OPERATING INSTRUCTIONS FOR INVERSE TIME OVERCURRENT RELAYS TYPES CDG 11, 12, 13 and 14NOTE. For the sake of convenience, all relays in this Instruction are referred to as single pole relays, i.e. CDG11, CDG12, CDG13 and cDGi4. The same general description and information is applicable for the double pole or triple pole versions which are designated CDG21 and CDG31 etc. CDGI1 Relay with CAGI3 instantaneous unit on drawout chassisINTRODUCTION =. wy ‘Type COG11 (Inverse Time) ‘Type COGI2 (Long Time Delay) Type CDGI3 (Very Inverse Time) Type CDGI4 (Extremely Inverse Time) RECEIVING, HANDLING AND STORAGE Receiving. Handling =. Storage United Kingdom « Overseas. Dusty Conditions INSPECTION. =. DESCRIPTION 5 we OPERATION INDICATORS. Series Seal-in Unit Shunt Connected Units INSTANTANEOUS OVERCURRENT RELAY INSTALLATION =, 0. Location 5 Mounting Drawout Case» Non-drawout Case ADJUSTMENTS AND TESTS PRIOR Drawout Relays Non-dravout Relays Relay Calibration « Relay Setting Inspection and Tests List of Tests Contacts. Bearings 5 Dust Filter |. Seal-in Contact Settings Contact Gaps. Contact Pressures < Special Tools. Faults and Their Ronedies Renewal Parts. (COMMISSIONING TEST SCHEDULE COMMISSIONING CONTENTS 13 B B 13 8 15 5 5 15 1 19OPERATING INSTRUCTIONS FOR Inverse Time-Overcurrent Relays Types CDG. II, 12, 13 and 14, 50 and 60 Hz INTRODUCTION The CDG tine-overcurrent relay is available with several types of time-current curves, The relays have the same basic constriction and vary only in minor details. COGI1 ANVERSE TIME) For general application as protection for phase and earth/ground faults, The $0 Ha version has a time current characteristic which conforms to B. 8. 142(1953) D612 (LONG TINE DELAY) For stand-by fault protection of neutral earthing/grounding resistors and for other applications where along time delay is required (30 seconds at § times tap value). D613 (VERY INVERSE TIME) Recommended where greater tine selectivity than the CDGL1 is required and the fault current at any point does not vary too widely with systen conditions. (©0614 (EXTREMELY INVERSE TINE) This relay has an even steeper time-current characteristic than the CDG13; permitting a graded setting in conjunction with fuses, With this characteristic it can also guard against overloading of machines and transformers by more closely matching the heating characteristics of protected apparatus than is obtained with the other relay characteristics, The application of these various types is shown in Fig.1 and explained in more detail in publication R-5226 Application of Inverse Time-Overcurrent Relays. Details of current ranges, ratings, ete., are given in the sales publication dealing with type CDG relays. (R-5090, R-5091, R-092 and R-5093). RECEIVING, HANDLING AND STORAGE RECEIVING Relays should be examined on receipt for dasage caused in transit, If the relays are not intended to be used at once they should be put back into their polythene pro- tective bags, See note under storage, overseas. HANDLING Care must be taken when unpacking and installing the relays so that none of the parts are danaged or their settings altered. The packing pieces shich hold the disc,mp ee et | I i” $ ‘me ras sete wooo i. § 1 le HG ie (RELAYS FITTED WITH SERES ELECTRICAL OPERATION INDICATORS) Co Connections for Typical Applications for CDG Relays Fig. 1.5 the packing behind the electrical operation indicator armature, and the rubber band holding the indicator shield must be carefully renoved before commissioning. When renoving relays from their cartons care must be taken that no foreign matter enters the relay to impair its operation, STORAGE UNITED KINGDOM. If the relays are not installed immediately they should be stored in their original cartons in a dry place, free from dust and damp. If humidity is high, ive. over 85% pesk value, a small source of heat should be applied in the storage room or container toraise the relay ambient temperature 10°C above the outside air temperaturt OVERSEAS, Relays shipped for export have a silica-gel unit inside the sealed polythene protective bag to absorb any moisture that may be present after prolonged storage in humid conditions. If the relays are to be stored for some time before putting into service, they should be returned to their protective bags after inspection, the silica-gel dried out fand the bags re-sealed; alternatively they should be stored in a container which has a source of heat sufficient to reise the relay temperature 10°C above the outside air ‘temperature. DUSTY CONDITIONS. For cement mills, four mills, steel mills, desert comtry, etc.,the drawout type case is sealed and a filter provided for ‘breathing’ as ambient con ditions change during day and night. ‘The dust filter detail 1s shown in Pig. 2; for projecting mounting relays, a hole must be provided in the panel to clear the filter intake. INSPECTION To withdraw the relay from a drawout case, loosen the cover nuts and remove the cover; rotate the latches and slide out the relay chassis. To inspect a non-dravout relay, loosen the cover mts and remove the cover, take off the nameplate, remove the knurled nuts securing the case wrapper to the base and take off the wrapper. The relay units on the backplate will now be accessible for inspection. DESCRIPTION ‘The type COG relay consists of an induction disc unit with an operation indi- cator and, in some forms, an instantaneous unit al] assembled on a standard franc. The disc shaft carries @ silver rod moving contact which completes the trip ctreuit through the fixed contact, the control spiral on the shaft serving as lead-in for the moving contact. Pomanent magnet darping is used to control the disc peed. Bxcept on the CDG12 which has two current tappings only, theoperating coil on the electro-magnet has seven taps, each of which is brought out to a socket on the plug setting bridge, The required tap is selected by means of @ plug which cm easily be inserted and withdrawn, Withdrawal of the plug from the bridge automatically brings the maximus current tap into circuit, enabling the setting to be changed under load conditions without risk of open-ciruiting the current-transformers. On the COG12 sinilar conditions obtain with the lower tap of the two withdram. The time setting 1s adjusted by the movement of the back-stop which 1s con- trolled by rotating aknurled moulded disc at the base of the graduated tine multiplier6 Dust filters Anoulded filter breather is fitted to dravout cases which equalises the pressure inside and outside the case without admitting dust 8) Relay Case Breather/Dust Filters should he examined once per year or more frequently if necessitated by site conditions. b) Access is from the rear of the relay case and the nylon filter elements (3) should be prized from the moulded filter body. ©) Wash the filter elements in water and detergent or some other suitable solvent 4) Rinse dry and replace clenents in filter body, 1. Assembly mounting 2. Grid breather 3. Plain washer 4. Bezel Locknut, 6. Locking ring 7. Filtering agent 8 ® |. Moulded rubber body Inner wall of case (@) Cb) 1a. Remove contents by unscrewing by Renove Filter pads by prising the bezel. out with mal! scresdeiver Fig.2. Two types of dust filterOPERATION INDICATORS Mechanical operation indicators can be supplied on the CDG1I relay but, only when the current controlled by the relay contacts does not exceed 10 amp. and only one pair of contacts is required, On all CDG relays electrical operation indicators can be used to control trip coil currents up to 30 amp., except the CDG14 which has a maximum of 15 amp. for series comections. A second electrically separate pair of contacts 1s provided for operating an alarm or remote indicator. ‘The electrical operation indicator may be series connected (current operated), or shunt connected (voltage operated), see fig. 3. SERIES SEAL-IN UNIT The series seal-in unit coil has two current taps, either of which may be ected by screw connections on the unit, The taps are each marked with the minigun anps, Tequired to operate the relay. ‘The taps normally supplied for 50 Hz operation a1 | wnewuw | 0,5. seconn ‘xrwrwum ] 0. 5 SECOND operatina | CURRENT con operating | CURRENT com. CURRENT | RATING — | RESISTANCE current | RATING | RESISTANCE (aupenes) | (AMPERES) | (ORME) (ivPRes) | (AMPERES) cous) or | 9.2 0.6 92 0,29 + oR, 0.3 22 21 24 188 0.031 ‘The taps normally supplied for 60 Hz operation are: urnrwox | 0,5 secon opeRaTING | CURRENT com connent | Ratino | RESISTANCE cawpenes) | (AMPERES) conus) 0.2 22 6.0 2.0 92 0,125 ‘The appropriate tap will be connected and the unit set before despatch, SHUNT CONNECTED UNITS Shunt connected operation indicators may take the form of either a shunt rein- forcing or shunt repeat unit, see fig.3. Note: ‘The settings for the seal-1n relay contacts are shown on page 15. INSTANTANEOUS OVERCURRENT RELAY The instantaneous unit, a CAGI3 relay, if provided, 1s mounted on the top left~ hand corner of the relay, with an operation indicator reset by a separate button at the bottom of the cover of the drawout case, or on the underside of the case in the non-dravout type,Fig. 3. Standard Tripping Circuits8 The pick-up current of this unit is adjusted by means of @ knurled knob which rotates a calibrated scale, See publication R-5078. INSTALLATION LOCATION The location should be dry, clean, free from dust and excessive vibration and reasonably well illuminated to facilitate inspection. MOUNTING The relay case should be mounted on a vertical panel surface (within 5°) so that the disc of the induction unit is approximately horizontal. DRAWOUT CASE ‘The dravout case is suitable for flush or surface mounting. For surface mounting two tapped bosses are provided on the back of the case for bolting to the panel. Separate fixing brackets, attached to the rear bosses, are provided for flush mounting. Por dimensioned drawings of the relay case, see fig. 4 NON-DRAWOUT CASE ‘The non-dravout case is for surface mounting. Fixing points, tapped OBA are provided on the backplate, For dimensioned drawings of the relay case, see fig. 5. ADJUSTMENTS AND TESTS PRIOR TO COMMISSIONING A record of the commissioning tests should be compiled in accordance with the specimen copy, fig.9; and by comparing all subsequent tests with this, the behaviour of the relay may be noted. DRAWOUT RELAYS It is desirable that secondary injection tests should be carried out, using portable test equipment type CFB - R-5187, (see fig.6a-for connections). To check the correct operation of the current-transformers and the relay secting accuracy, operation tests should be carried out when the relays are installed. For secondary injection tests on the relays in the drawout type case it is not necessary to interfere with switchboard wiring or disconnect the relay terminals since this is done by the test plug which is inserted between the contact fingers of the cradle and case, it is important to ensure that the current-transformers are short-circuited on the test plug It is also desirable that after these secondary injection tests, a final test of the trip cireuit should be made. ‘The pick-up of the relay and the time-overcurrent curve, should be checked by # secondary injection test, Any excessive friction due to dirty or damaged bearings or incorrect spring suppression will be indicated by an increase in the pick-up current. NON-DRANOUT RELAYS If connected through the MPG test block the procedure for injection testing is the sane as for the dravout relay, see fig, 6b- If connected through # link terminal board arrange the links so that the relay is transferred to the test circuit, and check that in test position the C.T's are shorted. ‘The time-multiplier and current plug settings are calibrated before despatch and SHOULD NOT REQUIRE ADJUSIVENT, Should the time-current characteristics have been lost, however, die to the brake magnet having been renoved or the control spring suppression altered, the relay can be re-calibrated as follows,aby saonr_vew S05 vey Ee sae Be sopeecrses Fig. 4. Drawout Case Outline and Panel Cutout Detailsu RELAY CALIBRATION 1. Set the time-multiplier on 1.0 and the plug in the centre tap of the plugboard, except on the COG12 which should be plugged into the higher tap. 2 Adjust the spring suppression by turing the snall disc between the tine-multiplier ‘and the spring until the following settings are obtained, ‘These sttings are in percentages of the plug setting values. TPE coatt coat2 coats coats 30 fz 60 Hz 50 and 60 Hz Elec, Operation Indicator ] Contacts close at tis 105 not more than: = |-—————}_ 100 120 130 Mechs Operation Indicator 117 107 Dise starting current] 103-105 95-105 95-105 | 103-105 | 103-105 3, If the time is not correct at ten times plug setting the permanent magnet position may require adjustment, but this would only be in the case of damage to the relay or replacenent of magnets, 4. Check the operating time at twice and ten times plug setting current using the tap value intended in service, Adjustment of this time at twice times plug setting can be obtained by a slight change in the spring suppression, 5. If the spring suppression has to be altered at twice tines plug setting current, the starting end closing current and the operating tine at ten tines plug setting current should be re-checked, as in para. 2 above Note: The time-miltiplier scale is calibrated at 10 times plug setting current, RELAY SETTING Choice of the time-current setting for the CDG relay 1s made by inserting a plug in the appropriate socket of the plug setting bridge and adjusting the time-mltiplier to the correct position. ‘The following example typifies the procedure in making a relay setting:~ Assume that @ type CDG relay is protecting @ systen where the nomal full load current is 400 amp, and the relay is required to trip in 1.8 sec. on a short-ctreuit current of 3300 aap. Assume also that the current-transformers have a 500/S ratio. The plug setting is found by dividing the full load current by the current-transformer ratio. In this case 400 divided by the current-transformer ratio equals 4 amp. The nearest tap above this figure is 5.0 amp. (on a 2,5 - 10 amp. relay) so this tap is then selected, Tb find the proper time setting to give 1.8 sec. time delay at 3300 amp. 3300 is divided by the current-transformer ratio, giving 33 amp secondary current. This secondary current is 6.6 times the 5 amp plug setting and by referring to the ‘time current nonogran on the relay label (i.e, for 3 sec. 50 Hz relay) it will be seen that a time of 3.8 sec, is given against a plug setting multiplier of 6.6. This is for a time multiplier setting of 1.0, Therefore, to obtain 1.8 sec. time delay the time multiplier dial is set to approx. 1.8, 9 This presupposes that the time 3. mltiplier curves are all proportional and although close enough for many purposes it is not exact, particularly at low T.M.S, Amore accurate solution may be obtained by reading directly from the time-current characteristic curves.‘Ten Pau OSE, SE 3 ee me camer mus pr reow si Seon ‘re canon Ra TOS eX ow. far pa Tac Fig. 5. Outline, Non-Drawout Cases13 The above refers to the standard inverse definite time curve (CDG11) but the sane procedure can be followed with the other curves, It must not be assumed that the T.M. curves are proportional on the very inverse and extrenely inverse relays; other- wise large errors will be introduced at the low T.m, settings. MAINTENANCE INSPECTION AND TESTS In addition to the complete testing of the relay characteristic at the time of the original installation of the relays there should also be a less detailed check every one or two years. More frequent maintenance is not required except in extrenely irty, danp or corrosive atuospheres for which special dust-proof and sealed cases are aval able, For these periodic tests it is only necessary to examine the magnetic gaps for dirt and to check the relay at its actual setting. If the air gaps are dirty they may be cleaned with a feather between the disc and the pole piece. If the pick-up of the relay has increased but the gaps are clean the bearings should be exanined ad clemed. Cracked jewel bearings are unlikely because they are spring momted, but they can be detected by passing # needle point over the jewel surface, LIST oF TESTS The following tests should be made:~ 1, Check the time-current characteristic curve at the appropriate time and current setting, 2 Check the minimun operating current. 3. Check the electrical operation indicator, if provided, for minimum pick-up by applying the appropriate d.c. current to terminals 3 and 4 (with main contacts closed) for series connected indicated (see fig. 7d); and by applying voltage to terminals 3 and 8 for shunt indicator (see fig. 7b, c and e). Check the pick-up of the instantaneous overcurrent unit, if provided, at the setting used, The electrical operation indicators should operate to expose their indicators and their contacts should renain closed until the test circuit switch 1s oper Shunt connected indicators should be tested for pick-up at 50% or more, of no! voltage. ‘CONTACTS Al contacts and dravout contact fingers should be inspected to ensure clean contact surfaces, When contacts require cleening a bumishing tool should be used. On no account should they be cleaned with knives, files or enery paper, as these may leave scratches or particles of enery dust which cause arcing and may prevent the contacts fron closing. Owing to the high contact pressure the contacts should require practical ly no attention, BEARINGS ‘The lower bearing consists of a spring loaded synthetic sapphire cup jewel and a phosphor-bronze ring mounted above it to prevent any lateral movenent of the highly polished steel rotor pivot. It can be resoved for inspection by turning the spring momnted holding clip at the bottom of the relay frane to the left or right, the bearing and mounting cen then be slid out.ele lO & EI Ee errr Fig. 6. a Connections for testing single pole CDG relays in drawout cases using overcurrent test equipment, type CFB. For triple pole relays each pole to be tested separately. Fig. 6. b Connections for testing single pole CDG relays in non-drawout cases using test block type PG, test plug and overcurrent test equipment, type CFB. For triple pole relays each pole to be tested separately.18 ‘The upper bearing consists of a steel guide pin extending through an axial hole in ® brass cap at the top ofthe rotor shaft, The guide pin end munting can be renoved by releasing the lock-nut at the top of the frame, It should not be removed while the bottom bearing is out as great care must be taken to prevent damage to the control spiral. If it is necessary to renove the disc to inspect the rotor bearings, the control spiral must be unsoldered at the leg on the spring adjuster and the clip renoved, The rotor can then be renoved without disturbing any other part of the relay. DUST FILTER Relays in dusty atmospheres should have a dust-seal and breather-filter. The filter contents should be exanined and replaced if choked with dust. When replacing the filter material, 1t should be coated with a thin film of light machine oil. SEAL-IN UNIT CONTACT SETTINGS Contact gaps When testing or re-setting contacts it is essential that the correct tools as mention- ed below, are used to carry out the works All settings are with relay de-energised, Nominal armature gap 0.060", Contact gap 0.070"/0, 080" Contact follow-through 0.020°/0,025", this can be checkod by closing the armature on to 2 0,012" feeler strip, when the tips should just make, Ontact pressures All pressures are to be taken at the tips. Pressure to cause lower contact to just touch upper contact: 22/24 grams. Pressure to lift upper contact just clear of contact support: 20/25 grams. SPECIAL TOOLS A special tool kit for relays isavailable which consists of the following tens: ~ 1, Inspection mirror - enables all parts of the relay to be easily and quickly examined, 2, Spring Setting tool - ty means of this tool contact gaps can be accurately adjusted to the required setting; the contact springs are bent at their clamping point so that kinking and deformation of the springs 1s avoided, 3. Contact gauge and - used to determine the contact operating force in grans. Burnishing tool ‘Two leaf springs are provided shich give values of two and ten grans per division wien deflected. The contact force may be measured by the deflections of these springs against an engraved seale, A barnishing tool for contact cleaning is also attached to this gauge. Being flexible, it can be compressed between the contacts to ensure ‘that the actual contact, points are cleaned.er | 3833333896 Fig. 7. Typical Wiring Diagram for CDG Relaysa FAULTS AND THEIR REMEDIES PauLT PROBABLE CAUSE REMEDY High value | 1. Faulty bearings 1, Gleam or replace bearings. of starting or closing | 2 Dirt on rotor 2% Gean rotor and air gaps of current, magnets. 3% Incorrect spring suppression | 3 Readjust spring suppression or, if spring danaged, replace unit, 4, Bxoess friction due to 4. Adjust latch of mechanical ‘the mechantcal operation indicator. indicator, 1f used, 5 Moving contact not in 5. Adjust to position shom correct post tion in in fle relation to disc shape Excessive | 1, Dirt on rotor 1, Clean rotor and air gaps of operating magnets. tine 2 Time dial or brake magnet Adjust time dial or brake setting not adjusted magnet setting, properly 3. Dirty or damaged contact 3. Clean or replace contacts, surfaces 4. Puilty restraint spring 4, Readjust spring swpression or if spring damaged, replace uit. 5. Moving contact not in Adjust to position shown in correct position in relation figs & to disc shape. Reduced 1, Paulty restraint spring Readjust spring suppression operating or if spring damaged replace time mit 2 Time dial, or brake maget | 2 Recalibrate in accordance setting, out of adjustment with page 11. 3 Moving contact not in 3, Adjust to position shom in ‘correct position in fig.8. elation to dise shape Contacts 1, Dirty or damaged contacts Clean or replace contacts. closing but not oper | 2, Faulty trip cireutt Gheck trip clreutt supply ating trip etreutt and continuity.18 S67 Backstor To L2SMIN CONTACT FOLLOW THRO" £09 14 ony, TWis_om To BE MAINTAINED Fig. 8. Disc Setting Dimensions19 FAULT ‘PROBABLE CAUSE REMEDY Relay does not Faulty current coil ctreutt Check coil and coil circuit, ‘operate on replace electro-angnet assexbly over-current if necessary. Seal-in relay Alara or oper- ation indicator not operating. Dirty or danaged contacts or Faulty electrical operation indicator. Open circuited col. Clean contacts of CDG unit, Check alarm circuit and trip circuit ensuring that positive side to terminal No.3 on relay case. Check coil continuity and pick-up values, Renew coil. High or low 1, Partial short-circuit of Check resistance and replace operating coll. coil if necessary. current or voltage 2 Incorrect contact settings, | 2 Reset contacts as shown on page 15. ‘CAGIS unit Relay does not | 1, Faulty coil. 1, Renew coil if necessary. operate on fault current. High or low 1, Incorrect contact or 1. Reset contacts as shown in operating control spring settings. 18/3705. current Mechanical operation indicator Indicator not Damage to operating arm, 1, Reset or replace, if operating. interlocking lever, or necessary. indicator latch. ‘hen ordering renewal parts describe the required part in detail. RENEWAL PARTS Also give the model nunber of the equipment for which these are required.COMMISSIONING TEST SCHEDULE FOR INVERSE TINE OVERCURRENT AND EARTH FAULT RELAYS, AND INSTANTANEOUS HIGH SET OVER- CURRENT RELAYS NAME OF POWER STATION OR SUBSTATION: ~ custouss - SYSTEM VOLTAGE: CIRCUIT DESIGNATION: - ORDER No: RELAY DETAILS SERIAL NUMBERS mee SETTING RANGE Red Yellow Blue | oF Phas earth CURRENT-TRANSFORMER DETAILS SERIAL NUMBER J RATIO MAKER, AccuRAce Red | Yetiow | ah Neutra / | i L I SECONDARY INJECTION TESTS OPERATING TIME AT: To. amay | puss | near Proe-ue = | TIwgs SRTTING MOLTEPLTER sumer | serrive 5 | CURRENT 2] 5 | 10 SETTING 100 | 1.0 = 100 “is over 100. 10 current | Yello" 100- 0:5 100- 10 Bie 100. 0:8 Berta7 25 or 50 10 Ground 25 oF 50. 0.5 INBT. 0/¢ RELAY | RELAY SETTING Red Phase ‘Tripping Yellow Phase current Blue Phase Fig. 9. Specimen commissioning test sheet.(ur policy s one of continuous product development and the ight is reserved to supply equipment which may vary lightly from that described. GEC Measurements the General Electric Company, p. St. Leonards Works Stafford ST17 4LX England Telephone: 0785 3261 Telex: 36240 Cables: Measurements Stafford Telex , of England Publication R-3401 J