Text

Struthers-Dunn Model 255XCXP Relay Root Cause Evaluation for Salem Nuclear Generation Station
	ML20133D225
Person / Time
Site:	Salem
Issue date:	10/30/1996
From:	Chiu C; FARWELL & HENDRICKS, INC.
To:	;
Shared Package
ML18102A725	List: ML20133D220; ML20133D225;
References
	FPI-96-829, NUDOCS 9701090073
	Download: ML20133D225 (65)
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Struthers-Dunn Model 255XCXP Relay Root Cause Evaluation for Salem Nuclear Generation Station October 30, 1996 FPI 96-829 l

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Struthers-Dunn Model 255XCXP Relay Root Cause Evaluation for i

Salem Nuclear Generation Station October 20, 1996 FPI 96-829 l

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Principal Investigators: James Riddle Mike Ramsey Technical

Contact:

Craig Bersak, PSE&G Approved By:

Dr.C[ngChiu i

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This report was prepared for Public Service Electric and Gas Company. No part of this document may be reproduced without the i consent of FPI, International.

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I Table of Contents Executive Summary.............................................. 1 Introduction................................................... 2 Failure Analysis .............................................. 3 ;

Visual Inspection......................................... 3 -

Electrical testing......................................... 5 Force-Balance Analysis.................................... 8 Analysis conclusions.......................................... 11 Root Cause Evaluation......................................... 12 Corrective Actions............................................ 13 l

Attachments: l l

I Photodocumentation II Correspondence - Application Information III Product Data

Executive Summary FPI, International received four (4) relays for failure analysis and Root Cause Evaluation from Public Service Electric and Gas Company, Salem Nuclear Generating Station. One of the relays was reported to have spuriously unlatched and a second relay was reported to not have latched on actuation. The other two relays, one a new style and the other an old style relay, were supplied as correlation samples.

Failure analysis confirmed the failure to latch of the one relay and the spurious unlatching, under mild mechanical shock, of the second relay. A significant finding was construction differences between the old style (1972 vintage) and new style relays (1995 vintage). The construction differences make the new type relays more prone to latching problems than the older style relay. The most significant difference is the lower latching force on the new style relays. This problem is the direct result of lower spring tension on the latch lever. Another significant concern l is the deviation of the electrical characteristics of the new release coils from the design specifications which indicate that the new relays are not direct replacements for the old relays.

The root cause of the two relay failures is design differences between the old and new relays that make the new relays more prone to latching problems and spurious unlatching than the old style relays.

The three corrective action recommendations are to (1) review safety related applications for susceptibility to failure of the new style relays and replace or rework relays which present significant compromise of plant safety, (2) review new relay I design to justify like for like compatibility with the old style relays and (3) conduct tests and measurements to determine adjustments to be made on new relays to assure operability in }

challenging environments. FPI, International has the expertise to l assist in implementing all the corrective actions.

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3 Introduction FPI, International received four (4) relays for failure analysis and Root Cause Evaluation from Public Service Electric and Gas Company, Salem Nuclear Generating Station. One of the relays was reported to have spuriously unlatched and a second relay was reported to not have latched on actuation. The other two relays were correlation samples. The component identification and system designation was supplied to FPI in a memo dated September 20, 1996 which is included in Attachment II at the end of this report. Additional background information was obtained via EAX on October 3, 1996, also included in Attachment II.

The failed relays are new components which had been recently installed in Bailey Meter Company Relay modules, part number 6615692A, as part of a general relay change out due,to the aging of the original relays which have been operating for the life of the plant. There have 5 reported failures of the new type relays. The relays are procured as Safety Related components after being dedicated by a third party vendor. The manufacturer, Magnacraft Struthers-Dunn does not supply the relay as Appendix B, Safety Related items. The Bailey Product Instructions and relay manufacturer data sheet are in attachment III at the end of I this report.

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Failure Analysis Visual Inspection The relays are Magnacraft Struthers-Dunn (S-D or MSD) model 255XCXP type latching relays. The operate coils are 24-28 VDC.

The release coils are also 24-28 VDC.

Relay #1 is an old relay, date code 7228. It was supplied as a correlation sample. The part markings are 255XCX111, manufactured by S-D. The plastic case was slightly darkened with age. The switch contacts were clean and the exterior of the coils showed no evidence of degradation which is usually seen as darkening or cracking of the insulation. The mechanical design of this relay is significantly different that the three new relays.

Relay #2 is a new relay, date code 9549. It was reported to have spuriously unlatched in service. It was later reported that the unlatching of this relay was concurrent with the actuation an adjacent relay in the same Bailey module. The part markings are 255XCX128. The suffixes in the part numbers is either for a Bailey (111) part or a Public Service (128) part. Internal inspect' ion revealed that this relay was essentially new. There was no evidence of aging on any of the internal components.

There was no evidence of any loose parts or gross misalignment c:

the coils or latching mechanism. No wear was evident on the latching mechanism or any other moving parts.

Relay #3 is a new relay, date code 9616. It was reported to ha..

failed to latch upon actuation while in service in a Bailey Re;i.

module. The part markings are 255XCX128. Internal inspection revealed that this relay was new. There was no evidence of ag:: .

on any of the internal components. There was no evidence of ar.

loose parts or gross misalignment of the coils or latching mechanism. No wear was evident on the latching mechanism or ar other moving parts.

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Relay #4 is a new stock relay, date code 96** (date code marking on case smudged). It was supplied as a correlation sample. The part markings are 255XCX128. Internal inspection revealed that this relay was new. There was no evidence of aging on any of the internal components. There was no evidence of any loose parts or gross misalignment of the coils or latching mechanism. No wear was evident on the latching mechanism or any other moving parts.

As was mentioned earlier, there are significant differences in the mechanical construction of the old relay and the three new relays. Most of the differences are in the reset coil and latch assembly.

1. The presence of a frame in the new relays is a major difference compared to the old re),y. On the old relay the reset coil assembly is attached directly to the top of the operate coil assembly. On the new relays the operate and reset assemblies are attached to a U shaped frame. The frame provides less torsional rigidity.to the assembly, especially-in the alignment of the resent and operate coils.

2. There are numerous alignment adjustments on the both the new and old assembles, all intended to precisely position the plastic latch on the reset coil armature to the latch lever on the operate coil armature. On the old style relay these adjustments are made with the hardware on rigid clamps which connect the reset coil assembly to the operated coil assembly. On the new style relay these adjustments are in the frame attachment hardware and in the case of the height ;

adjustment via shims between the reset coil assembly and the frame. The alignment scheme on the new style relays is less rigid then that on the old style relays.

3. The switch contact spring arms are significantly more bent, preloaded, on the new relays. This results in a higher contact force on the new relays but also a higher pull-in force of the operate coil and stronger pull-out force on the reset coil latch. j l

4. The reset coils are completely different on the old and new style relays. The coil resistance of the new reset coils is in the range of 460 Ohms and the old reset coils measures l 309 Ohms (cold). The core is also larger on the old style reset coil. The higher resistance on the new coils is disturbing because it is not in accordance with the data sheet specification. The electrical performance differences l will be discussed below in the Electrical Testing section of

! the report.

5. A most significant difference between the old and new style relays, as related to the failure mode, is the reset coil armature spring. The armature return spring on the old relay is significantly stretched in the latched and released states. This delivers significant force to the latch. The l return spring on the new relays is almost fully relaxed in j the released position and slightly stretched in the latched position. This condition provides reduced holding force to the latch. The details of this condition will be discussed on the Force Balance section of this report, l

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! Electrical testing l

l Initial electrical testing confirmed the failure to latch of the

3 relay. The #3 relay would not remain latched when the operate coil was actuated and power was removed. After the cover was removed the relay began to latch successfully. It was noted during removal of the cover that it was a tight fit and reinstallation of the cover confirmed that the tight fit was interfering with the relay frame, causing it to bend. Testing after the cover was reinstalled revealed that the relay would not latch. The presence of the cover is interfering with the alignment of the latch mechanism. It was noted during subsequent testing, after the cover was removed that the relay could be made to release with a minor flexing (twisting) of the frame.

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Initial electrical testing of relay #2 revealed that the relay would latch at normal voltage / current compared to #4 but could be made to unlatch under mild mechanical shock (pencil tap on side of case).

Initial electrical testing of #1 and #4 revealed that they both set and rest normally. Relay #4 could be made to release with moderate mechanical shock (screw driver handle tap to side of case) and #1 could be made to release under strong mechanical shock (banging relay on table top).

Static electrical testing was performed with a DMM in the resistance mode (Fluke 8060A) for coil resistance measurements and a millivolt meter and a constant current source (10.00 mA) for the switch contact resistance measurements. The switch contact resistances in the N/O and N/C states on all the relays were good, in the range of 0.001 Ohms. The coil resistance measurements on the relays revealed that there was a significant difference on the reset coils on the old and new style relays:

Sample Operate coil Reset coil

1 240 Ohms 309 Ohms

2 250 Ohms 460 Ohms

3 240 Ohms 470 Ohms

4 250 Ohms 460 Ohms The Struthers-Dunn specification sheet shows a nominal resistance for the operate coil of 250 Ohms and a nominal resistance for the reset coil of 300 Ohms. The higher resistance (more windings) of the new coils results in a lower current (cold) necessary to actuate the reset coil as indicated by the following data:

Sample Volts Release mA

1 24 VDC 78.2 mA

2 24 VDC 52.0 mA '

3 24 VDC 51.0 mA

4 24 VDC 52.5 mA I

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Again, The Struthers-Dunn data sheet specifies a nominal release current of 80 milli-Amps for these relays. The new relays are not in compliance with the published specifications.

Another result of the different release coil assembly is a lower reset voltage on the new relays due to the lower overcoming force necessary on the reset armature spring. The pick-up and drop-out

voltages are recorded as follows:

1 Pick-up = 16.8 VDC Release = 15.5 VDC Pick-up = 15.3 VDC

2 Pick-up = 12.9 VDC Release = 11.9 VDC Pick-up = 13.3 VDC

3 Pick-up = 14.0 VDC Release = 10.0 VDC Pick-up = 13.5 VDC

4 Pick-up = 15.9 VDC Release = 12.2 VDC Pick-up = 12.9 VDC Note that the release voltage is somewhat lower on the new relays which is a result of the lower return spring overcoming force as discussed in the Force Balance section of the report.

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Force Balance Analvsis A force-balance analysis was performed on the latching mechanism of the old relay compared to the new relays. Samples #1, #2 and

4 were used for the testing. Sample #3 was left intact for possible future testing as a worst case condition.

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Force Balance Diagram Force Balance Diagrams Umlatched Relay The above diagrams are the force balance schematics. The left schematic is in the latched position and the right schematic is in the unlatched position.

Relays #1 (Old Style) and #2 (New Style) were used to take direct measurements of the spring and latch geometries. The spring en the #1 relay was noted to be extended in both the latched and unlatched positions. The spring on the #2 relay appeared to n:-

be extended in the latched position.

The spring dimensions were taken from established reference points across the collapsed and extended spring coils. The spr. :

extension was measured on the release armature springs, in pla; .

in the latched and unlatched state. The springs were then removed from the relays and the K factor was measured. The i armatures were measured to obtained the lever ratio from the spring center of force to the lip of the latch. The following data was obtained:

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PARAMETER OLD #1 NEW #2 (66 gram /mm

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Spring Constant 78. 6 gram /D IA"4/kte Extended Length Latched 10.4 mm 6.3 mm JSto k Extended Length Unlatched 10.65mm 6.7 mm Collapsed Length (Removed) 8.5 mm 6.25mm Spring Force Latched 125.4 gram 3.93 gram Spring Force Unlatched 142.0 gram 35.0 gram Lever Ratio 2.64 : 1 3.2 : 1 Latched Clamping Force 47.5 gram 1.23 gram The latching force is significantly lower at the latch on the new relays than on the old relays. Combined with the higher switch contact spring tension on the new relays, which work to pull the relay open, the new relays are more susceptible, by design, to a failure to latch (based on minor misalignments) and spurious unlatching under minor mechanical shock.

A calculation was made to determine what adjustments would be necessary to increase the latching force on the new relays to that on the old relay. It was determined that bending the spring attachment tab approximately 1.88 mm open was sufficient to increase to latching force at the latch on the new relays to the 50 gram range measured on the old relays. This may be the most efficient fix for the weak latching problem.

However, simply bending the tabs on the reset relay armature may affect relay timing and release coil pick-up voltage. A simple experiment was performed on #2 to test the effect of bending the armature tab to open the spring. Note that this relay had been disassembled and the spring manipulated (loop opened) prior to the experiment. The relay was reassembled to approximate the original condition. The spring e c nsion measured 6.5 mm in the latched condition. The release vr.tage (worst case, cold) measured 11.62 volts at 24 mA. The tab on the release coil frame was bent open 1.9 mm. It was noticed that the opening of the tab caused the spring coils to open slightly but most of the stretch was taken up by opening of the coil attachment loop. The spring extension measured 6.9 mm in the latched position at the same I I

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datum as the original measurement. The extension resulted in a calculated 1-ncrease of the latching force from 2.45 gm to 12.3 gm at the latch. The pickup voltage measured 11.69 VDC at 24.8 mA after the bend. The conclusions from this experiment are that bending the tab out to extend the spring does not significantly affect the pickup voltage characteristics of the relay. One observation made during this experiment is that, as a rule of thumb, one must be able to see light between the' spring coils in order to assure some spring extension in the latched condition.

Light could not be detected in the original 6.5 mm extension but could be seen in the 6.9 mm extension. This parameter could be quantified as a spacing measurement between coil loops. The result of the bend is a SX increase in latching force between the two adjustments with no significant change in the electrical performance. Evaluate these results with caution, the effect on switching time has not been determined.

Analysis Conclusions Testing and failure analysis first confirmed the failure to latch on #3. This relay recovered the ability to latch when the cover was removed and failed when the cover was replaced. The latch could be made to release under mild twisting stress to the frame during testing with the cover removed. Relay #2 was made to unlatch under much lower mechanical shock stress than the old design #1 relay.

The old style and new style relays have significant design l differences especially in the latching mechanism. These differences contribute to the propensity for the failure to latch mechanism and the spurious release failure mechanism. The major differences are listed as follows: )

A. The presence of the surrounding frame in the new relays is a much less torsionally rigid system for maintaining the latching mechanism critical dimensionality than the old style direct bracket arrangement between the operate and reset coil assemblies.

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B. The lack of rigidity in the frame means that the latching adjustment tolerances must be maintained to a very precise degree to insure proper operation. The new style relays are prone to spuriously release under much lower mechanical

shock than the old style relays. Stress from pressure from l the cover caused relay #3 to fail due to distortion of the l frame.

l l C. The lower latching force on the new relays is the primary cause of the lowered ability of the new relays to latch and l remain latched. The most direct corrective action is to increase the spring force on the new relay reset latch armature.

t D. The electrical characteristics of the new release coils are significantly different than the old coil and are not in ccmpliance with the manufacturers published data. As a result of this difference (and the reset mechanism differences), the new relays are not "like for like" replacements for the old relays.

Root Cause Evaluation The root cause of the two relay failures is design differences between the old and new relays that make the new relays more prone to latching problems and spurious unlatching than the old style relays. Another significant concern is the deviation of the electrical characteristics of the new release coils from the design specifications which indicate that the new relays are not direct replacements for the old relays.

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Corrective Actions l

1 Three corrective actions are recommended. FPI, International has 1

the expertise to assist in implementing all the corrective !

actions.

1 First, a review should be performed of all the plant applications of the new relays for their adequacy in the operating and design ;

environment. Determine if the reliability of the new style relay 1 is adequate for the Safety Related applications at the Salem i Nuclear Generating Station. This corrective action is necessary to justify the installation of the new relays in safety critical 1 applications. If adequate justification cannot be made, the :

relays will have to be changed out.

Secondly, review the adequacy of the new relay design. This corrective action involves a review of the results of this analysis with the manufacturer and supplier in order to determine l the reasons for the design changes and the manufactures basis for assuming that the relays are interchangeable. This is especially critical in the lowering of the holding force on the reset coil latch and incidentally important on the release coil electrical parameter changes (which if justified would require a specification sheet change). We suspect that the coil changes are the result of maintaining switching time specifications but we do not have access to that design information.

1 Thirdly, conduct necessary tests, adjustments and experiments to justify the use of the new relays in challenging environments.

One experiment performed at FPI on the new relays determined that simply adjusting the spring tension on the release armature spring as little as 1 mm will increase the latching force to the range of the old style relays. This ad]ustment could potentially correct the problem. Similar mechanical adjustments or repairs may increase the reliability of the relays to acceptable levels. '

It is possible that augmented testing, dimensional verification or design change justification may ce adequate to assure the reliability of the replacement relays.

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1 It is a also incumbent on PSE&G to inform other users of this model relay _of the problems encountered with the spurious unlatching. A short report on the INPO Nuclear Network of the problems encountered at Salem would be a responsible action.

There may be Part 21 issues associated with the dedication of the

relays for Safety Related applications. This issue should be evaluated by the supplier.

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Attachment II Correspondence Application information

i MEMO To: Dr. Chong Chiu From: Craig D. Bersak (609) 339-7463, FAX (609)339-2210 g PSE&G Nuclear Business Unit, PO Box 236, Hancocks Bridge, NJ b8038

Subject:

Prooosal for Relay Failure Analysis Date: September 20,1996 l

The following is being provided in anticipation of approval of a Purchase Order by PSE&G, it is not authorization to begin work.

Enclosed are four relays for your evaluation.

Relay #1 was is an old relay that has NOT had a failure associated with it.

Relay #2 spuriously tripped from a latched condition to its reset condition.

Relay #3 failed to maintain itselflatched following an operate demand.

Relay # 4 is a new relay that has not been installed in a Salem system. The case was opened and the wire from pin 5 to the RESET coil repositioned due to its having been crimped.

Relay #2 (83 relay for 22RH29) functions as the AUTO-MANUAL relay for the RHR Heat Exchanger Bypass valve. Its failure occurred when it swapped to MANUAL (reset condition) as RHR loop flow was being reduced to its low flow setpoint. The low flow signal energizes a 219 style 115 Vac relay co-located with this relay in its Bailey Can. [The 83 relay is in the K1 position in the can, two 219 style relays are in the K2 and K3 position actuated on High and Low flow signals respectively.]

l Relay #3 (18SS relay for 22 BAT Pp)is the Slow Speed Start relay for a Boric Acid Transfer Pump, it failed to maintain the latched condition when the demand condition was removed. [The 83 relay is in the K1 position in the can, two 219 style 115 Vac relays are in the K2 and K3 position, actuated on High and Low flow signals l respectively.]

Additionally, I am including the followmg documentation:

Circuit diagrams for relays #2 and 3 Manufacturer's Specifications for 255 and 219 style relays Bailey Relay Module Technical Manual IfI can be of any assistance please call me at (609) 339-7463.

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MEMO 1

l To: Mr. James Riddle FAX (714)361-5479 l From: Craig D. Bersak (609) 339 7463, FAX (609)339-2210 l PSE&G Nuclear Business Unit, PO Box 236, Hancocks Bndge, NJ 08038

Subject:

Response to Questions from 10/2/96 l Date: October 3,1996 Here are answers to your questions from yesterday:

Are the capacitors electrolytic?

l Electrolytic capacitors are used in some Bailey control circuits. I looked over the Boric Acid Transfer Pump and 22RH29 control circuits and neither of these circuits use capacitors. You may be confbsing the contacts off of thgcontrol room's pushbutton stations for capacitors A pushbutton's contact appears as: }

T START The capacitors shomt in the Bailey manual, page 3, as part of the Suppression Circuit Board, are not in the models of the modules used at Salem (6615692Al, A2, A3)

Where electrolytic capacitors are used they are being inspected / tested and replaced when necessa:y.

What is the voltage at the relay cabinets?

The 28 VDC system voltage is norninally maintained between 28 to 30.3 VDC. Per a verbal discussion with a technician, they typically see 29+ VDC when they check at the back of a relay cabinet.

What is the significance of the suffixes -a 11, 128 on the relay ids?

I have not been ab!c to identify the specific special construction features identified by these suffrxes The S D catalog states "when a special type of construction is not covered by a

' common' fesrure or when it combines several of them, a special number is assigned at the factory. This numberwill always be '100' or g cater, and applies only to the relay to which it was assigned. I've tried repeatedly to contact Mr. Thomas Mahaffey, Production Engineering M:nger at Magnecraft/Struthers-Dunn (803) 395 8512, for the details with out his returning my calls. When I get in cor: tact with him I will inform you of the results l Should you need any other information please contact me.

.! i'??i32iME'CX?TE! IE/E N E! M .E0 "l l'.Hil

. 130iff.E '0G / 7-

ib'.'. A* EM 3.53. IJf f' f.I

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FAX :

To: Mr. James Riddle FAXs 714-3615479 l, From: Craig D. Bersak (609) 339-7463, FAX (609)339-2210 l PSE&G Nuclear Business Unit, PO Box 236, Hancocks Bridge, NJ 08038

Subject:

Relay sub numbers Date: October 3,1996 Spoke to Tom Mahaffey ofMSD, the suffix numbers mean that the relays were marked with a Bailey Part number (Suffix 111) or Public Service part number (Su& 128)

Otherwise they are the standard 255XCXP relays.

l l

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l Attachment III Product Data i

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j o S E CTIO N

. e a l ey es2-s2 I

PRODUCT INSTRUCTIONS i RELAY MODULE i

i 3T. NO. 6615692AO s ,

. 3

, i -

l l

D l BAILEY METER COMPANY

WICKLIFFE, OHIO 44092 s

L TH0 V8A L . . _ _ _ _ . -

i

=2 2

.8la:ihV i

j MODULE DESCRIPTION The Relay Module for Bailey 660 Systems is a three-unit wide (3-3/8 inches) module -rupta s w is w ee dzsigned for plug-in mounting in astandard y Bailey electronic systems cabinet (see Fig- 'I l ure 1). The unit is frequently used with the Type RZ Multiple Switch and Light Station 1

for contact interlock and signal light

%. . . ' ..*Wq' operation. -

{ _,,

i The module can contain three plug-in, ,

n

,, , , , u s e multiple-contact relays andis usedprimar- .

.tn%%1

} ily for interlocking or circuit protection. s% '1%!!!!!

1 As options, diodes can be added for selec- 'I

[t t!*!!!U i tive relay operation or a warning flasher , .",ilM ** U

! can be installed. 't),{' i.i.i.$.

I Three general purpose relays can be ;;;n;'.t'

] installed in one module. If a flasher is ;3:*,t;;

i used, height interference permits a max- .n;U;n imum of two latch type relays and one gen-i cral purpose relay to be installed in one .y,

k"k; i module. Relay variations are listed in -n .

! Table 1. The complete assembly of the "5E%#

p

module is shown in Figure 4. 55EN' ,,

All electrical connections are made '"'"

l thru one or two rectangular 32-pin con- i nectors mountedon the rear of the module. FIGURE 1 - Relay Module !

TABLE 1 l l

! Control Relay Relay Part No* Position

Type Voltage Contacts * (from front) l

6615661A1 General 118v, 60Hz DP-DT, + 1 N. O. & 1 N. C. '

i A2 Purpose 24v DC ,

j A3 125v DC l H2 A4 118v, 60Hz DP-DT, + 2 N. O. #N j A5 24v DC j A6 125v DC .

s l l A7 Latch 118v, 60Hz 3P-DT

) A8 Type" 24v DC A9 125v DC M or A10 118v, 60Hz 2N. O. + 2N. C. m ONLY

All 24v DC l A12 125v DC i *DP = Double Pole N.O. = Normally Open Contact ;

{ DT = Double Throw N. C. = Normally Closed Contact

- Flasher interference does not permit latch type relays installed in KX3 position.

! See Figure 4.

e ..m.. .m u _ .,. m.

,g

E92-52 Relay Module Page 3 O CIRCUIT DESCRIPTION d Suppression Circuit Board nector pins at rear of module. Diodes pro-vide selective relay operation on bidirec-Six sets of resistors (R1 thru R6) and tional operating voltages. See wiring sche-capacitors (C1 thru C6) can be provided on matic shown in Figure 2.

an optional suppression circuitboard (PCI).

l The circuit provides protection to the coil Flasher initiating contacts to prevent burning or erosion due to coil inductance. Incoming One optional flasher can be provided s transients are also suppressed with the ad- in the module. Circuit wiring for flasher J dition of this circuit. See Figure 2. must be provided external to module. In-Three sets of resistors and capacitors put voltage of flasher is 18 to 32v DC with are permanently connected to relay oper- a power consumption of 1 watt. Contact ating coils. Remaining sets must be con- rating is 0. 5a (resistive load) with a flash-nocted to the release coils when using a ing rate of 1/2 second on,1/2 second off, latch type relay and must be connected at Flash rate is not adjustable, installation.

Control Relay Blocking Diode Circuit Blocking diodes (CR1 thru CRG) are op Internal wiring diagrams for various tional and are located on rectangular con- types of relays are shown in Figure 3

. ...... m .. .. ...,

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.G Ji COMPONENT DESCAtPTIOff COMPCBi TNT DESCRIPTION COM PONENT DESCRIPTION C TWRU Re CAP. 49 MFD 100V R3 THRU 94 RSS 1840 t/tW X1, X3 e X3 RE1AT SOCKET SEE TABLE) 10% (sts TABLt) os PUSHER CAA TNRU CR4 DecDe senates KA CONTROL RELAY PC1 SUPPR CKT (SEE TABLE) KS CONTROL REMY COMPONENT Aart '

J1 A 13 RECT COMW KC C artSOL RELAY

& WE1.D 88UT A887 KD CorrTROL RE1.AY C3 CR4 R1 MODULE PT. NO. TNRU THRU THRU FLASHER ce cas na 6416403 A1 RE4D OMIT 8416092 A3 OMIT OM!? CMIT E

6418sa8A3 REQD REQD G418493A4 OMIT OMf7 6418491A10 R2GD OMIT T 4619402A10 EO OMff E REQD REQD REQD k 0418402A30

$618estA40 OMTT OM f7 FIGURE 2 - Schematic Wiring Diagram

/4)

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f f

mm r ,

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.........a..,

t co g., , , ,.

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.. ..: .. . .t . ... - s. e e s 9 m .

FIGURE 3 - Relay Internal Wiring Diagrams '

SERVICING Checkoperation of RelayModule by sub-stituting a known trouble-free module for 2. If modulehas plug-in relay installed in KX3 position, remove relay.

th) one in service. If trouble is definitely traced to the module, check for broken 3. Disconnect wires to flasher (12),

wires, damaged connectors or shorted Itads. If trouble continues after repair, 4. Disassemble flasher by removing consult a Bailey service representative or hex nuts (20) and washers (21).

r: turn unit to factory for repair.

5. Install new flasher and rewire in Flasher Replacement accordance with Figure 5 (R fer to Figure 4.) 6. Replace relay in KX3 position if removed in step 2

1. Remove fastener studs and pull Re- 7. Install Relay Module in systems cab-lay Module from systems cabinet, inet. Replace fastence studs and tighten.

REPLACEMENT PARTS A Parta Drawing covering the Relay There~ ore, when ordering parts, assure Module is shown in Figure 4. This drawing receipt of correct replacements by speci-will normally apply to the units furnished, fying on the order:

However, there may be individual dif-ferences in specific assemblies due to:

1. Complete nomenclature, code label

a. Design changes made since the number and part number of equipment for printing of this Instruction Section. which parts are desired,

b. Special design of equipment fur-

2. Parts Drawing number on which each port is illustrated. (The Parts Draw-nished to make it suitable for special application. ing Number is given in the title for the Figure.)

/a.T

Rslay Modulo E92-52 Page 5 23 7 O

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"Y ITEM PART No. NAME ITEM PART NO. NAME TTEM PART NO. NAME 1 SEE NOTE CODE 1ASEL li sell 334Al WINDOW 3 8433:13tAl 600DULE FRAME ASST 83 4616491Al FIASMER, SEE TASLE 19 4 44s1/4 PAN ND Send $ EXT, 3 lyf3alD1 F ASTENER STUD, IR EEN) AS REQD 18 StilfilAl RELAY SOCKET, 3 REQO 30 4-40 NEX Nttf, A8 REQD 4 191394A4 BRG WABMER, 3 REQD 14 $943TIAI RECTANGULAR CONN & St

$ 197301 All RETAINING RING,3RE@ NO. 4 TYPE B, PLAIN N WEla Nt,'T ASEY, WA$NER, At REQD 9 04134TBAl CKT SD WTG DRACKET 3 RIQD T 443643803 C ARD RETAINER 28 4 40s 31/4 PAN NEAD MACKINE l$ lH$333A4 alJCON RECT! PIER SCREW, A& REQD 4 48236304) SUPPRESSION CIRCVIT ON4H5), SEE TABLE 13 COMPONENT ANY, 4-40s 3/84 PAN MEAD SEMS EXT, 18 IN3141Al TY RAP Tit, 4 REQD AS REQO SEE T ASLE lf I N307Al LOCATION IASEL M 9 46tS834Al CARD NotmER 4-40 s f/4 PAN NEAD MACHINE 14 IM383 sal BO!&ERLESS TERB4!NALE, SCREW, AS REQD 10 64tt33&Al IDENTIFICATION CARD SEE TASLE AND

36 SE E " CONTRQL RELAY NOTE: SPECIFY hCMSER ON CODE LADEL WNEN ONDERING PARTS,

DOUDLE C0fL CONTROL RELAYS lHlHel T. 4. 9.10. II & til REQUIRE TWO ADDITIONAL SOLDERLES$ TERMINALS FOR CONNECTIONS TO SUPPREMION CIRCLTT COMPOSENT AS$Y.

" CONTROL RELAY PART NUMSERS L4ETED IN TARLE 1. PACE t go ITEM 8 ! TEM 13 TTEM 15 3E MIS 443Al onc? eR3Qo 33 M

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FIGURE 4 - Parts Drawing E92-58, Relay Module, Part No. 6615692AO

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e u y- v~v a e a s ;; , ; eu = = ?~ v 464 44 4 2 4 44444E 44444 4 2 FIGURE 5 - Relay Module Wiring Diagrar.

9 (6)

Instructionsfor Understanding Bailey Relay Cabinet 9 Arrangement and Wire Tabulations De Bailey Relay Cabinets are sectioned in 11 mws, which contain the following equipment and designations:

Row 1 16 34-pin Amphenol Set?es 93 Cable Comiectors. Cables that mute to the Control Conson plug in hem. %e cable connector position number is identifie( by numbers 1 thm 16. The pins on each connector are identified by letter designation A thru NN.

Rows 2 thru 9 Ba!!ey Relay Modules. h relay modules consist of thme relay sockets, '

identified as JCrl,10t2, and JtX3 (front to rear of module), a flasher relay (in some but not all modules), and two male 32-pin Amphenol Blue Ribbon style connecton (mounted to the rear of the module). Female 32-pin connecton are mounted on the back of the relay cabinet, while the rear doon of the cabinet provide access to this wiring. W pins of the connecton are identified by numbers 1 to 32, and them are 15 of these h connecton mounted per row on the cabinet's back panel.

Row 10 16 34-pin Amphenol Series 93 Cable Connectors. Cables that route to the Aux. Control System Terminal cabinets (located in the Relay Room, dimetly below the Control Room) ping in here. M cable connector position number is identified by numben 1 thm 16. h pins on each connector are identified by letter designation A thru NN.

Row 11 Service Section of the Cabinet. A 40-point terminal strip (which is identified as Postrion 1) and 10 circuit breakers (identified as Positions 2

- thru 11).

5

( l oa.)

w o O 5 '

22 REACTOR SHIELD VENTILATION FAN ROD' CONTROL REACT.

& iW PWR RELIEF VA BYPASS BREAKER *A*

& POPS CHAN 11 POS. IDENT. TYPE POS. JDENT. TYPE POS. IDENT. TYPE POS. IDENT. TYPE POS. IDENT. TYPE 1st WIRING POSN (X-1) 3 8 (X-1) 74-1 8 (X-1) !X-1) 74X/DC 2 (X-1) 74/OP 8 g (X-2) 6Y 1 (X-2) 63X 1 (X-2) (X-2i 74/AC 1 (X-2) 30 2 2nd WIRINGPOSN (X-3) 74/T 5 (X-31 3X 4 (X-3) 33X 1 (X-3) (X-3) 74/C 5 (F) FL-1 (F) FL-2 (F)

(F) FL-1 SCH.#203560-B-9776 i Jat WIR/NG POSN sci!! 203615-ABL-547

& 244085-B-9679 -

(JUMPER W/ RING / (6626556A2) (6626556A2) (6626556A2) (6615692A1) (66156S2A31 i 7 l l! t Typical Bailey Relay Cabinet Arrangement n __

(Front View)

L The wiring identifications for the Bailey Relay cabinets are shown as follows:

Q RC 6 6 t CABINET SERIES CABINET NO- WIRING

, ,f

_ RC25-6 POSIT /ON % w jN RQ_ 23 ~ (BLUERMODULE /BBONCWNNECTION CONNECTOF i u

ROW k PIN WIRING POSITION CAB /NETNO. 24 Fig. 1 Fig. 2 mamine the designation in Fig.1. De cabinet series and cabinet number is shown in the title block of the arrangement drawing, and identifies the parti r cabinet where the components are located (in this case, RC25-6). He bonom three characters, as shown, call out the row, Wringposition, and pin num De row esignation should be self explanatory (they are clearly represented on the arrangement drawings). Here are three Wring positions in each mo l where relay sockets X-1 and X-2 (designated as KXl and KX2 in PSBP #301699) are in the first Mringposition. Relay socket X-3 (KXJ on the PSDP) andi the flasher are in the second winni Position. De third Wring position (which is used for jumpering on the rear panel of the Bailey Relay cabinet) never has!

any equ9 ment locasal in k. I I

\

The rear or the Relay Module has two male Blue Ribbon Crnnectors mounted on the rear section, while the rear of the Bailey Re!ry Cabinet has three female Blue Ribbon Connectors mounted. 'Ihere are three wiring postrions in each module, and are numbered from the top to bottom, left to right. Since there are i 5 module slots per row, that yields 15 wiring positions. Note that there is never any equipment shown in

{' any wiring position divisible by three (3, 6, 9,12, & 15). For example, the location of the 74/OP relay for the Rod Control Reactor Bypass Breaker "A " is 6-6-13, or cabinet 6, row 6, and wiring position 13.

I The wiring in the cabinet is color-coded in the following manner:

1 .

! 118 VAC Line- Black l

118 VAC Neutral- White

118 VAC Ground - Green 28 VDC Positive - Brown .

28 VDC Negadve - Orange 125 VDC Positive - Blue 1 i'

125 VDC Negative - Yellow Computer Inputs and - Green

Alarms j Indication - Red 4

NOTES:

l 1. Only 2 wires per Blue Ribbon Connector pin may be terminated (Rows 2 thru 9), and the l maximum wire size is #18 AWG.

g 2. Only 1 wire per Amphenol Series 93 Connector pin (Rows 1 and 10), and the maximum wire size allowable is #22 AWG.

3. All soldering is to be performed by qualified personnel in accordance with the latest soldering procedure.

l D

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- _ . . ~ _ _ - _ .

_ ._____ - - . _ _ _ _ . _ - - _ _ . . _ . _ _ . - . . _ - . - - - - ~ _ - . . -- . . - - _ - . _

F

yyrg (As ssB0 Wit Olt ARRA38CENE887 3*a,,,a3 w IWIGDULE PART NUMBER 7 O -!>

l l vos.rAct 661562A1 (W/O FLASHER) I l

6626556A2 (WITH REPLACEMENT PLUG-IN FLASHER IDEC PART

GT3A-3AD24.MK834, CLASS / CODE X31-8554. THIS I i 118 YAC MAGNETIC MODULE FORMERLY USED FIRST GENERATION SMALL 2 24 E MAGNETIC KA PLUG-IN FLASHER BAILEY pal 1945741A1) 3 125 VDC MAGNETIC 6615632A3 (WITH *Hi-TEK" GREEN 1" x 2" x 3* BOLT-IN FLASHER)

MAGNETIC NOTE: DUNCO ~LA TCNWG" STYLE RELA YS MA Y 4 118 YAC i

NOTBE USED M THE ~KX3" RELAY SOCKETPOSITION i

5 24 YDC MAGNETIC KB IMTH THIS MODULE) 6 125 VDC MAGNETIC 691277A1 1* BLANK 1

7 118 VAC LATCH 6 2* N LATCH KC a 24 VDC .

691468A1 3" BLANK 9 125 VDC LATCH .

/% 6615710A1 FOR TIMER ,

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KA O KC x3 p 219'A AP [

V A255KCXP ~

219BBXF .

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' 3DT 81 - 9-18-96 10:28AX . PiC- 609t339t2210;: 2r 2 3 300 VOLT GENERAL PURPOSE .

2is PLUG-IN RELAYS S""

! Series 219 General Purpose Industnal Plug in Relays featurg i

g a 12 pin and a 14 pin size, tr0m 2 Form C to 4 Form C or 6 Form

y A/ Form B combinations. A lockmg Clip on the pli.sg is provided as standard. The coilis encapsulated for protection. Gold diffused

silver cedmsurn oxide contacts are standard. The screw terminal

' socket has all terminals on a single level, which facilitates the wir.

ing process. Nuclear qualified versions are available. Contact the

Socket 27390 factory for details.

DIMENSIONS inche " "a *'

it PIN MoosLe w,,,.,,

%PIM MODELs "*"

6 ace..e W','*"

) . , ~' *"'* a c 1 ,

MODELS AVAILAULE 4. P- b f

,,, ,[

e 12. PIN CONIACTS 14 PIN CONTACTS L.

.. h. amu

~

- ** W ]

1

' .e e. II c .:

e

'OLY 21998XP DPDT + 2 NO tt9xBxP DPDT 219X0XP 4 PDT 21eFXX* e PNO =*

a- 8k

$$'OL5 l

l

.e o c::: 219 ASAP DPDT A 1 NO 2190X8P 4 PNO e 2 PNC ,e C C#90" ge g c:::3 ,

4 i NC

.5 l

{c ]

h ig Mooe's wth a Menwei Opereaor leverts u oe Lu) lnercase overeg i ,7 L- rN hoseht try it uu:ti II , , t El q y l 16

n. .

i st pin Moo (Ls wims esuune d irem leem os eaciou

- if [ !

~ ,,is jb 14 pin MoDEL5

'I e

I . . . b f ) l .. , k,,f f., k,f l $. n... .m. ..1... m. .. 1. r. n. . n..

l . m. . .. m, ., I. n. . n. n.., .. . n. n, . n., ..

l 21DeeKP Ft IeZP 219 ASAP 219EDIP ,,

DP DT

Sko 210 DX5 P 219811P 08 07 OROT . t No 41 Mc 4PUT sono + tome IP%o CONTACT DATA standard Contacts Silver GENERAL DATA j Ratings Cadmium Oxide Gold Diffused insuletion:

~~ 1/4 surface.1/8 air Brook D6 electric: 1600 Volt AC Volte Meke Carry Operate Time: 25 ms max.

z Resist. Inductt Reiesse Time: 20 ms rnas.

y 24 Vdc 120 Vec 30A 10A 10A 10A Ambient Temperature Range: -10' to 4 60'C 4

30A 10A 10A 3A LHe hpoctancy: 10 minbn mchanical operadons

' 240 Vac 30A 10A SA 1A 100.000 at fieled Load 28 Vdc 30A 10A 10A 3A 500.000 at W Rated Load i

125 Voc 30A 10A 0 .%A 0.1 A Cover: Cleet Polycerbonete 125 Voc'SM 30A 10A 1.5A 0.5A Sockets: 12-om-#27390 i

125 Vdc*DM 30A 10A dA 1.5A 1d'0* -#333I7

' 250 Vde'SM 30A 10A 0.5A 150MA (See pedes 62 63 for Styles and 250 Vdc*DM 33A 10A 15A 0.6A Dimensons) rar n,#y .en es swure <em.c= -an reetary ior u t. a es4 tonne OPTIONS t6roucovo toed es dehned as coher reay coils Feature Suffir

' COlLDATA Indicetor Lemp: L AC Relays,50-60 Hz, SVA (Coil Data at 60 Hz) M49uel Actuator- M Fine Sny,r cold Diffused sifurcated Contactoi 33 l yo,,, Mnnemge,se open closed im ,ed.nce Reelet.r,ce. Permanent Magn B o 6 Ohm Ohms i

6 1500, Nuc.leur Quellflod Versione-Contact Factory 840. 7.2 1.1 12 75o. 410.

Co68 5uppreselon: V 27 42 24 375. 200. 120. 15.5 '

120 75. 40. 2700. 540. *' 4G CODE 243 32. 17. 13.400 2100. ,

DC Relays.1.8 Watts (2.5W at 125VDC) at 25'C Typical Type No. c 219 .? XBX'.'i P 7't"' "'Dl Mllflemporte Note Cod vattedefend L,. 9.', " s

. 1 j yen,g, ,, _

Resistance 1 een enso; . '

[J,.

Cold ._ 7 I Hot Cold, Ohme *

j 6 Seriers - '.,

385. 304. 15.5 l 219-Industdel Plug-in I

h(28)* 9' 2 Cont.cl Arrangements- .-'. ..

32 2

86'

62' 375' - . i'e ?* ; L. 4 115/125* 20' 16'

' 6200 XBX AtA 1 Form 2 Form A, C)2 Form C and 1 Form B) ^

- 1.~

j *No f E Stoct is voc and t 13 Voc reisys la.we easi'iout.stes Marnowd 24-28 voc and D3X 2 Form A & 2 Form C) .

XDX 4 Form C) '

i ts 125 vde <espectheir These re'eys operste si saw of the to-or vortesee enri vu <ce wnhan snowowe vernpersives nses et tne n>gner venace4 rXX 6 Form A) '. *

,V '

j 250/oc-Use 25/DC <eley end e senes res4ior (0.000 omme. 5W) noi need DXD 4 Form A & 2 Form B) '

Min. Operate; AC- es% of nomarui voLapo standard Naturo P-Polycarbonete Cover .

T - " "**" " # 'G' Mas. Overvoltage: liO% of norrinal Opdonel Featurse (See Options) indicator Lamo--Code L APPROVALS uenuai Actuator-code M J

2 e

. UL r seWhite Ca.rd.and, a . ru. . n ee Component Lletings: File #E13224 Blfurcated Con'a~-'%= 33

NOV-36' 96(TUE) 12:09 PSE10 HAGEN PROJE 609-339-2984 P.002 i,

POBLIC SERVICE ELECTRIC AND GAS COMPANY NUCLEAR DEPARTMENT i

SPECIFICATION NO, S-C-RCP-CD%343 l

1 REACTOR CONTROL AND PROTECTION SYSTEM CONTROL RELAYS ,

DETAILED SPECIFICATION j REFERENCE NO: N/A

]

IMPORTANT TO SAFETY: X

! YES NO 4

l Supervisor Supplier Qua:lty 1

Des!gn '

Verifiet Peer Reviewer Supervisor U

k,Me u n[#[f6 @r# Design 0 Onginal leave J.W. Shank y J. O'Connor vertfier yq.u..e Luh is/e'M

,.ee, Reviewer REV REVISION

SUMMARY

PREPARER /DATE APPROVALS /DATE FUNCTION I m .-g : wps:R : P3-EE-R R :A9 LS39

hui-2b'9b(Tut)12:09 PSEkG d' AGEN PJLOJECT 609-33M9H P.003 Specification No. S C-RCP-EDS-0343 Revision 0 Page i TABLE OF CONTENTS 1.0 SCOPE 1 2.0 DEFINITIONS 1 3.0 CODES, STANDARDS AND REGULATORY REQUIREMENTS 3 4.0 SUPPLEMENTAL DATA 4 5.0 DOCUMENT SUBMITTALS 4 S.0 DESIGN REQUIREMENTS 6 7.0 PERFORMANCE REQUIREMENTS 6 8.0 MATERIAL REQUIREMENTS 6 9.0 FABRICATION AND ASSEMBLY REQUIREMENTS 7 10.0 INSTALLATION REQUIREMENTS 7 11.0 INSPECTIONS AND TESTS 7 12.0 QUALIFICATION 7 13.0 CLEANING 9 14.0 MARKING AND IDENTIFICATION 9 15.0 PACKAGING, HANDLING AND STORAGE 10 16.0 DEFECTS AND NONCOMPLIANCES 10 17.0 RECORDS 10 i 18.0 OTHER REQUIREMENTS 10 l 19.0 RIGHT OF ACCESS 10 20.0 QA PROGRAM REQUIREMENTS 11 21.0 RELAY SPECIFIC REQUIREMENTS 12 l 21.1 219 Series 300 V General Purpose Plug-in Relay SpeciMcation Requirements 13 ;

21.2 B255 Series 300 V Larching Plug.In Relay Requirements 16 21.3 219 & B255 Series Mating Soc'ket Physical Dimensions 19 33/3 8:3636 939 CIS ~31d] ! L%89:8 : M-E-88 :M9 MM

nuv'40 voitutt le:UV ra ku dAut,N yxUJE0f 609-339-2984 P.004 Specification No. S-C-RCP EDS-0343 Revision 0 Page il LIST OF EFFECTIVEPAGE8 Paae Number Revision i 0 li 0 1

0 2 0 3 0 4 0 5 0 6 0 7 0 8 0 9 0 10 0 11 0 12 0 13 0 14 0 15 0 16 0 17 0 18 0 19 0 1

1 33/C #:3838 939 CIS -31d i Nd9t:1 : 96-93-11 A3 M

. _ _ _ _ _ _ _ - - - - - - - -- - - - ~ ~ ^

.. . .' . . w m u . v raceu anuta rnunW M9-339-1984 P.005 Specification No. S C-RCP EDS 0343 Revlelon 0 Page1 1.0 SCOPE '

This specification defines the construction, functional, performance, quality assurance and shipping requirements for Struthers-Dunn 219 and B255 Series general purpose and latching plug-in relays respectively. These relays are used in various applications in the Reactor Control and Protection System and various other control systems at Salem Nuclear Generating Station Units 1 and

2. An equivalent replacement relay is acceptable lf it meets all the requirements of this specification and has the same form, fit and function as the Struthers-Dunn 219 and 8265 Series relays.

It is not the intent herein to specify all details of design and construction. it .

shall be the responsibility of the Vendor to ensure that the equipment has been designed and fabricated in accordance with engineering codes, standards, and federal and state regulations in accordance with section 3.0 and 4.0 of this specification.

No deviation from this speelfication or applicable federal, state, and local codes and standards shall be accepted until approved by PSE&G. Devlations are considered departures from any requirements of this specification.

Nonconformances from federal, state, and local codes and standards must be submitted to the cognizant jurisdictional agency for authorization, prior to submittal to PSE&G, After ebtaining approval, Vendor shell promptly document and notify PSE&G of all deviations and nonconformances from the purchase order / contract. Further engineering, manufacturing or fabrication after detection of any deviation or nonconformance prior to PSE&G approval shall be at the Vendor's risk. No departures from this specification shall be binding on any party until an addendum or revision to the specification has been issued.

2.0 DEFINITIONS 2.1 Abbreviations / Definitions ANSI - American National Standards instituto Approved - this word, when applied by the Owner to the Vendor's drawings or documents, means that the drawings or documents are satisfactory from the stand. point of interfacing with all Owner-furnished componenh of the installation and/or that the Owner has not observed any statement or feature that appears to devlate from the specification's requirements. Except for the interfacing 33/t *;3636 939 019 - _ Gld - -

t M 9p 1 96-93-1,1 _ _ 39 M

1 .- . .

l suv-40 % 1 tut) 1 D10 PSEku liAGEN PROJECT 609-339-2984 P.006 l

l l

Specification No. S-C RCP EDS-0343 Revision 0 Page 2 l

with all Owner furnished components, the Vendor shall retain the I

I entire responsibility for complete conformance with all of the specification's requirements.

Class 1E - the safety classifloation of the electrical equipment and systems l that are essentist to emergency reactor shutdown, containment and reactor heet removal or are otherwise essential in preventing significant release of radioactive material to the environment.

I Design - the time during which satisfactory performance can be expected l

Ufe j for a specific set of service conditions, i NEM A - National Electrical Manufactures Association IEEE - Institute of Electrical and Electronic Engineers OBE- Operationel Basis Earthquake i

Owner - Public Service Electric and Gas, Newark, New Jersey l PSE&G - Public Service Electric And Gas PSIA - pounds per square inch absolute .

Seismic - indicates that the equipment has been classified and certified to Qualified meet its performance requirements during and following one SSE proceded by five CBE's. All seismically qualified equipment shall satisfy Category 1 seismic requirements.

Service - the interval from instellation to removal, during which the Ufe equipment may be subject to service conditions and service demands.

SQURTS - Seismic Qualification Report & Testing Standardization SSE- Safe Shutdown Earthquake Vendor - a company other submitting a proposal or selected to fulfill the requirements of this specification.

..W 'N

nuv 4o votive; u:lu rstku nut.A PWJECT 60(>-339-1984 P.001 Specification No. S-C-RCP-EDS 0343 Revision 0 Page 3 3.0 CODES, STANDARDS AND REGULATORY REQUIREMENTS 3.1 General l

i 3.1.1 Various codes and addenda, standardo, or other documents that are mentioned by short form name elsewhere in this specification are fully identified below. To the extent that these documents apply, as stated herein, the version of the document listed below shall be used. A later version of some of the dated documents may become mandatory under regulations that have jurisdiction. If this occurs, the mandated version of the document shall be used.

3.1.2 If there is, or seems to be, a conflict between this specification and a reference document, the matter shall be referred to the Owner who wifl provide written clarification.

3.2 Various applicable documents follow:

ANSI N46.2.2 - 1972 Packing, Shipping, Receiving, Storage, and Handling of items for Nuclear Power Plants ANSI N45.2.11 - 1974 Quality Assurance Requirements for the Design of Nuclear Power Plants IEEE 344 1975/B7 Recommended Practices for Seismic Quar ~catMn of Class 1E Equipment for Nuclear Power & .c.ating Stations SQTS 01-GSQTP General Selsrnic Qualification Technical Procedure Rev.4 SQTS 01-CR.1.SFP General Purpose Control Relays Seismic and Rev.5 Functional Proceduto ljL 508 - 18tliedition Stendards for Safety Industrial Control Equipment Regulatory Guide 1.38 Quality Assurance Requirements for Packaging, October 1978 Shipping, Receiving, Storage, and Handling of items for Water-Cooled Nuclear Plants (endorses ANSI N45.2.2-1972) t l

l gm 5ga t PM2MLLJfR-WL-U -

'N !

nuv-n nilet) 11:11 F5Eku llAGEN PROJECT 609-339-2984 P.008 Specification No. S-C RCP EDS 0343 Revision 0 Page 4 Regulatory Guide 1,64 Quality Assurance Requirements for the Design of October 1973 Nuclear Power Plants (endorses ANSI N45.2.11-1974)

Regulatory Gulde 1.100 Seismic Qualification of Electrical Equipment for Nuclear Power Plants (endorses IEEE 344-1975)

Title 10 Code of Federal Regulations i

Part 21 Reporting of Defects snd Noncomplitince Part 50 Domestic Licensing of Production and Utilization Facilities '

Appendix A General Design Criteria for Nuclear Povser Plants Appendix B Quality Assurance Requirements for Nuclear Plants i and Fuel Reprocessing Plants

)

4.0 SUPPLEMENTAL DATA i

4.1 The Public Service Electric and Gas Company's Salem Generating Stations have committed to meeting the requirements of the Regulatory Guides of Section 3.2. Compliance with the Regulatory Guides shall be secompilshed by satisfying the requirements of the associated ANSI, IEEE or ISA standards.

4.2 PSE&G - Standard Specification 0 01, ' Quality Requirements for Suppliers."

5.0 DOCUMENT SUBMITTALS 5.1 Equipment Qualification Reports 5.1.1 The Vendor shall supply the owner, for review and approval, four (4) copies of the quellfication report demonstrating compliance wls the I testing requirements of Section 12.0. Upon approval bythe Owner, this requirement may be wolved.

5.1.2 The qualification report shall document the results of the relay type testing performed and any enelyses associated with such testing.

5.1.3 Quellfication reports sh all include recorded date on all qualification tested semples.

PPR/A31RYrtff4UtRf4 .-5)Jldt : fNWa;3 ? (%-BL-JN :1MLJLG

- - . - - - - - -- - - - - - - - - - - ^ "- - ~

{ IM-26' 9b(REl 12:11 PSE&G HAGEN PROJECT 609-339-2914 P.009 l l

Specification No. S C-RCP EDS-0343 Revision 0 Page 5 5.1.4 The qualification report shall document, evaluate and disposition any malfunctions, anomalies or performance deviations which occurred during testing.

5.1.5 All test results shall be reviewed, approved and signed by qualified personnel.

5.1.6 The Vendor shall confirm In writing and shall submit a report, including calculations and/or test data, for approval by the Owner which supports his statement that the equipment furnished under the specification meets '

the requirements for the Safe Shutdown Earthquake, Operating Basis Earthquake, and any other effecte listed herein. The Vendor shell, ao part of his report, provide natural frequency dato determined by either analysis or test. The analysis or test shall confirm that the resulting deflections shall not cause damage to the equipment which may be detrimental to its capability to function as specified. The Vendor shall include a schedule of submittels, approvals, intedece resolutione, and certificates to be subrnitted to, or received from, the Owner, as discussed herein. When seismic quellfication le based on testing, e fully detailed test plan must be submitted to the Owner for approval prior to the initiation of testing, unless equipment has boon pre-qualified. Any de'viations from the approved test procedure must be approved by the Owner. Resolution of Engineering comments on module qualifications may require additional testing which will be negotiated.

5.1.7 All quellfication reports shall be of high quality and legibility. l 5.1.8 Manuele and reporte shall be bound so that copies of each page may be l easily mede and revised pages may be easily added.

5.1.9 Each qualification report submittal shall have a unique controt number for reference and control purposes.

5.1.10 Vendor provided qualification documentation should be identified with the PSE&G name and purchase order number.

5.1.11 A controlled copy of the qualification report shall be supplied with a purchased equipment whenever new qualification testing has been performed.

5.1.12 One controlled copy of each quellfication report shell be retained at the Vendor's file for future reference.

33/9 *:3636 939 CI9 e ' : @I : 96-93:II_ _ 49 N

Of-26'96ITUE)12:12 PSEkG HAGEN PROJECT 609-339-2984 p. 010 i

Specification No. 5 C-RCP EDS-0343 Revision 0 Page 6 4

6.0 DESIGN REQUIREMENTS 6.1 The relay physical dimensions and coil & contact configuration shell be as shown by Attachments for the appilceble relay type.

1 S.2 Relays shall plug into the socket assembly shows1 by Attachment for the applicable relay type.

6.3 Relays shall have a design life of not less then 40 years while in service under the mild environment defined in Section 6.4. The relay application (normally energized vs. normally de-energized) shall not affect the 40 year design life. The following exceptione shall apply:

maximum of 10 million mechanical operations

- 100,000 at rated load

, 500,000 et half rated load 8.4 Environmental Design Requirements 6.4.1 Relays shall be designed to operate in various instrument and relay racks

, with the following service condition environment:

' Minimum Maximum Temperature (*F) 40 140 .

Pressure (PSIA) 14.69 15.20 l Relative Humidity (%) 20 90 Radiation (Total Integrated Dose in RAOS-gamma for 40 yrs.) < 10' 7.0 PERPORMANCE REQUIREMENTS 7.1 The relays shall have performance characteristics which meet or exceed j the specific performanca requirements for each relay type in accordance i

with the Attachments to this specification. For specific performance i requirements for each relay type see the applicable Attschment.

8.0 MATERIAL REQ (llREMENTS i 8.1 Relays shall be constructed of high quality materials.

I 6

avv 40 rolluct 14 14 Othb NAbtN PK0dECT 609 339-2984 P.0li l

i Speciflection No. S-C RCP EDS 0343 j Revision 0 :

Page 7 l

9.0 FABRICATION AND ASSEMBLY REQUIREMENTS l 4

9.1 Relays shall be designed and constructed in accordance with the j l applicable Attachments. Equivalent replacement relays shall have the some physical dimensions, mounting, and coil and contact configuration i

as previously quellfied relays to achieve the form, fit and function of the j original relay.

1 .

I 9.2 Relay design, material and workmanship shall result in a high quality j product.

j 10.0 INSTALLATION REQUIREMENTS i 10.1 Relays shall be designed for mcunting in a souet in accordance with the applicable Attachment. Mounting may be In the vertical or horizontal j plane in various equipment racks.

]

11.0 INSPECTIONS AND TESTS l

11.1 The Owner's authorized representatives shall reserve the right to inspect i

l design, materials and workmanship end to report thereon, at any time j during the program of design, fabrication or testing.

i 1

12.0 QUAUFICATION a

^

12.1 Electrical and Environmental Qualification Requirements j 12.1.1 Relays shall be qualified for operation in the environment specified in i Section 6.4. Relay parts shall not be subject to degradation for the

) apecified life of the component.

12.1.2 Relays shall have UL 508 certification. The Vendor shall document the I

applicable parts of the liL 508 cortification. I l

! 12.1.3 Design changes, part substitutions and other modifications to previously

{

quellflod designs require either additional quellffcation testing or analyels

! to prove new designs are qualified or to confirm changes have no impact i

on previous qualification testing respectively. The Vendor shall notify l

and inform the Owner of design changes or modifications to previously :

approved dealens.

5p : MCl : L8 & f k B N

50V-2b' %iTUE) 11:12 PSEk0 MGEN PROJECT 609-339-2984 1

P.012 i

l Specification No. S-C-RCP-EDS-0343 Revision 0 Page8 12.2 Seismic Qualification Requirements 12.2.1 Selsmic Qualification adequacy of the equipment shall be established by the results of esismic tests performed in accordance with (EEE Stand 3rd 344-1975/1987 as appilcable and the combination of SQTS-01-GSQTP titled, " General Seismic Qualification Technical Procedure" and SQTS-01 CR-1-SFP titled, " General Purpose Control Relays Seismic and Functionri Procedure."

12.2.2 The Vendor shall qualify the equipment for the specified seismic l

requirement either by performing a similarity analysis to a previously l queiified equipment whose seismic qualification level is adequate to l envelope the required seismic response spectra for the new equipment, or by performing the required simulated solemic qualification tests.

Quellfication testing or snelysis should addrese relay mounting in the vertical or horizontal plane.

12.2.3 The equipment should be seismic tested to its fragility level or test response spectra (TRS) shall envelope the site specific required response spectra (RRS) when attached.

12.2.4 The mtnlmum acceptance criteria or each seismically testrd r#4de shall include the following:

No lose of function or ability to perfctm designed functions before, during and after testing.

No structural or niectrical failure which could compromise equipment integrity.

No adverse operation or misoperation before, during and after tet. ting. N'eximum allowable contact bounce (change of state) shall be 2 milliseconds during seismic testing. Test equipment shall be capable detecting contact beenc > of 2 milliseconds or shorter duration.

12.3 Prototype Testing 12.3.1 Qualification programa may be based on prototype testing of equipment.

A representative sample of each module type must be tested.

Engineering justification of the program must be provided to assure qualification of all equipment supplied.

5 O

N

nut-Jo yo utt.) u:la natu Mut..N FK m cr 609-339-2984 P,013 l , l

i i

l i

' Specifleetion No. S C RCP EDS 0343 Revision 0 j Page 9 Vendors may qualify equipment based on prior testing provided the test i

j report la available to the Owner and the Vendor submits a report showing that this prior test meets seismic testing requirements herein, j Changes to atendard quellfication documentation will be negotiated if review and approval requires modification.

A final analysis and/or test report shall be compiled by the Vendor and i submitted to the Owner for approval. It is required that the qualification i

document be complete and address fully the equipment being supplied in accordance with this specification, 12.4 Certification of Compliance 12.4.1 The seismic testing data report shall be stamped and signed by a Registered Professional Engineer. The Vendor shall submit a Certificate -

of .Compilence (COC) documenting compliance to the design and qualification requirements of the specification. The certificate should reference the applicable purchase order, this specification and the applicable qualification report. The certificate shell be signed by the appropriate Quality Assurance representative.

12.4.2 The assernblies used for seismic testing or quellfication shall not be used as a deliverable to the owner. These test speelmens are previously fatigued and are not suitable for operation.

12.4.3 The equipment shall perform its intended function when exposed to the service conditions environment spoolffed in Section 6.4 A Certificate of Conformance shall be supplied. Thle should state that the equipment will perfor'm its intended function within the appilcable accuracies when subjected to the environmental conditions identified herein.

13.0 CLEANING 13.1 Before testing and prior to shipping, relaya shall be thoroughly cleaned to remove dust, debris and other foreign materials. Cleaning agents used shall not damage finlohed surfaces or adverselyaffect materl&l properties and function of equipment.

14.0 MARKING AND IDENTIFICATION 14.1 Each relay shall have a nameplate which identifies the model number, part number, serial number, coil voltage rating and manufacturing date.

ER A R O:ff e M 4 U tR R +4M 'N '

OV-26' 96(TlEl 12:13 PSEkG llAGEN PROJECT 609-339-1984 P.014 l

Specification No. S-C-RCPJOS-0343 Revision 0 Page 10 15.0 PACKAGING, HANDt.ING AND STORAGE 15.1 The packaging, handling, storage and preparation of relays for shipment shall be in accordance with ANSI N45.2.2 level B requirements. Relays shall be thoroughly protected against the elements and damage during l transit and storage.

l 15.2 Equipment contents, part numbers and the Owner's purchase order number shall be clearly marked on shipped packages.

l 15.3 l Vendor shall provide to the owner instructions for applicable storing and handling instructions.

16.0 DEFECTS AND NONCOMPLIANCES 16,1 The equipment covered by this Specification is safety related and is subject to the requirements of 10CFR Part 2i for the reporting of defects and noncompliances.

17.0 RECORDS 17.1 See Section 5.0 of this spec.ification for all required documentation.

17.2 Qualification documentation and other correspondence related to the releys procured by this speelfication shall be retained by the Vendor for a minimum period of at least the equipment design life. These records should be forwarded to PSE&G for retention if they will not be retained by the Vendor.

17.3 All records shall be reproducible and capable of being microfilmed.

18.0 OTHER REQUIREMENTS 18.1 The terms and conditions of any warranty for the relays shall be clearly defined by the Vendor.

19.0 RIGHT OF ACCESS 19.1 The Owner shall have access to all vendor and sub tier facilities and records which are directly related to the relays procured by this specification.

met,:mm er# m .m , en : ma-u ma

suY-40 n t M ) 12:11 PSEkti !!AGEN PROJECT d

609 339-2994 P.015 Specification No. S.C.RCP EDS-0343 Revision 0 Page 11 19.2 The Owner shall notify the Vdndor seven (71 calender days in advance of such inspections.

20.0 QA PROGRAM REQUIREMENTS I 20.1 Suppliers of equipment to this specification are required to have a quality i assurance programs which comply with the requirements of 10CFR50, i " Quality Assurance Criteria for Nuclear Power Plants and Fuel Processing Plants," Appendix B and ANSI N45.2.11-1974 and demonstrate

.l implementation through audit'and/or inspection by the Owner.

! 20.2

The Vendor shall comply with PSE&G standard specification Q 01, Quality Assurance Requirements for Suppliers.

20.3 The Vendor's Quality Assurance Program shall be documented and shall 1

be approved by the Owner prior to the award of the contract.

j 20.4 Inspection and witnessing of in process testing shall to be made available i at the owner's discretion and dependent upon proper notification by the Vendor prior to the performance of in-process testing. The Vendor shall notify the Owner's Quality Assurance Drpartment by facsimile at (809) f 330 7707 at least 72 hours8.333333e-4 days <br />0.02 hours <br />1.190476e-4 weeks <br />2.7396e-5 months <br /> prior to all vendor hold points.

20.5 Prior to shipment, the Owner has the option of performing a deteited inspection of the assembled relays. This inspection shall not lessen the responsibility of the Vendor for the completeness and correctness of the modules.

20.6 Parts or materials indicating irremediable or injarious defects, improper fabrication, excessive repairs, and/or not in accordance with this ;

specification, the QA program, or approved drawings shall be subject to '

rejection. They shall also be subivet to repair or replacement by the Vendor if such conditions are discovered after delivery at the Owne(s facility.

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NOV-26' 96(TVE) !!:14 PSEkG HAGEN PROJECT 609-3392984 P.016 i

Specification _ No. S-C-RCP.EDS-0343 Revision 0 Page 12 21.0 RELAY SPECIFIC REQUIREMENTS i

j Note: A site specific required roeponse spectra (RRS) will be attached

, when required. Reference Section 12.2.3.

21.1 219 Series 300 V General Purpose Plug-in Relay Specification i

Requiremente 219 Series Relay Physical Dimensions and Contact Arrangement

] 21.2 8255 Series 300 V Latching Plug-in Relay Requirements B255 Series Relay Physical Dimensions and Contact Arrangement

21.3 219 & B255 Series Mating Socket Physical Dimensions i

1 i

l 1 4 I

i l

i I

I l

i l

l 1

33/918:3636 939 CIS *3ld : KdO9:1 : 96-93-11 :A8 M

. . . _ . . . _ . - - = _ _ _ _ . - _ _ _ - _ . . _ . . _ . - - - _ - . _ . . - . . -

av 4o 70 t tutJ u:M ntRU MUb.i PKunM 609-339-1984 P.0l?

Specification No. S-C-8CP-EDS 0343 Revision 0 Page 13

{

SECYlON 21.1

] 219 8eries 300 V General Purpose Plug in Relay Specification Requirements I

Reference:

Struthers Dunn Commerclet/ industrial Relays Catalog Type 219BBXP: Double pole, double throw plus 2 normally open sets of contacts Type 219ABAP:

Double-pole, double throw plus 1 normally-open and 1 normally-j closed set of contacts General Data:

insulation: 1/4" surface,1/8" ett 1

Dielectric: 1500 VAC minimum i

Operate Time: 25 ms maximum ~

Release Time: 20 ma maximum

. Coll.Qala:

}

120 VAC Relay, 50-60 Hz, 5 VA:

i

Voltage: 102 - 132 VAC Current: 75 mA open,40 mA closed (typical)

Impedance:

2700 ohms (typical)

Realstance: 640 ohme +/ 10%

24/28 VDC Relays, 2.3 W at 25'C:

4 Voltage: 19.2 - 30.8 VDC Current: 77 mA hot, 96 mA cold (typical)

] Resistance: 250 ohme +/- 10%

i 115/125 VDC Relaya, 2.6 W at 260C:

Voltage: 90 - 140 VOC i Current: 16 mA hot, 20 mA cold (typcial) i Resistence: 6200 ohms +/- 10%

i 4

1 1

35/91#:3656 959 919 -3!d : L109:1 ! 96-93-11 _

M N

.; s 1 aus-n 9b(1Ut.l 12:15 PSEk0 ifAGEN PROJE0T 609-339-2984 P.010 Specification No. S-C RCP-EDS-0343 Revision 0 Page 14 SECTION 21.1 219 Series 300 V General Purpose Plug in Relay Specification Requirements Contact Data:

Composition:

Gold diffused silver cadmium oxide contacts unless specified 1 otherwise 120 VAC: t 30 A make,10 A carry,10 A resistive break,3 A inductive break 24/28 VDC:

30 A make,10 A carry,10 A resistive break,3 A Inductive break 115/126 VDC: 30 A make,10 A carry,0.5 A reelstive break,0.1 A inductive break Ootional Features:

Indicator Lamp Coil suppression

.oy : WrmLLfs%-U N

Nov-2b' %ITUE) 12:15 PSEkG HAGEN PROJECT 609-339 1994 P.019 Specification No. S-C-RCP EDS-0343 Revision 0 Page 16 SECTION 21.1 1 1

DIMENSIONS inches

12. PIN MODELS tocung

-- Device -

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,f uo c on

& COVER-

o 0*

W CLEAR 2ge c=: POLY.

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CARBONATE o=

no C'=

1 Y L, I '

_l - - 2 '% -

, s'% ,

WIRING (circuits viewed / rom front of socket)

12. PIN MODELS LJ LJJ '

LJ L,1J

. M. , .C. T.."1.,

,. P. T.

1.. M. ..

21SBBXP \'

219ABAP DP.DT + 2NO DP-DT + 1 NO & 1 NC 219 Serlas Relav Physical Dimensions and Contact Arranaement gg/9ts:ge sa MB -W ' N -"

nut 40 30t:0:,1 14:13 rstau HAUbN PROJECT 609-339-1984 P.020 i

Specification No. S C RCP EDS-0343 i Revision 0 Page 16 SECT 10N 21.2 5256 Series 300 V Latchine Plue-In Malay Requirements

Reference:

Struthers Dunn Commercial / industrial Relays Catalog Type B255XCXP: Three pole, double throw General Data: '

Insulation: 1/4" surface,1/8" air Dielectric: 1500 VAC minimum i

Operate Time:

25 ms maximum, mechanic, ally latches until reset coilis energized, i even if power is interrupted l

Release Time: 20 me maximum, when reset coil is energized l Coil Data:

120 VAC Relay, 50-80 Hz, 6 VA:

Voltage: 102 132 VAC Beset Cell (3 VA):

Current @ 60 Hz: 22.6 mA (typical)

Realstance: 1700 +/- 10% ohms Qggrate Coil 15 val:

Current @ BO Hz: 76 mA open,40 mA closed (typical)

Resistance: 540 +/ 10% ohms 24/28 VDC Relays,2.3 W at 250C:

Volt:0e: 19.2 30.8 VDC j Reset Coll (1.7 Wl:-

l 1

Current: 70 mA (typicall Resistance: 340 +/ 10% ohms gg/ggs:ge ggi gg;9 4M : W R I ' @ @ II

. +

auv .o 9btTUE) 12:15 PSEk0 HAGEN PROJECT 609-339-2984 P.021 Specification No. S-C-RCP EDS 0343 Revision 0 Page 17 SECTION 21.2 B255 Series 300 V Latching Plug in Relay Requiremertts

_Qnerate Cell 12.3 Wl:

Current: 96 mA (typical)

Resistance: 250 +/ 10% ohms 115/125 VDC Relays, 2.5 W at 25'C:

Voltage: 90 - 140 VDC Reset Coil (1.Z,,W_l:

Current: 13.8 mA (typical)

Resistance: 9000 +/- 10% ohms Doerate Coil 12.5 W):

Current: 20 mA cold,16 mA hot (typical)

Realstance: 6200 +/- 10% ohms Centact Date:

Composition:

Gold diffused silver cadmium oxide contacts unless specified otherwise 120 VAC:

30 A make,10 A carry,10 A resistive break,3 A Inductive break 24/2B VDC:

30 A make,10 A carry,10 A resistive break,3 A inducti'ia break 115/125 VDC:

30 A make,10 A carry. 0.5 A resistive break,0.1 A inductive break l

Ootional Features:

Indicator Lamp Coil suppression l

l 4

g : 0 -

p g) 12:16 PSE10 HAGEN PROJECT 609 339-2984 P.022 Specificatlan No. S-C RCP EDS 0343 Revision 0 Page 18 SECTION 21.2 DIMENSIONS inches F ' " ^

WIRING (Circuita viewed CoVEH- from front of socket).

CLEAR POW- .

Operate Reset CARBONATE

, Y, 6 5 4 3 2 1 p 4' lie y

-. V 4e h(b()

cc, <

, 7 8 9 I L. 10 11 12 a s a w -

8255XCXP

f

! LOCKING DEVICE i

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I B255 Series Relav Physical Dimensions and Contact Arranaeme\ ,

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- - oo 'uasucI Lt:so t*stnt; gggg;W YKUJECT 609-339-2934 P. 023 Specification No, S.C RCP-EDS 0343 Revision O Page 19 SECTION 21.3 DIMENSIONS 2 32 E! -

lr %

21

32 -

L 82*6-32 vtnuinal, scagws H 420

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- w w L v v v-1 STE '27190 50Catl 219 (B255 Series Matina Socket Physical Dimensigna 33/35s:3886 939 CIS ~3td

- i KdIS:I : 96-93-II -----;M M

ML20133D225

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