R8557B KCGG

Service Manual Types KCGG 141, 241, 341 Overcurrent Relays
Service Manual Types KCGG 141, 241, 341 Overcurrent Relays
HANDLING OF ELECTRONIC EQUIPMENT

A person's normal movements can easily generate electrostatic potentials of several thousand volts. Discharge of these voltages into semiconductor devices when handling electronic circuits can cause serious damage, which often may not be immediately apparent but the reliability of the circuit will have been reduced. The electronic circuits of ALSTOM T&D Protection & Control Ltd products are immune to the relevant levels of electrostatic discharge when housed in their cases. Do not expose them to the risk of damage by withdrawing modules unnecessarily. Each module incorporates the highest practicable protection for its semiconductor devices. However, if it becomes necessary to withdraw a module, the following precautions should be taken to preserve the high reliability and long life for which the equipment has been designed and manufactured. 1. Before removing a module, ensure that you are at the same electrostatic potential as the equipment by touching the case. 2. Handle the module by its front-plate, frame, or edges of the printed circuit board. Avoid touching the electronic components, printed circuit track or connectors. 3. Do not pass the module to any person without first ensuring that you are both at the same electrostatic potential. Shaking hands achieves equipotential. 4. Place the module on an antistatic surface, or on a conducting surface which is at the same potential as yourself. 5. Store or transport the module in a conductive bag. More information on safe working procedures for all electronic equipment can be found in BS5783 and IEC 60147-0F. If you are making measurements on the internal electronic circuitry of an equipment in service, it is preferable that you are earthed to the case with a conductive wrist strap. Wrist straps should have a resistance to ground between 500k 10M ohms. If a wrist strap is not available, you should maintain regular contact with the case to prevent the build up of static. Instrumentation which may be used for making measurements should be earthed to the case whenever possible. ALSTOM T&D Protection & Control Ltd strongly recommends that detailed investigations on the electronic circuitry, or modification work, should be carried out in a Special Handling Area such as described in BS5783 or IEC 60147-0F.
SAFETY SECTION
This Safety Section should be read before commencing any work on the equipment. Health and safety The information in the Safety Section of the product documentation is intended to ensure that products are properly installed and handled in order to maintain them in a safe condition. It is assumed that everyone who will be associated with the equipment will be familiar with the contents of the Safety Section. Explanation of symbols and labels The meaning of symbols and labels which may be used on the equipment or in the product documentation, is given below.
Caution: refer to product documentation
Caution: risk of electric shock
Protective/safety *earth terminal
Functional *earth terminal. Note: this symbol may also be used for a protective/ safety earth terminal if that terminal is part of a terminal block or sub-assembly eg. power supply.
*Note:The term earth used throughout the product documentation is the direct equivalent of the North American term ground.
Installing, Commissioning and Servicing

Equipment connections Personnel undertaking installation, commissioning or servicing work on this equipment should be aware of the correct working procedures to ensure safety. The product documentation should be consulted before installing, commissioning or servicing the equipment. Terminals exposed during installation, commissioning and maintenance may present a hazardous voltage unless the equipment is electrically isolated. If there is unlocked access to the rear of the equipment, care should be taken by all personnel to avoid electric shock or energy hazards. Voltage and current connections should be made using insulated crimp terminations to ensure that terminal block insulation requirements are maintained for safety. To ensure that wires are correctly terminated, the correct crimp terminal and tool for the wire size should be used.
Before energising the equipment it must be earthed using the protective earth terminal, or the appropriate termination of the supply plug in the case of plug connected equipment. Omitting or disconnecting the equipment earth may cause a safety hazard. The recommended minimum earth wire size is 2.5 mm2, unless otherwise stated in the technical data section of the product documentation. Before energising the equipment, the following should be checked: Voltage rating and polarity; CT circuit rating and integrity of connections; Protective fuse rating; Integrity of earth connection (where applicable) Equipment operating conditions The equipment should be operated within the specified electrical and environmental limits. Current transformer circuits Do not open the secondary circuit of a live CT since the high voltage produced may be lethal to personnel and could damage insulation. External resistors Where external resistors are fitted to relays, these may present a risk of electric shock or burns, if touched. Battery replacement Where internal batteries are fitted they should be replaced with the recommended type and be installed with the correct polarity, to avoid possible damage to the equipment. Insulation and dielectric strength testing Insulation testing may leave capacitors charged up to a hazardous voltage. At the end of each part of the test, the voltage should be gradually reduced to zero, to discharge capacitors, before the test leads are disconnected. Insertion of modules and pcb cards These must not be inserted into or withdrawn from equipment whilst it is energised, since this may result in damage. Fibre optic communication Where fibre optic communication devices are fitted, these should not be viewed directly. Optical power meters should be used to determine the operation or signal level of the device.
Older Products
Electrical adjustments Equipments which require direct physical adjustments to their operating mechanism to change current or voltage settings, should have the electrical power removed before making the change, to avoid any risk of electric shock. Mechanical adjustments The electrical power to the relay contacts should be removed before checking any mechanical settings, to avoid any risk of electric shock. Draw out case relays Removal of the cover on equipment incorporating electromechanical operating elements, may expose hazardous live parts such as relay contacts. Insertion and withdrawal of extender cards When using an extender card, this should not be inserted or withdrawn from the equipment whilst it is energised. This is to avoid possible shock or damage hazards. Hazardous live voltages may be accessible on the extender card. Insertion and withdrawal of heavy current test plugs When using a heavy current test plug, CT shorting links must be in place before insertion or removal, to avoid potentially lethal voltages.
Decommissioning and Disposal

Decommissioning: The auxiliary supply circuit in the relay may include capacitors across the supply or to earth. To avoid electric shock or energy hazards, after completely isolating the supplies to the relay (both poles of any dc supply), the capacitors should be safely discharged via the external terminals prior to decommissioning. Disposal: It is recommended that incineration and disposal to water courses is avoided. The product should be disposed of in a safe manner. Any products containing batteries should have them removed before disposal, taking precautions to avoid short circuits. Particular regulations within the country of operation, may apply to the disposal of lithium batteries.
Technical Specifications
Protective fuse rating The recommended maximum rating of the external protective fuse for this equipment is 16A, Red Spot type or equivalent, unless otherwise stated in the technical data section of the product documentation. Insulation class: IEC 601010-1: 1990/A2: 1995 Class I EN 61010-1: 1993/A2: 1995 Class I Installation Category (Overvoltage): IEC 601010-1: 1990/A2: 1995 Category III EN 61010-1: 1993/A2: 1995 Category III This equipment requires a protective (safety) earth connection to ensure user safety. Distribution level, fixed installation. Equipment in this category is qualification tested at 5kV peak, 1.2/50s, 500, 0.5J, between all supply circuits and earth and also between independent circuits. Compliance is demonstrated by reference to generic safety standards. Compliance with the European Commission Low Voltage Directive. 1993/A2: 1995 1992/A11: 1997 Compliance is demonstrated by reference to generic safety standards.
Environment:
IEC 601010-1: 1990/A2: 1995 Pollution degree 2 EN 61010-1: 1993/A2: 1995 Pollution degree 2 73/23/EEC
Product safety:
EN 61010-1: EN 60950:
SERVICE MANUAL KCGG 141, 241, 341
R8557B Contents
CHAPTER 1. CHAPTER 2 CHAPTER 3 CHAPTER 4 CHAPTER 5 CHAPTER 6 CHAPTER 7 CHAPTER 8 APPENDIX 1 APPENDIX 2 APPENDIX 3 APPENDIX 4
INTRODUCTION HANDLING AND INSTALLATION RELAY DESCRIPTION APPLICATION OF PROTECTION FUNCTIONS MEASUREMENT AND RECORDS SERIAL COMMUNICATIONS TECHNICAL DATA COMMISSIONING RELAY CHARACTERISTIC CURVES LOGIC DIAGRAMS CONNECTION DIAGRAMS COMMISSIONING TEST RECORD
Types KCGG 141, 241, 341 Overcurrent Relays Service Manual
Chapter 1 Introduction
R8557B Chapter 1 Contents
1. 2. 2.1 2.2 2.3 2.4 2.4.1 2.5
USING THE MANUAL INTRODUCTION KCGG 141 three phase overcurrent and earth fault protection KCGG 241 three phase overcurrent and earth fault protection KCGG 341 three phase overcurrent and earth fault protection Protection features of KCGG 141, KCGG 241 and KCGG 341 relays Simplified settings configuration Features available by model
1 1 1 2 2 2 2 3
SERVICE MANUAL KCGG141, 241, 341
R8557B Volume 1 Chapter 1 Page 1 of 3
Section 1.
USING THE MANUAL
This manual provides a description of the KCGG 141/241/341 overcurrent protection from K Range Series 2 numerical relays. It is intended to guide the user through the application, installation, setting and commissioning of the relays. The manual has the following format : Chapter 1. Introduction An introduction on how to use this manual and a general introduction to the relays covered by the manual. Chapter 2. Chapter 3. Handling and Installation Precautions to be taken when handling electronic equipment. Relay Description A detailed description of the features that are common to KCGG 141, 241 and 341 relays Chapter 4. Application of Protection Functions An introduction to the applications of the relays and special features provided. Chapter 5. Section 6. Section 7. Measurements and Records How to customise the measurements and use the recording features. Control Functions and Serial Communications Hints on using the serial communication feature. Technical Data Comprehensive details on the ratings, setting ranges and specifications etc. Section 8. Appendix Commissioning A guide to commissioning, problem solving and maintenance. Appendices include relay characteristic curves, logic diagrams, connection diagrams and commissioning test records.
Section 2.
INTRODUCTION
The K Range of numerical relays has been enhanced to include a range of relays for three phase overcurrent and earth fault protection with reduced inputs/outputs. The three models covered by this manual are supplied with a fixed configuration that simplifies their application. 2.1 KCGG 141 three phase overcurrent and earth fault protection This relay draws power from the substation battery, or a secure AC supply, to power its internal circuits. It will normally be used with shunt tripping arrangements. It is available either preconfigured with simplified settings (KCGG 141) or customer configurable (KCGG 142 02). This service manual applies to the KCGG 141 simplified settings relay. The service manual R8551 applies to the KCGG 142 02 customer configurable relay.
2.2
KCGG 241 three phase overcurrent and earth fault protection This relay can draw the energy necessary to power its internal circuits from the line current transformers and hence can be applied to impose no continuous drain on the station battery. It is therefore ideal for those situations where the battery is not supervised. These installations would normally be provided with a battery for tripping the circuit breaker and a shunt trip arrangement would be typical. However, if there is no station battery and the circuit breaker has a suitably sensitive trip mechanism, the capacitor discharge trip feature of this relay may be used to power the trip circuit. Additionally this relay may be powered from an auxiliary AC supply, such as the lighting supply in the substation, or from the VT on the circuit breaker. Under fault conditions, when this voltage supply may be lost, the relay will be powered from the current transformers, but at all other times the voltage supply will power the relay. This will allow settings to be applied, lower earth fault to be detected and serial communications to be established.
2.3
KCGG 341 three phase overcurrent and earth fault protection This relay is based on the KCGG 241 and can be used in similar installations. An additional electromechanical element is incorporated in this relay so that it may be used in AC Series trip circuits.
2.4 2.4.1
Protection features of KCGG 141, KCGG 241 and KCGG 341 relays Simplified settings configuration Two stages of overcurrent protection Two stages of earth fault protection Measurement of current and frequency Fault records for last 5 faults Event records for the last 50 events Disturbance record for the last fault Serial communications
2.5
Features available by model

Feature KCGG 141 simplified settings KCGG 241 KCGG 341
Protection Overcurrent Earth fault Measurement Frequency Current Thermal ammeter(s) Thermal demand(s) Thermal state Programmable I/O Logic inputs Output relays Control Auxiliary timers Remote setting change Records Fault records Event records Disturbance records 5 50 1 5 50 1 5 50 1 1 3 4 3 4 3 4
Chapter 2 Handling and Installation
1. 1.1 1.2 2. 3. 4. 5.
GENERAL CONSIDERATIONS Receipt of relays Electrostatic discharge (ESD) HANDLING OF ELECTRONIC EQUIPMENT RELAY MOUNTING UNPACKING STORAGE
1 1 1 1 2 2 3
Section 1.
1.1
GENERAL CONSIDERATIONS
Receipt of relays Protective relays, although generally of robust construction, require careful treatment prior to installation on site. Upon receipt, relays should be examined immediately to ensure no damage has been sustained in transit. If damage has been sustained during transit, a claim should be made to the transport contractor, and ALSTOM T&D Protection & Control should be promptly notified. Relays that are supplied unmounted and not intended for immediate installation should be returned to their protective polythene bags.
1.2
Electrostatic discharge (ESD) The relays use components that are sensitive to electrostatic discharges. The electronic circuits are well protected by the metal case and the internal module should not be withdrawn unnecessarily. When handling the module outside its case, care should be taken to avoid contact with components and electrical connections. If removed from the case for storage, the module should be placed in an electrically conducting antistatic bag. There are no setting adjustments within the module and it is advised that it is not unnecessarily disassembled. Although the printed circuit boards are plugged together, the connectors are a manufacturing aid and not intended for frequent dismantling; in fact considerable effort may be required to separate them. Touching the printed circuit board should be avoided, since complementary metal oxide semiconductors (CMOS) are used, which can be damaged by static electricity discharged from the body.
Section 2.
HANDLING OF ELECTRONIC EQUIPMENT
A persons normal movements can easily generate electrostatic potentials of several thousand volts. Discharge of these voltages into semiconductor devices when handling electronic circuits can cause serious damage, which often may not be immediately apparent but the reliability of the circuit will have been reduced. The electronic circuits are completely safe from electrostatic discharge when housed in the case. Do not expose them to risk of damage by withdrawing modules unnecessarily. Each module incorporates the highest practicable protection for its semiconductor devices. However, if it becomes necessary to withdraw a module, the precautions should be taken to preserve the high reliability and long life for which the equipment has been designed and manufactured. 1. Before removing a module, ensure that you are at the same electrostatic potential as the equipment by touching the case. 2. Handle the module by its frontplate, frame or edges of the printed circuit board. Avoid touching the electronic components, printed circuit track or connectors. 3. Do not pass the module to another person without first ensuring you are both at the same electrostatic potential. Shaking hands achieves equipotential.
4. Place the module on an antistatic surface, or on a conducting surface which is at the same potential as yourself. 5. Store or transport the module in a conductive bag. If you are making measurements on the internal electronic circuitry of an equipment in service, it is preferable that you are earthed to the case with a conductive wrist strap. Wrist straps should have a resistance to ground between 500k 10M. If a wrist strap is not available, you should maintain regular contact with the case to prevent a build-up of static. Instrumentation which may be used for making measurements should be earthed to the case whenever possible. More information on safe working procedures for all electronic equipment can be found in BS5783 and IEC 60147-OF. It is strongly recommended that detailed investigations on electronic circuitry, or modification work, should be carried out in a Special Handling Area such as described in the above-mentioned BS and IEC documents.
Section 3.
RELAY MOUNTING
Relays are dispatched, either individually, or as part of a panel/rack assembly. If loose relays are to be assembled into a scheme, then construction details can be found in Publication R7012. If an MMLG test block is to be included it should be positioned at the right hand side of the assembly (viewed from the front). Modules should remain protected by their metal case during assembly into a panel or rack. The design of the relay is such that the fixing holes are accessible without removal of the cover. For individually mounted relays, an outline diagram is normally supplied showing the panel cut-outs and hole centres. These dimensions will also be found in Publication R6557.
Section 4.
UNPACKING
Care must be taken when unpacking and installing the relays so that none of the parts is damaged, or the settings altered and they must only be handled by skilled persons. The installation should be clean, dry and reasonably free from dust and excessive vibration. The site should be well lit to facilitate inspection. Relays that have been removed from their cases should not be left in situations where they are exposed to dust or damp. This particularly applies to installations which are being carried out at the same time as construction work.
Section 5.
STORAGE
If relays are not to be installed immediately upon receipt they should be stored in a place free from dust and moisture in their original cartons. Where de-humidifier bags have been included in the packing they should be retained. The action of the de-humidifier crystals will be impaired if the bag has been exposed to ambient conditions and may be restored by gently heating the bag for about an hour, prior to replacing it in the carton. Dust which collects on a carton may, on subsequent unpacking, find its way into the relay; in damp conditions the carton and packing may become impregnated with moisture and the de-humidifier will lose its efficiency. Storage temperature 25C to +70C.
Chapter 3 Relay Description
1. 2. 2.1 2.2 2.3 2.4 2.5 3. 3.1 3.2 3.3 3.4 3.5 3.6 3.7 3.8 3.9 3.10 3.11 3.12 3.13 3.14 4. 4.1 4.2 4.3 4.4 5. 5.1 5.2 5.3 5.4 5.5 6. 6.1 6.2 6.3 7. 8. 8.1 8.2 8.3 8.4 8.5
RELAY DESCRIPTION USER INTERFACE Frontplate layout LED indications Keypad Liquid crystal display Flag display format MENU SYSTEM Default display Accessing the menu Menu contents Menu columns System data Fault records Measurements 1 Measurements 3 Earth fault 1 Phase fault 1 Logic (KCGG 341 menu only) Input masks Relay masks Recorder masks ACCESS TO MENU Quick guide to menu controls Negotiating the menu Resetting trip indication Clearing fault records ACCESS TO SETTINGS To enter setting mode To escape from the setting mode Changing setting values To accept the new setting Entering text ACCESS TO ADVANCED SETTINGS Changing function links Setting communication address Setting the relay with a PC or laptop ALARM FLAGS EXTERNAL CONNECTIONS Auxiliary powered relays Dual powered relays Powered from current transformers alone Special application notes for dual powered relays Powered from an auxiliary AC voltage and from current transformers
1 2 2 3 3 3 3 5 5 6 6 7 7 8 8 8 9 9 10 10 10 10 11 11 12 12 13 13 13 13 13 14 14 14 14 14 15 15 16 17 17 17 18 18
8.6 8.7 8.8 8.9 8.10 8.11 8.12 8.13 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Figure 7. Figure 8.
Dead substation protection Logic control inputs Analogue inputs Output relays Output relay minimum dwell time Capacitor discharge tripping AC series tripping Improving reliability of trip and closing contacts Front plate layout Flag display format Menu format Start up time delay Example connection of logic inputs Capacitor discharge trip AC series trip arrangement, KCGG 341 Contact reinforcing circuit
19 19 20 21 21 21 22 22 2 4 5 18 20 21 22 23
Section 1.
RELAY DESCRIPTION
The KCGG 141/241/341 relays use numerical techniques to derive protection and control functions. They have four multiplexed analogue inputs, sampled eight times per power frequency cycle. The Fourier derived power frequency component returns the rms value of the measured quantity. To ensure optimum performance, frequency tracking is used. The channel that is tracked is chosen on a priority basis, a, b, c. Frequency tracking is not employed on the residual current, to ensure maximum harmonic rejection. In the absence of a signal to frequency track, the sampling frequency defaults to the rated frequency of the power system. Four output relays are programmed to respond to a selection of protection functions and three logic inputs are allocated to control functions. The logic inputs are filtered to ensure that induced AC current in the external wiring to these inputs does not cause an incorrect response. The relays are powered from either a DC, or an AC, auxiliary supply which is transformed by a wide ranging DC/DC converter within the relay. This provides the electronic circuits with regulated and galvanically isolated supply rails. The power supply also provides a regulated and isolated field voltage to energise the logic inputs. The dual powered version of the relay draws its energising supply from the current transformers in the absence of an auxiliary voltage supply. This makes it suitable for application where the auxiliary supply is not reliable, or not available. This can be used in shunt trip, capacitor discharge and AC series trip arrangements. An interface on the front of the relay allows the user to navigate through the menu to access data, change settings and reset flags etc. As an alternative the relay can be connected to a computer via its serial communication port and the menu accessed on-line. This provides a more friendly and intuitive method of setting the relay, as it allows a whole column of data to be displayed at one time instead of just a single menu cell. Computer programs are also available which enable setting files to be generated off-line and these files can then be down loaded to the relay via the serial port. In addition to protection and control functions the relays can display all the values that are measured and many additional ones that are calculated. Useful time stamped data for post fault analysis is stored in event records and disturbance records. This data is available via a serial communication port for access locally and/or remotely, with a computer. Remote control actions can also be made and to this end many relays from the K Range have been integrated into SCADA systems.
Section 2.
USER INTERFACE
The front plate of the relay provides a man machine interface, providing the user with a means of entering settings to the relay, displaying measured values, fault records and alarms. The series 2 relays have additional graphics to assist the user. The area in which the fault flags are displayed is divided up to denote the area associated with each phase and there is a marked position for the appropriate phase colours to be marked and for labels to be affixed to denote the use of the three overcurrent stages and the three auxiliary timers.
Relay types
Model number
KCGG141
Liquid crystal display
SETTING GROUP FAULT No A
KCGG14101102125 No P967701
Serial number
B
F n _ 2 G2 A _ _ * B _ _ * AU X 1 C*
C
STAGE 1 STAGE 2 STAGE 3
F E D C B A 9 8 7 6 5 4 3 2 1 0
AUX TIMER
* *
Digit identifiers
TRIP
ALARM HEALTHY
Entry keys
LED indicators
Ratings
In 1 A V 110/125 V Vn 110 V 50/60 Hz
Figure 1. Front plate layout

2.1 Frontplate layout The frontplate of the relay carries a liquid crystal display (LCD) on which data such as settings and measured values can be viewed. The data is accessed through a menu system. The four keys [F]; [+]; [] and [0] are used to move around the menu, select the data to be accessed and enter settings. Three light emitting diodes LEDs indicate alarm, healthy and trip conditions. A label at the top corner identifies the relay by both its model number and serial number. This information uniquely specifies the product and is required when making any enquiry to the factory about a particular relay. In addition, there is a rating label in the bottom corner which gives details of the auxiliary voltage and current ratings. Two handles, one at the top and one at the bottom of the frontplate, will assist in removing the module from the case.
2.2
LED indications The three LEDs provide the following functions: GREEN LED Indicates the relay is powered up and running. In most cases it follows the watchdog relay, but dual powered relays are the exception because the watchdog does not operate for loss of auxiliary supply. Such a condition would be considered a normal operational condition when the relays are energized from line current transformers alone.
YELLOW LED Indicates alarm conditions that have been detected by the relay during its self checking routine. RED LED 2.3 Keypad The four keys perform the following functions: [F] [+] [-] [0] Note: 2.4 - function select/digit select key/next column - put in setting mode/increment value/accept key/ previous column - put in setting mode/decrement value/reject key /next column - reset /escape/change default display key Only the [F] and [0] keys are accessible when the relay cover is in place. Indicates a protection trip that has been issued by the relay.
Liquid crystal display The liquid crystal display has two lines, each of sixteen characters. A back-light is activated, when any key on the frontplate is momentarily pressed and will remain lit until ten minutes after the last key press. This enables the display to be read in all conditions of ambient lighting. The numbers printed on the frontplate just below the display, identify the individual digits that are displayed for some of the settings, ie. function links, relay masks etc. Additional text around the display is used to define the areas in which the various parts of the fault information will be found.
2.5
Flag display format When the fault flags are displayed, the record number is displayed in the top four left-hand digits of the display. Fn, Fn-1, ........Fn-4, to denote the last and previous fault flags. The unlatched current state of the fault flags can be viewed in menu cell 0023 in the System Data column, denoted by Fnow. The two characters after the record number indicate the setting group that was in operation during the fault. These relays have only one setting group so G1 will be displayed. When Fnow is displayed, the setting group is that currently active. The next most important areas are the four each marked by a circle. These circles are over printed with a letter (A, B, or C) to indicate the phase, or a symbol to represent an earth fault. Alternatively a coloured disc may be stuck over the circles to indicate the phases by a colour eg. red, yellow and blue. There are four characters on the display associated with each of these four areas to flag operation of the start and operation of the three overcurrent stages for that phase.
SETTING GROUP FAULT No
F n _ 2G2 A _ _ * B _ _ * AU X
AUX TIMER
STAGE 1 STAGE 2 STAGE 3
C*
C
F E D C B A 9 8 7 6 5 4 3 2 1 0
* *
ALARM HEALTHY
Figure 2. Flag display format
TRIP
Consider the four digits above the circle marked | |. If the relay trips during a fault involving phase C then the first digit will be the letter C to indicate the current exceeded the > threshold and that the protection has started. The next three characters are flags for each of the two overcurrent stages (t>, t>>) associated with that phase (phase C in this example) and an asterisk (*) will be displayed for the stage, or stages that have operated. Thus: C Would indicate that a current above the > setting had been detected by the phase C element during the fault (START condition). would indicate the first overcurrent stage (t>) had operated would indicate the second stage (t>>) had timed out.
C* C_*
Flag information is similarly provided for the other two phases and for earth faults. The six characters at the left hand side of the display on the bottom line identify the auxiliary function AUX1. Two printed panels below the display may be used to indicate the function of the auxiliary and the function performed by the main overcurrent functions. The appropriate pre-printed labels can be affixed in these two areas. Operation of the thermal element is indicated by the Letter T in the bottom right hand character.
Section 3.
MENU SYSTEM
F1
F2
F3
F4
F5
F
LONG
F
LONG
F
LONG
F
LONG
F
LONG
F SHORT
F SHORT
F SHORT
F SHORT
F SHORT
Figure 3. Menu format

Data within the relays is accessed via a menu table. The table is comprised of cells arranged in rows and columns, like a spreadsheet. A cell may contain text, values, settings or functions. The first cell in a column, the column heading, contains text identifying the data grouped under it in that column. 3.1 Default display The configured default display appears on power-up. Whilst the default display is visible it is possible to scroll through the available options with a momentary press of the [0] key. The last default display selected by this means will be returned automatically 15 minutes after the last key press, but this will not affect the display that appears on power-up. Following a protection trip the display will change automatically from the selected default display to that for the fault flags for the last fault and the red trip led will be lit to draw attention to the fact. Whilst the fault flags are displayed the trip led can be reset by holding down the [0] for at least one second. The trip LED will be reset and the display will change to the default display that was last selected. The flag information will not be lost by this action, it is only cleared from the display and can still be accessed under FAULT RECORDS. The display of the trip flags will remain the default display until the trip LED is reset. To return to the default display without waiting for the 15 minute delay to expire move to a column heading and pressing the [0] key for 1 second.
3.2
Accessing the menu To move from the default display the [F] should be pressed momentarily and the display will change to [0000 SYSTEM DATA], the column heading for the first menu column. The [F] key can now be used with short presses to step down the System Data column. Pressing the [F] and [0] keys together and holding for one second can be used to step up the menu column to the previous item. A long press of the [F] key, greater than one second, will display the next column heading. The only settings that can be changed with the cover in place are those that can be reset either to zero or some preset value. When such a cell is displayed its value can be reset by a long press of the [0] key, provided the cell is not password protected. A short press of the [0] key will switch on the back light without changing the display in any way. With just these two keys, the menu can be scanned with the cover in place and reset actions can be effected. To change any other settings the cover must be removed from the relay to gain access to the [+] and [] keys that are used to increment or decrement a value. When a column heading is displayed the [] key will change the display to the next column and the [+] key will change the display to the previous column, giving a faster selection. When a cell that can be changed is displayed, the action of pressing either the [+] or [] keys will put the relay in setting mode indicated by a flashing cursor in the display. To escape from the setting mode without making any change, the [0] key should be depressed for one second. Section 5.3 gives instructions for changing the various types of settings. Configuration settings which can be changed include the selection of time curves, function links and CT ratios. Individual protection settings and some reset functions, are protected from change when the relay cover is in place.
3.3
Menu contents Related data and settings are grouped in separate columns of the menu. Each column has a text heading (in capital letters) that identifies the data contained in that column. Each cell may contain text, values, settings and/or a function. The cells are referenced by the column number/row number. For example 0201 is column 02, row 01. When a cell is displayed the four digits at the top left hand corner of the LCD indicate the column number and row number in the menu table. Those cells that do not provide any useful purpose are not made available in the factory configuration.
3.4
Menu columns Col No 00 01 02 04 05 06 09 0C Heading SYSTEM DATA FLT RECORDS MEASURE 1 MEASURE 3 EARTH FLT 1 PHASE FLT 1 LOGIC RECORDER Description Settings and data for the system relay and serial communications. Fault records for the last five faults Directly measured quantities (V and etc.) Calculated (additional) Earth fault protection settings - Group 1 Phase fault protection settings - Group 1 Settings for miscellaneous functions used in the logic Settings for the disturbance recorder [READ] . [SET]. [RESET]. Description Column heading Product description (user programmable text) Plant reference (user programmable text) Model number that defines the product Serial number - unique number identifying the particular product Default sampling frequency - must be set to power system frequency Indicates the Courier communication level supported by the product Communication address (1 to 255) Software reference for the product Indicates the current status of all the logic inputs Indicates the current status of the output relay drives Indicates the current state of internal alarms Error in factory configuration settings Operating in uncalibrated state Error detected in stored settings Protection out of servive and not functioning No A/D samples but still in service
Cells that are read only are marked Cells that can be set are marked Cells that can be reset are marked 3.5 System data Display 0000 SYSTEM DATA 0004 Description 0005 Plant 0006 Model 0008 Serial No. 0009 Freq 000A Comms Level 000B Rly Address 0011 Software 0020 Log Status 0021 Rly Status 0022 Alarms 0 Uncfg 1 Uncalib 2 Setting 3 No Service 4 No Samples Status READ SET SET READ READ SET READ SET READ READ READ READ READ READ READ READ READ
R8557B Volume 1 Chapter 3 Page 8 of 23 READ SET READ Fourier not being performed Test watchdog by setting this bit to 1 Indicates the current status of the fault flags (These flags are not latched) Description Column heading Number of fault record displayed - may be selected (Fn; Fn-1;........Fn-4) Flags (latched) indicating the functions that operated during the fault Highest value of current measured in phase A during the fault Highest value of current measured in phase B during the fault Highest value of current measured in phase C during the fault Highest value of residual current measured during the fault Press [0] key when this cell is displayed to clear all fault records Description Column heading Measured current in phase A Measured current in phase B Measured current in phase C Measured residual current Measured power system frequency F Description Column heading Thermal ammeter reading in phase A Thermal ammeter reading in phase B Thermal ammeter reading in phase C Thermal state % Peak thermal ammeter reading in phase A demand value Peak thermal ammeter reading in phase B demand value
5 No Fourier 6 Test Wdog 0023 FnowG1 3.6 Fault records Display 0100 FLT RECORDS 0101 Fault No 0102 Fn G1 0103 a 0104 b 0105 c 0106 o 0110 Clear=O 3.7 Measurements 1 Display 0200 MEASURE 1 0201 a 0202 b 0203 c 0204 o 020C F 3.8 Measurements 3 Display 0400 MEASURE 3 0404 th A 0405 th B 0406 th C 0407 Thermal 040A Pk th A 040B Pk th B
Status READ READ READ READ READ READ READ RESET
Status READ READ READ READ READ READ Status READ READ READ READ SET SET SET
R8557B Volume 1 Chapter 3 Page 9 of 23 SET Peak thermal ammeter reading in phase C demand value Description Column heading Software links that are used to select the available optional earth fault functions Overall ratio of the line or neutral CT feeding the earth fault protection elements Selected characteristic from the definite time or 10 inverse time options Current setting for start output and first earth fault stage Time multiplier setting that will be used with a selected inverse time curve Time delay that will be effective when the definite time characteristic is selected Hold time for which the current must remain below o> before timer resets to zero Current setting for second earth fault stage Time delay for second earth fault stage Description Column heading Software links that are used to select the available optional phase fault functions Overall ratio of the line CT feeding the phase fault protection elements Selected characteristic from the definite time or 10 inverse time options Current setting for start output and first overcurrent stage Time multiplier setting that will be used with a selected inverse time curve Time delay that will be effective when the definite time characteristic is selected Hold time for which the current must remain below > before timer resets to zero Current setting for second overcurrent stage Time delay for second overcurrent stage Thermal current rating (Trip at 1.05 th) Setting for thermal time constant
040C Pk th C 3.9 Earth fault 1 Display 0500 EARTH FLT 1 0501 EF Links 0502 CT Ratio 0504 Curve 0505 o> 0506 to>/TMS 0507 to>/DT 0508 toRESET 0509 o>> 050A to>> 3.10 Phase fault 1 Display 0600 PHASE FLT 1 0601 PF Links 0602 CT Ratio 0604 Curve 0605 > 0606 t>/TMS 0607 t>/DT 0508 tRESET 0609 >> 060A t>> 0613 th> Trip 0614 TC
Status READ SET SET SET SET SET SET SET SET SET Status READ SET SET SET SET SET SET SET SET SET SET SET
3.11
Logic (KCGG 341 menu only) Display 0900 LOGIC 0903 tAUX1 Status READ SET Description Column heading Auxiliary timer 1 setting
3.12
Input masks These are pre-configured and do not appear in the menu. Refer to applications diagrams Figures 1, 2 and 3 for input configurations.
3.13
Relay masks These are pre-configured and do not appear in the menu. Refer to applications diagrams Figures 1, 2 and 3 for output configurations.
3.14
Recorder masks If event or disturbance records are required then the relay must be powered from a secure ac or dc supply. The recorder is pre-configured to trigger on energisation of the external trigger input (L2). It is also triggered by the energisation of the START relay output (RL0) in the KCGG 141 and KCGG 241 or by the energisation of the TRIP relay output (RL3) in the KCGG 341. Display 0C00 RECORDER 0C01 Control 0C02 Capture 0C03 Post Trigger Status READ SET SET SET Description Column heading Control : default value is 'running' Capture : default value is 'samples' The default setting of the recorder post trigger is 384 for the KCGG 141 and the KCGG 241 and is 128 for the KCGG 341
Section 4.
ACCESS TO MENU
With the cover in place on the relay access is limited to the [F] and [0] keys. The Any menu cell can be accessed and its value or text read, but no change can be made to settings other than resetting the trip indication and the fault records. 4.1 Quick guide to menu controls
Current display Default display Key press [0] long [0] short [F] [+] [] Fault flags after a trip [0] short [F] [0] long [+] [] Column heading [0] short [0] long [F] long [F] short [] [+] Any menu cell [F] short [F] long [F] + [0] [0] short [0] long Effect of action Back-light turns ON no other effect Steps through the available default displays steps down to column heading SYSTEM DATA Back-light turns ON no other effect Back-light turns ON no other effect Back-light turns ON no other effect steps down to column heading SYSTEM DATA without resetting the fault flags resets trip LED and returns default display Back-light turns ON no other effect Back-light turns ON no other effect Back-light turns ON no other effect Re-establishes password protection immediately and returns the default display move to next column heading steps down the menu to the next item in the column move to next column heading move to previous column heading steps down the menu to the next item in the column displays the heading for the next column steps back up the menu to the previous item Back-light turns ON no other effect Resets the value if the cell is resettable

Key press [+] or [] [0] [+] [] [F] [F] Effect of action Puts the relay in setting mode. The password must first be entered for protected cells Escapes from the setting mode without a setting change Increments value with increasing rapidity if held Decrements value with increasing rapidity if held Changes to the confirmation display If function links, relay or input masks are displayed the [F] key will step through them from left to right and finally changing to the confirmation display Confirms setting and enters new setting or text Returns prospective change to check/modify Escapes from the setting mode without a setting change
Current display Any settable cell Setting mode
Confirmation mode
[+] [] [0]
The actions shown in the shaded area can only be performed when the cover is removed. [F]long [F]short [F] [0]Long 4.2 - means press F key and hold for longer than 1 second. - means press F key and hold for less than 1 second. - means press the F key length of time does not change the response. - means press the 0 key to perform a reset function when a resettable cell is displayed.
Negotiating the menu After being left for some time the relay will show the selected default display. Short presses of the [0] key will step through all the available options. As supplied the default will be to display the three phase currents and if no key presses are made for at least 15 minutes the display will revert to this display. A short press of the [F] key will change the display to menu cell [0000 SYSTEM DATA], the heading for the first menu column. Long presses of the [F] key will then step across the column headings in sequence. When the desired column is reached a short press will move down the column one step at a time. The previous cell can be accessed by pressing the [0] key and the [F] key together and holding them down for at least 1 second. At any point in the menu, a long press of the [F] key will cause the next column heading to be displayed. When any column heading is displayed a long press of the [0] key will return the default display.
4.3
Resetting trip indication The TRIP LED can be reset when the flags for the last fault are displayed. They are displayed automatically in the default display after a trip occurs, or can be selected in the fault record column, menu cell [0102 Fn G1]. The reset is effected by depressing the [0] key for 1 second whilst this cell is displayed.
Resetting the fault records as described in the next section will also reset the trip LED indication. Function link SD5 will be set to 0 for the relays as supplied. The trip LED can only be manually reset. 4.4 Clearing fault records The fault records are a group of cells that can be reset and to reset them the last cell under [FLT RECORDS] must be selected. (This will will be menu cell [0110 Clear=0]) and then the [0] key held depressed for at least one second to effect the reset of all five fault records at the same time. If the records are not cleared, the oldest record will be overwritten by the next new fault record.
Section 5.
ACCESS TO SETTINGS
The menu table for the simplified settings KCGG141/241/341 relays has no cells password protected. Changes may be made to the protection settings including CT ratio, operation time characteristics, current thresholds and time delay settings. To change these settings the protective front cover has to be removed from the relay. The [+] and [-] keys can then be accessed and these are the keys used to increment or decrement the settings. 5.1 To enter setting mode Give the [F] key a momentary press to change from the selected default display and switch on the back-light; the heading SYSTEM DATA will be displayed. Use the [+] and [-] keys, or a long press of the [F] key, to select the column containing the setting, or text that is to be changed. Then with the [F] key step down the column until the contents of that cell are displayed. Press the [+] key to put the relay into the setting mode. Setting mode will be indicated by a flashing cursor on the bottom line of the display. If the cell is read-only then the cursor will not appear and the relay will not be in the setting mode. 5.2 To escape from the setting mode If at any time you wish to escape from the setting mode without making a change to the contents of the selected cell: Hold the [0] key depressed for one second, the original setting will be returned and the relay will exit the setting mode. 5.3 Changing setting values Move through the menu until the cell that is to be edited is displayed. Press the [+] or [] key to put the relay into the setting change mode. A cursor will flash in the extreme left hand position on the bottom line of the display to indicate that the relay is ready to have the setting changed. The value will be incremented in single steps by each momentary press of the [+] key, or if the [+] key is held down the value will be incremented with increasing rapidity until the key is released. Similarly, the [] key can be used to decrement the value. Follow the instructions in Section 5.4 to exit from the setting change. Note: When entering a CT RATIO the overall ratio should be entered, ie. a 2000/5A CT has an overall ratio of 400:1. With rated current applied the relay will display 5A when CT RATIO has the default value of 1:1 and when the ratio is set to 400:1 the displayed value will be 400 x 5 = 2000A.
5.4
To accept the new setting Press the [F] key until the confirmation display appears: Are You Sure? + = YES = NO . 1. Press the [0] key if you decide not to make any change. 2. Press the [] key if you want to further modify the data before entry. 3. Press the [+] to accept the change. This will terminate the setting mode.
5.5
Entering text Menu cells [0004 Description] and [0005 Plant Ref] give the relay description and the plant reference respectively. These two cells have 16 characters on the bottom line that may be changed as required. To do so, first select the menu cell and enter setting mode by pressing either the [+] or [] key. The cursor will flash in the position of the extreme left character. Then using the [+] and [] keys select the character to be displayed. The [F] key may then be used to move the cursor to the position of the next character and so on. Follow the instructions in Section 5.4 to exit from the setting change.
Section 6.
ACCESS TO ADVANCED SETTINGS
Settings and text in certain cells of the menu can be changed via the user interface. To do this the cover must be removed from the front of the relay so that the [+] and [] keys can be accessed. 6.1 Changing function links Select the page heading required and step down to the function links SD Links, EF Links, PF Links, or LOG Links and press either the [+] or [] to put the relay in a setting change mode. A cursor will flash on the bottom line at the extreme left position. This is link F; as indicated by the character printed on the frontplate under the display. Press the [F] key to step along the row of links, one link at a time, until some text appears on the top line that describes the function of a link. The [+] key will change the link to a 1 to select the function and the [] key will change it to a 0 to deselect it. Follow the instructions in Section 5.4 to accept the new setting and exit from the setting change, or the instruction in Section 5.2 to escape without making a change. Not all links can be set, some being factory selected and locked. The links that are locked in this way are usually those for functions that are not supported by a particular relay, when they will be set to 0. Merely moving the cursor past a link position does not change it in any way. 6.2 Setting communication address The communication address will be set to 255, the global address to all relays on the network, when the relay is first supplied. Reply messages are not issued from any relay for a global command, because they would all respond at the same time and result in contention on the bus. Setting the address to 255 will ensure that when first connected to the network they will not interfere with communications on existing installations. The communication address can be manually set by selecting
the appropriate cell for the SYSTEM DATA column, entering the setting mode as described in Section 5.1 and then decrementing or incrementing the address. Then exit setting mode as described in Section 5.4. 6.3 Setting the relay with a PC or laptop Connection to a personal computer (PC), or lap top, via an K-Bus/RS232 interface Type KITZ 101 will enable settings to be changed more easily. Software is available for the PC that allow on line setting changes in a more user friendly way, with a whole column of data being displayed instead of just single cells. Setting files can also be saved to floppy disc and downloaded to other relays of the same type. There are also programs available to enable settings files to be generated off-line, ie. away from the relays that can be later down-loaded as necessary. The communication connections and available software are covered in the applications chapter of this manual.
Section 7.
ALARM FLAGS
A full list of the alarm flags will be found in Section 3.5 and they are located in cell 0022 of the SYSTEM DATA column of the menu. They consist of seven characters that may be either 1 or 0 to indicate the set and reset states respectively. The control keys perform for this menu cell in the same way as they do for function links. The cell is selected with the function key [F] and the relay then put in the setting mode by pressing the [+] key to display the cursor. The cursor will then be stepped through the alarm word from left to right with each press of the [F] key and text identifying the alarm bit selected will be displayed. The only alarm flag that can be manually set is bit 6, the watchdog test flag. When this flag is set to 1 the watchdog relay will change state and the green LED will extinguish. When any alarm flag is set the alarm LED will be continuously lit. Note: No control will be possible via the key pad if the Unconfigured alarm is raised because the relay will be locked in a non-operative state.
Section 8.
EXTERNAL CONNECTIONS
Standard connection table Function Earth terminal Watchdog relay (Break contact) 48V field voltage Capacitor trip voltage Not used Auxiliary voltage input Not used Auxiliary relay coil Not used A phase current B phase current C phase current Neutral current Not used Not used Not used Not used Not used Not used Not used Not used Not used Not used Key to connection tables [+] and [] (+) and () indicate the polarity of the dc output from these terminals. indicate the polarity for the applied dc supply. In In In In b [+] [+] (+) (+) Terminal 1 3 5 7 9 11 13 15 17 19 21 23 25 27 29 31 33 35 37 39 41 43 45 47 49 51 53 55 2 4 6 8 10 12 14 16 18 20 22 24 26 28 30 32 34 36 38 40 42 44 46 48 50 52 54 56 m [] [] () () Function Not used Watchdog relay (Make contact) 48V field voltage Capacitor trip voltage Not used Auxiliary voltage input Not used Auxiliary relay coil Not used
Out A phase current Out B phase current Out C phase current Out Neutral current (+) (+) (+) (-) Output relay 0 Output relay 1 Output relay 2 Output relay 3 Opto control input L0 Opto control input L1 Opto control input L2 Common L0/L1/L2 K-Bus serial port K-Bus serial port
All relays have standard Midos terminal blocks to which connections can be made with either 4mm screws or 4.8mm pre-insulated snap-on connectors. Two connections can be made to each terminal.
8.1
Auxiliary powered relays The auxiliary voltage may be DC or AC provided it is within the limiting voltages for the particular relay. The voltage range will be found on the frontplate of the relay; it is marked Vx = (24V to 125V) or (48V to 250V). An ideal supply to use for testing the relays will be 50V DC or 110V AC because these values fall within both of the auxiliary voltage ranges. The supply should be connected to terminals 13 and 14 only. To avoid any confusion it is recommended that the polarity of any applied voltage is kept to the Midos standard: for dc supplies the positive lead connected to terminal 13 and the negative to terminal 14. for ac supplies the live lead is connected to terminal 13 and the neutral lead to terminal 14.
8.2
Dual powered relays Dual powered relays derive power from the current transformer circuit and may be used with this power source alone. However, the application of an auxiliary DC or AC voltage will enable lower earth fault settings to be used. It will also enable settings to be applied and data to be read when the load current is insufficient to power the relay and also allow communications to be maintained at such times. When powered from the CT circuit alone, the 48V field voltage will be available to power the opto-isolated control inputs when the protection starts up. The phase fault current setting range is limited to the minimum current levels at which the power requirements of the relay can be maintained, see Technical Data, Section 5. This model of relay is rated for an auxiliary voltage Vx = (100V to 250V). Note: The capacitance discharge circuit is not isolated from the auxiliary supply and to prevent the relay from being damaged, no external ground connection should be made to this circuit.
8.3
Powered from current transformers alone When powered from the current transformer circuit alone, the minimum current to operate the relay is that required to establish the power supply rails within the relay. Lowering the design value of this parameter increases the burden on the current transformers and the power dissipated within the relay case. The limits are therefore a compromise based on these factors: Minimum current to power the relay for phase faults = 0.4n Minimum current to power the relay for earth faults = 0.2n However, a combined three phase and earth/ground fault relay will operate with lower earth/ground fault current settings when the load current in the protected circuit is sufficient to power the relay ie. greater than 0.4n. Settings less than 0.2n are provided for earth faults, but they must be used with discretion. When switching onto a fault, the relay will be delayed in operation by the start up time and this delay will need to be taken into account in any grading exercise. The delay is the time taken by the processor to initialise its registers, read in settings from non-volatile memory and perform self checks. There will be an additional delay whilst the power supply builds up, but this will be less significant when using an inverse time/current characteristic as the power supply delay similarly varies with current. The start-up time is not reduced by lowering the time multiplier setting.
With prefault load current there will be no start-up time and the relays will operate within their normal time settings.
0.8
0.6
Time (seconds)
0.4
0.2
0 1 7 10 70 100
Multiple of minimum current to power the relay
Figure 4. Start up time delay

Note: Where the start-up delay cannot be tolerated it is recommended that the relay is also powered from an auxiliary AC voltage supply so that it can be up and running before a fault occurs. It will also make stored disturbance and event records more secure, because they are discarded when the relay powers down. 8.4 Special application notes for dual powered relays The KCGG 241/341 relays are fitted with three opto-isolated inputs and four relay outputs, but at the claimed minimum operating current they cannot all be energised at the same time. If they are, then the minimum operation current will be increased. However, in applications requiring a dual powered relay it is unlikely that more than two output relays will be energised at any one time. The following table shows how the minimum operating current varies with the number of output relays (does not include the watchdog) and inputs that are to be energised at the same time. No. of relays energised 3 opto-inputs energised 2 opto-inputs energised 8.5 2 1.2 x min 1.1 x min 4 1.3 x min 1.2 x min
min = 0.4n for phase faults and 0.2n for earth/ground faults. Powered from an auxiliary AC voltage and from current transformers The addition of an auxiliary AC, or DC, voltage supply to power the relay will: 1. enable the settings to be changed when the protected circuit is de-energised. 2. enable records to be retrieved and control functions to be carried out over the communication link. 3. reduce the burden on the line CTs. When using an auxiliary AC voltage, it may be lost during a fault, when power will be drawn from the current transformer circuit to maintain the relay in a fully
operational state. However, if the source of the auxiliary voltage is carefully chosen it is unlikely to be lost completely during earth faults but it may collapse to 50% of its rated value. Provided the voltage is still above the minimum required to power the relay, very low earth fault settings can be successfully applied. In the absence of the auxiliary voltage the relay is not guaranteed to operate for earth fault currents less than 0.2n. No alarm is given for loss of the ac auxiliary voltage, unless it is externally monitored by a separate supervision relay. 8.6 Dead substation protection The dual powered relays derive power for the electronics and the trip coil of the circuit breaker from the line current transformers and optionally from an auxiliary voltage supply. Applying one of these relays on the incoming feeder to the substation will ensure that the substation is still protected in the event of complete failure of the auxiliary supplies. 8.7 Logic control inputs There are three optically coupled logic control inputs to the relay. They are rated at 48V and the power supply within the relay provides an isolated field voltage to energise them. This arrangement keeps the power consumption of these inputs to a minimum and ensures that they always have a supply to energise them when the relay is operational. This is particularly important for the dual powered relay when there is no auxiliary supply voltage available and the relay is energised by the current from the line current transformers. Software filtering is applied to prevent induced AC signals in the external wiring causing operation of logic inputs. This is achieved by sampling the logic inputs eight times per cycle and five consecutive samples have to indicate that the input is energised in a positive sense before it is accepted. This ensures that the inputs are relatively immune to spurious operation from induced ac signals in the wiring. The capture time is: 12 2.5ms at 50 Hz 10.4 2.1ms at 60 Hz. Note: These inputs will not capture a fleeting contact unless it dwells in the closed state for a time exceeding the above values. The opto-isolated logic control inputs (L0, L1, L2) have their common connection on terminal 52. When they are to be energised from the field voltage terminal 52 must be connected to terminal 8, the negative of the field voltage. The logic inputs can then be energised by connecting a volt free contact between the positive of the field voltage, terminal 7, and the terminal for the appropriate logic input. The circuit for each opto-isolated input contains a blocking diode to protect it from any damage that may result from the application of voltage with incorrect polarity. Where the opto-isolated input of more than one relay is to be controlled by the same contact it will be necessary to connect terminal 7 of each relay together to form a common line. In the example circuit below, contact X operates L1 of relay 1 and contact Y operates L0 of relay 1 as well as L0 and L1 of relay 2. L2 is not used on either relay and has no connections made to it.
L0 L1 L2
46 48 50 52
46 48 50 52
L0 L1 L2
X _ 8
Y 8 7 _ 48V + Relay 2
48V 7 + Relay 1
Common line
Figure 5. Example connection of logic inputs

The logic inputs can be separated into two isolated groups when it is necessary to energise some from the station battery. The logic inputs are rated at 48V and it will be necessary to connect an external resistor in series with the input if the battery is of higher rated voltage. The value of this resistor should be 2400 for every additional 10V. The field voltage is not earthed and has insulation rated for 2kV for 1 minute. Thus if necessary the positive terminal of the field voltage could be connected to the positive terminal of external battery. Also the two separate groups of logic inputs could be energised from separate batteries. 8.8 Analogue inputs The relays have four analogue inputs, each fed via an input transducer, a low pass filter and a three range scaling amplifier. The analogue signals are sampled eight times per cycle on each channel as the sampling rate tracks the frequency of the input signal. The wide setting range provided on the auxiliary powered version of the relays is sufficient to enable the 5A version of the relay to operate from either 1A or 5A current transformers and this version of the relay can be used where dual rated relays are specified. Alternatively, the wide setting range makes the relay suitable for use on circuit breakers that may be applied to a wide range of load circuit ratings with only one current transformer ratio. For example a circuit breaker rated at 2000A and fitted with current transformers rated at 2000/10A (or 2000/2A) and relays rated at 5A (or 1A) could be applied to circuits with load ratings from 100A to 2000A. The dual powered relays have a narrower setting range and must be used with current transformers that match their current rating. Thermal dissipation is the limitation for the upper end of the setting range and the energy required to power the relay is the limitation at the lower end. When the relay is powered from an additional auxiliary voltage source, earth fault settings can be applied below that at which the relay can derive sufficient power from the CTs. For this reason the earth fault setting range has not been restricted.
8.9
Output relays Four output relays are provided preconfigured to operate in response to a selection of the available protection and control functions by the setting the OUTPUT MASKS. In addition there is a watchdog relay which has one make and one break contact. Thus it can indicate both healthy and failed conditions. As these contacts are mainly used for alarm purposes, they have a lower rating than the programmable outputs. The terminal numbers for the output relay contacts are given in the table at the start of Section 8.
8.10
Output relay minimum dwell time Outputs from t>, t>>, to> and to>> have a minimum dwell of 100ms. The thermal trip will have an inherent delay dependent on the selected time constant. The contact dwell ensures a positive trip signal is given to the circuit breaker. All other outputs such as >, >>, o> and o>> have no deliberate dwell time added to them. This is because they are either followed by a timer, or used for control purposes which require a faster reset time.
8.11
Capacitor discharge tripping Dual powered relays may use either of the above methods. In addition, these particular relays charge an internal capacitor from the current circuit and also from the auxiliary voltage circuit. This capacitor is 680F and it is charged to 50V dc. It may be discharged directly into a suitably sensitive trip coil via one of the programmable output relays. The minimum energy fed to the trip coil is that from the capacitor, but in most cases it will be supplemented by a current from the auxiliary voltage circuit and/or the current circuit. When energized from current alone the lowest current for which the relay will operate will be that necessary to start up the power supply. To be able to use lower fault settings an auxiliary supply will be required. The capacitance discharge circuit is not isolated from the auxiliary supply and to prevent the relay from being damaged, no external ground connection should be made to this circuit.
Relay RLY3
42 44 9 + 10 Trip
Figure 6. Capacitor discharge trip
8.12
AC series tripping
Relay RLY3
a TC b To line CTs c TC
21 22
42 44 9 +
23 24
10
25 26
Tripping Relay
18
TC
27
17
28
Figure 7. AC series trip arrangement, KCGG 341

As an alternative, the trip capacitor in the dual powered relays may be discharged into an auxiliary tripping relay. This scheme is supplied as the KCGG 341 relay. This relay will be de-energised in the quiescent state, with its break contacts short circuiting the trip coils of the circuit breaker. The trip coils are connected in series with the current transformer secondary circuit so that, when the auxiliary relay is operated, the full secondary current is diverted through the trip coils. To cover all fault conditions, three trip coils are required. Note: Withdrawing the KCGG 341 from an energised panel may energise the circuit breaker trip coils. 8.13 Improving reliability of trip and closing contacts In the event of the circuit breaker failing to trip, the relay contacts are called upon to break the trip coil current. The majority of protective relays are not rated for this duty and their contacts may be damaged as a result. This problem can be eliminated if a relay with heavy duty contacts is interposed between the output contacts of the protective relay and the circuit breaker trip circuit. Replacing this relay can be more economic than the repair costs for the protective relay and the overall fault clearance time need not be increased as a result. If the interposed relay is connected as a shunt repeat relay, the protection will trip the circuit breaker directly and then be backed-up by the contacts of the interposing relay. On breaking, the protective relay will reset first so that the interposing relay performs the actual circuit interruption.
Similarly the breaking duty of the relay contacts may not be rated for the circuit breaker closing current and in such cases an interposing relay will be necessary.
Prima CG4 Blocking diode KCGG
Trip coil CB
Prima
Figure 8. Contact reinforcing circuit
Chapter 4 Application of Protection Functions
1. 1.1 1.1.1 1.1.2 1.1.3 1.1.4 1.1.5 1.1.6 1.2 1.2.1 1.2.1.1 1.2.1.2 1.2.1.3 1.2.1.4 1.2.1.5 1.2.1.6 1.2.1.7 1.2.1.8 2. 3. 3.1 3.2 4. 4.1 4.2 4.3 4.4 5. 5.1 5.2 5.3 6. 7. 8. 8.1 8.2 8.3 8.4 8.5 8.6
CONFIGURATION Fixed configuration of KCGG 141, 241 and 341 KCGG 141 and KCGG 241 fixed configurations KCGG 341 fixed configuration First stage overcurrent and earth fault START function First stage overcurrent and earth fault time delay First stage overcurrent and earth fault available time delay characteristics Second stage overcurrent and earth fault time charcteristics Relay scheme configuration Changing the configuration of the relay System data (SD) Earth fault links (EF) Phase fault links (PF) Logic links (LOG) Typical use of logic inputs for KCGG 141, 241 Typical use of logic inputs for KCGG 341 Typical use of output relays for KCGG141, 241 Typical use of output relays for KCGG 341 OVERCURRENT AND EARTH FAULT PROTECTION SECOND STAGE OVERCURRENT AND EARTH FAULT LOGIC Transformer inrush currents Sensitivity to harmonics GENERAL APPLICATION FEATURES Matching the reset time response of an electromechanical relay Time graded protection Protection against intermittent recurrent faults Autoreclose inhibition of instantaneous low set (KCGG 141 and KCGG 241 only) BLOCKED OVERCURRENT PROTECTION Blocked IDMT overcurrent Blocked short time overcurrent Protection of busbars on radial system RECTIFIER PROTECTION HIGH IMPEDANCE DIFFERENTIAL BUSBAR AND RESTRICTED EARTH FAULT PROTECTION THERMAL OVERCURRENT Thermal state Thermal trip and alarm levels Operation time Thermal memory Thermal reset Application of thermal protection
1 1 2 2 3 3 4 5 5 5 5 6 6 7 7 7 7 7 8 8 9 9 10 10 10 10 11 12 12 13 13 14 15 15 16 16 16 17 17 17
Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Figure 7. Figure 8. Figure 9.
Relay logic diagram for KCGG 141 and KCGG 241 configurations. Relay logic diagram for KCGG 341 configuration Available overcurrent characteristics and their settings Second stage overcurrent logic Matching electromechanical reset time Intermittent recurrent fault Blocked IDMT overcurrent Blocked overcurrent for busbar protection Protection for silicon rectifiers
1 3 8 9 10 11 12 13 14 14 16
Figure 10. Matching curve to load and thermal limit of rectifier Figure 11. Thermal alarm and trip logic
R8557B Chapter 4 Page 1 of 18
Section 1.
CONFIGURATION
The configuration of the relay is the interconnection between the various protection and control elements within the product. With electromechanical relays this was formed by the internal wiring between the various elements and the external case terminals. Thus if the configuration was changed the internal connection diagram for the relay and the external case connection diagram had to be changed, or new ones prepared. With the K Range of numerical relays the configuration is in software. The KCGG 141, 241, 341 relays are provided with fixed configurations that will suit the majority of standard overcurrent applications. More flexibility is provided by the KCGG 142 full functionality relay which has further settings available. The user can then make changes to the internal logic of the relay by setting software links. Additionally the output relays and logic inputs can be reassigned to different functions. Refer to manual R8551 for information about this relay. 1.1 Fixed configuration of KCGG 141, 241 and 341
0A01 Blk to> 7 6 5 4 3 2 1 0 o> 0B01 o> Start 7 6 5 4 3 2 1 0 EF1
0 1
&
to>
0B03 to> 7 6 5 4 3 2 1 0
Stage 1 earth fault Start earth fault Stage 2 earth fault
0A02 Blk to>> 7 6 5 4 3 2 1 0 o>>
&
to>>
0B04 to>> 7 6 5 4 3 2 1 0
0A04 Blk t> 7 6 5 4 3 2 1 0 >
&
t>
0B08 tA> 7 6 5 4 3 2 1 0 0B09 tB> 7 6 5 4 3 2 1 0 0B0A tC> 7 6 5 4 3 2 1 0 0B06 > Start 7 6 5 4 3 2 1 0
Stage 1 overcurrent
>1 = 0A05 Blk t>> 7 6 5 4 3 2 1 0 >> 0A09 EXT. TRIGGER 7 6 5 4 3 2 1 0 RLY3 PF0
0 1
Start overcurrent
PF1
0 1
&
t>>
>1 =
0B0B t>> 7 6 5 4 3 2 1 0
Stage 2 overcurrent
>1 =
Latch flags Generate fault record Copy to event records Latch red trip LED >1 = 0B18 th Trip 7 6 5 4 3 2 1 0
Fault record and flag latch initiation
Thermal phase element
Thermal trip
SD F E D C B A 9 8 7 6 5 4 3 2 1 0 LOG F E D C B A 9 8 7 6 5 4 3 2 1 0
EF1 F E D C B A 9 8 7 6 5 4 3 2 1 0
PF1 F E D C B A 9 8 7 6 5 4 3 2 1 0
Figure 1. Relay logic diagram for KCGG 141 and KCGG 241 configurations.
1.1.1
KCGG 141 and KCGG 241 fixed configurations This configuration is designed for the more common applications and provides: 8 IDMT characteristics plus definite time for stage 1 (t>/to>) Instantaneous overcurrent for stage 2 (t>>/to>>) Blocking feature for first overcurrent stage Blocking feature for second overcurrent stage Output relays: RLY0 = START RLY1 = Phase fault RLY2 = Earth fault RLY3 = Main shunt trip relay L0 = Block first stage t>/to> L1 = Block second stage t>>/to>> L2 = External trigger (>/o>) (t>/t>>/th trip) (to>/to>>) (t>/to>,t>>/to>>,th trip)
Logic inputs for:
Settings are limited to: Rated frequency 50Hz or 60HZ Current settings Time/current characteristic 1.1.2 KCGG 341 fixed configuration This configuration is designed for the more common applications and provides: One setting group. 8 IDMT characteristics plus definite time for stage 1 (t>/to>) Instantaneous overcurrent for stage 2 (t>>/to>>) Blocking feature for first and second overcurrent stages Output relays: RLY0 = Auxiliary timer 1 RLY1 = Phase fault and thermal trip RLY2 = Earth fault RLY3 = Main Trip Relay L0 = Initiate auxiliary timer 1 L1 = Block t>/to>/t>>/to>> L2 = External trigger (AUX 1) (t>/t>>/th trip) (to>/to>>) (t>/to>,t>>/to>>,th trip)
Logic inputs for :
Internal auxiliary trip relay for AC series trip function
0A01 Blk to> 7 6 5 4 3 2 1 0 o> 0A02 Blk to>> 7 6 5 4 3 2 1 0 o>>
&
to>
0B03 to> 7 6 5 4 3 2 1 0
Stage 1 earth fault
EF1
0 1
&
to>>
0B04 to>> 7 6 5 4 3 2 1 0
Stage 2 earth fault
0A04 Blk t> 7 6 5 4 3 2 1 0 >
&
t>
0B08 tA> 7 6 5 4 3 2 1 0 0B09 tB> 7 6 5 4 3 2 1 0 0B0A tC> 7 6 5 4 3 2 1 0
Stage 1 overcurrent
PF1
0 1
0A05 Blk t>> 7 6 5 4 3 2 1 0 >> 0A09 EXT. TRIGGER 7 6 5 4 3 2 1 0 RL3
&
t>>
>1 =
0B0B t>> 7 6 5 4 3 2 1 0
Stage 2 overcurrent
>1 =
Latch flags Generate fault record Copy to event records Latch red trip LED
0A0A Aux1 7 6 5 4 3 2 1 0
tAux1
0B10 Aux1 7 6 5 4 3 2 1 0
Time delay for series trip
PF0
0 1
>1 = Thermal trip
0B18 th Trip 7 6 5 4 3 2 1 0
EF1 F E D C B A 9 8 7 6 5 4 3 2 1 0
PF1 F E D C B A 9 8 7 6 5 4 3 2 1 0
Figure 2. Relay logic diagram for KCGG 341 configuration

Settings are limited to: Rated frequency 50Hz or 60HZ Current settings Time/current characteristic The logic diagram and the connection diagram for these relays are to be found at the back of this manual. 1.1.3 First stage overcurrent and earth fault START function Available on the KCGG 141/241 relays As soon as the earth fault o> threshold is exceeded an instantaneous output is available from relay RLY0. The phase element also provides a start output from relay RLY0 when the current exceeds the > threshold. 1.1.4 First stage overcurrent and earth fault time delay The first overcurrent and earth fault stage elements (t>/to>) incorporate an integral time delay after the current threshold measurement. This allows the relay to be time graded with other similar protective relays, as well as being graded on current threshold. When the delay time expires the output relays preconfigured with to>, tA>, tB> and tC> will be energised, causing them to pick-up. The thermal trip will
energise relay RL3 after the thermal element has timed out. The Relay RLY3 is the main trip relay and is therefore includes all these trip functions. A delayed reset is provided with the t>/to> time delays and the time set for this timer determines the duration that the current must remain below the threshold I>/ o> before the time delay register is reset to zero. There is an exception to this when the protection trips, because for this condition the time registers t>/to> are reset immediately. For the majority of applications the reset delay could be set to zero. For others a more appropriate setting can be used and some example applications are given later. 1.1.5 First stage overcurrent and earth fault available time delay characteristics Nine time characteristics are available and the general mathematical expression for the curves is:
k t = TMS
where
f a 1 s
TMS If Is k, c, a
+c
seconds
= Time Multiplier (0.025 to 1.5 in step 0.025) = Fault current = Overcurrent setting = Constants specifying curve Name DT SI30xDT VI30xDT EI10xDT LTI30xDT MI VI EI STI30xDT RECT IEC Curve A B C D E F k 0 0.14 13.5 80 120 0.103 39.22 56.4 0.05 45900 c 0 to 100 0 0 0 0 0.228 0.982 0.243 0 0 a 1 0.02 1 2 1 0.02 2 2 0.04 5.6
Curve No. 0 1 2 3 4 5 6 7 8 9
Description Definite Time Standard Inverse Very Inverse Extremely Inverse Long Time Inverse Moderately Inverse Very Inverse Extremely Inverse Short Time Inverse Rectifier Protection
Although the curves tend to infinity at the setting current value (Is), the guaranteed minimum operation current is 1.05Is 0.05Is for all inverse characteristic curves, except curve 9 for which the minimum operating current is 1.6Is0.05Is (see section on rectifier protection). Curves numbers 1, 2, 4, and 8 become definite time for currents in excess of 30 x Is. Curve 3 becomes definite time for currents above 10 x Is to give extra time grading steps at high current levels. Curves 1, 2 and 3 are curves A, B and C in IEC 60255-3. Curves 5, 6 and 7 are slightly different in that they tend to a definite operating time given by the constant (a) at high fault levels. Curves 5, 6 and 7 were proposed by IEEE/ANSI for inclusion in the IEC standard IEC 60255-3 as curves D, E and F.
Note: Definite time characteristic and the start functions operate at Is0.05s. 1.1.6 Second stage overcurrent and earth fault time charcteristics The second overcurrent and earth fault stage are each followed by a definite time delay. For these elements to operate the Fourier derived value of current must exceed the set threshold, or the peak value of the current must exceed twice the set threshold. This latter function ensures faster operation for currents above twice setting whilst ensuring negligible transient overreach. The time delays for this stage have a definite time characteristic and they reset instantaneously. Operation of these time delays can be blocked by energising logic input (L1). If the time delay has started it will be reset by the application of the blocking signal. 1.2 Relay scheme configuration Case connection diagrams will be found at the back of this manual for applicable models. These diagrams give the appropriate terminal numbers to which the external wires must be connected. In particular, it will show the terminal numbers to which the current transformer connections are to be made. Enough information is available from the logic and case connection diagrams to enable the full external wiring diagrams to be drawn and the operation of complete protection and control scheme to be understood. A setting record should be filled in with the settings of the links shown as blank spaces on the system data, earth fault 1 and phase fault charts found in Appendix 4 Section 2 of this manual. Each scheme of protection and control will have its own particular scheme configuration settings. These can be named appropriately and the name entered as the description in cell 0004 in the system data column of the menu. If the scheme is likely to become a standard that is to be applied to several installations it would be worthwhile storing the configuration on a floppy disc so that it can be downloaded to other relays. The configuration file can be made even more useful by adding appropriate general settings for the protection and control functions. It will then only require the minimum of settings to be changed during commissioning the installation. 1.2.1 Changing the configuration of the relay 1. Select the system data column of the menu and then step down to the cell [0003] containing the SD links. Press the [+] key to put the relays into setting mode and use to [F] key to step through the options. The option will be shown in abbreviated form on the top line of the display as each function link is selected. To select an option set the link to 1 with the [+] key and to deselect it set it to 0 with the [] key. SD links SD 0 SD 7 Remote settings enabled (default setting = 1) Enable storage of logic events (default setting = 1) 1.2.1.1 System data (SD)
Other SD links are not used. When the selection has been completed continue to press the [F] key until the confirmation display appears and confirm the selection.
2. Step down the menu to cell [0004 Description] and enter a suitable name for the configuration. A maximum of sixteen characters are available. 3. Step down one cell [0005 Plant Ref.], where a suitable reference can be entered for the plant that the relay is to protect. If the configuration is for a relay that is to be applied to one particular circuit, then the reference by which the circuit is known can be entered at this time. A maximum of sixteen characters are available. 4. Now move down the system data column to cell [0009 Freq] and set the frequency to 50Hz or 60Hz as appropriate. This is an important setting because it will be the default frequency used by the A/D converter when appropriate signals are not available for frequency tracking. 5. If the address of the relay on the serial communication bus is known then it can be entered at this time in cell 000B. This concludes the settings that can be entered in this menu column at this time. 1.2.1.2 Earth fault links (EF) 1. Select the column EARTH FAULT (1) and EF Links. Press the [+] key to put the relay into setting mode and set the links to 1 that enable the required options available via links EF0 to EFA. EF0 EF 1 Link not used En Io>> 1= enable earth fault stage 2 ( 0 = earth fault stage 2 disabled)
EF 2 to EF F links not used For KCGG 141, 241 and 341 relays the Io>> elements are responsive to peak measurement so that they respond faster, but they will be more sensitive to harmonic currents that create peaks on the waveform. 2. When the selection has been completed continue to press the [F] key until the confirmation display appears and then confirm the selection. 3. Next enter the time delay and current setting characteristics for the to> and to>> elements in cells 0505 to 050A. 1.2.1.3 Phase fault links (PF) 1. Select the PF Links under the PHASE FAULT (1) menu column heading and put the relay into setting mode by pressing the [+] key. Step through the function links with the [F] key and set the links for the options required. The thermal characteristic can be enabled by setting PF0 = 1 The second stage phase fault overcurrent element can be set by PF1 = 1 PF 0 PF 1 En Therm En I>> 1=enable thermal element 1=enable stage 2 overcurrent
PF 2 to PFF links are not used For KCGG 141, 241 and 341 relays the >> elements are responsive to peak measurement so that they respond faster, but they will be more sensitive to harmonic currents that create peaks on the waveform. 2. When the selection has been completed continue to press the [F] key until the confirmation display appears and confirm the selection.
3. Next enter the time delay and current setting characteristics for the t> and t>> elements in cells 0604 to 060A. 1.2.1.4 Logic links (LOG) 1. The auxiliary timer AUX 1 can be set in the KCGG 341 relay under the LOGIC menu column heading in cell 0903. Put the relay into setting mode by pressing the [+] key. 2. When the selection has been completed continue to press the [F] key until the confirmation display appears and confirm the selection. 1.2.1.5 Typical use of logic inputs for KCGG 141, 241 L0 L1 L2 L0 L1 L2 RLY0 RLY1 RLY2 RLY3 Blk t>/to> Blk t>>/to>> EXT TRIP Aux 1 Blk t>/to>/t>>/to>> EXT TRIP START t>/t>>/Ith(RL1) to>/to>> TRIP [Block 1st stage elements] [Block 2nd stage elements] [external trip input from other protection] [Input to aux timer from from earth fault trip relay RL2] [Block 1st and 2nd stage elements] [external trip input from other protection] [combined phase and earth start] [combined phase and thermal trip] [earth fault trip] [Shunt trip output for combinphase, thermal and earth fault trip] [time delayed output of earth fault to trip AC series trip auxiliary relay] [combined phase and thermal trip] [earth fault trip] [Shunt trip output for combinphase, thermal and earth fault trip]
1.2.1.6 Typical use of logic inputs for KCGG 341
1.2.1.7 Typical use of output relays for KCGG141, 241
1.2.1.8 Typical use of output relays for KCGG 341 RLY0 RLY1 RLY2 RLY3 Aux1 t>/t>>/Ith to>/to>> TRIP
Section 2.
OVERCURRENT AND EARTH FAULT PROTECTION
Two independent time delayed overcurrent stages are provided for each phase and residual current input. In addition there is a thermal overcurrent characteristic function. The settings are marked I>/t>; I>>/t>> and Ith>/TC; shown appropriately in the diagram below. These settings affect all three phases equally.
Ith TC I>
Time
t>
I>>
t >>
Current
Figure 3. Available overcurrent characteristics and their settings

The earth fault elements have similar settings marked Io>/to> and Io>>/to>> there being no thermal element associated with this input. Both the peak value and the Fourier derived rms value of the power frequency component of the fault current are used to derive the protection functions. Each value has its own associated characteristics that can be used to advantage. For example, a change in the peak value may be detected in one half cycle of fault current and so this measurement is used for the undercurrent elements to obtain the fast reset required by breaker fail applications. The Fourier derived values are particularly useful for earth fault applications due to their high rejection of harmonic currents, in particular the third harmonic.
Section 3.
SECOND STAGE OVERCURRENT AND EARTH FAULT LOGIC
The second overcurrent and earth fault stages must be selected by setting links PF1 and EF1 = 1 as appropriate for their associated settings to appear in the menu table. For these elements to operate the Fourier derived value of current must exceed the set threshold, or the peak value of the current must exceed twice the set threshold. This latter function ensures faster operation for currents above twice setting whilst ensuring negligible transient overreach. The time delays for the second stage overcurrent elements can be blocked by the energisation of logic input L1. (This input also blocks the first stage overcurrent in the KCGG341). If the time delay has started it will be reset by the application of the blocking signal. Each phase fault and earth fault element has its own independent time delay to ensure correct discrimination and fault indication.
EF1 0 1
0A02 BLK to>> 7 6 5 4 3 2 1 0 o>>
to>>
&
to> >
0B04 7 6 5 4 3 2 1 0
Stage 2 Earth fault
PF1 0 1
0A05 BLK t>> 7 6 5 4 3 2 1 0 >>
&
t> >
0B0B t>> 7 6 5 4 3 2 1 0
Stage 2 Overcurrent
Figure 4. Second stage overcurrent logic

3.1 Transformer inrush currents The I>>/Io>> elements, may be used as high-set instantaneous elements. The design is such that they do not respond to the DC transient component of the fault current. The principle of operation allows the current settings to be set down to 35% of the prospective peak inrush current that will be taken by a transformer when it is energised. To a first approximation the peak inrush is given by the reciprocal of the per unit series reactance of the transformer. 3.2 Sensitivity to harmonics The sampling frequency of the digital/analogue converter is synchronised to the power frequency by a frequency tracking algorithm. This improves both accuracy of measurement and the harmonic rejection. The tracking follows the analogue phase inputs with a preference to track the voltage inputs, but in their absence the current inputs are tracked. When the signal levels are too small to track, the sampling frequency defaults to the set system frequency. It is important that this has been correctly set in menu cell 0009. The fundamental component of the residual voltage and current is usually relatively small and this can result in the harmonic content being predominant. Frequency tracking does not take place on the residual signals because it can lockin to a sub-harmonic of the predominant frequency resulting in a reduced harmonic rejection level. An example where this would become a problem is when a transformer is energised and an almost pure second harmonic current can appear in the neutral circuit. With frequency tracking of this signal the harmonic rejection could fall significantly. For this application a multiphase relay is best suited as it will give maximum harmonic rejection whilst tracking the phase quantities. The I>>/Io>> elements in the KCGG relays respond to the peak value and the fourier derived values. This allows them to respond more quickly to an overcurrent condition, but at the same time it reduces the harmonic rejection.
Section 4.
4.1
GENERAL APPLICATION FEATURES
Matching the reset time response of an electromechanical relay
tReset s
Figure 5. Matching electromechanical reset time

The reset characteristic of an electromechanical relay is inverse and the reset timer can be used to give the relay a reset characteristic which approximates to this as shown in the diagram. It should be noted that the tRESET is not affected by the time multiplier setting and must therefore be set to the required delay. 4.2 Time graded protection Inverse definite minimum time relays are time graded such that the relay nearer to the fault operates faster than the relays nearer to the source. This is referred to as relay co-ordination because if the relay nearest to the fault does not operate, the next one back towards the source will trip in a slightly longer time. The time grading steps are typically 400ms, the operation times becoming progressively longer with each stage. Where difficulty is experienced in arranging the required time grading steps the use of a blocked overcurrent scheme should be considered (described in a later section). Note: The dynamic range of measurement is typically 820 times minimum setting. 4.3 Protection against intermittent recurrent faults This type of fault is also sometimes referred to as a pecking or flashing fault. A typical example of an intermittent recurrent fault would be one in a plastic insulated cable where, in the region of the fault, the plastic melts and reseals the cable, extinguishing the fault but after a short time the insulation breaks down again. The process repeats to give a succession of fault current pulses each of increasing duration with reducing intervals between, until the fault becomes permanent. When the reset time of the overcurrent relay is less than the interval between the fault current pulses, the relay will be continually reset and not be able to integrate
up to the trip level until the fault becomes permanent. Having the reset time set to give as long a delay as possible, but less than that which would interfere with normal operation of the protection and control system, will help to eliminate some less common health and safety problems. Overcurrent relays in Midos K Range have provision for adjusting the reset delay to values between 0 and 60 seconds for timers t>/to>. Reset times of 60 seconds are most suited to cable applications where autoreclose is not generally permitted. For overhead lines with fast reclosing equipment, it can be an advantage to set the reset time to zero; this will ensure that all relays will have fully reset before a reclosure takes place and that some relays will not be held part way towards operation as a result of the last fault. When grading with electro-mechanical relays which do not reset instantaneously, the reset delay can be used to advantage to gain closer discrimination. In these instances the reset time should be set to a value less than the dead time setting of any autoreclose relays on the system. Sensitive earth/ground fault relays will also benefit from having the reset time set as high as possible so that fault current pulses are summated. Any reset delay will give an improvement in the detection of intermittent faults.
2000A 0.2s 0A Trip level Reset time = 5s Reset time = 0s 3.0s 0.3s 2.0s 0.5s
Figure 6. Intermittent recurrent fault

4.4 Autoreclose inhibition of instantaneous low set (KCGG 141 and KCGG 241 only) Second stage blocking is available with the KCGG 141 and the KCGG 241 relays so these may be used in simple autoreclose schemes. When overcurrent relays from the Midos K Range are used with autoreclose relays the I>>/Io>> elements may be used as low set instantaneous elements. The associated time delays t>>/to>> would be set to zero seconds to effect rapid fault clearance. Although the timer is set to zero, its output still may be blocked via one of the logic inputs to the relay. Blocking this element instead of the trip path, with a contact of the autoreclose relay, will ensure correct flagging at all times.
Section 5.
BLOCKED OVERCURRENT PROTECTION
This type of protection (KCGG 141 and KCGG 241) is applicable to radial feeder circuits where there is little or no back feed. For parallel feeders, ring circuits, or where there can be a back feed from generators, directional relays should be considered. 5.1 Blocked IDMT overcurrent
Figure 7. Blocked IDMT overcurrent

This application relies on the up-stream IDMT relay being blocked by the start output from a down-stream relay that detects the presence of fault current above its setting. Thus for a fault below relay C, the start output from relay C will block operation of relay B and the start output of relay B will block operation of relay A. Hence all three relays could have the same time and current settings and the grading would be obtained by the blocking signal received from a relay closer to the fault. This gives a constant, close time grading, but there will be no back-up protection in the event of the pilots being short circuited. Note: There is a small window where operation may not occur with this arrangement. This occurs because the start relay picks-up at the current setting (I>), but the IDMT curve requires the current to be 1.05> before it operates. Hence the down-stream relay should have a slightly lower current setting than the up-stream relay to prevent this situation arising. Alternatively, the up-stream relay may have an increased current flowing through it due to the load current for other feeders and this would be a solution.
5.2
Blocked short time overcurrent Reduced fault clearance times and increased security can be obtained by using blocked short time overcurrent protection. For this the I>>/t>> and the Io>>/to>> elements are used with their current threshold set above the transient load level and setting t>>/to>> to 80ms for non-directional relays. This time delay is for worst case conditions and may be reduced, depending on the system X/R and maximum fault level. The time delays t>>/to>> are arranged to be blocked by the start output of the downstream relay when the downstream relay detects a fault current flowing. The short time delay is essential to ensure that the blocking signal will be received by the upstream relay before operation can occur. The inverse time overload elements should be graded in the normal way for cascade operation and to provide overload and backup protection. The short time elements, operating in the blocking mode, then provide an instantaneous zone of protection. Overcurrent relays are adequate for non-cascade operation on radial circuits, but for ring circuits, or where there are parallel feeds, it will be necessary to use directionalised overcurrent relays.
5.3
Protection of busbars on radial system This can be achieved with overcurrent relays on radial circuits. The short time lags (t>>/to>>) of the relay on the incoming feeder should be set to 80ms and an logic input should be energised via the start contact of any KCGG 141 or KCGG 241 relay on an outgoing feeder that detects fault current flowing from the busbar to a feeder. The 80ms time delay is for worst case conditions and may be reduced for applications where the system X/R ratio is low (<10), but settings below 50ms may not ensure stability.
Incomer
KCGG 241 F1
Block short time overcurrent
KCGG 141
KCGG 141
KCGG 141
KCGG 141
F2
F3
F4
F5
Feeder 1
Feeder 2
Feeder 3
Feeder 4
Figure 8. Blocked overcurrent for busbar protection

The use of a dual powered relay on the incoming feeder can also be considered to provide dead substation protection.
Section 6.
RECTIFIER PROTECTION
A B C
A B C Rs N
+
Transformer Rectifier
Protection
Figure 9. Protection for silicon rectifiers
10000 Typical thermal limit for silicon rectifier Protection curve

Time (seconds)
1000
100
Instantaneous overcurrent
10 Typical load area
0.1 1 2 3 4 5 6 7 8 Multiple of rated current
Figure 10. Matching curve to load and thermal limit of rectifier

The rectifier protection feature has been based upon the inverse time/current characteristic as used in the MCTD 01 and the above diagram shows a typical application. The protection of a rectifier differs from the more traditional overcurrent applications in that many rectifiers can withstand relatively long overload periods without damage, typically 150% for 2 hours and 300% for 1 minute.
The relay I> setting of the relay should be set to the rated rms value of the current that flows into the transformer when the rectifier is delivering its rated load. The relay will give a start indication when the current exceeds this setting but this is of no consequence because this function is not used in this application. Curve 9 should be selected for the inverse time curve and this cuts-off for currents below 1.6 times allowing the rectifier to carry 150% overload for long periods. If this is not acceptable the I> setting can be adjusted to move the cut-off point relative to the current scale. The operation time can be modified by adjustment of the time multiplier setting (TMS) so that it lies between the limiting characteristic of the rectifier and the allowable load area. Typical settings for the TMS are: Light industrial service TMS = 0.025 Medium duty service TMS = 0.1 Heavy duty traction TMS = 0.8 The high set is typically set at 8 times rated current as this ensures HV AC protection will discriminate with faults covered by the LV protection. However, it has been known for the high set to be set to 4, or 5, times where there is more confidence in the AC protection. Use of the thermal element between 70% and 150% of rated current could enhance the protection. It is also common practice to provide restricted earth fault protection for the transformer feeding the rectifier. See Section 7 below.
Section 7.
HIGH IMPEDANCE DIFFERENTIAL BUSBAR AND RESTRICTED EARTH FAULT PROTECTION
For application notes on high impedance differential busbar and restricted earth fault protection please refer to publication R6142. Note that the supervision function referrred to in this publication can not be implemented using KCGG 141, 241 or 341 relays.
Section 8.
THERMAL OVERCURRENT
The thermal overload protection shares the time constant setting with the thermal ammeters and thus a compromise will be necessary if they are to be used at the same time. It is recommended that the time constant is chosen to suit the protection in such instances. The settings for the time constant (TC), the continuous thermal current rating (Ith>) and the thermal alarm (th>) will be found in the menu columns containing the phase fault settings. The time constant can be set between 1 minute and 120 minutes in 1 minute steps and the thermal current setting (Ith>) can be adjusted between 0.08In and 3.2In. The thermal protection responds to I2 and will operate faster as the current increases, but for currents in access of 5.3 times rated current the operation time will remain the same as that for 5.3 times rated current. This will not be a problem in practice because the normal IDMT, or definite time, protection will normally have taken over at a lower level of current.
0 1 PF0 0A11 RESET Ith 7 6 5 4 3 2 1 0
Alarm Trip Thermal reset
1 1
0B17 th ALARM 7 6 5 4 3 2 1 0 0B18 th TRIP 7 6 5 4 3 2 1 0
Figure 11. Thermal alarm and trip logic

8.1 Thermal state In simplified terms the thermal state is a percentage thermal current limit that has been attained by the thermal replica. The thermal state will be found under MEASURE 3 in cell 0407 and can be displayed on the front of the relay by viewing this cell or selecting it from the default display. The thermal state = I2[1-e-t/T]/[Ith>]2 x 100 = %Ith> Final value of thermal state = [highest thermal ammeter reading]2 [continuous thermal current limit]2 x100%
The thermal state will tend to 100% when the highest of the three thermal ammeters is displaying a current equal to the set thermal current limit (Ith>). The time to reach 100% will depend upon: Applied current Prefault load current Thermal time constant Continuous thermal rating 8.2 Thermal trip and alarm levels A thermal trip will be given via the output mask [0B18 th Trip] when the thermal state reaches 110%. This is equivalent to the current being in excess of 1.05Ith>. It should be noted that the thermal trip will remain asserted until the replica cools and the thermal state falls below the trip level. 8.3 Operation time The operation time characteristic is given by he following expression: t = T.LOGe where t T Ix P P = = = = = time in minutes selected time contstant current in multiples (Ith>) (per untit of prefault load)2 (IL/Ith>)2
Ix2 P Ix2 1.10
The characteristic curves will be found in the appendix to this document where the times are shown as a multiple of the selected time constant for various levels of prefault load.
8.4
Thermal memory When the auxiliary energising supply is lost the thermal state is stored in non volatile memory. On restoration of the supply the thermal state is restored. However, if the stored value of the thermal state is in excess of 90%, the restored thermal state will be set to 90%.
8.5
Thermal reset The thermal state can be reset to zero performing a reset function on cell [0407 Thermal] under MEASURE 3. This can be achieved via the user interface of the relay by pressing the reset key [0] for one second whilst this cell is displayed, or by a 'reset cell' command via the serial port. Note: The thermal state cannot be reset whilst viewing cell 0407 from the default display. If the thermal state is greater than 90% it will be reset to 90% after a break in the auxiliary supply. If link PF0 = 0, then the thermal state will not reset to zero when the thermal element is enabled. If the thermal protection is not to be used the thermal state should be manually reset to zero to clear the memorised state.
8.6
Application of thermal protection The thermal protection characteristic can be used to protect electrical equipment in such a way that the full thermal capacity is utilised with due regard to the thermal inertia, but in a manner that prevents unacceptable temperatures from being attained. It can be applied to standard high voltage cables with natural cooling and to dry type power transformers. The setting (Ith>) should be set to the maximum continuously rated current for the protected item of plant. If the current transformer (CT) ratio has been entered then this will be in primary quantities, but if the CT ratio has been set to 1:1 then the continuous rated current entered should be that referred to the secondary winding of the CT. The appropriate thermal time constant (T) must be entered and the following table gives some suggested values for typical cables. The curves for the thermal characteristic are to be found in the appendix to this document and it will be seen that they take due account of the pre-load current. The typical values of time constants in the following table are paper insulated lead sheathed cables, or polyethylene insulated cables laid above ground or in conduits.
Conductor cross section (mm)2 25 35 50 70 95 120 150 185 240 300
Rated voltage of cable 6 to 11kV T minutes 10 10 10 15 15 20 25 25 40 40 22kV T minutes 15 15 15-25 25 25 25 40 40 40 60 33kV T minutes 40 40 40 40 50 60 60 60 66kV T minutes 60 60 60 60 75 90
Typical time constant values for cables

Other protectable items Dry-type transformers Air-cored reactors Capacitor banks Overhead lines from Busbars 100mm2 Cu or 150mm2 Al T minutes 40 40 10 10 60
Typical time constants for other protected plant items
Chapter 5 Measurement and Records
R8557A Chapter 5 Contents
1. 1.1 1.2 2. 2.1 2.2 2.3 2.4 3. 3.1 3.2 3.3 4. 4.1 4.2 4.3 4.4 5. 5.1 5.1.1 5.1.2 5.2 5.3 6. 6.1 6.2 6.3 Figure 1.
MEASURE 1 Current Frequency FAULT RECORDS Generating fault records Accessing fault records Resetting fault records Fault passage information EVENT RECORDS Triggering event records Time tagging of event records Accessing and resetting event records DISTURBANCE RECORDS Recorder control Recorder capture Recorder trigger Notes on recorded times ALARM RECORDS Watchdog Auxiliary powered relays, KCGG 141 Dual powered relays, KCGG 241, 341 Trip indication Alarm indication MEASURE 3 Thermal ammeter Thermal state Peak demand Record initiation logic
1 1 1 1 1 2 2 2 2 3 3 3 3 4 4 4 4 5 5 5 5 5 5 6 6 7 7 2
Section 1.
MEASURE 1
The same menu cells used by the KCGG overcurrent range have been retained for measurement values. 1.1 Current Current is measured once per power frequency cycle and Fourier is used to extract the fundamental component. Measurements are made for each of the three phase currents (a, b, c) and the residual circuit current (o). These values are stored in menu cells 0201, 0202, 0203 and 0204 respectively. 1.2 Frequency The sampling frequency of the A/D converter is synchronised to the power system frequency when there is a signal of sufficient strength to reliably make a frequency measurement. In the absence of a signal to frequency track the sampling frequency defaults to the power frequency setting in menu cell 0009. For protection functions the measured frequency defaults to the power frequency setting when the current and voltage is zero. The displayed frequency measurement will also be the sampling frequency, but in this case it will read 0 when the frequency tracking stops.
Section 2.
FAULT RECORDS
A full fault record is stored for each of the last five faults, with the new record overwriting the oldest one. These records are stored in non volatile memory and are retained when the relay is powered down. Fault records contain the following information: fault flags measured phase currents residual current time from trip command to cessation of current flow When the record opens the values of current are stored and if the current should rise further, the current values are refreshed. The fault flags will be latched when the current falls below the undercurrent thresholds (o</<) or the initiating function resets. The circuit breaker clearance time is also estimated as being the time from the trip initiation to the current falling below the undercurrent threshold, less the time taken for the undercurrent element to reset. Fault records are copied to the event recorder and stored with a time tag. 2.1 Generating fault records Fault records are generated when output relay RLY3, or a logic input assigned in the input mask [0A09 EXT TRIGGER], is energised. The fault flags will be latched in response to these two inputs.
0A09 EXT. TRIGGER 7 6 5 4 3 2 1 0 RLY 3 1
Latch flags Generate fault records. Copy to event records Fault record and flag latch initiation
Latch red trip LED
Figure 1. Record initiation logic

2.2 Accessing fault records Fault records can be accessed by selecting display cell [0101Fault No Fn] in the [FLT RECORD] column menu. The fault number (Fn) denotes the record for the last fault and the record for previous faults can be selected by successive long presses of the [0] key. Fn-1 is the previous fault and Fn-2 is the one before that etc. The [0] key enables fault record selection with the cover in place on the relay, but for remote selection the selection can be made with the usual change setting commands as this will give a quicker response. With the cover removed and menu cell [0101 Fault No] displayed the [+] and [] keys can be used to change to the required record number. 2.3 Resetting fault records All five fault records can be cleared by selecting cell 0110, the last cell under fault records and pressing the [0] key for 1 second. Note: If fault records are being viewed with ACCESS or PAS&T software; hit return key and then select the reset cell option to reset all fault five records. 2.4 Fault passage information If the fault records are generated by relay RLY3 they will still be generated for faults that are cleared by the relay tripping as well as for those passing through the protected section. The disturbance recorder, if set to trigger when relay RLY3 picks up, will only capture a record for faults cleared by RLY3 operating.
Section 3. EVENT RECORDS

Fifty time tagged event records can be stored, after which the oldest record is overwritten. They are stored in volatile memory and will be lost if the relay is powered down. The event records can only be accessed via the serial communication port and PC software is available to support the automatic extraction and storing of these records. The following items are recorded with a time tag by the event recorder: Fault records: fault flags, fault currents and voltages. Setting changes made via the user interface on the front of the relay Local, or remote, change of setting group Logic events: status change of logic inputs and/or output relays Alarms: internal equipment alarms detected by self monitoring functions.
3.1
Triggering event records Event records are triggered automatically in response to the functions listed in the previous section.
3.2
Time tagging of event records Relays in K Range do not have a real time clock. Instead, they each have a freerunning 32-bit counter that increments every 1 millisecond. When an event occurs, the value of this millisecond counter is recorded (Ta) and stored in the event buffer. When the event is extracted, the present value of the millisecond counter is also sent in the message (Tb). The master station must record the actual time at which it received the event message (Tc). This is equivalent to Tb if we consider the transmission time of the event over the communication network to be negligible. It then calculates how long ago the event occurred by: How long ago Real time = = = (Tb Ta) milliseconds ago (time message was received) - (how long ago it occurred) (Tc) (Tb - Ta)
Time tagging is to a resolution of 1 millisecond, the incrementation rate of the counter and remain valid for approximately 49 days. However, the crystal to control the timing has a nominal accuracy of 50 ppm, is not externally synchronised and has no temperature compensation. It can therefore introduce an error of 1 second in every 5.5 hours. The event recording was originally designed for use with automatic extraction programs running on a personal computer (PC) when these timing errors would be insignificant. Refer to Section 4.4 for notes on recorded times, as these apply equally to event records. 3.3 Accessing and resetting event records Event records cannot be viewed on the relay and can only be accessed via the serial communication port of the relay. A PC with suitable software, such as PAS&T, can automatically extract the records, display them on a screen, print them, or store them to either a floppy disc or to the hard disc of the computer. When a new record is generated the oldest event record is automatically overridden and the event flag set. The PAS&T software responds to this flag and extracts the record. When all records have been read, the event flag resets.
Section 4.
DISTURBANCE RECORDS
The internal disturbance recorder has one channel allocated to each of the measured analogue quantities; one to record the control inputs and one to record the relay outputs. As with the event recorder, when the buffer is full the oldest record is overwritten. Records are deleted if the auxiliary supply to the relay is removed. This ensures that when the buffer is read the contents will all be valid. The disturbance recorder is stopped and the record frozen a set time after a preset trigger has been activated. The recorder is automatically reset 3 seconds after current in the circuit is restored provided it exceeds the threshold of the undercurrent elements <. Each sample has a time tag attached to it so that when the waveform is reconstituted it can be plotted at the correct point against the time scale, thus ensuring that the time base is correct and independent of the frequency.
The overcurrent relays measure eight samples per cycle, but the method of recording allows the analysis program to perform with records that may have a different sample rate. The records have to be read via the serial communication port and suitable additional software is required to reconstruct and display the waveforms. Only one complete record is stored and the recorder must be reset before another record can be captured. 4.1 Recorder control The recorder is reset either manually by setting the RECORDER control menu cell 0C01 to 'running' or by extracting the stored data via the K-Bus communications. The recorder control cell displays the state of the recorder. a) RUNNING c) STOPPED recorder storing data (overwriting oldest data). recorder stopped and record ready for retrieval. b) TRIGGERED recorder stop delay triggered. When this cell is selected, manual control is possible and to achieve this the relay must be put into the setting mode by pressing the (+) key. A flashing cursor will then appear on the bottom line of the display at the left hand side. The (+) key will then select 'running' and the () key will select 'triggered'. When the appropriate function has been selected the [F] key is pressed to accept the selection and the selected function will take effect when the [+] key is pressed to confirm the selection. To abort the selection at any time, press the reset key [0]. 4.2 Recorder capture The recorder capture default value for normal use is set to 'samples' in the RECORDER menu cell 0C02. This captures the samples obtained from the A/D converter and the status of the logic inputs and relay outputs. It can also be set to 'magnitudes' to capture the Fourier derived amplitudes or 'phases' to capture the Fourier derived phase angles. 4.3 Recorder trigger The recorder is triggered either by the operation of relay RL3 or by activation of the external trigger input L2. The Post Trigger setting determines the length of the trace that occurs after the stop trigger is received. The default values are 48 cycles for the KCGG 141 and the KCGG 241 relays and 16 cycles for the KCGG 341 relay. 4.4 Notes on recorded times The times recorded for the opto-isolated inputs are the times at which the relay accepted them as valid and responded to their selected control function. This will be 12.5 2.5ms at 50Hz (10.4 2.1ms at 60Hz) after the opto-input was energised. The time recorded for the output relays is the time at which the coil of the relay was energised and the contacts will close approximately 5ms later. Other time tags are generally to a resolution of 1ms for events and to a resolution of 1s for the samples values.
Section 5.
5.1 5.1.1
ALARM RECORDS
Watchdog Auxiliary powered relays, KCGG 141 The watchdog relay will pick up when the relay is operational to indicate a healthy state, with its make contact closed. When an alarm condition is detected that requires some action to be taken, the watchdog relay will reset and its break contact will close to give an alarm.
5.1.2
Dual powered relays, KCGG 241, 341 The watchdog relay operates in a slightly modified way on this version of the relay. It does not initiate an alarm for loss of auxiliary power, as this may have been taken from an insecure source, or it may be powered solely from the current circuit. Operation of the watchdog is therefore inverted so that it will pick up for a failed condition, closing its make contact to give an alarm and in the normal condition it will remain dropped off with its break contact closed to indicate a healthy state. The green LED will usually follow the operation of the watchdog in either of the two above cases. It will be lit when the relay is powered-up, operational and no abnormal conditions have been detected for healthy conditions. The watchdog can be tested by setting alarm flag 6 to 1 in menu cell 0022 in the SYSTEM DATA column of the menu.
5.2
Trip indication Relay RLY3 is the main trip relay and controls the fault record generation. The trip LED will be lit following any protection trip that is assigned to operate output relay RLY3, or when a logic input that has been assigned in input mask [0A09 EXT TRIP] has been energised.
5.3
Alarm indication The alarm LED will flash when the password has been entered. It will be lit and remain steady when an internal fault has been detected by its self test routine. The alarm flags can then be accessed to determine the fault, provided the relay is still able to perform this function. See Chapter 3, Section 3.5 and Section 7 for more information on alarm flags. The alarm flags are located in cell 0022 of the SYSTEM DATA column of the menu. This consists of seven bits that may be either 1 or 0 to indicate the set and reset states respectively. The cell is selected with the function key [F] and the relay then put in the setting mode by pressing the [+] key to display the cursor. The cursor will then be stepped through the alarm word from left to right with each press of the [F] key and text identifying the alarm bit selected will be displayed. The only alarm flag that can be manually set is bit 6, the watchdog test flag. When this flag is set to 1 the watchdog relay will change state and the green LED will extinguish. When any alarm flag is set the amber alarm LED will be continuously lit. Note: No control will be possible via the key pad if the Unconfigured alarm is raised because the relay will be locked in a non-operative state.
0022 0 1 2 3 4 5 6
Alarms Uncfg Uncalib Setting No Service No Samples No Fourier Test Wdog
READ READ READ READ READ READ READ SET
Indicates the current state of internal alarms Error in factory configuration settings Operating in uncalibrated state Error detected in stored settings Protection out-of-service and not functioning No A/D samples but still in service Fourier is not being performed Test watchdog by setting this bit to "1"
Section 6.
6.1
MEASURE 3
Thermal ammeter The thermal ammeters have a representative characteristic similar to that produced by a bi-metal type of instrument, where the movement would be proportional to the bending of the bi-metal strip as a result of the heat applied. Its time/position characteristic is essentially exponential during the heating and cooling cycle and its response is measured in time constants. This type of instrument does not respond to minor rises or dips in the measured current. It displays a steady measurement of the average current over the demand period, equal to six times the selected time constant. In the event of the auxiliary supply to the relay being lost the thermal values are remembered and restored when the supply is re-established. The setting for the time constant is in menu cells 0614 and is adjustable from 1 to 120 minutes in 1 minute steps. However, the time constant is shared with the thermal protection and if the thermal protection is in use its time constant settings will probably be given priority over the instrument requirements. UK applications Electricity Supply Industry Specification ESI 50-2 states that the preferred time lag is 30 minutes and this shall be equal to 6 time constants. Thus for this application the time constant should be set to 5 minutes. US applications In the USA the response of such devices is expressed as the time to reach 90% of the prospective current and the generally accepted time would seem to be in the order of 15 minutes. The time to reach 90% of final value is 2.3 time constants and so for such applications the recommended time constant would be 15/2.3 = 6 minutes. Note: Link PF0 =1 for the thermal ammeters to operate. If PF0 = 0 then they will neither increment nor decrement. It is recommended that the thermal demand registers are manually reset to zero after setting PF0 = 0 as this will clear the thermal memory of the ammeters.
The thermal ammeters cannot be directly reset by performing a reset cell operation on menu cell 0404, 0405 or 0406. They only reset when the peak demand registers are reset (see Section 3.3).
6.2
Thermal state The thermal state is a measure of the percentage of the limiting thermal capacity that the protected item of plant is estimated to have reached. The maximum current that the device can withstand continuously should be entered as the setting for (Ith>) in the phase fault settings of the relay (cells 0613 and 0813). The time constant will compensate for the cooling effects resulting from heat being radiated to the surroundings. When a current equal to Ith> is applied the thermal state will reach 100% after approximately 6 times the set time constant. Normal load current will be less than Ith> and the thermal state, being proportional to I2 will be considerably lower than 100%. On loss of the auxiliary supply the thermal state is memorised and when the supply is restored the thermal state is restored to the memorised value unless the stored value is greater than 90% when it will be restored to 90%. For resetting Cell 0407 under MEASURE 3 should then be displayed and the [0] key pressed for 1 second. This does not reset the thermal ammeters or the peak demand values.
6.3
Peak demand The peak demand is the highest value the thermal ammeters have attained since they were last reset and the demand for each phase is recorded separately. The peak demand can be reset by selecting one of the peak demand values in the menu, cells 040A, 040B, or 040C, and pressing the reset key [0]. This will also cause the thermal ammeters to reset at the same time but the thermal state will not be reset.
Chapter 6 Serial Communications
1. 2. 2.1 2.2 2.3 3. 3.1 3.2 3.3 3.4 3.5 3.6 4. 4.1 4.2 4.3 4.4 4.5 4.6 4.7 4.8 4.9 4.10 4.11 5. 5.1 Figure 1.
COURIER LANGUAGE AND PROTOCOL K-BUS K-Bus transmission layer K-Bus connections Ancillary equipment SOFTWARE SUPPORT Access PAS&T K-Graph Courier-Com PC requirements Modem requirements DATA FOR SYSTEM INTEGRATION Relay address Measured values Status word Logic input status word Output relay status word Alarm indications Event records Notes on recorded times Protection flags Fault records Disturbance records SETTING CONTROL Remote setting change K-Bus connection diagram
1 1 2 2 3 3 3 3 4 4 4 4 5 5 6 6 6 6 6 7 7 7 8 8 9 9 2
Section 1.
COURIER LANGUAGE AND PROTOCOL
Serial communications are supported over K-Bus, a multi-drop network that readily interfaces to IEC 60870-5 FT1.2 Standards. The language and protocol used for communication is Courier. It has been especially developed to enable generic master station programs to access many different types of relay without the continual need to modify the master station program for each relay type. The relays form a distributed data base and the master station polls the slave relays for any information required. This includes: 1. Measured values 2. Menu text 3. Settings and setting limits 4. Fault records 5. Event records 6. Disturbance records 7. Plant status Software is available to support both on-line and off-line setting changes to be made and the automatic extraction and storage of event and disturbance records as described in Section 3. Courier is designed to operate using a polled system, which prevents a slave device from communicating directly to a master control unit when it needs to inform it that something has happened; it must wait until the master control unit requests the information. A feature of Courier is that each piece of information is preceded by a data type and length code. This gives the receiving device the necessary data to interpret the message. The Courier communication manual describes various aspects of this language and other communication information necessary to interface these devices to other equipment. It gives details on the hardware and software interfaces as well as guidelines on how additional devices should implement the Courier language so as to be consistent with all other devices.
Section 2.
K-BUS
K-Bus is a communication system developed to connect remote slave devices to a central master control unit, thus allowing remote control and monitoring functions to be performed using an appropriate communication language. It is not designed to allow direct communication between slave devices, but between a master control unit and several slave devices. The main features of K-Bus are cost effectiveness, high security, ease of installation and ease of use. Each relay in the K Range has a serial communication port configured to K-Bus standards. The port has the same reliability as the protective relays themselves and does not result in their performance being degraded in any way. Error checking and noise rejection have been of major importance in its design.
2.1
K-Bus transmission layer The communication port is based on RS485 voltage transmission and reception levels with galvanic isolation provided by a transformer. A polled protocol is used and no relay unit is allowed to transmit unless it receives a valid message, without any detected error and addressed to it. Transmission is synchronous over a pair of screened wires and the data is FM0 encoded with the clock signal to remove any dc component so that the signal will pass through transformers. With the exception of the master units, each node in the network is passive and any failed unit on the system will not interfere with communication to the other units. The frame format is HDLC and the data rate is 64kbits/s.
2.2
K-Bus connections Connection to the K-Bus port is by standard Midos 4 mm screw terminals or snapon connectors. A twisted pair of wires is all that is required; the polarity of connection is not important. It is recommended that an outer screen is used with an earth connected to the screen at the master station end only. Termination of the screen is effected with the U shaped terminal supplied and which has to be secured with a self tapping screw in the hole in the terminal block just below terminal 56, as shown in the diagram. Operation has been tested up to 32 units connected along a 1,000 metres of cable. The specification for suitable cable will be found in the technical data section. The method of encoding the data results in the polarity of the connection to the bus wiring being unimportant. Note: K-Bus must be terminated with a 150 resistor at each end of the bus. The master station can be located at any position, but the bus should only be driven from one unit at a time.
K-Bus Screened 2 core cable
Figure 1. K-Bus connection diagram
56
54
2.3
Ancillary equipment The minimum requirement to communicate with the relay is a K-BUS/IEC 60870-5 converter box type KITZ and suitable software to run on an IBM or compatible personal computer. RS232 interconnection lead for connecting the KITZ to a personal computer (PC) and software as described in Section 3.
Section 3.
3.1 Access
SOFTWARE SUPPORT
The Courier Access program is supplied with each KITZ and it allows on-line access to any relay or other slave device on the system. It polls all available addresses on the bus to build a list of the active relays. Each relay can be programmed with a product description (16 characters) and a plant reference (16 characters). A particular relay may then be chosen and accessed to display a table listing the menu column headings. Selecting a heading from the list and pressing the return key of the computer returns the full page of data that has been selected. Selecting a setting from the displayed page and pressing the return key again will bring up the setting change box displaying the current setting value and the maximum and minimum limits of setting that have been extracted from the relay. A new setting may be typed in and entered. The new value will be sent to the relay and the relay will send back a copy of the data it received. If the returned value matches what was sent, it is judged to have been received correctly and the display asks for confirmation that the new setting is to be entered. When the execution command is issued the relay checks the setting is within limits, stores it, then replies to state if the new value has been accepted, or rejected. If the setting selected is password protected, the relay will reply that access is denied. Any data received in error is automatically resent, any data not understood, but received without error is ignored. Thus setting changes by this route are secure! A complete setting file can be extracted from the relay and stored on disc and printed out for record purposes. The stored settings can also be copied to other relays, or transferred to other programs such as PAS&T and COURIER-COMM. Control commands, such as close/trip of a circuit breaker, are actioned in the same way as setting changes and can be achieved with this program by using the setting change mechanism. This program supports modem connection but it cannot extract event or disturbance records. 3.2 PAS&T The Protection Access Software and Toolkit (PAS&T) program performs all the functions described for the Access program, but additionally it can perform the following functions: 1. Generate a table of all circuit breakers that can be controlled via the relays connected to K-Bus. These are listed by their plant reference and their open/ closed status is displayed. Selecting a circuit breaker from this table enables it to be controlled with all the background security described for setting changes. 2. Automatically extract event records, displays them on screen, prints, or stores them to disk.
3. Automatically extracts disturbance records and stores them to disk in COMTRADE format. 4. Polls the relay for selected data at set intervals and displays the values on screen, or stores a selected number of values that it can plot on screen to show trend information. 5. Displays coded or decoded messages on screen to monitor the communication system. 6. The Auto-addressing feature automatically allocates the next available address on the bus to a new relay. 3.3 K-Graph Is supplied with PAS&T and it can display disturbance records and print them. The COMTRADE format in which the files are stored can also be loaded into an Excel, or similar spreadsheet program. 3.4 Courier-Com Courier-Com is a Windows based setting program that can be used off-line, ie. without the relays being connected. Setting files can be generated in the office and taken to site on floppy disc for loading to the relays. This program can be used to down-load the settings to the relay, alternatively ACCESS or PAS&T may be used. 3.5 PC requirements To operate fully, the above programs require: IBM PC/XT/AT/PS2 or true compatible. 640 kBytes of main memory RAM Graphics adapter CGA, EGA, VGA or MDA Serial adapter port configured as COM1 or COM2 (RS232) Floppy disc drive 3.5 inch MS-DOS 3.2 or later/IBM PC-DOS 3.2 or later Parallel printer port for optional printer. Additional equipment Printer (optional) RS-232 link. KITZ 101 K-Bus/RS232 communication interface. Modem (optional) 3.6 Modem requirements ALSTOM T&D Protection and control have adopted the IEC 60870-5 ft1.2 frame format for transmitting the courier communication language over RS-232 based systems, which includes transmission over modems. The IEC 60870-5 ft1.2 specification calls for an 11-bit frame format consisting of 1 start bit, 8 data bits, 1 even parity bit and 1 stop bit. However, most modems cannot support this 11-bit frame format, so a relaxed 10-bit frame format is supported by the Protection Access Software & Toolkit and by the KITZ, consisting of 1 start bit, 8 data bits, no parity and 1 stop bit.
Although Courier and IEC 60870 both have inherent error detection, the parity checking on each individual character in the 11-bit frame provides additional security and is a requirement of IEC 60870 in order to meet the error rate levels it guarantees. It is therefore recommended that modems should be used which support these 11-bit frames. The following modems have been evaluated for use with the full IEC 60870-5 ft1.2 protocol and are recommended for use: Motorola Codex 3265 or 3265 Fast Other modems may be used provided that the following features are available (refer to the modem documentation for details on setting these features): Must support an 11 bit frame (1 start bit, 8 data bits, 1 even parity bit and 1 stop bit). This feature is not required if the 10-bit frame format is chosen. Must be possible to disable all error correction, data compression, speed buffering or automatic speed changes. Must save all the settings required to achieve a connection in non-volatile memory. This feature is only required for modems at the relay end of the link. Notes: 1. The V23 asymmetric data rate (1200/75bits/s) is not supported 2. Modems made by Hayes do not support 11 bit characters.
Section 4.
4.1
DATA FOR SYSTEM INTEGRATION
Relay address The relay can have any address from 1 to 254 inclusive. Address 255 is the global address that all relays, or other slave devices, respond to. The Courier protocol specifies that no reply shall be issued by a slave device in response to a global message. This is to prevent all devices responding and causing contention on the bus. All relays are supplied with their address set to 255 to ensure that when connected to an operational network they will not have a conflicting address with another device that are already operational. To make the new devices fully operational they must have their address set. The address can be changed manually by entering the password and changing the address by the setting change method via the user interface on the front of the relay. Alternatively, if the software running on the PC supports auto-addressing, the relay address can be set to 0 and the auto-addressing feature of the PC software turned on. The relay will then be automatically set to the next available address on the bus. PAS&T software supports both these feature. If the address is 255, or unknown, the device address can be changed by sending a new address, in a global message, to a device with a particular serial number. This method is useful for devices that are not provided with a user interface with which to read, or change the current address. This is supported by both PAS&T, ACCESS and Courier-Com.
4.2
Measured values Any measured value can be extracted periodically by polling the relay. Measured values are stored in the same menu locations in the KCGG/KCEG relays and the KMPC measurement centre.
4.3
Status word A status byte is contained in every reply from a slave device. This is returned by the relay at the start of every message to signal important data on which the Master Station may be designed to respond automatically. The flags contained are: Bit 0 Bit 1 Bit 2 Bit 3 Bit 4 Bit 5 Bit 6 Bit 7 1 = Disturbance record available for collection 1 = Plant status word changed (not used) 1 = Control status word changed (not used) 1 = Relay busy, cannot complete reply in time 1 = Relay out of service 1 = Event record available for retrieval 1 = Alarm LED lit 1 = Trip LED lit
Bits 6 and 7 are used to mimic the trip and alarm indication on the frontplate of the slave devices. They cannot be used to extract fault and alarm information from a slave device because they cannot be guaranteed to be set for a long enough period to be identified. Bits 5 and 0 enable the master station to respond automatically and extract event records and disturbance records, if they are so programmed. 4.4 Logic input status word The status of the logic control inputs can be observed by polling menu cell 0020, where the lowest 3 bits of the returned value indicates the status of each of the 3 logic inputs. No control actions are possible on this cell other than to read it. 4.5 Output relay status word The status of the output relays can be observed by polling menu cell 0021, where the lowest 4 bits of the returned value indicates the status of each of the 4 output relays. No control actions are possible on this cell other than to read it. 4.6 Alarm indications The status of the internal alarms produced by the relays self test routine can be observed by polling menu cell 0022, where the lowest 7 bits of the returned value indicates the status of each of the alarms. No control actions are possible on this cell except for bit 6 which can be set/reset, in order to test the watchdog relay. Bit 0 Bit 1 Bit 2 Bit 3 Bit 4 Error in factory configuration detected (relay inoperative) Error in calibration detected (relay running in uncalibrated state) Error detected in stored settings (relay operational, check settings) No Service (protection out of service) No samples (A/D converter not sampling)
Bit 5 Bit 6 4.7
No Fourier (Fourier routine not being performed) Test watchdog (set to 1 to test and reset to 0 afterwards)
Event records An event may be a change of state of a control input or an output relay; it may be a setting that has been changed locally; a protection or control function that has performed its intended function. A total of 50 events may be stored in a buffer, each with an associated time tag. This time tag is the value of a timer counter that is incremented every 1ms. The event records can only be accessed via the serial communication port when the relay is connected to a suitable master station. When the relay is not connected to a master station the event records can still be extracted within certain limitations: The event records can only be read via the serial communication port and a K-Bus/IEC60870-5 interface unit will be required to enable the serial port to be connected to an IBM or compatible PC. Suitable software will be required to run on the PC so that the records can be extracted (eg. PAS&T or ACCESS). When the event buffer becomes full the oldest record is overwritten by the next event. Records are deleted when the auxiliary supply to the relay is removed to ensure that the buffer does not contain invalid data. Dual powered relays are most likely to be affected. The time tag will be valid for 49 days assuming that the auxiliary supply has not been lost within that time. However, there may be an error of 4.3s in every 24 hour period due to the accuracy limits of the crystal. This is not a problem when a master station is on line as the relays will usually be polled once every second or so. The contents of the event records are documented in Chapter 5, Section 3.
4.8
Notes on recorded times As described in Chapter 5, Section 3.2 the event records are appended with the value of a 1 millisecond counter at the time of the event and the current value of the counter is appended to the start of each reply from a relay. Thus it is possible to calculate how long ago the event took place and subtract this from the current value of the real time clock in the PC. If transmission is to be over a modem there will be additional delays in the communication path. In which case the KITZ can be selected to append the real time at which the message was sent and this value can then be used in the conversion of the time tags. With this method of time tagging, the time tags for all relays on K-Bus will be accurate, relative to each other, regardless of the accuracy of the relay time clock. See also Chapter 5, Section 3.2 for additional information on time tagging accuracy.
4.9
Protection flags The protection flags hold the status of the various protection elements in the relay and it is from these that the fault flags are generated. They are transmitted in the event records as part of a fault record and this is the only way they can be accessed.
The following table lists the protection flags: Bit position 0 1 2 3 4 5 6 7 12 13 14 15 20 24 31 Hexadecimal mask 0x00000001L 0x00000002L 0x00000004L 0x00000008L 0x00000010L 0x00000020L 0x00000040L 0x00000080L 0x00001000L 0x00002000L 0x00004000L 0x00008000L 0x00100000L 0x01000000L 0x80000000L Protection function PhA lowset trip PhB lowset trip PhC lowset trip E/F lowset trip PhA 1st Highset trip PhB 1st Highset trip PhC 1st Highset trip E/F 1st Highset trip PhA lowset forward/normal start PhB lowset forward/normal start PhC lowset forward/normal start E/F lowset forward/normal start Thermal overload AUX1 trip Thermal overload alarm
Bits 8 - 11, 16-19, 21-23, and 25-30 are not used in KCGG141, 241 or 341. This 32 bit word can be found in packet #4 of the event record as the menu cell value. A decoded text form can be found in packet #3 as the ASCII Text Description of the event (refer to Courier User Manual). The value can be decoded to establish which elements were operated at the time of the event. 4.10 Fault records Although fault records are stored in the event records and they may be extracted in this way, it may be necessary in some instances to extract the fault records directly. To do this, the record number must be first entered in menu cell 0101 so that the correct fault record can be extracted. Fn is the record for the last fault; Fn-1 is the previous fault record and Fn-4 is the oldest record. Then the values for menu column 01 should be requested. The Courier User Guide will give the detailed commands associated with these functions. 4.11 Disturbance records The setting up of the disturbance recorder in the relays, is fully described in Chapter 5, Section 4 of this manual. If the extraction of these records is to be incorporated in some bespoke software program, reference should be made to the Courier User Guide for the relevant commands that are necessary to extract the records. It is recommended that all such records are stored in a COMTRADE format to enable commercially available programs to use the files. COMTRADE includes minimum and maximum values for each analogue channel. In all relays these are 0 and 32767.
Section 5.
SETTING CONTROL
Control functions via KCGG 141/241/341 relays can be performed over the serial communication link. They include change of individual relay settings or operating and latching selected output relays. CRC and message length checks are used on each message received. No response is given for received messages with a detected error. The Master Station can be set to resend a command a set number of times if it does not receive a reply or receives a reply with a detected error. Note: Control commands are generally performed by changing the value of a cell and are actioned by the setting change procedure, as described in Chapter 6, Section 3.1, and have the same inherent security. No replies are permitted for global commands as this would cause contention on the bus; instead a double send is used for verification of the message by the relay for this type of command. Confirmation that a control command, or setting change, has been accepted is issued by the relay and an error message is returned when it is rejected. Note that the command to change setting group will give an error message as the group 2 settings are disabled in the KCGG 141/241/341 range of relays. 5.1 Remote setting change This range of relays will respond to setting change commands via the serial port as link SD0 is set to 1. No password is required with the KCGG 141/241/341 relays to change the settings.
Chapter 7 Technical Data
1. 1.1 1.2 2. 2.1 2.2 2.3 3. 3.1 3.2 4. 4.1 4.2 4.3 5. 5.1 5.2 6. 7. 7.1 7.2 7.3 7.4 7.5 7.6 8. 8.1 8.2 8.3 9. 10. 11. 11.1 11.2 11.3 12. 13. 14. 14.1 14.2 14.3 14.4 14.5
RATINGS Inputs Outputs BURDENS Current circuits Auxiliary voltage Opto-isolated inputs OVERCURRENT SETTING RANGES Auxiliary powered relays Dual powered relays TIME SETTING RANGES Inverse definite minimum time (IDMT) Definite independent time Auxiliary time delays OTHER PROTECTION SETTINGS Thermal Ratios MEASUREMENT (DISPLAYED) ACCURACY Reference conditions Current Time delays Thermal Auxiliary timer Measurements INFLUENCING QUANTITIES Ambient temperature Frequency (with frequency tracking) Auxiliary supply FREQUENCY RESPONSE OPTO-ISOLATED INPUTS OUTPUT RELAYS Output relays Watchdog Auxiliary VAA relay OPERATION INDICATOR COMMUNICATION PORT HIGH VOLTAGE WITHSTAND Dielectric withstand IEC 60255-5: 1977 High voltage impulse IEC 60255-5: 1977 Insulation resistance IEC 60255-5: 1977 EMC compliance Fast transient IEC 60255-22-4: 1992
1 1 1 2 2 3 3 3 3 3 4 4 4 5 5 5 5 5 5 5 5 5 6 6 6 6 6 6 6 7 7 7 7 8 8 8 8 9 9 9 9 9 9
14.6 14.7 15. 16. 16.1 16.2 16.3 16.4 16.5 16.6 17. 17.1
Electrostatic discharge test IEC 60255-22-2: 1996 High frequency disturbance IEC 60255-22-1: 1988 PRODUCT SAFETY ENVIRONMENTAL Temperature IEC 60255-6: 1988 Humidity IEC 60068-2-3: 1969 Enclosure protection IEC60529: 1989 Vibration IEC 60255-21-1: 1988 Shock and bump IEC 60255-21 2: 1988 Seismic IEC 60255-21-3: 1993 CURRENT TRANSFORMER REQUIREMENTS Requirements for KCGG 141 and KCGG 241 Auxiliary powered relays KCGG 141 Dual powered relays KCGG 241 Limits of error for accuracy classes 5P and 10P Requirements for KCGG 341
9 9 9 10 10 10 10 10 10 10 10 10 10 11 11 11
17.2
Section 1.
1.1 Inputs
RATINGS
Current input (In) Auxiliary powered KCGG 141 Dual powered KCGG 241 Dual powered KCGG 341
Rated (In) (A) 1 5 1 5 1 5
Continuous (xIn) 3.2 3.2 2.4 2.4 2.4 2.4
3s (xIn) 30 30 30 30 30 30
1s (A) 100 400 100 400 100 150
Note: A combined rating of a 5A phase fault and a 1A earth fault is not appropriate for a dual powered relay. The second overload rating for KCGG 341 is restricted to 150A rms. This limitation is due to the rating of the auxiliary VAA contacts. Operative range Auxiliary voltage (Vx) Auxiliary powered KCGG 141 Dual powered KCGG 241, 341 Frequency (Fn) Frequency tracking Rated voltage (V) 24-125 48-250 100-250 DC supply (V) 19-150 33-300 60-300 AC supply (V) 50-133 87-265 60-265 Crest (V) 190 380 380
Nominal rating (Hz) 50 or 60
Operative range (Hz) 45-65
Note: All KCGG relays are set to frequency track only. Logic inputs DC input range 1.2 Outputs Field Voltage Capacitor Trip 48V dc (Current limited to 60mA) 50V dc (680F capacitor - Energy = 0.85J) Rating (Vdc) 50 Off state (Vdc) 12 On state (Vdc) 35
Section 2.
2.1
BURDENS
Current circuits Auxiliary powered In In In In = = = = 1A 1A 5A 5A Phase 0.06 0.06 0.006 0.006 Earth 0.06 0.06 0.006 0.006 Conditions ohms ohms ohms ohms at In at 30In at In at 30In
Dual powered Self-powered from the CT inputs only Phase Earth In=1A 8.1 5.4 2.1 0.8 0.46 0.35 0.32 0.333 0.220 0.091 0.037 0.026 0.022 0.021 27.3 11.4 5.2 2.6 2.0 1.8 1.6 1.082 0.454 0.207 0.103 0.078 0.073 0.070
Conditions ohms ohms ohms ohms ohms ohms ohms ohms ohms ohms ohms ohms ohms ohms at at at at at at at at at at at at at at 0.5In for Vx = 0V 1.0In for Vx = 0V 2.0In for Vx = 0V 5.0In for Vx = 0V 10In for Vx = 0V 20In for Vx = 0V 30In for Vx = 0V 0.5In for Vx = 0V 1.0In for Vx = 0V 2.0In for Vx = 0V 5.0In for Vx = 0V 10In for Vx = 0V 20In for Vx = 0V 30In for Vx = 0V
In=5A
Dual powered Powered from a separate auxiliary supply In=1A 0.58 0.45 0.37 0.33 0.31 0.31 0.31 0.034 0.027 0.024 0.022 0.021 0.021 0.021 2.7 2.3 2.0 1.9 1.9 1.9 1.7 0.106 0.088 0.078 0.072 0.071 0.069 0.062 ohms ohms ohms ohms ohms ohms ohms ohms ohms ohms ohms ohms ohms ohms at at at at at at at at at at at at at at 0.5In for Vx =110V 1.0In for Vx = 110V 2.0In for Vx = 110V 5.0In for Vx = 110V 10In for Vx = 110V 20In for Vx = 110V 30In for Vx = 110V 0.5In for Vx = 110V 1.0In for Vx = 110V 2.0In for Vx = 110V 5.0In for Vx = 110V 10In for Vx = 110V 20In for Vx = 110V 30In for Vx = 110V
In=5A
Note: With respect to the dual powered KCGG 341 relay, the actual burden figures will be 0.03 greater than those stated. This is to allow for the additional contact resistance of the auxiliary VAA relay that is now in series with the CT inputs. AC series trip coil burden must also be added when sizing circuit CTs. Refer to Section 17.
2.2
Auxiliary voltage DC supply 6.0W at Vx max with no output relays or logic inputs energised 10W at Vx max with all output relays and logic inputs energised AC supply 12VA at Vx max with no output relays or logic inputs energised 18VA at Vx max with all output relays and logic inputs energised
2.3
Opto-isolated inputs DC supply 0.25W per input (50V, 10k)
Section 3.
3.1
OVERCURRENT SETTING RANGES
Auxiliary powered relays Threshold (Is) Phase fault Standard earth fault Special earth fault Reset I> I>> Io> Io>> Io> Io>> General 0.08 3.2In 0.08 32In 0.005 0.8In 0.005 8.0In 0.02 3.2In 0.02 32In 0.95Is Threshold (Is) Phase fault Standard earth fault Special earth fault Reset I> I>> Io> Io>> Io> Io>> General 0.4 2.4In 0.4 32In 0.005 0.6In 0.005 8.0In 0.02 2.4In 0.02 32In 0.95Is Step size 0.01In 0.01In 0.0025In 0.0025In 0.01In 0.01In Step size 0.01In 0.01In 0.0025In 0.0025In 0.01In 0.01In
3.2
Dual powered relays
Note: When the relay is powered from the current transformers alone, operation is not guaranteed for phase faults below 0.4In, nor for earth faults below 0.2In unless the load current is above 0.4In. The maximum setting is also limited to 2.4In when CT powered. The number of output relays and optoinputs that are operated will affect the minimum operating current as below. (Imin = 0.4In for phase faults and 0.2In for earth faults.) Number of relays energised 3 opto-inputs energised 2 opto-inputs energised 2 1.2 x Imin 1.1 x Imin 4 1.3 x Imin 1.2 x Imin
Section 4.
4.1
TIME SETTING RANGES
Inverse definite minimum time (IDMT) Nine inverse reset time characteristics are available and the general mathematical expression for the curves is:
k t = TMS
If a 1 Is
+c
seconds
where TMS If Is
= Time Multiplier (0.025 to 1.5 in 0.025 steps) = Fault current = Overcurrent setting
k, c, a = Constants specifying curve Curve No. 0 1 2 3 4 5 6 7 8 9 Description Definite Time Standard Inverse Very Inverse Extremely Inverse Long Time Inverse Moderately Inverse Very Inverse Extremely Inverse Short Time Inverse Rectifier Protection Name DT SI30xDT VI30xDT EI10xDT LTI30xDT MI VI EI STI30xDT RECT IEC Curve A B C D E F k 0 0.14 13.5 80 120 0.103 39.22 56.4 0.05 45900 c 0 to 100 0 0 0 0 0.228 0.982 0.243 0 0 a 1 0.02 1 2 1 0.02 2 2 0.04 5.6
Although the curves tend to infinity at the setting current value (Is), the guaranteed minimum operation current is 1.05Is 0.05Is for all inverse characteristic curves, except curve 10 for which the minimum operating current is 1.6Is 0.05Is. Curves numbers 1, 2, 4, and 8 become definite time for currents in excess of 30xIs. Curve 3 becomes definite time for currents above 10xIs to give extra time grading steps at high current levels. Curves 1, 2 and 3 are curves A, B and C in IEC60255-3. Curves 5, 6 and 7 are slightly different in that they tend to a definite operating time given by the constant (a) at high fault levels. Curves 5, 6 and 7 were proposed by IEEE/ANSI, for inclusion in the IEC standard IEC60255-3, as curves D, E and F. 4.2 Definite independent time Setting range to>/t> tRESET to>>/t>> Definite time Definite time Definite time 0 to 100s 0 to 60s 0 to 100s Step size 0.01s 0.1s 0.01s
4.3
Auxiliary time delays tAUX1 Definite time Setting range 0 to 28 days Step size 0.01s min graded
Section 5.
5.1
OTHER PROTECTION SETTINGS
Thermal Time Constant Current Rating Ith> 1 to 120 minutes step 1 minute 0.08In to 3.2In step 0.01In 9999 : 1 Default = 1 : 1
5.2
Ratios CT ratios
Section 6.
Current
MEASUREMENT (DISPLAYED)
(0 64)In x CT ratio 45 65 (or 0 ) amps per phase Hz
Frequency
Section 7.
7.1
ACCURACY
Reference conditions Ambient temperature Frequency Time multiplier setting Auxiliary voltage 20C 50Hz or 60Hz (whichever is set) 1.0 24V to 125V (auxiliary powered) 48V to 250V (auxiliary powered) 100V to 250V (dual powered) Minimum operation Reset Repeatability Minimum operation 5% 5% 2.5% 20% (@ minimum setting) 10% (@2x minimum setting) 5% (@ >4x minimum setting) Reference range Operating time (t>/to>) IDMT except (EI) and (Rectifier) Extremely inv (EI) Rectifier Definite time 5% + (20 to 40)ms 7.5% + (20 to 40)ms 7.5% + (20 to 40)ms 0.5% + (20 to 40)ms 2Is to 30Is 2Is to 10Is 2Is to 5Is 3Is to 30Is
7.2
Current Overcurrent
Earth Fault
7.3
Time delays
Repeatability Overshoot time Reset time t>/to> Disengagement
Inverse time Definite time Less than 50ms Definite time I>/Io> t>/to> t>>/to>>
2% 40ms 0.5% or10ms when current reduced to zero. 1% 50ms typically 30ms typically 30ms* typically 50ms*
* The disengagement time is affected if measuring circuit resets within 100ms of pick-up. 7.4 Thermal Thermal (Ith>) Operation time 7.5 Auxiliary timer Operating time Disengagement time 7.6 Measurements Current Frequency 2%In (typical) - Reference range = setting range (45-65Hz) 0.02Hz (typical) set time 0.5% (set time) + 15 to 35ms 15 to 30ms (including output relay and opto input) minimum operation 5% 2% of TC from 1.2Ith> to 4Ith>
Section 8.
8.1
INFLUENCING QUANTITIES
Ambient temperature Operative range Current settings Operation times 25C to +55C 1% 1% 46 to 65Hz 1% 1% Nominal 24/125V 48/250V 100/250V Current settings Operation times 0.5% 0.5% Operative range 19 to 150V dc (aux powered) 50 to 133V ac (aux powered) 33 to 300V dc (aux powered) 87 to 265V ac (aux powered) 60 to 300V dc (dual powered) 60 to 265V ac (dual powered)
8.2
Frequency (with frequency tracking) Operative range Current setting Operating times
8.3
Auxiliary supply
Section 9.
FREQUENCY RESPONSE
The KCGG 141, KCGG 241 and KCGG 341 overcurrent relays are pre-set to frequency track and are set to respond to peak values. This follows the standard configuration for a KCGG relay and gives the fastest response by using the peak value of the first half cycle of a fault waveform to calculate trip time.
Section 10. OPTO-ISOLATED INPUTS

Number of inputs Capture time Release time Minimum operating voltage Maximum operating voltage Input resistance 3 (L0 to L2) 12.5 2.5ms at 50Hz 10.4 2.1ms at 60Hz 12.5 2.5ms at 50Hz 10.4 2.1ms at 60Hz >35V dc 50Vdc 10k (add 12k for every additional 50V in excess of 50V) 2k for single input at 40V min. 1k for 2 inputs in parallel at 40V min. 0.5k for 4 inputs in parallel at 40V min. 50V rms (thermal limit) 250V rms via 0.1F
Maximum series lead resistance
Maximum ac induced loop voltage Maximum capacitance coupled ac voltage
Section 11. OUTPUT RELAYS

11.1 Output relays Number of outputs Type Rating Make Carry Break 4 (RL0 to RL3) 1 make 30A and carry for 0.2s 5A continuous DC 50W resistive 25W inductive (L/R = 0.04s) AC 1250VA (maxima of 5A) Subject to maxima of 5A and 300V >10,000 operations
Durability
11.2
Watchdog Type Rating Make Carry Break 1 make + 1 break 10A and carry for 0.2s 5A continuous DC 30W resistive DC 15W inductive (L/R = 0.04s) AC 1250VA (maxima of 5A) Subject to a maxima of 5A and 300V >10,000 operations 2 sets of break contacts wired in parallel for each phase Carry Break Voltage 10A continuous 5000VA with maxima of 150A and 150V (when unshorting the circuit breaker trip coil) Subject to maxima of 150V and 15,000W
Durability 11.3 Auxiliary VAA relay Type AC Rating
Section 12. OPERATION INDICATOR

3 light emitting diodes internally powered. 16 character by 2 line liquid crystal display (with backlight). Hand reset electromechanical flag for the auxiliary VAA element (KCGG 341 only).
Section 13. COMMUNICATION PORT

Language Transmission Format Baud Rate K-Bus Cable Length Bus Loading Courier Synchronous RS485 voltage levels HDLC 64kbit/s Screened twisted pair 1000m 32 units (mulitdrop system)
Section 14. HIGH VOLTAGE WITHSTAND

14.1 Dielectric withstand IEC 60255-5: 1977 2.0kV rms for one minute between all terminals and case earth, except terminal 1. 2.0kV rms for one minute between terminals of independent circuits, including contact circuits. 1.5kV rms for 1 minute across open contacts of output relays 0 to 3. 1.0kV rms for 1 minute across open contacts of the watchdog relay. 14.2 High voltage impulse IEC 60255-5: 1977 5kV peak, 1.2/50s, 0.5J three positive and three negative impulses applied: across terminals of the same circuit. between terminals of independent circuits. between all terminals connected together and case earth except teminal 1. 14.3 14.4 Insulation resistance IEC 60255-5: 1977 >100M when measured at 500Vdc EMC compliance 89/336/EEC Compliance to the European Commission Directive on EMC is claimed via the Technical Construction File route. EN50081-1 EN50082-2 Generic Standards are used to establish conformity. 14.5 14.6 Fast transient IEC 60255-22-4: 1992 Class IV Class 3 (8kV) Class 2 (4kV) 14.7 Class III 4kV, 2.5kHz applied to all inputs and outputs discharge in air with cover in place point contact discharge with cover removed 2.5kV peak between independent circuits and case 1.0kV peak across terminals of the same circuit Electrostatic discharge test IEC 60255-22-2: 1996
High frequency disturbance IEC 60255-22-1: 1988
Section 15. PRODUCT SAFETY

EN 61010-1:1993/A2:1995 Compliance is demonstrated by reference to EN 60950: 1992/A11:1997 Generic Safety Standards
Section 16. ENVIRONMENTAL

16.1 Temperature IEC 60255-6: 1988 Storage and transit Operating 16.2 16.3 16.4 25C to +70C 25C to +55C
Humidity IEC 60068-2-3: 1969 56 days at 93% relative humidity and 40C Enclosure protection IEC60529: 1989 IP50 (Dust protected) Vibration IEC 60255-21-1: 1988 Vibration response, energised Vibration endurance, non-energised Class 1 Class 1 Class 1 Class 1 Class 1 Class 1
16.5
Shock and bump IEC 60255-21 2: 1988 Shock response, energised Shock withstand, non-energised Bump, non-energised
16.6
Seismic IEC 60255-21-3: 1993 Seismic, energised
Section 17. CURRENT TRANSFORMER REQUIREMENTS

17.1 Requirements for KCGG 141 and KCGG 241 CT requirements for use in typical applications are shown below. These CT requirements are based on a maximum prospective fault current of 50x relay rated current (In) and the relay having a maximum high-set setting of 25In. The CT requirements are designed to provide operation of the phase and earth fault elements. Where the criteria for a specific application are in excess of those detailed above, or the actual lead resistance exceeds the limiting value quoted, the CT requirements may need to be increased. CT requirements for a variety of further applications are provided in publication R6096. Auxiliary powered relays KCGG 141 Relay and CT secondary rating 1A 5A Nominal output 2.5VA 7.5VA Accuracy class 10P 10P Accuracy limit factor 20 20 Limiting lead resistance (one way) 0.6 0.06
Dual powered relays KCGG 241 Relay and CT secondary rating 1A 5A Nominal output 7.5VA 10VA Accuracy class 10P 10P Accuracy limit factor 15 20 Limiting lead resistance (one way) 0.7 0.06
Where the K Range relays are being used for restricted earth fault protection the CTs must be sized to assure stability as described in Chapter 4, Section 5.10. The accuracy class of the CTs should be chosen to suit the required accuracy of measurement values. Limits of error for accuracy classes 5P and 10P Accuracy class 5P 10P Current error (%) 1 3 Composite error (%) 5 10
The accuracy limit factors detailed above should be used to ensure full range fault recording. 17.2 Requirements for KCGG 341 The requirements for the dual powered KCGG 341 AC Series Trip relay will be the same as those for the KCGG 241 plus additional burden requirements as described below. In brief, when a fault current is detected, the relay is tripped and the circuit breaker trip coil is connected in series with the current inputs. The additional resistance of the trip coil will need to be considered when determining the line CT requirements. This will be similar to having additional cable resistance. Depending on the overall resistance then the use of larger CTs may be required. For further assistance contact our Applications Department.
Chapter 8 Commissioning
1. 2. 3. 3.1 3.2 4. 4.1 4.1.1 4.1.2 4.1.3 4.2 4.2.1 4.2.2 4.2.2.1 4.2.2.2 4.2.3 4.2.4 4.2.8 4.2.9 4.2.10 5. 5.1 5.1.1 5.1.1.1 5.1.1.2 5.1.1.3 6. 6.1 7. 8. 8.1 8.2 8.2.1 8.2.3 8.2.4 8.2.5 8.2.6 8.2.7 8.2.8 8.3 8.3.1 8.3.2
INTRODUCTION SETTING FAMILIARISATION EQUIPMENT REQUIRED FOR COMMISSIONING Minimum equipment required for KCGG relays Optional equipment PRODUCT CHECKS With the relay de-energised Visual inspection Insulation External wiring With the relay energised Watchdog contacts Light emitting diodes (LEDs) Testing the alarm LED Testing the trip LED Liquid crystal display (LCD) Field voltage supply Communications ports Current inputs Energisation from line current transformers (KCGG 241 and KCGG 341 relays only) SETTING CHECKS Demonstrate correct relay operation Non-directional phase fault test (KCGG 141 relays) Connect the test circuit Perform the test Check the operating time ON-LOAD CHECKS Check current transformer connections (KCGG relays) FINAL CHECKS PROBLEM SOLVING Protection settings Alarms Watchdog alarm Cell [0022 Alarms] link 1 = 1 Cell [0022 Alarms] link 2 = 1 Cell [0022 Alarms] link 3 = 1 Cell [0022 Alarms] link 4 = 1 Cell [0022 Alarms] link 5 = 1 Fault flags will not reset Records Problems with event records Problems with disturbance records
1 3 3 3 3 4 4 4 5 5 7 7 7 7 7 7 7 9 9 10 10 10 10 11 11 11 12 12 12 13 13 13 13 14 14 14 14 14 14 15 15 15
8.4 8.4.1 8.4.2 8.5 9. 9.1 9.2 9.2.1 9.2.1.1 9.2.1.2 9.2.1.3 9.2.2 9.2.2.1 9.2.2.2 9.2.2.3 9.3 9.3.1 9.3.1.1 9.3.1.2 9.3.2 9.3.3 9.3.4 9.4 Figure 1. Table 1 Table 2 Table 3 Table 4 Table 5 Table 6 Table 7 Table 8
Communications Measured values do not change Relay no longer responding Thermal state MAINTENANCE Maintenance period Maintenance checks Remote testing Alarms Measurement accuracy Trip test Local testing Alarms Measurement accuracy Trip test Method of repair Replacing a PCB Replacement of user interface Replacement of main processor board Replacing output relays Replacing the power supply board Replacing the back plane (size 4 and 8 cases) Recalibration Connection to test block Functions of keys Watchdog contact status Operational range of auxiliary supply Opto-isolator connections Settings for output tests Current inputs and corresponding displayed values for KCGG 141, KCGG 241 and KCGG 341 Injected currents for line current transformer energisation tests Characteristic operating times for I>
15 15 16 16 16 16 17 17 17 17 17 17 17 17 17 18 18 18 18 18 19 19 19 6 2 6 6 8 9 10 10 11
Section 1.
INTRODUCTION
The KCGG relays are fully numerical in their design, implementing all protection and non-protection functions in software. The relays employ a high degree of self-checking and, in the unlikely event of a failure, will give an alarm. As a result of this, the commissioning tests do not need to be as thorough as with non-numeric electronic or electro-mechanical relays. To commission numeric relays, it is only necessary to verify that the hardware is functioning correctly and the application-specific software settings have been applied to the relay. It is considered unnecessary to test every function of the relay if the settings have been verified by one of the following methods: Extracting the settings applied to the relay using appropriate setting software (preferred method) Via the operator interface. To confirm that the product is operating correctly once the customers settings have been applied, a test should be performed on a single element. Unless previously agreed to the contrary, the customer will be responsible for determining the application-specific settings to be applied and testing scheme logic applied by external customer wiring. Blank commissioning test and setting records are provided in Appendix 4 for completion as required. BEFORE CARRYING OUT ANY WORK ON THE EQUIPMENT, THE USER SHOULD BE FAMILIAR WITH THE SAFETY SECTION AND CHAPTER 2, HANDLING AND INSTALLATION, OF THIS MANUAL.
Current Display Default display
Key Press [F] short or [F] long [+] [-]

Effect of Action Display moves to menu column heading SYSTEM DATA Backlight turns ON - no other effect Backlight turns ON - no other effect Steps through the available default displays Backlight turns ON - no other effect Display moves to menu column heading SYSTEM DATA Backlight turns ON - no other effect Backlight turns ON - no other effect Backlight turns ON - no other effect Resets trip LED and returns to default display Move to next item in menu column Move to next column heading Move to previous column heading Move to next column heading Backlight turns ON - no other effect Returns to default display Move to next item in menu column Move to next column heading Backlight turns ON - no other effect Resets the value if the cell is resettable Puts relay in the setting mode (flashing cursor on bottom line of display). Changes to the confirmation display. If function links, relay or input masks are displayed, the [F] key will step through them from left to right and finally changing to the confirmation display Increments value - rapidly increases if held depressed Decrements value - rapidly decreases if held depressed Escapes from the setting mode without the setting being changed Confirms setting and enters the new value Returns prospective value of setting for checking and further modification. Escapes from the setting mode without a setting change
[0] short [0] long Fault flags after a trip [F] short or [F] long [+] [-] [0] short [0] long Column heading [F] short [F] long [+] [-]

[0] short [0] long Any menu cell [F] short [F] long [0] short [0] long A settable cell Setting mode [+] or [-] [F]
[+] [-] [0] Confirmation mode [+] [-] [0]
Only available with front cover removed
Table 1 Functions of keys
Section 2.
SETTING FAMILIARISATION
When commissioning a KCGG relay for the first time, sufficient time should be allowed to become familiar with the method by which the settings are applied. Chapter 3, Section 3 contains a detailed description of the menu structure of the KCGG relays but the key functions are summarised in Table 1. With the cover in place only the [F] and [0] keys are accessible. Data can only be read or flag and counter functions reset. No protection or configuration settings can be changed. Removing the cover allows access to the [+] and [] keys. Settings can be changed and there is greater mobility around the menu. In Table 1, [F] long indicates that the key is pressed for at least 1 second and [F] short for less than 0.5 second. This allows the same key to perform more than one function. Alternatively, if a portable PC is available together with a K-Bus interface and suitable setting software, the menu can be viewed a page at a time to display a full column of data and text. Settings are also more easily entered and the final settings can be saved to a file on a disk for future reference or printing a permanent record. Refer to the software user manual for details and allow sufficient time to become familiar with its operation if it is being used for the first time.
Section 3.
3.1
EQUIPMENT REQUIRED FOR COMMISSIONING
Minimum equipment required for KCGG relays Overcurrent test set with interval timer Multimeter with suitable ac current range, and ac and dc voltage ranges of 0n 440V and 0 250V respectively Audible continuity tester (if not included in multimeter)
3.2
Optional equipment Multi-finger test plug type MMLB01 (if test block type MMLG installed) An electronic or brushless insulation tester with a dc output not exceeding 500V (for insulation resistance testing when required) A portable PC, with appropriate software and a KITZ101 K-Bus/IEC 60870-5 interface unit (if one is not already installed at site) will be useful and save considerable time. However, it is not essential to commissioning. A printer (for printing a setting record from the portable PC).
Section 4.
PRODUCT CHECKS
These product checks cover all aspects of the relay that need to be checked to ensure that it has not been physically damaged prior to commissioning, is functioning correctly and all input quantity measurements are within the stated tolerances. If the application-specific settings have been applied to the relay prior to commissioning, it is advisable to make a copy of the settings so as to allow their restoration later. This could be done by: Obtaining a setting file on a diskette from the customer. (This requires a portable PC with appropriate software for transferring the settings to the relay) Extracting the settings from the product itself. (This again requires a portable PC with appropriate software) Manually creating a setting record. This could be done using a copy of the setting record located in Appendix 4. 4.1 With the relay de-energised The following group of tests should be carried out without the auxiliary supply being applied to the relay and the trip circuit isolated. The measured currents must not be applied to the relay for these checks. If an MMLG test block is provided, this can easily be achieved by inserting test plug type MMLB01 which effectively open-circuits all wiring routed through the test block. Before inserting the test plug, reference should be made to the scheme diagram to ensure that this will not potentially cause damage or a safety hazard. For example, the test block may also be associated with protection current transformer circuits. It is essential that the sockets in the test plug, which correspond to the current transformer secondary windings, are linked before the test plug is inserted into the test block. DANGER: Never open circuit the secondary circuit of a current transformer since the high voltage produced may be lethal and could damage insulation. If an MMLG test block is not provided, the line current transformers should be shortcircuited and disconnected from the relay terminals. Where means of isolating the auxiliary supply and trip circuit (eg. isolation links, fuses, MCB, etc.) are provided, these should be used. If this is not possible, the wiring to these circuits will have to be disconnected and the exposed ends suitably terminated to prevent them being a safety hazard. 4.1.1 Visual inspection Loosen the cover screws and remove the cover. The relay module can now be withdrawn from its case. In accordance with Chapter 2, Section 2 (Handling of Electronic Equipment), carefully examine the module and case to see that no physical damage has occurred since installation. Check that the serial and model numbers on the front plate and label on the left-hand, inside face of the case are identical. The only time that the serial numbers may not match is when a failed relay has been replaced to provide continuity of protection.
The rating information on the front of the relay should also be checked to ensure it is correct for the particular installation. Visually check that the current transformer shorting switches, fitted on the terminal block inside the rear of the case, are wired into the correct circuit. The shorting switches are between terminals 21 and 22, 23 and 24, 25 and 26, and 27 and 28 for all versions of KCGG. Ensure that, while the relay module is withdrawn, the shorting switches are closed by checking with a continuity tester. Note: The circuit breaker trip coils may trip if an AC series trip relay, KCGG 341, is withdrawn from its case. The trip coils should be disabled if required. Ensure that the case earthing connection, above the rear terminal block, is used to connect the relay to a local earth bar. Where there is more than one relay in a tier, it is recommended that a copper earth bar should be fitted connecting the earth terminals of each case in the same tier together. However, as long as an adequate earth connection is made between relays, the use of a copper earth bar is not essential. 4.1.2 Insulation Insulation resistance tests only need to be done during commissioning if the customer requires them to be done and they have not been performed during installation. If insulation resistance tests are required, isolate the relay trip contacts and re-insert the relay module. Isolate all wiring from the earth and test the insulation with an electronic or brushless insulation tester at a dc voltage not exceeding 500V. Terminals of the same circuit should be temporarily strapped together. The main groups of relay terminals are: a) Current transformer circuits b) Auxiliary voltage supply (also capacitive discharge circuit on KCGG 241 and KCGG 341 relays). c) Field voltage output and opto-isolated control inputs. d) Relay contacts. e) Communication port. f) Case earth. The insulation resistance should be greater than 100M at 500V. On completion of the insulation resistance tests, ensure all external wiring is correctly reconnected to the unit. 4.1.3 External wiring Check that the external wiring is correct to the relevant relay diagram or scheme diagram. The relay diagram number appears on a label on the left-hand, inside face of the case and the corresponding connection diagram can be found in Appendix 3 of this manual. If an MMLG test block is provided, the connections should be checked against the scheme diagram. It is recommended that the supply connections are to the live side of the test block as shown below. The wiring should be checked against the schematic diagram for the installation to ensure compliance with the customers normal practice.
Test block MMLG
KCGG Relay
+
Auxiliary supply
13
14
13
15
16
14
Figure 1. Connection to test block

4.1.4 Watchdog contacts If not already done to perform the insulation resistance tests, isolate the relay trip contacts and re-insert the relay module. Using a continuity tester, check the watchdog contacts are in the states given in Table 2 for a de-energised relay. Relay Type KCGG 141 KCGG 241 and KCGG 341 3 and 5 4 and 6 3 and 5 4 and 6 Terminals Closed Open Closed Open Contact state Relay de-energised Relay energised Open Closed Closed Open
Table 2
4.1.5
Watchdog contact status
Auxiliary supply The relay can be operated from either an ac or a dc auxiliary supply but the incoming voltage must be within the operating range specified in Table 3. Without energising the relay, measure the auxiliary supply to ensure it is within the operating range. Relay type Auxiliary Powered only Dual powered Relay rating (V) 24/125 48/250 100/250 DC operating AC operating range (V) range (V) 19 150 33 300 60 300 50 133 87 265 60 265 Maximum crest voltage (V) 190 380 380
Table 3
Operational range of auxiliary supply
It should be noted that the relay can withstand an ac ripple of up to 12% of the upper rated voltage on the dc auxiliary supply. However, in all cases the peak value of the auxiliary supply must not exceed the maximum crest voltage. Do not energise the relay using the battery charger with the battery disconnected as this can seriously damage the relays power supply circuitry.
Energise the relay if the auxiliary supply is within the operating range. If an MMLG test block is provided, it may be necessary to link across the front of the test plug to restore the auxiliary supply to the relay. 4.2 With the relay energised The following group of tests verify that the relay hardware and software is functioning correctly and should be carried out with the auxiliary supply applied to the relay. The measured currents must not be applied to the relay for these checks. Withdrawing the KCGG 341 from the case may energise trip coil if currents are present. 4.2.1 Watchdog contacts Using a continuity tester, check the watchdog contacts are in the states given in Table 2 for an energised relay. Note: The watchdog contacts in a dual powered relay do not normally pick up when the supply is applied. The contacts pick up when the relay is not healthy and the auxiliary supply is applied. 4.2.2 Light emitting diodes (LEDs) On power up the green LED should have illuminated and stayed on indicating the relay is healthy. The relay has non-volatile memory which remembers the state (on or off) of the yellow alarm and red trip LED indicators when the relay was last powered, and therefore these indicators may also be on. If either the alarm or trip, or both, LEDs are on then these should be reset before proceeding with further testing. If the LEDs successfully reset (the LED goes out), there is no testing required for that LED because it is known to be operational. 4.2.2.1 Testing the alarm LED The alarm LED may be tested by stepping through the SYSTEM DATA menu to cell [0022 Alarms]. Setting bit 6 (Test Wdog) to 1 will light the orange alarm LED. Resetting bit 6 to zero will reset the alarm and turn the larm LED off. 4.2.2.2 Testing the trip LED The trip LED can be tested when the overload checks are carried out and the trip output relays RL3 trips. 4.2.3 Liquid crystal display (LCD) There are no in-built self test routines for the LCD. The display itself can be checked by moving around the relay menu looking for pixels (the dots on the display used to form the text) that are not working. There is an integral backlight in the display that allows settings to be read in all conditions of ambient lighting. It is switched on when any key on the frontplate is momentarily pressed and is designed to switch off 10 minutes after the last key press. Check that the backlight switches off as it will impose an unnecessary burden on the station battery if it stays on. 4.2.4 Field voltage supply The relay generates a field voltage of nominally 48V that should be used to energise the opto-isolated inputs. Measure the field voltage across terminals 7 and 8. Terminal 7 should be positive with respect to terminal 8 and the voltage should be within the range 45V to 60V when no load is connected.
4.2.5
Capacitor trip voltage (KCGG 241 and KCGG 341 relays only) The relay generates a capacitor trip voltage of nominally 50V. Measure the field voltage across terminals 9 and 10. Terminal 9 should be positive with respect to terminal 10 and the voltage should be within the range 45V to 55V when no load is connected.
4.2.6
Input opto-isolators This test checks that all the opto-isolated inputs are functioning correctly. The KCGG 141, KCGG 241 and KCGG 341 have only 3 opto-isolated inputs (L0, L1 and L2). To allow the opto-isolated inputs to work, terminal 8 (field voltage supply negative) should be linked to terminal 52 for all models. The opto-isolated inputs can then be individually energised by connecting terminal 7 (field voltage supply positive) to the appropriate opto-isolated input listed in Table 4. Note: The opto-isolated inputs may be energised from an external 50V battery in some installations. Check that this is not the case before connecting the field voltage otherwise damage to the relay may result. Opto-isolator Terminal number L0 46 L1 48 L2 50
Table 4
Opto-isolator connections
The status of each opto-isolated input can be viewed using cell [0020 Log Status]. When each opto-isolated input is energised one of the characters on the bottom line of the display will change to indicate the new state of the inputs. The number printed on the frontplate under the display will identify which opto-isolated input each character represents. A 1 indicates an energised state and a 0 indicates a de-energised state. 4.2.7 Output relays This test is to check that all the output relays are functioning correctly. Connect an audible continuity tester across the terminals corresponding to the output relay to be monitored given in Table 5. Operation of output relay will be confirmed by the continuity tester sounding for the duration of the trip pulse time. Select a definite time (DT) curve from the earth fault 1 menu cell 0504 and also from the phase fault 1 menu cell 0604. Select zero time delays in menu cells 0507 and 0607. KCGG 141 and KCGG 241 Inject current o into terminals 27 and 28 above the setting as shown in cell 0505. This will trip the earth fault element and energise relays RL0, RL2 and RL3. Inject current A into terminals 21 and 22 above the setting as shown in cell 0605. This will trip the phase fault element and energise relays RL0, RL1 and RL3. KCGG 341 Inject current o into terminals 27 and 28 above the setting as shown in cell 0505. This will trip the earth fault element and energise relays RL2 and RL3. Inject current A into terminals 21 and 22 above the setting as shown in cell 0605.
This will trip the phase fault element and energise relays RL1 and RL3. Set the auxiliary timer tAUX1 to zero time in menu cell 0903. Energise the logic input L0 by connecting terminals 7 and 8 to terminals 46 and 52 respectively. This will trip output relay RL0. Output relay 0 1 2 3 Terminal numbers 30 and 32 34 and 36 38 and 40 42 and 44
Table 5
4.2.8
Settings for output tests
Communications ports This test should only be performed where the relay is to be accessed from a remote location and a portable PC has not been used to read and change settings during commissioning. It is not the intention of the test to verify the operation of the complete system from the relay to the remote location, just the relays K-Bus circuitry and the protocol converter. Connect a portable PC running the appropriate software to the incoming (remote from relay) side of the protocol converter and ensure that the communications settings in the application software are set the same as those on the protocol convertor. Check that communications with the relay can be established.
4.2.9
Current inputs This test verifies the accuracy of current measurement is within the acceptable tolerances. All relays will leave the factory set for operation at a system frequency of 50Hz. If operation at 60Hz is required on a KCGG relay, this must be set in cell [0009 Freq]. Press the [+] key until the displayed frequency is 60Hz, then press the [F] key once followed by the [+] key to confirm the change. Apply rated current to each current transformer input in turn, checking its magnitude using a multimeter. Refer to Table 6 for the corresponding reading in the relays MEASURE 1 column and record the value displayed. All measured current values on the relay should equal the applied current multiplied by the current transformer ratio set in the [0502 CT Ratio] cell for earth fault current transformer inputs or [0602 CT Ratio] cell for phase current transformer inputs, as applicable. The measurement accuracy of the relay is 2%. However, an additional allowance must be made for the accuracy of the test equipment being used.
Current applied to Terminals 21 and 22 Terminals 23 and 24 Terminals 25 and 26 Terminals 27 and 28
Menu cell [0201 a] [0202 b] [0203 c] [0204 o]
Table 6
4.2.10
Current inputs and corresponding displayed values for KCGG 141, KCGG 241 and KCGG 341
Energisation from line current transformers (KCGG 241 and KCGG 341 relays only) This test ensures that the KCGG 241 or KCGG 341 relay will operate from the line current transformers should the auxiliary voltage be unavailable or has failed. The currents used in the tests are the minimum values for which the relay should operate, regardless of setting. Remove the auxiliary supply from the relay. Inject the current stated in Table 7 to the relay terminals specified. In each case the relay should power up correctly with the LCD showing the default display and the green healthy LED illuminated. Repeat the field supply and capacitor trip voltage tests (4.2.4 and 4.2.5 respectively) with the relay powered from the injected current. Injected current 0.4 x n Terminals Inject into 21 and 23 25 and 21 23 and 25 0.2 x n 23 and 28 Link together 22 and 24 26 and 22 24 and 26 24 and 27
Table 7
Injected currents for line current transformer energisation tests
Note: For 0.2 x In, the relay may chatter due to the loading effect of the energised output relays. This is unlikely to occur when the relay is in service because it will not be powered from the earth fault current only.
Section 5.
5.1
SETTING CHECKS
Demonstrate correct relay operation This test, performed on a single element, demonstrates that the relay is operating correctly at the preconfigured settings. The test performed will depend on the protection functions provided by the relay under test. The test is usually on stage 1 of the phase fault function.
5.1.1
Non-directional phase fault test (KCGG 141 relays) This test demonstrates that stage 1of the KCGG phase fault function (t>) operates within the stated tolerance at the customer settings.
5.1.1.1 Connect the test circuit Determine which output relays have been selected to operate when a t> trip occurs from the applications diagram. The associated terminal numbers can be found either from the external connection diagram (Appendix 3) or Table 5. Connect the output relay so that its operation will trip the test set and stop the timer. Connect the current output of the test set to terminals 21 and 22 (A phase current transformer input) of the relay and ensure that the timer will start when the current is applied to the relay. 5.1.1.2 Perform the test Ensure that the timer is reset. Apply a current of twice the setting in cell [0605 I>] to the KCGG and note the time displayed when the timer stops. 5.1.1.3 Check the operating time Check that the operating time recorded by the timer is within the range shown in Table 8. Characteristic DT SI30xDT VI30xDT EI10xDT LTI30xDT MI VI EI STI30xDT RECT Operating time at 2s and TMS=1 Nominal (seconds) [0607 t>/DT] setting 10.03 13.50 26.67 120.0 7.61 14.06 19.04 1.78 966 Range (seconds) [0607 t>/DT] 0.5% 9.53 10.53 12.83 14.18 25.33 28.00 114.00 126.00 7.23 7.99 13.35 14.76 18.09 20.00 1.69 1.87 917 1014
Table 8
Characteristic operating times for >
Note: Except for the definite time characteristic, the operating times given in Table 8 are for a TMS of 1. Therefore, to obtain the operating time for other TMS settings, the time given in Table 8 must be multiplied by the relays actual TMS setting. This setting can be found in cell [0606 t>/ TMS]. In addition, for all characteristics, there may be an additional delay of up to 0.04s and an additional allowance must be made for the accuracy of the test equipment being used.
Section 6.
ON-LOAD CHECKS
Remove all test leads, temporary shorting leads, etc. and replace any external wiring that has been removed to allow testing. If it has been necessary to disconnect any of the external wiring from the relay in order to perform any of the foregoing tests, it should be ensured that all connections are replaced in accordance with the relevant external connection or scheme diagram. The following on-load measuring checks ensure the external (customer) wiring to the current and voltage inputs is correct but can only be carried out if there are no restrictions preventing the energisation of the plant being protected. 6.1 Check current transformer connections (KCGG relays) Measure the current transformer secondary values. Ensure the current flowing in the neutral circuit of the current transformers is negligible. Compare the values of the secondary phase currents with the relays measured values, which can be found in the MEASURE 1 menu column. If the current transformer ratios (cells [0502 CT Ratio] and [0602 CT Ratio] for earth and phase currents respectively) are set to 1:1, the displayed values are in secondary Amperes. The relay values should be within 2% of the applied secondary currents. However, an additional allowance must be made for the accuracy of the test equipment being used. Otherwise, if the current transformer ratios (cells [0502 CT Ratio] and [0602 CT Ratio] for earth and phase currents respectively) are set greater than 1:1, the displayed values are in primary Amperes. In this case the relay values will be equal to the applied secondary currents multiplied by the appropriate current transformer ratio setting. Again the relay values should be within 2% plus an additional allowance for the accuracy of the test equipment being used. It should be noted that earth fault relays are not energised under normal load conditions and it is therefore necessary to simulate a phase to neutral fault. It is therefore necessary to temporarily disconnect one or two of the line current transformer connections to the relay and short the terminals of these current transformer secondary windings.
Section 7.
FINAL CHECKS
The tests are now complete. Remove all test or temporary shorting leads, etc. If it has been necessary to disconnect any of the external wiring from the relay in order to perform the wiring verification tests, it should be ensured that all connections are replaced in accordance with the relevant external connection or scheme diagram. If a MMLG test block is installed, remove the MMLB01 test plug and replace the MMLG cover so that the protection is restored to service. Ensure that all event records, fault records, disturbance records, alarms and LEDs have been reset before leaving the relay. Replace the cover on the relay.
Section 8.
PROBLEM SOLVING
BEFORE CARRYING OUT ANY WORK ON THE EQUIPMENT, THE USER SHOULD BE FAMILIAR WITH THE SAFETY SECTION AND CHAPTER 2, HANDLING AND INSTALLATION, OF THIS MANUAL.
8.1
Protection settings Settings for high sets not displayed Note there is only one setting group in these relays. Set cell [0601 PF Links] link 1 to 1 to turn on >> settings. Set cell [0501 EF Links] link 1 to 1 to turn on o>>settings.
8.2
Alarms If the watchdog relay operates, first check that the relay is energised from the auxiliary supply. If it is, then try to determine the cause of the problem by examining the alarm flags in cell [0022 Alarms]. This will not be possible if the display is not responding to key presses. Having attempted to determine the cause of the alarm it may be possible to return the relay to an operable state by resetting it. To do this, remove the auxiliary power supply from the relay for approximately 10 seconds before re-establishing the supply. If the relay is powered from the CT circuit as well, remove this source of supply as well, possibly by withdrawing the module from its case. Note: The circuit breaker trip coils may trip if an AC series trip relay, KCGG 341, is withdrawn from its case. The trip coils should be disabled if required. The relay should return to an operating state. Recheck the alarm status in cell [0022 Alarms] if the alarm LED is still indicating an alarm state. The following notes will give further guidance:
8.2.1
Watchdog alarm Auxiliary powered relays: the watchdog relay will pick up when the relay is operational to indicate a healthy state, with its normally open contact closed. When an alarm condition that requires some action to be taken is detected, the watchdog relay resets and its normally closed contact will close to give an alarm. Note: The green LED will usually follow the operation of the watchdog relay. Dual powered relays: the watchdog relay operates in a slightly different way on this version of the relay, because it does not initiate an alarm for loss of the auxiliary power supply. This is because the auxiliary power supply may be taken from an insecure source or the relay may be powered solely from the current circuit. Operation of the watchdog is therefore inverted so that it will pick-up for a failed condition, closing its make contact to give an alarm and in the normal condition it will remain dropped-off with its break contact closed to indicate that it is in a healthy state. Note: The green LED will usually operate in the opposite way to the watchdog relay (ie. the LED will be on when the watchdog relay is de-energised and vice versa).
There is no shorting contact across the case terminals connected to the break contact of the watchdog relay. Therefore, the indication for a failed/healthy relay will be cancelled when the relay is removed from its case. If the relay is still functioning, the actual problem causing the alarm can be found from the alarm records in the cell [0022 Alarms] (see Chapter 3, Section 3.5). 8.2.2 Cell [0022 Alarms] link 0 = 1 For an Uncfg configuration alarm, the protection is stopped and no longer performing its intended function as there will be an error in the factory configuration settings. To return the relay to a serviceable state, the initial factory configuration will have to be reloaded and the relay re-calibrated. It is recommended that the work be carried out at the factory, or entrusted to an approved service centre. 8.2.3 Cell [0022 Alarms] link 1 = 1 For an Uncalib calibration alarm, the protection will still be operational but there will be an error in its calibration that will require attention. It may be left running provided the error does not cause any problems with incorrect tripping. To return the relay to a serviceable state, the initial factory configuration will have to be reloaded and the relay re-calibrated. It is recommended that the work be carried out at the factory, or entrusted to an approved service centre. 8.2.4 Cell [0022 Alarms] link 2 = 1 A Setting alarm indicates that the area of non-volatile memory where the selected protection settings are stored has been corrupted. The current settings should be checked against those applied at the commissioning stage or any later changes that have been made. If a personal computer (PC) is used during commissioning then it is recommended that the final settings applied to the relay are copied to a floppy disk with the serial number of the relay used as the file name. The settings can then be readily loaded back into the relay if necessary, or to a replacement relay. 8.2.5 Cell [0022 Alarms] link 3 = 1 The No Service alarm flag can only be observed when the relay is in the calibration or configuration mode when the protection program will be stopped. 8.2.6 Cell [0022 Alarms] link 4 = 1 The No Samples alarm flag indicates that there is no output from the analogue to digital convertor, although the relay will remain in service. If this flag should be set to 1, please contact the factory or an approved service centre for advice. 8.2.7 Cell [0022 Alarms] link 5 = 1 The No Fourier alarm flag indicates that the Fourier analysis algorithm is no longer running. If this flag should be set to 1, please contact the factory or an approved service centre for advice. 8.2.8 Fault flags will not reset These flags can only be reset when the flags Fn are being displayed or by resetting the fault records (cell [0110 Clear=0]). For more details refer to Chapter 3, Section 4.4.
8.3 8.3.1
Records Problems with event records Fault records will only be generated if RLY3 is operated because this relay is the trigger to store the records. Fault records can be generated in response to another protection operating if one of its trip contacts is used to operate RLY3 via an opto-isolated input on the K relay. This will result in the fault values, as measured by the K relay, being stored at the instant RLY3 resets. The flag display (cell [0102 Fn G1]) will include a flag to identify the auxiliary input that initiated the record. Fault currents recorded are lower than actual values, as the fault is interrupted before measurement is completed. Few fault records can be stored when many changes in the state of logic inputs and relay outputs are stored in the event records. The event records are erased if the auxiliary supply to the relay is lost for a period exceeding the hold-up time of the internal power supply. Events can only be read via the serial communication port and not on the LCD. The oldest event is overwritten by the next event to be stored when the buffer becomes full. When a master station has successfully read a record, it usually clears it automatically. When all records have been read, the event bit in the status byte within the master station program is set to 0 to indicate that there are no longer any records to be retrieved.
8.3.2
Problems with disturbance records Only one record can be held in the buffer and the recorder must be reset before another record can be stored. The disturbance records are erased if the auxiliary supply to the relay is lost for a period exceeding the hold-up time of the internal power supply. Disturbance records can only be read via the serial communication port. It is not possible to display them on the LCD. The disturbance recorder is reset manually. When a master station has successfully read a record, it will clear the record automatically and the disturbance record bit in the status byte within the master station program will then be set to 0 to indicate that there is no longer a record to be retrieved.
8.4
Communications An address (cell [000B Rly Address]) cannot be allocated automatically unless the address is first manually set to 0. This can also be achieved by a global command including the serial number of the relay. The relay will not communicate replies if the relay address is set to 255, the global address for which no replies are permitted.
8.4.1
Measured values do not change Values in the MEASUREMENTS (1) columns are snap-shots of the values at the time they were requested. To obtain a value that varies with the measured quantity, it should be added to the poll list as described in the user manual for the access software being used.
8.4.2
Relay no longer responding Check if other relays that are further along the bus are responding. If this is the case, the relays communication processor should be reset by removing the auxiliary supply from the relay for at least 10 seconds before re-energising it. This should not be necessary as the reset operation occurs automatically when the relay detects a loss of communication. If relays further along the bus are not communicating, check to find out which are responding to the master station. If some are responding, the position of the break in the bus can be determined by deduction. If none is responding, check for data on the bus or reset the communication port driving the bus with requests. Check there are not two relays with the same address (cell [000B Rly Address]) on the bus.
8.5
Thermal state Thermal ammeter time constants The setting for the time constant (cell [0814 TC]) is shared between the thermal ammeter and the thermal protection. Priority would normally be given to the thermal protection.
Section 9.
9.1
MAINTENANCE
Maintenance period It is recommended that products supplied by ALSTOM T&D Protection & Control Ltd receive regular monitoring after installation. As with all products some deterioration with time is inevitable. In view of the critical nature of many of these products and in the case of protective relays, their infrequent operation, it is desirable to confirm that they are operating properly at regular intervals. The typical life of these products is about 20 years, although many are in satisfactory service considerably longer than this. Maintenance periods will depend on many factors, such as: the operating environment the accessibility of the site the amount of available manpower the importance of the installation in the power system the consequences of failure If a Preventative Maintenance Policy exists within the customers organisation then the recommended product checks should be included in the regular programme. It should be noted that K Range Midos relays are self-supervising and so require less maintenance than earlier designs of relay. Most problems will result in an alarm so that remedial action can be taken. However, some periodic tests could be done to ensure that the relay is functioning correctly and the external wiring is intact. The following sections suggest checks that can be performed either remotely over the communications link using a PC running appropriate software or at site.
9.2
Maintenance checks BEFORE CARRYING OUT ANY WORK ON THE EQUIPMENT, THE USER SHOULD BE FAMILIAR WITH THE SAFETY SECTION AND CHAPTER 2, HANDLING AND INSTALLATION, OF THIS MANUAL.
9.2.1
Remote testing If the relay can be communicated with from a remote point, via its serial port, then some checks can be carried out without actually visiting the site.
9.2.1.1 Alarms The alarm status should first be checked to identify if any alarm conditions exist. The alarm records (cell [0022 Alarms]) can then be read to identify the nature of any alarm that may exist. 9.2.1.2 Measurement accuracy The values measured by the relay can be compared with known system values to check that they are in the approximate range that is expected. If they are, then the analogue/digital conversion and calculations are being performed correctly. 9.2.1.3 Trip test The relay provides phase overcurrent protection and the load current can be read on each phase in the MEASURE 1 column. Reduce the stage 1 phase fault setting (cell [0605 >]) to a known value that is less than the load current. The relay should trip in the appropriate time for the given multiple of setting current and time multiplier setting (cell [0606 t>/TMS]). The settings can then be returned to their usual value and the relay will reset but note the circuit breaker can not be re-closed from the output relays of the KCGG 141, 241, 341. If a failure to trip occurs, view cell [0021 Rly Status] whilst the test is repeated. This will check that the output relay is being commanded to operate. 9.2.2 Local testing When testing locally, similar checks to those for remote testing may be carried out to ensure the relay is functioning correctly. 9.2.2.1 Alarms The alarm status LED should first be checked to identify if any alarm conditions exist. The alarm records (cell [0022 Alarms]) can then be read to identify the nature of any alarm that may exist. 9.2.2.2 Measurement accuracy The values measured by the relay can be checked against known values injected into the relay via the test block, if fitted, or injected directly into the relay terminals. Suitable test methods will be found in Sections 4.2.9 and 4.2.10 of this chapter which deal with commissioning. These tests will prove the calibration accuracy is being maintained. 9.2.2.3 Trip test The relays provide phase overcurrent protection, the main trip relay should be tested by reducing the stage 1 phase fault setting (cell [0605 >]) to a known value that is less than the load current. The relay should trip within the appropriate time for the given multiple of setting current and time multiplier setting (cell [0606 t>/TMS]). The settings can then be returned to their usual value and the circuit breaker re-closed.
9.3
Method of repair BEFORE CARRYING OUT ANY WORK ON THE EQUIPMENT, THE USER SHOULD BE FAMILIAR WITH THE SAFETY SECTION AND CHAPTER 2, HANDLING AND INSTALLATION, OF THIS MANUAL. THIS SHOULD ENSURE THAT NO DAMAGE IS CAUSED BY INCORRECT HANDLING OF THE ELECTRONIC COMPONENTS.
9.3.1
Replacing a PCB Re-calibration is not usually required when a PCB is replaced unless it happens to be one of the two boards that plugs directly on to the left hand terminal block as these directly affect the calibration.
9.3.1.1 Replacement of user interface Withdraw the module from its case. Remove the four screws that are placed one at each corner of the front plate. Remove the front plate. Lever the top edge of the user interface board forwards to unclip it from its mounting. Pull the PCB upwards to unplug it from the connector at its lower edge. Replace with a new interface board and re-assemble in the reverse order. 9.3.1.2 Replacement of main processor board This is the PCB at the extreme left of the module, when viewed from the front. To replace this board: First remove the screws holding the side screen in place. There are two screws through the top plate of the module and two more through the base plate. Remove screen to expose the PCB. Remove the two retaining screws, one at the top edge and the other directly below it on the lower edge of the PCB. Separate the PCB from the sockets at the front edge of the board. Note that they are a tight fit and will require levering apart, taking care to ease the connectors apart gradually so as not to crack the front pcb card. The connectors are designed for ease of assembly in manufacture and not for continual disassembly of the unit. Re-assemble in the reverse of the above sequence, making sure that the screen plate is replaced with all four screws securing it. 9.3.2 Replacing output relays The main processor board is removed and replaced as described in Section 9.3.1.2 above. It should be noted when replacing output relays that the PCBs have through plated holes. Care must therefore be taken not to damage these holes when a component is removed, otherwise solder may not flow through the hole to make a good connection to the tracks on the component side of the PCB.
9.3.3
Replacing the power supply board Remove the two screws securing the right hand terminal block to the top plate of the module. Remove the two screws securing the right hand terminal block to the bottom plate of the module. Remove the two screws securing the back plane. Unplug the back plane from the power supply board. Remove the securing screws at the top and bottom of the power supply board. Withdraw the power supply board from the rear, unplugging it from the front bus. Re-assemble in the reverse order of the above sequence.
9.3.4
Replacing the back plane (size 4 and 8 cases) Remove the two screws securing the right hand terminal block to the top plate of the module. Remove the two screws securing the right hand terminal block to the bottom plate of the module. Remove the two screws securing the back plane. Unplug the back plane from the power supply board. Twist outwards and around to the side of the module. Replace the PCB and terminal block assembly. Re-assemble in the reverse order of the above sequence.
9.4
Recalibration Recalibration is not usually required when a PCB is replaced unless it happens to be the processor board that plugs directly on to the left hand terminal block as this one directly affects the calibration. Although it is possible to carry out recalibration on site, this requires test equipment with suitable accuracy and a special calibration program to run on a PC. It is therefore recommended that the work is carried out at the factory, or entrusted to an approved service centre. After calibration, the relay will need to have all the settings required for the application re-entered if a replacement board has been fitted. Therefore, it is useful if a copy of the settings is available on floppy disk. Although this is not essential, it can reduce the time taken to re-enter the settings and hence the time the protection is out of service.
Appendix 1 Relay Characteristic Curves
R8557B Appendix 1 Contents
1. 2. 3. Figure 1: Figure 2: Figure 3: Figure 4:
TIME/CURRENT CHARACTERISTICS RELAY CHARACTERISTIC CURVES THERMAL TIME/CHARACTERISTIC WITH PREFAULT LOAD Operating times KCGG I>> and Io>> IDMT curves: IEC and special application curves IDMT curves: ANSI/IEEE curves Thermal time/current characteristic with prefault load
1 2 4 1 2 3 4
R8557B Appendix 1 Page 1 of 4
Section 1.
TIME/CURRENT CHARACTERISTICS
150 135 120 Operating time 105 90 75 60 45 30 15 0 1 10 Multiple of setting (xs) 100 Maximum Minimum
Figure 1: Operating times KCGG I>> and Io>>
Section 2.
RELAY CHARACTERISTIC CURVES
10000
Rectifier curve 1000
Operating time (seconds)
100
10
LTI 30xDT
SI 30xDT 1 EI 10xDT VI 30xDT STI 30xDT
0.1 1 LTI 30xDT SI 30xDT* EI 10xDT* VI 30xDT* STI 30xDT Long time inverse Standard inverse Extremely inverse Very inverse Shot time inverse All characteristics are definite time above 30x except extremely inverse. 10 Multiples of setting 100
*IEC standard characteristic
Figure 2:
IDMT curves: IEC and special application curves
10000
1000
Operating time (seconds)
100
10
MI 1 VI
EI
0.1 1 10 Multiples of setting MI VI EI Moderately inverse Very inverse Extremely inverse 100
All characteristics are definite time above 30x except extremely inverse.
Figure 3:
IDMT curves: ANSI/IEEE curves
Section 3.
THERMAL TIME/CHARACTERISTIC WITH PREFAULT LOAD
10.000
1.000
Time (x t)
0.100
No pre-fault load Pre-fault load at 50% thermal state 0.010 Pre-fault load at 70% thermal state Pre-fault load at 90% thermal state
0.001 1 2 3 Current (xlth>) 4 5 6
Figure 4: Thermal time/current characteristic with prefault load
Appendix 2 Logic Diagrams
Figure 1: Figure 2:
Scheme logic diagram KCGG 141, 241 Scheme logic diagram KCGG 341
1 2
0A01 Blk to> 7 6 5 4 3 2 1 0 o>
&
to>
0B03 to> 7 6 5 4 3 2 1 0 0B01 o> Start 7 6 5 4 3 2 1 0
Stage 1 earth fault Start earth fault Stage 2 earth fault
EF1
0
1
0A02 Blk to>> 7 6 5 4 3 2 1 0 o>>
&
to>>
0B04 to>> 7 6 5 4 3 2 1 0
0A04 Blk t> 7 6 5 4 3 2 1 0 >
&
t>
0B08 tA> 7 6 5 4 3 2 1 0 0B09 tB> 7 6 5 4 3 2 1 0 0B0A tC> 7 6 5 4 3 2 1 0 0B06 > Start 7 6 5 4 3 2 1 0
Stage 1 overcurrent
>1 = 0A05 Blk t>> 7 6 5 4 3 2 1 0 >> 0A09 EXT. TRIGGER 7 6 5 4 3 2 1 0 RLY3 Latch red trip LED PF0
0
1
Start overcurrent
PF1
0
1
&
t>>
>1 =
0B0B t>> 7 6 5 4 3 2 1 0
Stage 2 overcurrent
Latch flags Generate fault record Copy to event records
Thermal trip >1 =
0B18 th Trip 7 6 5 4 3 2 1 0
EF1 F E D C B A 9 8 7 6 5 4 3 2 1 0
PF1 F E D C B A 9 8 7 6 5 4 3 2 1 0
Figure 1: Scheme logic diagram KCGG 141, 241
0A01 Blk to> 7 6 5 4 3 2 1 0 o> 0A02 Blk to>> 7 6 5 4 3 2 1 0 o>>
&
to>
0B03 to> 7 6 5 4 3 2 1 0
Stage 1 earth fault
EF1
0
1
&
to>>
0B04 to>> 7 6 5 4 3 2 1 0
Stage 2 earth fault
0A04 Blk t> 7 6 5 4 3 2 1 0 >
&
t>
0B08 tA> 7 6 5 4 3 2 1 0 0B09 tB> 7 6 5 4 3 2 1 0 0B0A tC> 7 6 5 4 3 2 1 0
Stage 1 overcurrent
PF1
0
1
0A05 Blk t>> 7 6 5 4 3 2 1 0 >> 0A09 EXT. TRIGGER 7 6 5 4 3 2 1 0 RLY3
&
t>>
>1 =
0B0B t>> 7 6 5 4 3 2 1 0
Stage 2 overcurrent
Latch flags Generate fault record Copy to event records Latch red trip LED
0A0A Aux1 7 6 5 4 3 2 1 0
tAux1
0B10 Aux1 7 6 5 4 3 2 1 0
Time delay for series trip
PF0
0
1
>1 = Thermal trip
0B18 th Trip 7 6 5 4 3 2 1 0
EF1 F E D C B A 9 8 7 6 5 4 3 2 1 0
PF1 F E D C B A 9 8 7 6 5 4 3 2 1 0
Figure 2:
Scheme logic diagram KCGG 341
Appendix 3 Connection Diagrams
Figure 1: Figure 2: Figure 3:
Typical application diagram KCGG 141 Typical application diagram KCGG 241 Typical application diagram KCGG 341
1 2 3
A P2 P1
4 WD 6 3 WD 21 30 RL0 32 34 RL1 24 25 38 RL2 40 42 RL3 44 26 27 28 36 22 23 5 13
A S2
14
S1 Relay failed RL0 Start (I>/Io>) RL1 Phase fault (t>/t>>/th TRIP) RL2 Earth fault (to>/to>>) RL3 Trip (to>/to>>/t>/t>>/th TRIP)
B C
AC/DC supply Vx Relay healthy
Phase rotation
Case earth
1 3
KCGG 141
Block to>/t>
L0 L1 L2 52 50 1 48 46
5 7 9
4 6 8 10
13
14
29 31 33 35 37 39 41
30 32 34 36 38 40 42
Block to>>/t>> External trigger Logic input common
17 19 21
18
20 22
23
24
43 45 47 49 51
44 46 48 50 52
25
26
53
54
Case earth connection

54
27
28
55
56
SCN
56
K-Bus communications port SCN

7 8
Module terminal blocks viewed from rear (with integral case earth strap)
Notes: 1 (a)
CT shorting links make before (b) and (c) disconnect. (b) Short terminals break before (c) (c) Long terminals Pin terminal (PCB type) (d) 2 CT connections are typical only. 3 Earth connections are typical only.
+48V field voltage
Figure 1:
Typical application diagram KCGG 141
A P1
Series Reg
A
WD 6 3 WD 5 30 RL0 32
P2 Relay failed Relay healthy RL0 Start (I>/Io) RL1 Phase fault (t>/t>>/th TRIP) RL2 Earth fault (to>/to>>) RL3 Trip (to>/to>>/t>/t>>/th TRIP) S1
14 9 10 21 34 RL1 36 38 RL2 40 42 RL3 44 24 25 26 27 28 22 23
13
S2 Supply to trip coil
AC/DC supply Vx
B C
Phase rotation
Case earth
1 3 5 7 9
4 6 8 10
29 31 33
13
14
35 37 39 41
30 32 34 36 38 40 42
17 19 21
18 20 22
23
24
43 45 47 49 51
44 46 48 50 52
KCGG 241
25
26
53
54 1
27
28
55
56
SCN Case earth connection Block to>/t>

L0 L1 L2 52 50 48 46 54
Module terminal blocks viewed from rear (with integral case earth strap) Block to>>/t>> External trigger Logic input common
Notes: 1 (a)
56

7 8
+48V field voltage
Figure 2:
A P1
WD 6 3 WD 5 30 RL0 32 34 RL1 36 38 RL2 40 42 RL3 44 24 25 TC TC 28 26 27 22 23 13
Series Reg
A S1 Supply to trip aux

9 10 14
P2 Relay failed Relay healthy RL0 Auxiliary timer 1 RL1 Phase fault (t>/t>>/thtrip) RL2 Earth fault (to>/to>>) RL3 Any Trip (to>/to>>/t>/t>>/thtrip)
S2
AC/DC supply Vx
B C
Phase rotation
21 TC
Case earth
1 3 5 7 9
4 6 8 10
Trip auxiliary
18
17
13
14
29 31 33 35 37 39 41
30 32 34 36 38 40 42
KCGG 341
1
17 19 21
18 20 22
23
24
43 45 47 49 51
44 46 48 50 52
Case earth connection

54
25
26
53
54
27
28 L0 46 48 50 52 L1 L2
55
56
Initiate auxiliary timer 1 Block to>/to>>/t>/t>> External trigger Logic input common
SCN
56

7 8
Module terminal blocks viewed from rear (with integral case earth strap)
Notes: 1 (a)
+48V field voltage
TC = ac series trip coil.
Figure 3:
Appendix 4 Commissioning Test Record
1 2
COMMISSIONING TEST RECORD SETTING RECORD REPAIR FORM
1 5 7
Section 1.
COMMISSIONING TEST RECORD
Date Station Circuit System Frequency
Front plate information Multifunctional overcurrent relay type Model number Serial number Auxiliary Voltage Vx Rated Current In KCGG________
*Delete as appropriate 4 4.1 4.1.1 Product checks With the relay de-energised Visual inspection Module and case damaged? Model numbers on case and front plate match? Serial numbers on case and front plate match? Rating information correct for installation? All current transformer shorting switches closed? Case earth installed? 4.1.2 4.1.3 Insulation resistance correct? External wiring Wiring checked against diagram? Test block connections checked? Yes/No* Yes/No/na* Yes/No* Yes/No* Yes/No* Yes/No* Yes/No* Yes/No* Yes/No/Not Tested*
4.1.4
Watchdog contacts With auxiliary supply off Terminals 3 and 5 Terminals 4 and 6 Open/Closed* Open/Closed* ______V ac/dc*
4.1.5 4.2 4.2.1
Auxiliary supply With the relay energised Watchdog contacts With auxiliary supply on Terminals 3 and 5 Terminals 4 and 6
Open/Closed* Open/Closed*
4.2.2
Light emitting diodes Relay healthy (green) LED working? Alarm (yellow) LED working? Trip (red) LED working? Yes/No* Yes/No* Yes/No*
4.2.3
Liquid crystal display All pixels working? Backlight switches on and off? Yes/No* Yes/No*
4.2.4
Field supply voltage Relay energised from auxiliary supply Relay energised from line current transformers (KCGG 241 and KCGG 341 only) ______V dc ______V dc/na*
4.2.5
Capacitor trip voltage Relay energised from auxiliary supply Relay energised from line current transformers (KCGG 241 and KCGG 341 only) ______V dc ______V dc/na*
4.2.6
Input opto-isolators Input L0 working? Input L1 working? Input L2 working? Yes/No* Yes/No* Yes/No*
4.2.7
Output relays Output RL0 working? Output RL1 working? Output RL2 working? Output RL3 working? Yes/No* Yes/No* Yes/No* Yes/No* Yes/No/na*
4.2.8 4.2.9
K-Bus communications working? Current inputs CT ratio (phase currents) CT ratio (Zero sequence current) Input CT Applied value _______A/na* _______A/na* _______A/na* _______A/na*
_______:1A _______:1A/na* Relay value _______A _______A _______A _______A
Ia Ib Ic Io
5 5.1 Setting checks Customers settings applied?
Yes/No* ____________________ Yes/No* Yes/No* t>/to> _________A _________s _________s
If settings applied using a portable computer and software, which software and version was used? 5.2 5.3 Settings on relay verified? Protection function timing tested? Function tested Applied current Expected nominal operating time Actual operating time 6 On-load checks Test wiring removed? Disturbed customer wiring re-checked? On-load test performed?
Yes/No/na* Yes/No/na* Yes/No*
CT wiring checked? CT ratio (Phase currents) CT ratio (Earth fault currents) Currents: Applied value _______A/na* _______A/na* _______A/na* _______A/na*
Yes/No/na* ____:1A/na* ____:1A/na* Relay value _______A _______A _______A _______A
Ia Ib Ic Io
7 Final checks Test wiring removed?
Yes/No/na* Yes/No/na* Yes/No* Yes/No* Yes/No* Yes/No* Yes/No*
Disturbed customer wiring re-checked? Event records reset? Fault records reset? Disturbance records reset Alarms reset? LEDs reset?
Commissioning Engineer
Customer Witness
Date
Date
Section 2.
Date Station Circuit
SETTING RECORD
Engineer Date System Frequency
Front plate information Multifunctional overcurrent relay type Model number Serial number Auxiliary Voltage Vx Rated Current In KCGG________
0000 0003 0005 0006 0008 0009 000A 000B 0011
SYSTEM DATA SD Links Plant Model Serial No. Frequency Comms Level Rly Address Software Ref.
D C B
A 9 8 7 6 5 4 3 2 1 0 0 0 0 0 0 0 0
0 0 0 0
0 0
0500 0501 0502 0504 0505 0506 0507 0508 0509 050A 0600 0601 0602 0604 0605 0606 0607 0608 0609 060A 0613 0614
EARTH FLT 1 EF Links CT Ratio Curve
F E D C 0 0 0 0
A 9 8 0
7 6 5 4 3
2 1 0 0
0 0
0 0 0 0 0 0 0
Io>
to/TMS to/DT toRESET
Io>>
to>> PHASE FLT 1 PF Links CT Ratio Curve F E D C B A 9 8 7 6 5 4 0 0 3 2 1 0
0 0 0 0
0 0 0
0 0 0 0 0
I>
t/TMS t/DT tRESET
I>>
t>>
Ith> Trip
TC
0C00 0C01 0C02 0C03
RECORDER Control Capture Post Trigger
E D C
B A 9
8 7 6 5 4 3 2
1 0
REPAIR FORM
Please complete this form and return it to ALSTOM T&D Protection & Control Limited with the equipment to be repaired. This form may also be used in the case of application queries.
ALSTOM T&D Protection & Control Ltd St. Leonards Works Stafford ST17 4LX, England For: After Sales Service Department ________________________ Model No: Serial No: __________________ __________________
Customer Ref:
ALSTOM Contract Ref: ________________________ Date: 1. ________________________
What parameters were in use at the time the fault occurred? AC volts DC volts AC current Frequency _____________ Power supply _____________ Battery/Power supply _____________ Main CT/Test set _____________
2. 3. 4.
Which type of test was being used? ____________________________________________ Were all the external components fitted where required? (Delete as appropriate.) List the relay settings being used ____________________________________________________________________________ ____________________________________________________________________________ ____________________________________________________________________________ Yes/No
5.
What did you expect to happen? ____________________________________________________________________________ ____________________________________________________________________________ ____________________________________________________________________________ ____________________________________________________________________________
continued overleaf
6.
What did happen? ____________________________________________________________________________ ____________________________________________________________________________ ____________________________________________________________________________ ____________________________________________________________________________
7.
When did the fault occur? Instant Time delayed By how long? Yes/No Yes/No ___________ Intermittent Yes/No
(Delete as appropriate).
8.
What indications if any did the relay show? ____________________________________________________________________________ ____________________________________________________________________________ ____________________________________________________________________________
9.
Was there any visual damage? ____________________________________________________________________________ ____________________________________________________________________________ ____________________________________________________________________________
10. Any other remarks which may be useful: ____________________________________________________________________________ ____________________________________________________________________________ ____________________________________________________________________________
______________________________________ Signature ______________________________________ Name (in capitals)
_______________________________________ Title _______________________________________ Company name
A L S T O M T & D P r o t e c t i o n & C o n t r o l L t d St Leonards Works, Stafford, ST17 4LX England Tel: 44 (0) 1785 223251 Fax: 44 (0) 1785 212232 Email: pcs.enquiries@tde.alstom.com Internet: www.alstom.com
1999 ALSTOM T&D Protection & Control Ltd Our policy is one of continuous product development and the right is reserved to supply equipment which may vary from that described.
Publication R8557B
Printed in England.

R8557B KCGG

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Service Manual Types KCGG 141, 241, 341 Overcurrent Relays

Service Manual Types KCGG 141, 241, 341 Overcurrent Relays

HANDLING OF ELECTRONIC EQUIPMENT

Caution: refer to product documentation

Caution: risk of electric shock

Protective/safety *earth terminal

Installing, Commissioning and Servicing

Decommissioning and Disposal

SERVICE MANUAL KCGG 141, 241, 341

Types KCGG 141, 241, 341 Overcurrent Relays Service Manual

SERVICE MANUAL KCGG 141, 241, 341

R8557B Chapter 1 Contents

1. 2. 2.1 2.2 2.3 2.4 2.4.1 2.5

SERVICE MANUAL KCGG141, 241, 341

R8557B Volume 1 Chapter 1 Page 1 of 3

USING THE MANUAL

SERVICE MANUAL KCGG141, 241, 341

R8557B Volume 1 Chapter 1 Page 2 of 3

SERVICE MANUAL KCGG141, 241, 341

R8557B Volume 1 Chapter 1 Page 3 of 3

Features available by model

Types KCGG 141, 241, 341 Overcurrent Relays Service Manual

Chapter 2 Handling and Installation

SERVICE MANUAL KCGG 141, 241, 341

R8557B Chapter 2 Contents

SERVICE MANUAL KCGG141, 241, 341

R8557B Volume 1 Chapter 2 Page 1 of 3

HANDLING OF ELECTRONIC EQUIPMENT

SERVICE MANUAL KCGG141, 241, 341

R8557B Volume 1 Chapter 2 Page 2 of 3

SERVICE MANUAL KCGG141, 241, 341

R8557B Volume 1 Chapter 2 Page 3 of 3

Types KCGG 141, 241, 341 Overcurrent Relays Service Manual

Chapter 3 Relay Description

SERVICE MANUAL KCGG 141, 241, 341

R8557B Chapter 3 Contents

SERVICE MANUAL KCGG 141, 241, 341

R8557B Chapter 3 Contents

SERVICE MANUAL KCGG 141, 241, 341

R8557B Volume 1 Chapter 3 Page 1 of 23

SERVICE MANUAL KCGG 141, 241, 341

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Figure 1. Front plate layout

SERVICE MANUAL KCGG 141, 241, 341

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R8557B Volume 1 Chapter 3 Page 4 of 23

SETTING GROUP FAULT No

SERVICE MANUAL KCGG 141, 241, 341

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Figure 3. Menu format

SERVICE MANUAL KCGG 141, 241, 341

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SERVICE MANUAL KCGG 141, 241, 341

R8557B Volume 1 Chapter 3 Page 7 of 23

SERVICE MANUAL KCGG 141, 241, 341

Status READ READ READ READ READ READ READ RESET

SERVICE MANUAL KCGG 141, 241, 341

SERVICE MANUAL KCGG 141, 241, 341

R8557B Volume 1 Chapter 3 Page 10 of 23

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R8557B Volume 1 Chapter 3 Page 11 of 23

SERVICE MANUAL KCGG 141, 241, 341