Wabtec RMS Mors Smitt 4M400 User Manual

Test block system, advanced protection devices

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4M400 / 4M420 User Guide

Test Block System

RMS Mors Smitt

Advanced Protection Devices

User Guide

Page 1 of 26

4M400_User_Guide_v01.0 15/01/25

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Due to RMS continuous product improvement policy this information is subject to change without notice.

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Page 1 4M400 / 4M420 User Guide Test Block System RMS Mors Smitt Advanced Protection Devices User Guide Page 1 of 26 4M400_User_Guide_v01.0 15/01/25 www.morssmitt.com/rms Visit for the latest product information. Due to RMS continuous product improvement policy this information is subject to change without notice.
Page 2: About This Manual
Any and all such liability is disclaimed. Contact Us RMS Mors Smitt 19 Southern Court • Keysborough 3173 • AUSTRALIA Phone +61 3 8544 1200 • Web Email sales.rms@wabtec.com http://www.morssmitt.com/rms Page 2 of 26 4M400_User_Guide_v01.0 15/01/25 www.morssmitt.com/rms Visit for the latest product information.
Page 3: Table Of Contents
Contents Contents .......................... 3 Documentation ........................ 4 Technical Bulletin ..........................4 User Guide ............................4 Introduction ........................5 Test Block System ......................6 Test Block Components ........................6 Test Block Usage ......................7 Placing into the test state ........................7 Stage 1 Isolation ............................
Page 4: Documentation
Documentation Technical Bulletin The detailed technical attributes, functional description & performance specifications for the 4M400 are described in the product Technical Bulletin. The order of precedence for product information is as follows: • Technical Bulletin • User Guide User Guide This User Guide covers all 4M400 test block versions &...
Page 5: Introduction
Introduction 4M400 Test blocks enable test technicians to quickly and safely isolate protection relays so that test signals may be injected and system performance verified. The 4M400 Test Block system is designed as a general-purpose isolation and test signal injection point.
Page 6: Test Block System
Test Block System Test Block Components The 4M400 Test Block system is made up of 4 main components. • Test Block • Isolation Plug • Test Block Cover • 4M420 Test Plug 4M400 Test Block Complete 4M400 Test Block Front Cover Removed - Stage 1 Isolation 4M400 Test Block 4M420 Test Plug Isolation Plug Removed - Stage 2 Isolation...
Page 7: Test Block Usage
Test Block Usage Placing into the test state Stage 1 Isolation Undo Front Cover Thumbscrews to allow Front Front Cover Removed - Stage 1 Isolation Cover Removal Completed Stage 2 Isolation Plug Extraction Withdraw Isolation Plug - to Automatically short Isolation Plug Removed - Stage 2 Isolation CT circuits and then isolate remaining circuits Completed...
Page 8: Test Plug Insertion
Test Plug Insertion Test Plug inserted into test block, tighten thumb 4M420 Test Plug may be inserted into test block screws to retain in position Test Plug ready for testing Page 8 of 26 4M400_User_Guide_v01.0 15/01/25 www.morssmitt.com/rms Visit for the latest product information. Due to RMS continuous product improvement policy this information is subject to change without notice.
Page 9: Placing Into The Normal Service State
Placing into the normal service state Test Plug Extraction Loosen the thumb screws to enable test plug Test Plug extracted and test block ready for extraction isolation plug insertion Stage 2 Isolation Plug Insertion Isolation Plug ready for insertion into the test block Isolation Plug inserted Page 9 of 26 4M400_User_Guide_v01.0 15/01/25...
Page 10: Stage 1 Restoration - Test Block Cover Fitted
Stage 1 Restoration – Test Block Cover Fitted Test Block Cover restoration Tighten Test Block Cover screws Complete 4M400 Test Block all circuits back in service NOTE It is imperative that the test block cover is securely fitted to the test block via the cover thumbscrews to ensure that product ingress protection levels are maintained, and the isolation insert is held in the recessed state within the test block to ensure circuit continuity.
Page 11: Installation
Installation Test Block Location The purpose of the 4M400 Test Block is to provide a convenient and safe means of undertaking routine or emergency secondary injection testing of Protection and Metering schemes. The positioning of the 4M400 Test Block should ideally be on the front of the cubicle or panel and near the equipment to be tested.
Page 12: Safety Section
Safety Section This Safety Section should be read before commencing any work on the equipment. The information in the Safety Section of the product documentation is intended to ensure that products are properly installed and handled in order to maintain them in a safe condition. It is assumed that everyone who will be associated with the equipment will be familiar with the contents of the Safety Section.
Page 13: Unpacking
Unpacking Upon receipt inspect the outer shipping carton or pallet for obvious damage. Remove the individually packaged relays and inspect the cartons for obvious damage. To prevent the possible ingress of dirt the carton should not be opened until the relay is to be used.
Page 14 Individual inner packing carton with lid open showing 4M400 Test Block. Inner packing carton with lid open showing 4M420 Test Plug. 4M400 Isolation Plug shown removed from the 4M400 outer case. Page 14 of 26 4M400_User_Guide_v01.0 15/01/25 www.morssmitt.com/rms Visit for the latest product information. Due to RMS continuous product improvement policy this information is subject to change without notice.
Page 15: Accessories Supplied With Each Relay
Accessories Supplied With Each Relay Self threading M4 mounting screws M4 terminal screws with captured lock washers Storage & Handling If damage has been sustained a claim should immediately be made against the carrier, also inform Relay Monitoring Systems Pty Ltd and the nearest RMS agent When not required for immediate use, the relay should be returned to its original carton and stored in a clean, dry place.
Page 16 Equipment Operating Conditions The equipment should be operated within the specified electrical and environmental limits. Protective relays, although generally of robust construction, require careful treatment prior to installation and a wise selection of site. By observing a few simple rules the possibility of premature failure is eliminated and a high degree of performance can be expected.
Page 17 Current Transformer Circuits Do not open the secondary circuit of a live CT since the high voltage produced may be lethal to personnel and could damage insulation. External Resistors Where external resistors are fitted to relays, these may present a risk of electric shock or burns, if touched.
Page 18: 4M400 Applications
4M400 Applications Order Code Cross Reference Chart A functionally equivalent 4M400 Test Block solution is available for most common test block systems available on the market. RMS Codes MMLG-01 2RMLG-01 4M400-06 MMLG-02 2RMLG-02 4M400-07 MMLG-07 2RMLG-07 4M400-07 MMLG-08 2RMLG-08 4M400-08 2RMLG-09 4M400-09 The above 4M400 variants provide internal CT shorting as standard.
Page 19: Application For A 3 Phase Overcurrent And Ef Protection Scheme
Application for a 3 Phase Overcurrent and EF Protection Scheme RMS Order Code 4M400-06 The Even Numbered terminals of the 4M400 Test Block correspond to the BLACK coloured Even Numbered sockets of the 4M320 Test Plug (access to the Protection scheme). The Odd Numbered terminals of the 4M400 Test Block correspond to the YELLOW coloured Odd Numbered sockets of the 4M320 Test Plug (access to the potentially live supplies).
Page 20: Application For A Directional 3 Phase Overcurrent And Ef Protection Scheme
Application for a Directional 3 Phase Overcurrent and EF Protection Scheme Scheme is also applicable for Distance Protection Schemes. RMS Order Code 4M400-07 The Even Numbered terminals of the 4M400 Test Block correspond to the BLACK coloured Even Numbered sockets of the 4M420 Test Plug (access to the Protection scheme). The Odd Numbered terminals of the 4M400 Test Block correspond to the YELLOW coloured Odd Numbered sockets of the 4M420 Test Plug (access to the potentially live supplies).
Page 21: Application For 3 Phase Ct's And Core Balance E/F Ct
Application for 3 Phase CT’s and Core Balance E/F CT RMS Order Code 4M400-08 The Even Numbered terminals of the 4M400 Test Block correspond to the BLACK coloured Even Numbered sockets of the 4M420 Test Plug (access to the Protection scheme). The Odd Numbered terminals of the 4M400 Test Block correspond to the YELLOW coloured Odd Numbered sockets of the 4M420 Test Plug (access to the potentially live supplies).
Page 22: Application For Differential Protection Of Transformers
Application for Differential Protection of Transformers RMS Order Code 4M400-09 The Even Numbered terminals of the 4M400 Test Block correspond to the BLACK coloured Even Numbered sockets of the 4M420 Test Plug (access to the Protection scheme). The Odd Numbered terminals of the 4M400 Test Block correspond to the YELLOW coloured Odd Numbered sockets of the 4M420 Test Plug (access to the potentially live supplies).
Page 23: Commissioning
Commissioning Commissioning Preliminaries Carefully examine the module to ensure that no damage has occurred during transit. Check that the model number and rating information are correct. Insulation The test block, and its associated wiring, may be insulation tested between: - all electrically isolated circuits - all circuits and earth An electronic or brushless insulation tester should be used, having a dc voltage not exceeding 1000V.
Page 24: Functionality Testing Of 4M400 Test Block With 4M420 Test Plug
Functionality Testing of 4M400 Test Block with 4M420 Test Plug Item Description Complete With the Isolation Plug removed insert the 4M420 Test Plug Confirm continuity from the 4M420 test points to the secondary equipment under test Returning the 4M400 to the normal service state Item Description Complete...
Page 25: Maintenance
Maintenance Mechanical Inspection Relay Assembly Inspect the relay for obvious signs of damage or ingress of moisture or other contamination. Relay Module Isolate the relay, remove the front cover & carefully withdraw the relay module from the case. Care must be taken to avoid subjecting the relay element to static discharge which may damage or degrade sensitive electronic components.
Page 26: Test Intervals
Relay Case Inspect the outer terminals checking insulation integrity & tightness. Inspect inside the case and use a blower to remove any dust. Inspect the inner terminals for worn, distorted or tarnished contacts and if necessary clean the contacts using a brush dipped in a suitable substance. Case outer terminals Case inner terminals Module plug in terminals...

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Rms mors smitt 4m420