4722jb-Kfbf Rev 6 Manuel Idc20k_gb

GILLAM - FEi

Written by : J. Bonardot / K. Flammang Date : 11/03/2013 Ref. Doc. : 4722JB-KFbf Revision : 6 GILLAM - FEi SA Mont Saint-Martin 58 4000 LIEGE �: (+32) 4/232 95 95 - Fax: (+32) 4/223 42 76 BELGIUM

E-mail : [email protected] Internet : www.gillam-fei.be

IDC20K

Current generator for testing railway circuit-breakers

User Guide

GILLAM - FEi

4722JB-KFbf – Rev. 6 IDC20K

11/03/2013 User Guide

REV. DATE SUBJECT MODIFIED

PAGES

0 13/04/11 First release

1 14/04/11 Addition of software part 3,8�12

2 15/04/11 Revision of software part

3 05/08/2011 Addition of language configuration (§3.7) 6-8

4 23/08/11 Modifications 2, 4

5 15/05/2012 Addition chapter 4 10-12

6 11/03/2013 Reports management / Curve 3 stages / Curve profile

§1.1, 3.2, 3.4, 3.10

HISTORY SHEET

GILLAM - FEi

4722JB-KFbf – Rev. 6 IDC20K


TABLE OF CONTENTS

1. Introduction....................................................................................................................... 1

1.1. Equipment presentation ......................................................................................................1

1.2. Contents of this user guide ..................................................................................................1

2. Equipment Description ..................................................................................................... 2

2.1. The ICK20 control module..................................................................................................2 2.1.1. A Man Machine Interface................................................................................................................ 2 2.1.2. A control module situated in a 2U rack........................................................................................... 2

2.2. IJK20 injection modules ......................................................................................................3

2.3. Connection ............................................................................................................................3

3. software Description.......................................................................................................... 5

3.1. Starting-up ............................................................................................................................5

3.2. The menu...............................................................................................................................6

3.3. Injectors status .....................................................................................................................6

3.4. Current curve loading..........................................................................................................7 3.4.1. Parameterizable function loading .................................................................................................... 7 3.4.2. Curve profile ................................................................................................................................... 9 3.4.3. File loading...................................................................................................................................... 9

3.4.3.1. Files format............................................................................................................................ 9 3.4.3.2. File opening ........................................................................................................................... 9

3.5. Current curve injection .....................................................................................................10

3.6. Curve saving .......................................................................................................................10

3.7. Language configuration.....................................................................................................10

3.8. Curves display configuration ............................................................................................11

3.9. Calibration ..........................................................................................................................11

3.10. Injection report recording module ...................................................................................12 3.10.1. Activate / Deactivate reports management ............................................................................... 12 3.10.2. Report recording....................................................................................................................... 12 3.10.3. List of recorded reports ............................................................................................................ 13

4. DC circuit breaker Testing procedure ............................................................................ 15

4.1. Prerequisite.........................................................................................................................15

4.2. Determining circuit breaker dI /dt threshold..................................................................16

4.3. Determining circuit breaker Imax....................................................................................17

GILLAM - FEi

4722JB-KFbf – Rev. 6 IDC20K 1


1. INTRODUCTION

1.1. Equipment presentation

The current injector (IDC20K) is a modular designing equipment aimed at testing circuit-breakers used in high voltage direct current traction networks, or any other intense direct current equipment. Tests are performed on insulated devices of the traction network, by injecting by means of large section cables an arbitrary shape current, with a maximum value of 20000A and a maximum duration of 1800ms. The maximum usable period depends on the intensity of the injected current. The current limit for a duration of 1800ms is about 700A per injector. If the user generates a curve which exceeds the limits of the injectors, a notice shall inform the user that it's not possible to inject this curve. A standard 230V 16A main supply switch is required for its power supply.

1.2. Contents of this user guide

• Equipment description

• Sub-assemblies connection instructions

• Presentation of the graphical interface

• Description of software, functionalities, parameters

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2. EQUIPMENT DESCRIPTION

The equipment's design is modular and transportable; it is integrated in transportation cases. It includes among others a control case and maximum eight identical injection cases. The number of injection cases depends on the current required for the test planned, considering that each injection module is able to supply a maximum current of 2500A. Each module's connecting cables are included in their respective case.

2.1. The ICK20 control module

This module, located in a case, includes two elements :

2.1.1. A Man Machine Interface

It is composed of a PC located in a 1U high slide drawer. From the PC screen, you can :

• Supervise the operation of each connected injector, especially the good condition of its electrical connection to the control module and to the main supply, its load state and a possible failure occurred during an injection.

• Create in graphical form the selected instruction current wave to realize the test.

• Realize the injection by "left click" with confirmation by "Enter".

• View the current shape really injected during the test, upon selection, on a separate graph or stacked on the instruction; during a circuit-breaker test, the opening time of this one appears clearly on the return wave.

• Store results of tests and various instructions for future use.

2.1.2. A control module situated in a 2U rack

This module is electrically connected on the front panel to 230V main supply by means of cables. It has a power on switch and eight connectors numbered from 1 to 8 that allow creating a link by means of a cable specific for each injector used for the test. This control rack, which is connected by USB link to the PC, realizes in fact a supervision and control interface electrically insulated between the PC and the injectors.

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2.2. IJK20 injection modules

The injection module has the form of a 3U 19" rack situated in a case. This case is provided with two front and rear covers; it allows this way storing on the rear part the two power cables, the connecting cable to the control module and the mains cable. A 10 points connector is present on the injection module front panel to allow connection to the control module. On the front panel, you can also note two power terminals, a red and a black one, that will be connected to the tested device by means of "push pull" connectors of power cables of respective colors. Two connectors, input and output, situated on the front panel allow to chain the power supply of X modules dedicated to testing. The first injector is connected by means of its input switch to a mains switch by means of a standard cord; the mains is then chained towards the other modules by means of the various mains input, output switches and the short, male female mains cables. When an injection module is properly connected, on one hand to 230V mains and, on the other hand, to control module, and when the latter and the PC are under power, a waiting time of about 10 minutes is required to realize the first load necessary to perform tests. After a first injection, a maximum reload duration of one minute is required before realizing a new injection.

2.3. Connection

1) Injection modules can equally be placed flat, stacked or put vertically, with horizontal front panel, one next the other, next to the device to be tested.

2) Power cables are 3 meters long.

Connect, on one hand, power cables marked in red and black to power terminals of the same colors on each injector module used; a male female foolproofing allows to avoid polarity reversal.

3) Connect, on the other hand, other cable ends to the device to be tested by means of

two copper plates (one + one -) especially arranged for the test and equipped one with terminals and the other with pin-head adapters compatible with the cables and sufficient in number to connect the quantity of modules required for the test.

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4) Connect to 50Hz alternating 230V mains the first module by means of a mains cord

usually available in the control case, and then chain all the other injectors at "input" and "output" mains switches level, by means of "male" and "female" mains cables present in each injector case.

5) Connect by means of the multipair linking cable the "control" input of each injector

module to one of the eight "control to power injectors" outputs of the control module. There is no connection sequence to follow; for instance the injector module that will be connected to output "4" shall be considered as being injector n°"4" at visual interface level.

6) For usability, the control case can be located at about 3 meters far from the injectors

group (length of multipair connecting cables). 7) Connect also the control rack to 50Hz alternating 230V mains by means of the second

mains cord located in the control case. 8) Power on the unit through M / A switch on the front panel of the control device.

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3. SOFTWARE DESCRIPTION

3.1. Starting-up

To start the program, the user must execute the « IDC.exe » file, situated in the installation folder (ProgramFiles…) or use the shortcut on the « Desktop ». The software main window is composed of :

− A table of LEDs showing injectors status, − Graphs showing sent and received curves, − A tool for generating short-circuit or constant curve on a given maximum intensity, − A panel allowing to select the number of required injectors and to realize the

injections.

The detection and the connection with the control module are carried out automatically at starting-up or when powering on the control module. If the control module is not detected, check whether cables, power supply and USB are properly connected and whether the module is on.

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3.2. The menu

• File « Open » allows loading a file containing points that show a current curve. The currently supported file type is « .ddl » (see § 3.4.2). « Save » allows saving the resulting curve or the theoretical curve in a file at « .ddl » format. « Close » closes the program.

• Configuration « Graphs » allows merging both graphs in a single one. « Log book » displays messages on the operating status of the control module. « Language » language selection (French, English, Spanish). « Calibration » displays a panel allowing to calibrate the control module. « Auto. report » activates or deactivates automatic recording of injection reports.

• Module

« Injection » realizes the curve injection (see § 3.5).

3.3. Injectors status

Injectors status is represented by the following panel :

This panel displays for each injector the 3 status in which an injector can be :

• Injector connected (green) / not connected (grey)

• Injector charged (green) / discharged (red)

• Error (red on) / no error (grey)

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3.4. Current curve loading

Curve loading can be performed in two ways. Curves can be generated either using a parameterizable function, simulating a resistant circuit with or without any train on the line (load current), or loading the DDL file containing a current curve representation.

3.4.1. Parameterizable function loading

The following panel allows generating following 4 types of parameterizable curves :

� Curve simulating a resistant circuit with or without train on the line � A constant on a given maximum current � A curve with 3 stages � A curve with N stages

To generate a short circuit curve, default displayed parameters are the typical values of a 3kV network (Belgium). These include following parameters :

• Voltage of the substation in Volts • Inductance in kilometres of catenary circuit + return by rails and ground • Resistance in kilometres of the same circuit • Fault resistance • Distance in kilometres between fault and substation • Load current (train on the line)

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The curve with 3 stages is characterized by following parameters :

Stage 1 : S1 and I1 Stage 2 : S2 and I2 Stage 3 : S3 and I3 In's correspond to the threshold of stage N and Sn to the slope to reach this stage. The curve with N stages is composed of following parameters : I1 : initial current to be reached S1 : the slope to reach I1 Ip : the intensity difference between the different stages Sp : the slope to reach the next stage (Ip+1) Nb. P: the number of stages to be generated.

For each curve type, the number of injectors required to inject the current curve is then automatically configured.

I3 [A]

i(t)

t

S1 [A/msec]

Curve in 3 stages

S2 [A/msec]

S3 [A/msec]

T [msec]

I2 [A]

I1 [A]

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3.4.2. Curve profile

To avoid re-introducing curve parameters at each use, the application allows recording curve profiles to be generated. Indeed, each curve generated by means of parameterizable functions can be recorded and easily reloaded. In the curve generation panel there are two buttons «Record » and « Load ». To define a profile, the user must select a curve type and position curve parameters. Once this step is achieved, you just have to click on the « Record » button to save a file with « .pcu » extension corresponding to the profile defined by the user. A curve profile loading is achieved by clicking on the « Load » button in the curve generation panel. A dialog box shall appear and prompt the user to select a file with « .pcu » extension. Once the file has been selected, the curve generation panel shall be completed with profile information and the associated curve shall be automatically generated and ready to be injected.

3.4.3. File loading

3.4.3.1. Files format

The application allows loading files with a « .dll » extension. « .dll » files are provided by GILLAM-FEi and present on the computer driving the control module.

3.4.3.2. File opening

File loading can be realized in several ways : • Through menu « File » � « Open », • Through icon , • Selecting the file in Windows and dragging it on the application main window

(Drag and drop).

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3.5. Current curve injection

To realize an injection, following conditions should be respected :

• A curve must be loaded; • The number of connected and ready injectors must be sufficient to provide the

current quantity required to generate the current curve.

When above mentioned conditions are fulfilled, the user is able to realize the injection, either by clicking on « Injection » or by following the menu option. After the injection, the curve of the current really injected is displayed in the second graph. In case of error during the injection, a restart of control module and software is imperative.

3.6. Curve saving

The software allows saving the result of an injected curve at « .ddl » format. Recording is performed through « File » � « Save » menu or through icon. A curve can be saved as an image. Graph saving in an image format is realized by right-ckick on the selected curve and by selecting « Save image as … » in the pop-up menu.

3.7. Language configuration

The application can be configured in different languages (French, English, Spanish) through the « language selection » panel accessible through the menu.

Max intensity according to injectors number

Records the selection permanently.

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3.8. Curves display configuration

By default, each curve is drawn in a separate area as shown below :

Through the « Configuration » menu, you can configure curves display to compare both curves on the same graph; you just have to select « Overwritten » in the « Configuration » � « Graphs » menu to get the following display :

3.9. Calibration

The calibration panel, accessible from the « Configuration » menu, allows to send a 4mA or 20mA signal on the eight outputs of the control module.

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3.10. Injection report recording module

To ensure traceability of the tests performed with the current injector, the IDC20K application can save automatically a report after each injection. The recorded reports can be consulted and exported in PDF or CSV format.

3.10.1. Activate / Deactivate reports management

By default, reports management is activated. The icon in the toolbar indicates whether reports management is activated or deactivated by the presence or absence of a blue frame. The user can deactivate or activate reports recording at any time by a single click on this icon.

3.10.2. Report recording

If reports management is activated, the panel below shall automatically appear after each injection allowing the user to record a report.

The report is divided in two parts. The first one includes the data that should be entered manually by the user :

� A report name � A box to be checked if the tested circuit

breaker is open � A comment

The second part correspond to the fields automatically filled in by the application :

� Theoretical maximum intensity of the injection

� Maximum intensity detected during the injection

� Injection date

After having filled in the different fields, the user can record the report by clicking on the « Record » button. To cancel report recording, you just have to close the form or click on the « Cancel » button, a dialog box informs the user that the report shall not be recorded and closes the form if the user confirms record cancel.

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3.10.3. List of recorded reports

The panel below, accessible by clicking on the icon in the toolbar, allows viewing all recorded reports.

On the left part, you can see the list of recorded reports displayed as a tree structure. Reports are grouped by injection date, which allows having a quick view on the tests performed on a precise date. Each root element corresponds to a date and each child element represents an injection report. A report display in the right part is realized by selecting a report in the tree structure. The right part of the panel formats the information included in the selected report. You will find all the information entered manually by the user, those entered automatically by the application and a graphical representation of the theoretical curve and of the curve resulting from the injection. The application allows also exporting a report in CSV or PDF format. In case of export in CSV format, the file shall have the following structure :

Report name ; [Report name] ; Date Hour : [Report date] ; Theo. Imax : [Theoretical Imax] ; Imax Inj. : [Imax during the injection] ; Activate : [circuit breaker opening YES/NO] ; Theoretical curve ; 1 ;[P1] ; … N,[Pn] ; Resulting curve ; 1 ;P1 ; … N ;[Pn] ;

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Reports exported in PDF have the following shape :

The last functionality of this panel allows reloading the theoretical or injection curve in the application. This way it's possible to reproduce a test previously recorded very easily. To

realize loading, you just have to select a report and click on the icon to load the theoretical curve. In the application's main window, you will find the curve that you have just loaded.

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4. DC CIRCUIT BREAKER TESTING PROCEDURE

4.1. Prerequisite

The way of determining the current or the di/dt parameter required to activate a circuit breaker consists in applying several injections of a curve type « constant » by increasing the maximum current or the di/dt after each test to provoke circuit breaker opening. The application proposes two types of curves. To realize this test, select the option « Constant » in the curve generation panel. The user can then define 3 variables :

� Imax : the maximum current that shall be injected. � di/dt : the value of the slope to reach Imax. � Period : injection duration (max : 500msec).

A click on « Generate» shall display a curve similar to the one below :

Attention, before each injection, all connected injectors must be loaded. The procedures described in following chapters is based on theoretical examples. Real examples are available in the application note IDC01 ref : 4786RNrn rev.0

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4.2. Determining circuit breaker dI /dt threshold

To realize this test, make sure that the circuit breaker shall not open in case of maximum current threshold overshoot. It's necessary to know this threshold (Idisj) and to configure the Imax variable (curve generation panel) to a value lower than 20% at Idisj. If the user doesn't know the activation threshold value, Imax must be defined with a value arbitrarily low, for instance 1000A. This test is composed of a succession of injections for which the di/dt parameter shall be increased progressively till reaching a value that provokes circuit breaker opening. For instance : A circuit breaker having a threshold Idisj of 3750A

1. We shall have : 20% of Idisj � Imax = 3000A. 2. Set Imax to 3000A and di/dt to 40A/ms. 3. Click on "Generate" and then on "Inject". 4. If the circuit breaker is activated, increase the value of dI /dT by 10A/ms and repeat

point 2. Continue as long as the circuit breaker is not activated. 5. Once the injection has provoked circuit breaker opening, you shall have a first idea of

the value of di/dt necessary for the activation. 6. If you want to have a more accurate value of di/dt, repeat previous steps reducing the

di/dt steps between the injections. You will find below the graph summarizing the above described test :

Test di/dt

0

500

1000

1500

2000

2500

3000

3500

1 6 11 16 21 26 31 36 41 46 51 56 61 66 71 76 81 86 91 96 101

t (ms)

I (A)

Seuil dIdT

In this example, the only moment when the circuit breaker shall open shall be during the last test with a di/dt of 100A/ms. We can conclude that the activation threshold on di/dt is between 100A/ms and 90A/ms.

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4.3. Determining circuit breaker Imax

First, you have to make sure that the activation shall not be provoked by a different condition from current threshold overshoot. You must then know the circuit breaker di/dt threshold and configure the di/dt parameter (curve generation panel) with a value lower than di/dt threshold. If the user doesn't know this value, he/she can try to determine it by following the procedure described in chapter 2 with an Imax selected arbitrarily low. As for the previous test, this test is composed of a succession of injections for which we shall progressively increase the value of the injected current. For instance :

1. Start by positioning the Imax variable to 1000A and the di/dt parameter below the circuit breaker activation threshold (ex : 70 A/ms).

2. Generate the curve and click on "Inject". 3. If the circuit breaker doesn't open, increase the Imax variable to 500A and then repeat

those actions by increasing the Imax value at each test. 4. In case the circuit breaker has opened, we can reduce the Imax value by steps of 50A

and start the test again to determine more accurately the current required to provoke a circuit breaker activation.

You will find below the graph summarizing the above described test :

Test Imax

0500

10001500200025003000350040004500

1 6 11 16 21 26 31 36 41 46 51 56 61 66 71 76 81 86 91 96 101

t (ms)

I (A)

I Disj

In the above mentioned example, the circuit breaker shall be activated only during the 6th test with an Imax of 3500A. We can deduce that the activation threshold on Imax is between 3000A and 3500A.

4722jb-Kfbf Rev 6 Manuel Idc20k_gb

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