1.1 BCM-200 Manual

Instruction Manual
BCM-200
Breaker Condition Monitor
Document ID: 40-8420 (80-8630-04)
www.qualitrolcorp.com
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©2008 QUALITROL Company LLC, an ISO 9001 system certified company. All rights reserved. Information subject to change without notice.
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Contents
Contents
Chapte7r 1: About This Manual .....................................................................1
Who Should Read this Manual? .....................................................................2
How to Use this Manual ...................................................................................2
Where to Go for Further Help..........................................................................2
Chapter 2: Introduction...................................................................................3
What is a BCM 200 Breaker Condition Monitor? ..........................................4
System Layout ..................................................................................................5
Chapter 3: Hardware and Software ................................................................7
Calibration................................................................................................................ 8
Power Supply ........................................................................................................... 8
Analog Inputs........................................................................................................... 8
3 DC Coupled Isolated Analog Inputs ............................................................................. 8
3 AC Coupled Isolated Analog Inputs ............................................................................. 8
Digital Inputs............................................................................................................ 9
Alarm Outputs.......................................................................................................... 9
Communication Ports ........................................................................................... 10
RS232 Port................................................................................................................... 10
RS485 Port................................................................................................................... 10
LEDs ...................................................................................................................... 13
BCM 200 Installation ......................................................................................14
Mode Selection ...................................................................................................... 14
Mode 1 (Recommended).............................................................................................. 14
Mode 2 ......................................................................................................................... 14
Mode 3 ......................................................................................................................... 14
Mode 4 (Under Development)....................................................................................... 14
Adding Substation and Breaker information to Replay 97............................... 17
Creating and Selecting Substations where BCMs are to be Used................................. 17
Entering Circuit Breaker information ............................................................................. 18
Entering BCM 200 (Device) Information ....................................................................... 18
Associating Substation Circuit Breakers with Installed BCM 200s ................................ 18
Contents
Configuring Replay 97 Communication....................................................................... 18

Configuring the BCM 200...................................................................................... 20
Configuration Parameters............................................................................................. 20
General ........................................................................................................................ 21
Events .......................................................................................................................... 22
Parameters................................................................................................................... 23
AC Currents.................................................................................................................. 25
Coil Channels ............................................................................................................... 26
Absolute Limits ............................................................................................................. 27
Operation Limits ........................................................................................................... 28
Battery Channel, Serial................................................................................................. 29
Save and Close ............................................................................................................ 30
Save and Send ............................................................................................................. 30
Physical Installation of the BCM 200 ................................................................... 30
Capture of Reference Data using Learn Mode .................................................... 36
Step 1........................................................................................................................... 37
Step 2........................................................................................................................... 37
Step 3........................................................................................................................... 37
Step 4........................................................................................................................... 37
Alarms List ............................................................................................................. 37
Alarms Listed in Log and Operate Breaker Condition Relay ......................................... 37
Alarms Listed in Log and Operate BCM Malfunction Relay........................................... 38
Other Alarms Listed in Log ........................................................................................... 38
Appendix A: Technical Specifications ........................................................40
Inputs...................................................................................................................... 41
Analog Inputs ............................................................................................................... 41
Analog Accuracy........................................................................................................... 41
Analog Resolution ........................................................................................................ 41
Event Inputs ................................................................................................................. 41
Event Accuracy............................................................................................................. 41
Outputs................................................................................................................... 41
Alarms .......................................................................................................................... 41
RS232 .......................................................................................................................... 41
RS485 .......................................................................................................................... 41
Contents
Recording............................................................................................................... 42
Memory................................................................................................................... 42
Triggering............................................................................................................... 42
Performance........................................................................................................... 42
Operating Voltage......................................................................................................... 42
Isolation........................................................................................................................ 42
Fast Transient .............................................................................................................. 42
SWC............................................................................................................................. 42
Impulse Withstand ........................................................................................................ 42
Operating Temperature Range ..................................................................................... 42
Connections ........................................................................................................... 42
Physical Dimensions............................................................................................. 43
Weight..................................................................................................................... 43
Appendix B: Profiling Technique ................................................................44
Event Profiler ......................................................................................................... 45
Current Profiler ...................................................................................................... 45
Coil Profiler ............................................................................................................ 45
Profile ..................................................................................................................... 46
Contact Duty Calculations .................................................................................... 46
S IX TYC .............................................................................................................47
About This Manual
Chapter 1
About This Manual
About This Manual
Who Should Read this Manual?

This chapter explains how to use this manual. It provides a guide to the following:
• An explanation of which chapters deal with the various aspects of the BCM 200
Breaker Condition Monitor
• The ability to find information quickly and easily in the manual.
The manual assumes no previous knowledge of operation of this type of test equipment. Although
details are given on the manner in which the BCM 200 should be used, reference should also be made
to the help menu within Replay 97 software for further instructions.
How to Use this Manual
This section explains how to use the BCM 200 Breaker Condition Monitor manual
effectively.
• First time users of the BCM 200 should read the introduction in Chapter 2 which describes
the capabilities of the system.
• Chapter 3 describes the function and operation of the BCM 200 hardware and provides
the user with information on important software points.
• Appendix A gives a technical specification for the BCM 200.
• Appendix B gives details on the profiling technique.
Where to Go for Further Help

If problems are experienced with the setup or the use of the BCM 200 Breaker Condition
Monitor, please contact:
QUALITROL LLC
1385 Fairport Road
Fairport, New York 14450
USA
(585) 586-1515
(585) 377-9613 FAX
http://www.qualitrolcorp.com
Introduction
Chapter 2
Introduction
Introduction
What is a BCM 200 Breaker Condition Monitor?
The BCM 200 is the newest addition to the QUALITROL range of circuit breaker testing and
monitoring equipment. This permanently installed microprocessor based system monitors
and records each operation of the circuit breaker and automatically compares this data with
Absolute Limits, set as part of the configuration. In addition recorded data is automatically
compared with a known good reference record, or fingerprint, stored in memory. Any
parameters outside user defined Operation Limits cause an alarm. The BCM 200 has the
added advantage that it can perform accumulated contact duty calculations for the fault
currents interrupted by each phase of the breaker.
When any of the recorded parameters of the breaker or accumulated contact duty exceed
pre-programmed limits, the BCM 200 will generate software and hardware alarms to indicate
that the breaker should be inspected.
The technique of comparing a breaker operation profile with a known good profile to detect
changes in the breaker condition has been used by QUALITROL/Hathaway with a high
degree of success for a number of years. It was pioneered in the late 1980's in a joint
development with Southern California Edison and in excess of 15,000 breakers are currently
monitored using this method.
The BCM 200 records waveform data for each breaker operation and retains data for
approximately the last ten breaker operations in memory (depending on record size).
Summary information for breaker operations is also stored in memory along with a log of
alarms. This data can be automatically retrieved, analysed and archived using Replay 97, a
Windows based Master Station software package.
The BCM 200 can be configured to record data on transitions on any event input or on
detecting fault current. Figure 1 shows a typical BCM 200 recording of a breaker trip
operation.
Introduction
Figure 1 – Breaker Trip Operation
System Layout
The BCM 200 is a compact (267mm x 130mm x 54mm / 10.5” x 5.12” x 2.13”) circuit breaker
monitoring device designed to be installed in the breaker control cabinet. With an integral terminal
block for user connections and external split-core CT’s for AC current measurement, installation can be
carried out in an efficient and cost effective manner.
The BCM 200 is equipped with six analog channels and four digital event or status inputs. Analog
inputs are provided for open and close coil currents, battery voltage and the three phase line currents.
Event inputs are typically used for monitoring the “A” and “B” contacts and open and close initiate
signals. Alternatively, one of the event inputs can be used to monitor spring recharging motor or
compressor operation.
Introduction
Figure 2 – BCM 200 System Layout
Hardware and Software
Chapter 3
Hardware Description
The following section provides information on the hardware contained in a BCM 200 Breaker
Condition Monitor.
Calibration
The BCM 200 is factory calibrated and there is no need for further calibration at the time of installation
or commissioning. Calibration values are saved in archive, and using BCMCAL.exe on the Replay
97 CD, can be uploaded into a BCM or downloaded from a BCM for recordkeeping.
Power Supply
The BCM 200 is fitted with a wide ranging universal power supply that can operate on both AC and
DC voltages (85 -264Vac or 80 - 340Vdc). Terminations for power input are P7-1, & 2. Earth ground
is terminated to P6-15.
Analog Inputs
3 DC Coupled Isolated Analog Inputs
Battery Input
Selectable full scale voltage ranges of up to 150 or 300Vdc are available using jumper J6. Jumper J6 in
“b” position for 150 V, and “a” position for 300 V range. Terminations for Battery input are P7-3 (-),
& 4(+). Range value, graphical label, and units are entered as part of software configuration.
Trip / Close Coil Current Inputs

These inputs have a full scale voltage input of 1Vdc which is developed across a resistance shunt when
the coils are energised. Each shunt has a tap for 5, 10 and 20A maximum coil currents. Special shunt
configurations can be substituted to provide higher current ranges. Terminations for Trip coil input are
P7- 5, & 6. Terminations for Close coil input are P7-7, & 8. Shunt values are entered as part of the
configuration of the BCM 200 using the Master Station software, Replay 97.
3 AC Coupled Isolated Analog Inputs
Phase Current Inputs

The BCM 200 has three AC analog inputs which are used to monitor the three phase currents. These
signals are taken from external 1000:1 split core CT’s which are connected to the secondary of the
existing protection transformers. Jumper positions are available for each input to give a nominal input
of 1A or 5A (input through split core CT). The full scale for these inputs is 20 times nominal, i.e. 20A
and 100A to allow for over-range. Terminations for Phase Current inputs are P7-9, & 10 for phase A,
P7-11, & 12 for phase B, and P6-1, & 2 for phase C.
The jumper positions for battery and AC current inputs are shown in Table 1, below.
Signal Ranges Jumper Position
300Vdc J6a
Battery Input 150Vdc J6b
1A nominal J5a
Phase Input A 5A nominal J5b
1A nominal J4a
Phase Input B 5A nominal J4b
1A nominal J3a
Phase Input C 5A nominal J3b
Table 1
Digital Inputs
The BCM 200 has four digital inputs that are typically configured for:
• Trip initiation
• Close initiation
• Auxiliary A contact
• Auxiliary B contact
Using Replay 97 the BCM 200 can be configured to be triggered and record data on transition of any
of these inputs. The digital inputs have an operating range between 20Vdc and 150Vdc. For input
voltages higher than 150Vdc, an external resistor (18K ohms 7 Watt) should be inserted in series with
the positive wire of each input to give a range of 150Vdc and 350Vdc. Events 1 through 4 are
terminated at P6-3 & 4, P6-5 & 6, P6-7 & 8 and P6-9 & 10 respectively.
Alarm Outputs
The BCM 200 has two normally open alarm outputs:
• Relay Output 1 (P6-11 and 12) - Breaker condition alarm
• Relay Output 2 (P6-13 and 14) – BCM 200 malfunction alarm
Contact rating: 1 Form A, 5A@30Vdc or 250Vac.
Communication Ports
The BCM 200 has two serial ports - one RS232 port and one RS485 port.
RS232 Port
The RS232 port is available on the 9-way D type connector, P3. Communication between your
computer and the BCM 200 should be made with the provided serial communication cable part number
103825-001. This is a NULL modem cable with receive and transmit lines crossed (i.e. 3 to 2, and 2
to3, terminal 5, ground is straight through).
RS485 Port
The RS485 port is available on screw terminals at P1; allowing up to 32 BCM 200 units to be
networked via a twisted pair “daisy chain”. An example of this type of RS485 network is shown in
Figure 3. The jumper positions are set as shown in Table 2.
Hardware and
Twisted Pair *Software
Terminator J9 Addresses
Master a 0
Slave #1- #N-1 b
Slave #N (last one) a 1 - 31
Table 2
*Refer to “Entering BCM 200 (Device) Information” later in this chapter.
10
Figure 3 – Typical RS485 Network
For correct operation when networking multiple BCM 200s, the hardware and software addresses must
match.
The hardware address is set by SW1, which may be found by removing the BCM 200 screening box
lid. Figure 4 shows all the possible hardware addresses.
The software address is specified using Replay 97 in the Add New Device and the Edit Device
Details dialogs.
11
Figure 4 - SW1 Settings
12
LEDs
The BCM 200 has LEDs to indicate:
• System healthy
• Breaker condition
• Communication activity
Figure 5 BCM 200 LED’s
13
BCM 200 Installation

The installation process involves five steps:
• Selecting the BCM 200 operating mode
• Add substation and breaker information to Replay 97
• Configuring the BCM 200, with particular attention to shunt values and CT ratios
• Physical installation of the BCM 200
• Capture of reference data using Learn Mode
Mode Selection
The operating mode must be selected in accordance with how the BCM 200 is installed. The modes
currently supported are described below.
The mode is selected on the Events tab of the BCM Configuration Settings dialog.
The event inputs on the BCM 200 are fully isolated and therefore can share auxiliary contact terminals
with other devices without causing interference. These inputs are not polarity sensitive.
Mode 1 (Recommended)
Event 1: Trip Initiate
Event 2: Close Initiate
Event 3: A Contact
Event 4: B Contact
Mode 2
Event 3: A Contact and B Contact
Event 4: Spare, e.g, Interposing Relay Initiate
Mode 3
Event 3: A Contact
Event 4: Spare
Mode 4 (Under Development)

Event 3: A Contact Pulse from Proximity Switch
Event 4: B Contact Pulse from Proximity Switch
14
Figure 6 – Trip Testing Modes
Note: The analysis of event inputs is carried out on signal transitions irrespective of polarity
15
Figure 7 – Close Testing Modes
16
Adding Substation and Breaker information to Replay 97
Replay 97 software is used to configure the BCM 200, retrieve recorded data and display, analyse
and present this data.
Creating and Selecting Substations where BCMs are to be Used
From Replay 97 Task Manager double-click on the Devices icon in the left pane, the Device List, to
display the list of supported devices. Then double-click on the BCM200 folder or click on the “+” sign
to expand the list of substations (if any) currently configured for BCMs.
Click on the substation to select it, or if it does not exist right-click on the BCM folder to display the
Add New Station menu that can be used to create a new substation where BCM information is to be
added. Click on this menu to display the Add New Station to Device dialog.
Use the Existing Stations tab in this dialog to select the substation name from the list of substations
that are currently configured for other devices or use the Create New tab to create a new station. The
software is now ready to accept BCM information for the selected substation.
The right pane, the List View, has four different view options that are selected by clicking on the tabs
at the bottom of the screen.
The Records tab displays a list of records available that have been retrieved from devices in the
selected substation.
The Devices tab displays a list of devices (BCM 200s) that are currently installed in the selected
substation.
The Breakers tab displays the list of circuit breakers in the selected station that are available to be
monitored by the installed BCM 200s.
The Query tab can be used with Microsoft Access 97 to display lists of records that are created using
queries in Access 97.
17
Figure 8 – Replay 97 Task Manager showing Add new Station to Device Dialog
Entering Circuit Breaker information

Select the required station by double-clicking on the station folder in the left pane and then select the
Breakers tab in the right pane to show a list of breakers currently entered in the database for the
selected station. Right-click anywhere in the right pane to display the Add New Breaker menu, and
click on this option to display the Add Breaker dialog. Enter the data in the appropriate fields that
describe the circuit breaker and click on the Accept button when complete to store the data in the
database. Repeat these steps for each breaker to be added to the selected station.
Entering BCM 200 (Device) Information

Click on the Device tab in the right pane to display a list of currently installed BCM 200s in the
selected substation. Right-click anywhere in the right pane to display the Add New Device menu, and
click on this option to display the Add Device dialog. Enter information that describes the BCM 200 in
the appropriate fields and click on the Accept when complete to store the information to the database.
Repeat these steps for each device to be installed in the substation.
Associating Substation Circuit Breakers with Installed BCM 200s
Select the Devices tab, right-click on the required BCM 200 name to display the menu and click on the
Breaker Settings option to display the Breaker Settings dialog. This dialog is used to define which
of the circuit breakers in the substation is to be monitored by the selected BCM 200. The left pane, the
18
Breaker List, contains a complete list of all the breakers in the substation. By selecting a breaker from
this list and clicking on the Add>> button the breaker is added to the right hand pane. Click on the
Done button when finished to save settings to the database.
Configuring Replay 97 Communication
From Replay 97 Task Manager select the Configure Comms option from the Comms menu. The
Configure Communications dialog will be displayed:
Current Communication Status

This enables the user to view the number of comms tasks in progress and the number of jobs in queue.
Figure 9 – Configure Communications Dialog
Current Communication Status

This enables the user to view the number of comms tasks in progress and the number of jobs in queue.
Modem Hold Time

This is the modem hold time in seconds. To change this, type in the number the modem is to be held for
(default 3).
Enable Auto Comms

Enable this checkbox to activate auto comms
19
Modem Connect Wait

This is the modem Connect wait time in seconds. To change this, type in the number the modem is to
wait to connect..
TCP/IP - Local Ethernet (Under Development)

Enable this checkbox to activate TCP/IP connection on a local network. For BCM 200, do not enable
this checkbox.
Port Status
This drop-down menu enables the selection of the port status. Selection choices are Modem Attached,
or Direct connect(232 cable).
Port Speed
This drop-down menu enables the selection of the modem speed (default 9600).
Modem
This drop-down menu enables selection of the desired modem, if multiple modems are available
(Modems drop down is obtained and created in “Modem List” in same window.
Configuring the BCM 200
The following section provides information on the Replay 97 software used to configure a BCM 200
Breaker Condition Monitor.
Configuration Parameters
The BCM 200 can be configured prior to installation. Jumper positions should be set according to
Table 1 and parameters entered in the following Replay 97 dialogs. Each dialog contains default
settings which can be altered if operational experience indicates this is necessary.
The configuration of the BCM 200 in divided into three main parts:
? Device Configuration
? Absolute Limits
? Operation Limits
Each of these is stored separately with its own unique name and a complete BCM 200 configuration
consists of a combination of the three parts. The Device Configuration contains all the Operational
Parameters and configuration for the BCM 200 while the Absolute and Operation Limits contain the
values against which each circuit breaker operation is compared.
20
From Replay 97 Task Manager right-click on the required BCM 200 name in the right pane to
display the menu and click on Configure Device to display the BCM 200 Configuration Settings
dialog. This dialog contains nine different tabs, each tab invokes a dialog in which data can be entered.
In most cases the default settings can be used.
Those items identified by will need to be set for each breaker.
General
Click on the General tab. The BCM Configuration Settings General dialog will be displayed:
Figure 10 – BCM 200 Configuration Settings General Dialog
Device Details
This displays general BCM 200 details including Station, BCM ID and model.
Breakers
This displays details of the circuit breaker monitored by the BCM 200.
21
Selected Configuration
This drop-down menu enables the selection of existing device configuration. In this way the same
configuration can easily be used on similar breakers in different substations.
New
Click on the New button to create a new Device configuration. The new configuration created in this
way is a copy of the currently selected configuration which can then be renamed and edited as required.
Events
Click on the Events tab. The BCM Configuration Settings Events dialog will be displayed:
Figure 11 – BCM Configuration Settings Events Dialog
Event 1 / 2 / 3 / 4
This provides text boxes to enter event input labels.
Enable Triggering
This provides check boxes to enable or disable triggering on input transitions for each event
Event Debounce Time

This provides the ability to set the event debounce time.
22
BCM Mode
This allows selection of the BCM mode (as described in Mode Selection earlier in this chapter) by
clicking on the up or down arrow beside the field.
Parameters
Click on the Parameters tab. The BCM Configuration Settings Parameters dialog will be
displayed:
Figure 12 – BCM Configuration Settings Parameters Dialog
Pre-trigger Time
This is the amount of data recorded before the trigger condition
Trigger Op-Limit Time

The maximum amount of data that is recorded when a trigger condition exists continuously.
Post-Trigger Time
The amount of data recorded after the trigger condition ends
23
Alarm Relay on Time

When an alarm condition occurs the alarm relay closes for a time set using the Alarm Relay on Time
drop-down menu. Setting the time to Continuous causes the relay to be latched when an alarm
condition occurs. This condition is cleared using the Clear Alarm LED button in the Alarm Log
dialog accessible using the Device Configuration menu.
X/Y/C
Breaker contact duty is accumulated using the formula SI X

TYC where I is the interrupted fault
current and t is the breaker arcing time. The variables x, y and c are user definable in the Contact Duty
dialogs. With the default settings of x=2, y=1, c=1 the formula is i2t.
Arcing Time From

This drop-down menu allows the selection of the method for defining T during a trip operation. The
options available are Trip, A Contact and Fixed. During a close operation the only method available
is Fixed.
The Trip method uses the trip initiate event signal to begin counting the time to be used in the contact
duty calculation.
The A Contact is the same as the Trip method with the exception that the A contact event signal is
used instead of the trip initiate.
The Fixed method allows a set time to be entered for the trip arcing time.
Offset (Trip)
This enables an offset to be entered (in milliseconds) to delay the start time as required. The end time
will be when the phase currents are interrupted.
Close Arcing Time

This enables a fixed arcing time to be entered for a close operation.
Record No. Preset

The BCM record number can be preset to a desired value by typing the value into this field and clicking
on the check box to enable it. This is typically set to match the operation count).
24
Phase A / B / C Preset
The accumulated contact duty, measured in A2s can be preset by typing the values into these fields and
clicking on the check boxes to enable these values. These values take effect when the configuration is
uploaded to the BCM 200.
Op-Count Preset
The breaker operation count can be preset by typing the value into this field and clicking on the check
box to enable it.
AC Currents
Click on the AC Currents tab. The BCM Configuration Settings AC Currents dialog will be
displayed:
Figure 13 – BCM Configuration Settings AC Currents Dialog
Channel Label
This is the channel label. Enter a maximum of 24 characters.
Channel Units
This is the channel input quantity units (default amps).
25
Channel Trigger
This is the analog over trigger level set in percent of full scale. A trigger level of 0% will disable
analog over trigger.
Note: Refer to “Analog Inputs” earlier in this chapter for details of full scale.
Current Range
This is the CT nominal current range. Click on the radio button to select 1A or 5A.
Note: It is important that the current range selection matches the physical jumper selection. Refer to
“Table 1” earlier in this chapter for details on the jumper positions.
CT:1 Ratio
This is the primary CT ratio. Enter the number expressing the ratio to 1 of the primary CT, e.g, for a
CT of 1200:5 enter 240.
Line Frequency
This is the power system line frequency. Click on the radio button to select 50Hz or 60Hz.
Coil Channels
Click on the Coil Channels tab. The BCM Configuration Settings Coil Channels dialog will be
displayed:
Figure 14 – BCM Configuration Settings Coil Channels Dialog
26
Channel Label
This is the channel label. Enter a maximum of 24 characters.
Channel Units
This is the channel input quantity units (default amps).
Trip / Close Coil Range and Shunts

This is the resistance of the three shunts for trip and the three shunts for close coil current inputs. Click
on the radio button to select which of the three configured shunts is being used for the trip and close
channels.
Disable Close Coil Analysis

Enable this checkbox to disable analysis on the close coil when operated by AC.
Absolute Limits
Click on the Absolute Limits tab. The BCM Configuration Settings Absolute Limits dialog will be
displayed:
Figure 15 – BCM Configuration Settings Absolute Limits Dialog
Each data record is compared against the Absolute Limits settings. If any of the parameters are outside
the limits, an alarm is generated and the Alarm Relay closes. During this process the Accumulated
Contact Duty and Breaker Operation Counter are updated and compared against their limits. If either
are exceeded then the alarm is generated.
27
Enable
Enable this checkbox to allow checking of each record against the Absolute Limits. If this box is NOT
checked then none of the records are checked against these absolute limits.
Absolute Limits
This drop-down menu enables the selection of a set of Absolute Limits from those already existing in
the database.
New
Click on the New button to create a new set of Absolute Limits. The new limits created in this way are
a copy of the currently selected limits which can then be edited as required.
Min / Max
Options to set maximum value for breaker contact duty, maximum number of breaker operations and
maximum and minimum values for other listed parameters. Until more experience is gained with the
specific breaker type being tested, the default settings will usually suffice. These values may be
determined after a fingerprint profile is taken and the records are reviewed.
Operation Limits
Click on the Operation Limits tab. The BCM Configuration Settings Operation Limits dialog will
be displayed:
Figure 16 – BCM Configuration Settings Operation Limits Dialog
28
Each data record, trip or close is compared against its respective reference fingerprint record using the
Operation Limits and if any of the parameters is outside these tolerance limits an alarm is generated and
the Alarm Relay closes. All Operation Limit values are set in percent and are checked with respect to
the reference fingerprint records.
Enable
Enable this checkbox to allow checking of each record against the Operation Limits
Operation Limits
This drop-down menu enables the selection of an existing set of Operation Limits from those already
existing in the database.
New
Click on the New button to create a new set of Operation Limits. The new limits created in this way are
a copy of the currently selected limits which can then be edited as required.
Battery Channel, Serial

Click on the Battery Channel, Serial tab. The BCM Battery Channel, Serial dialog will be
displayed:
Figure 17 – BCM Configuration Settings Battery Channel, Serial Dialog
29
Channel 5 Label
This is the battery label.
Channel 5 Units
This is the battery channel input units
Battery Voltage Range

Click the radio button to set this to 150V or 300V.
Baud Rate
This is the BCM RS232 port baud rate.
Note: If the baud rate is changed, the user will no longer be able to communicate with the BCM 200
until Replay 97 is reconfigured to the new baud rate.
Modem String One / Two / Three

These are three modem strings used to configure the BCM 200 modem. (On power up, the BCM 200
detects the presence of a modem and automatically sends the modem strings).
Save and Close

When configuration of the BCM 200 is complete, click on the Save and Close button to store the new
configuration to the database.
Save and Send
If the BCM 200 is connected to the computer either directly or by modem, then click on the Save and
Send button to save the configuration to the database and upload it to the BCM 200.
Physical Installation of the BCM 200
The BCM 200 can be physically mounted inside the breaker cabinet. It is recommended that it is
mounted on pillars to provide a gap between the circuit board and the cabinet wall.
Electrical connections for each of the modes are shown in Figures 18 - 21.
30
31
Figure 18 – BCM Mode 1 (Breaker in Open Position)
32
33
34
Figure 21 – BCM Mode 4 (Under Development)
TRIP/CLOSE COIL TRIP/CLOSE COIL
COIL RATING < 5 AMPS COIL RATING < 10 AMPS

5A 5A
0.10 O 0.10 O
SHUNT SHUNT
10 A 10 A
BCM 200 + BCM 200 +
COIL 0.05 O COIL 0.05 O
INPUT - INPUT -
20 A 20 A
0.05 O 0.05 O
C C
- VDC - VDC
TRIP/CLOSE COIL
5A
0.10 O
SHUNT
10 A
BCM 200 +
COIL 0.05 O WIRE
INPUT - JUMPER
20 A
0.05 O
COIL RATING < 12 AMPS
- VDC
TRIP/CLOSE COIL
TRIP/CLOSE COIL
5A
5A
0.10 O 0.10 O
SHUNT SHUNT
10 A 10 A
BCM 200 + BCM 200 +
COIL 0.05 O COIL
WIRE 0.05 O WIRE
INPUT - INPUT - JUMPER JUMPER
20 A 20 A
0.05 O 0.05 O
C C
- VDC - VDC
35
COIL RATING < 40 AMPS COIL RATING < 50 AMPS

TRIP/CLOSE COIL 5A 5A
TRIP/CLOSE COIL
0.10 O WIRE 0.10 O
SHUNT JUMPER
SHUNT
10 A 10 A
BCM 200 + BCM 200 +
COIL 0.05 O COIL 0.05 O
INPUT - WIRE INPUT -
20 A WIRE
JUMPER 20 A JUMPER
0.05 O 0.05 O
C C
- VDC - VDC
The drawings above, indicate the several possible connections to the BCM Trip Coil Input. Example
#1: The + Trip Coil input to the BCM 200 would be connected to the 5 amp tap if the Trip Coil
rating is below 5 amps. You should allow for a 20% Trip Coil current overshoot value should the
resistance of the Trip Coil change after having been in service for many years. Example #3: The
connections as shown using jumpers between the shunt taps create a 12 amp shunt. This could be
desirable if the Trip Coil rating is 10 amps and you wish to have a 20% allowance.
The Trip Coil input to the BCM 200 will measure the voltage drop across the selected shunt section that is
connected in series with the Trip Coil. The only time that shunt taps would be connected together would be if
a desired shunt resistance value must accommodate a Trip or Close Coil current level that is something other
than the provided 5A,10A,20A tap values.
The C terminal of the shunt should always be connected to the battery negative. The – terminal of the Trip
Coil input on the BCM 200 should always be connected to the C terminal of the shunt. The + terminal of the
Trip Coil input on the BCM 200 should be connected to the terminal of the shunt (5 A, 10 A, 20 A) that most
closely matches the rated full-scale current of the trip coil. PLEASE NOTE: The bottom side of the Breaker
Trip Coil must be connected to the same shunt terminal that the BCM Trip Coil Input + terminal is connected
to if the Trip Coil current is above 20amps, or 12 amps as shown in the above examples.
The intent of the above connections is to produce 1 VDC, rated full-scale voltage, at the Trip/Close Coil input
of the BCM 200.
Capture of Reference Data using Learn Mode
Once installed on the breaker, the BCM 200 is ready to be programmed with the open and close
reference records that it will use to compare with all future records.
Use the following procedure to configure the BCM 200 for Learn Mode:
36
Step 1
Ensure the breaker is in the closed position.
Step 2
Put the BCM 200 in Learn Mode by holding down the Alarm Clear button for 10 seconds. This will
automatically clear any existing reference records in the BCM 200 memory.
The green Status LED will respond by flashing rapidly. The user is allowed 60 seconds to complete
steps 3. If step 3 is successfully completed, another 60 seconds is allowed to complete step 4 before
Learn Mode will timeout.
Step 3
Perform a manual open operation.
Step 4
Perform
Perform a manual
a manual close operation.
close operati
After performing step 4, the BCM 200 will return to normal operating mode if no errors are detected.
If the BCM 200 detects a difference in the signals recorded compared to the connection mode selected
or if any of the reference records parameter exceed those in the absolute limits, then the Status LED
will turn red constantly, indicating a problem. The reference records should then be downloaded to
Replay 97 for investigation.
Alarms List
Alarms Listed in Log and Operate Breaker Condition Relay
Alarm Description
2306 Incorrect event mode detected
2311 Re-strike detected
2320 Abs. operational count limit exceeded
2336 Abs. phase A i²t limit exceeded
2352 Abs. phase B i²t limit exceeded
2368 Abs. phase C i²t limit exceeded
2384 Abs. coil area limit exceeded

37
2400 Abs. coil time limit exceeded
2416 Abs. peak coil current limit exceeded
2432 Abs. battery ripple limit exceeded
2448 Abs. battery high volts limit exceeded
2464 Abs. battery low volts limit exceeded
2480 Abs. battery volt drop limit exceeded
2496 Abs. breaker response time limit exceeded
2512 Abs. breaker operate time limit exceeded
2560 Op. coil area limit exceeded
2576 Op. coil time limit exceeded
2592 Op. peak coil current limit exceeded
2624 Op. battery high volts limit exceeded
2640 Op. battery low volts limit exceeded
2672 Op. breaker response time limit exceeded
2688 Op. breaker operate time limit exceeded
Alarms Listed in Log and Operate BCM Malfunction Relay
Alarm Description
1796 RAM test fail
2081 Configuration set to default values
2082 Calibration constants defaulted
2084 Trip Profile defaulted
2085 Close Profile defaulted
2117 Clear all running totals
Other Alarms Listed in Log
38
Alarm Description
1793 Alarm log was cleared
1794 Boot block module boot
1797 256k of RAM detected
1798 512k of RAM detected
2065 Configuration loaded from flash
2066 Calibration constants loaded from flash
2069 Trip profile loaded from flash
2070 Close profile loaded from flash
2118 Force all running totals as in configuration
2119 Totals loaded from flash
2129 Record lost due to collision
2304 Abs. unknown record type
2305 Abs. multiple breakers operated
2104 Record memory cleared
2105 Summary memory cleared
Alarm Description
2113 Learn Mode initiated
2114 Learn Mode timeout
2115 Trip profile recorded
2116 Close profile recorded
2308 t forced to half cycle because negative
2309 Insufficient pre-trigger for analyse
39
Technical Specifications
Appendix A
40
This section contains the technical specification for the BCM 200 Breaker Condition Monitor.
Inputs
Analog Inputs
3 AC Channels
Dedicated to measuring AC currents via split-core CTs.
CT Burden
0.05VA
3 DC Channels
Dedicated to measuring the open and close coil currents and station battery voltage.
Shunt Resistance
0.2W (5A), 0.1W (10A), 0.05W (20A).
Analog Accuracy
Better than 1%.
Analog Resolution
10 bits.
Event Inputs
Four event channels. Ranges; 20 - 150Vdc or 150 - 350Vdc with external resistor.
Note: Refer to Chapter 3 “Digital Inputs” for more information.
Event Accuracy
1ms.
Outputs
Alarms
Two N/O relay contacts for BCM 200 Malfuction and Breaker Condition Alarms. Contact; 1
Form A, 5A @ 30Vdc or 250Vac.
RS232
For communications to a PC or modem.
RS485
For networking up to 32 BCMs to a PC or modem.
41
Recording
2kHz sample rate.
Memory
1Meg
Triggering
Change in any event state or detection of over-current on any phase.
Performance
Operating Voltage
85 - 264Vac, 80 - 340Vdc.
Isolation
All inputs 2.5kVac channel to channel and channel to earth.
Fast Transient
Class 4, 4kV IEC 255-22-4 (IEC 801-4).
SWC
(1MHz damped sine wave).
Common Mode
2.5kV (IEC 255-22-1).
Differential Mode
1.0kV (IEC 255-22-1).
Impulse Withstand
Common Mode
5.0kV, 0.5J (IEC 255-5).
Differential Mode
5.0kV, 0.5J (IEC 255-5).
Operating Temperature Range

-30 to +60ºC (-22 to +140ºF).
Connections
All breaker connections are terminated on a 6/32” (4.76mm) terminal block.
42
Physical Dimensions
267mm (10.5”) x 130mm (5.12”) x 54mm (2.13”).
Weight
2kg (4.5lbs).
43
Profiling Technique
Appendix B
Profiling Technique
44
Profiling Technique
After a breaker operation record has been acquired by the BCM 200, it must be analysed. This analysis
process includes the following tasks:
§ Record verification
§ Timing analysis
§ Record summarisation
§ Profiling and finger print comparison
Depending on the complexity of the recorded data, the analysis will take anything from a few seconds
to a few minutes to complete.
Event Profiler
For every breaker monitored a set of events must be analysed. The analysis of these events will
produce the following information for each event channel:
§ The time in milliseconds from the beginning of the record to the first valid detected
event transition.
§ The time in milliseconds from the start of the record to the second valid detected event
transition.
§ The number of detected and valid event transitions detected within the entire record.
Any debounce requirements are accounted for in these calculations.
Current Profiler
Profile information for each of the available current channels is also produced. For open and close
records, the initial and post RMS values are calculated the same way. The initial RMS value is
calculated over one cycle starting at a half cycle from the start of the record. The post RMS value is
calculated over one cycle starting one and a half cycles from the end of the record. For an open record
the final RMS value is calculated over one cycle starting prior to the i_end_time. The i_end_time is the
time in milliseconds from the start of the record at which it is determined that the arc current ends.
The close operation does not create arcing currents of the same magnitude as open operations so the
calculations differ slightly. The i_end_time is replaced by a user specified constant close_arc_time.
The final RMS value is ignored.
Coil Profiler
The calculations are the same for both open and close records.
45
Profiling Technique
A start time is calculated which is the time in milliseconds from the start of the record until a
continuous rise in amplitude is detected in the relevant channel. An end time is also calculated which is
the time in milliseconds from the start of the record until the amplitude of the coil current returns to the
pre-trigger level. The difference between these times is also calculated.
The peak amplitude value is detected which is the highest value detected during the coil active time.
This value is averaged over a number of samples to eliminate any spikes. The sum of all the sample
amplitudes detected between the start time and the end time is used to calculate the area. This value is
scaled to the units amps-seconds.
Profile
The record is checked for the various parameters required and the relevant calculations are performed.
The calculations are the same for open and close records. The battery ripple is an indication of the
amount of ripple detected upon the battery signal and can indicate how well the charging circuit is
performing. The ripple is calculated over a cycle, from the beginning of the record.
The following formula is used:

n
R= S (M - Si)2 / M
i=0
Where:
R is ripple.
Si is the value of the ith sample.
M is the mean of all n samples.
n is the number of samples.
The battery_hi_volts parameter is the highest level of the battery signal calculated over the whole
record. This is calculated as an average over a number of samples so spikes will be eliminated.
Battery_lo_volts is the lowest level of the battery signal over the whole record and again this is
calculated as an average.
The battery_drop is the difference between the battery_hi_volts and the battery_lo_volts.
The response_time is the time in milliseconds taken by the breaker to respond to the open or close
initiates until the “a” or “b” contact changes state.
The operate time is the time in milliseconds, taken by the breaker to operate, i.e. the time between the
“a” and “b” contacts operating.
These times are calculated differently depending on whether the record is a open or a close or whether
the BCM is in multiple or single mode.
Contact Duty Calculations

46
Profiling Technique
Contact duty values are calculated using the following formula:
S IX TYC
Where:
I is the final RMS value for the phase A, B or C current.
T is the integration time from the trigger.
C is a user specified constant.
X is a user specified constant.
Y is a user specified constant.
If the record is an open, T depends on the offset_type. If the record is a close, T becomes the close arc
time.
47
Profiling Technique
QUALITROL® Field Services

QUALITROL® provides on-site commissioning/ start-up and comprehensive maintenance contracts to all customers
worldwide. To further improve reliability, an extended warranty is available on selected products commissioned by
QUALITROL®.
QUALITROL® Educational Services
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About QUALITROL
QUALITROL® manufactures substation and transformer monitoring and protection devices used by electric utilities and
manufacturing companies. It is the global leader in sales and installations of transformer asset protection equipment, fault
®
recorders and fault locators. Established in 1945, QUALITROL produces thousands of different types of products on
demand, each customized to customers' unique requirements.
®
©2008 QUALITROL Company LLC, an ISO 9001 system certified company. All rights reserved. Information subject to change without notice.
All trademarks are properties of their respective companies, as noted herein. 00-00000-00.
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Instruction Manual

Configuring Replay 97 Communication....................................................................... 18

Who Should Read this Manual?

How to Use this Manual

• Appendix A gives a technical specification for the BCM 200.

• Appendix B gives details on the profiling technique.

Where to Go for Further Help

What is a BCM 200 Breaker Condition Monitor?

Figure 1 – Breaker Trip Operation

Figure 2 – BCM 200 System Layout

3 DC Coupled Isolated Analog Inputs

Trip / Close Coil Current Inputs

3 AC Coupled Isolated Analog Inputs

Phase Current Inputs

Signal Ranges Jumper Position

Battery Input 150Vdc J6b

Phase Input A 5A nominal J5b

Phase Input B 5A nominal J4b

Phase Input C 5A nominal J3b

Contact rating: 1 Form A, 5A@30Vdc or 250Vac.

Slave #1- #N-1 b

Slave #N (last one) a 1 - 31

*Refer to “Entering BCM 200 (Device) Information” later in this chapter.

Figure 3 – Typical RS485 Network

Figure 4 - SW1 Settings

The BCM 200 has LEDs to indicate:

Figure 5 BCM 200 LED’s

BCM 200 Installation

Mode 4 (Under Development)

Figure 6 – Trip Testing Modes

Figure 7 – Close Testing Modes

Adding Substation and Breaker information to Replay 97

Creating and Selecting Substations where BCMs are to be Used

Entering Circuit Breaker information

Entering BCM 200 (Device) Information

Associating Substation Circuit Breakers with Installed BCM 200s

Configuring Replay 97 Communication

Current Communication Status

Figure 9 – Configure Communications Dialog

Current Communication Status

Modem Hold Time

Enable Auto Comms

Modem Connect Wait

TCP/IP - Local Ethernet (Under Development)

Configuring the BCM 200

In most cases the default settings can be used.

Those items identified by will need to be set for each breaker.

Figure 10 – BCM 200 Configuration Settings General Dialog

Figure 11 – BCM Configuration Settings Events Dialog

Event Debounce Time

Figure 12 – BCM Configuration Settings Parameters Dialog

Trigger Op-Limit Time

Alarm Relay on Time

Breaker contact duty is accumulated using the formula SI X

Arcing Time From

Close Arcing Time

Record No. Preset

Figure 13 – BCM Configuration Settings AC Currents Dialog