosis methods.
Note that, if somehow reparation is needed for the device, there is no need to remove the cabling from
LTR-400 terminals. Simply draw out the internal unit to replace it immediately with a
spare unit. □
TESTING, MAINTENANCE AND REPARATION OF LTR-400
OPERATING LTR-400
COMMISSIONING LTR-400
SETTING LTR-400
CABLING LTR-400
MOUNTING LTR-400
PACKING AND LABELING INFORMATION
TECHNICAL DESCRIPTION
INTRODUCTION
