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DCRM Workshop PGCI Bhiwadi

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SCOPE

Welcomes all of you to Workshop on


Dynamic Contact Resistance
Measurement………..at
POWERGRID BHIWADI SUBSTATION

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We at SCOPE ...
Enjoy designing test equipment for
demanding applications...
Tricky measurements in tough
environments are our prime
motivators.

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The SCOPE range covers...
Indigenous Testing Instruments
 Circuit Breaker Timers and Analyzers
 Contact Resistance Meter
 Transformer Winding Resistance Meter
International Representations
 Fully automatic Relay Testing Kit
 Thermo vision Camera
 Capacitance and Tan Delta
 Insulation and Earth Resistance Meters

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SCOPE Range …

 Automated testing systems for OEMs

 Now Testing and Commissioning also in


the name of “ Isosceles”

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The Company

 Operational since 1988


 Dedicated to the innovative use of
electronics for test and measurement
 Has own R & D, Manufacturing,
Marketing and Customer Service
 Nationwide spread of customers

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Objectives….

 To study the dynamic performance testing of


CBs.
 To study the usage of instruments for above
purpose.
 To master the practical techniques to carry out
correct measurement under site conditions.
 To enable usage of this data for future reference.

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The way we proceed...
 DCRM … the concept
 Equipment introduction
 Making connections
 Power on
 Settings
 Testing
 Troubleshooting
 Dos and Don’ts
 Field Testing Of Circuit Breakers
 Analysis of Graphs

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DCRM….Definition

Dynamic Contact Resistance Measurement


is a signature of change in contact
resistance of CB during operation.

It plots the variation in contact resistance while first, the


arcing, and then the main contacts engage and

disengage during C-O operation.

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Why DCRM…

Reflects useful information on Contact


conditions
Gives prior indication of deterioration
Operating mechanism linkages
Certain mechanical weaknesses,
undetected by travel measurement,
are reflected in DCRM measurement.

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What is DCRM ?
…. Concept and it’s importance

Static Contact Resistance Dynamic Contact Resistance


measurement : measurement :

1. The CB is in closed condition. 1. The CB undergoes CO operation.


2. Current is injected in CB 2. The current is injected in CB contacts
contacts and millivolt drop is and continuous samples of millivolt
measured only at once. drop are taken.
3. The contact resistance value 3. Thus contact resistance variation of
reflects the contact resistance at both main & arcing contacts is
that particular contact condition measured on time scale.
only.

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The Static contact Resistance
measurement

CB Interrupter

Voltage Pickups

Current Injection
Millivolt R=V/I
Trolley
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A Look at Contact Assembly…
Incoming
Outgoing
Flange
Flange

Main
Contact, Main
Moving Contact,
Fixed
Arcing Fixed
Arcing
Moving Contact, contact
contact,
contact Moving Holder
Fixed
Holder

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Lets see an actual operation

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Moving Contact

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Fixed Contact

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Dynamic Resistance
Measurement…

CB in Motion..!!
Voltage Pickups
Current Injection

Dynamic Resistance Oscilloscope


meter

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CB Contacts during Make and Break …

Contact
Resistance
Event

Main
Arcing
Contact
Contact

Break
Make

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Typical graph of DCRM…

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Typical graph of DCRM… Tripping portion
zoomed

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A Look at Practical resistance
values…

Our Observations in last 5 years

Main contacts: 40 to 80 micro-ohms


Arcing contacts: 125 to 600 micro-ohms
Flange to flange joints: 100 to 1000 micro-ohms

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What is DCRM ?
…. Concept and it’s importance
Why 100 Amp DC?
Main contact composition.
Arcing contact composition.
Function of arcing tip.
Effect of fault tripping.
Co-relation of DCRM curve
with travel curve.
x
Assessment of arcing tip length.
Scheduling of PMI.

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Equipment used...

CB

DCRM
PC
HISAC 2406
PRINTER

HISAC
MB 3.0

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Equipment used...
C.B. Operational Analyser : HISAC 2406

What does it measure ?

 Operation times of 12 main & 12 PIR contacts simultaneously.


 Bounces / Chattering during operation.
 Coil current characteristics.
 Auxiliary contact status.
 Contact / mechanism travel / velocity.
 Overshoot / rebound of contact.
 Wipe of contacts.
 and now… Dynamic contact resistance.

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Equipment used...
C.B. Operational Analyser : HISAC 2406

DCRM demands…

 Travel channel of Analyser should be optimized to do


sensitive measurement of variable voltages from 20 mV
to 5 V without adding it’s own off-set or non-linearity.
 The time resolution of 100 µSec. in order to record small
variation in contact resistance.

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Equipment used ...

New up-gradation in HISAC 2406


 Precision amplifiers in voltage input circuitry in place of
present ones.
 Higher sampling speed - 10 kC in place of present 5 kC on
all channels doubling the time resolution.
 Change of associated hardware for operation at higher
speed.
 Loading of new software.
 Enhancement in accuracy & noise performance.

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Equipment used ...
Dynamic Contact Resistance Meter : DCRM 100 B

Four Wire Measurement Method

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Equipment used ...
Dynamic Contact Resistance Meter : DCRM 100 B

It injects 100 A DC in
breaker contacts and
measures the millivolt
drop generated
across contacts
dynamically. It relays
it to travel channel of
HISAC 2406.

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Equipment used ...
Dynamic Contact Resistance Meter : DCRM 100 B

 Advantages over earlier versions of DCRM …


 Increased current injection duration.
 Fine variation in resistance is accurately reflected.
 Low Cost battery.
 R=V/I. Calibration in resistance units.
 Up gradable for future needs.
 Manual supervision is not required.
 The dynamic current can also be measured.
 MCB protection.
 Disadvantages:
 Periodic charging is required for battery.
 Battery needs replacement after approximately 1000 operations.

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Equipment used ...
Transducers and Fixtures

SCOPE has developed Transducers with Fixtures for following


CBs:

 LTF 150 B : For BHEL make 400 kV SF6 CB.


 245KV MOCB, HLR 2502E– BHEL Make
 TLH 150 + Fixture : For TELK make 400 kV SF6 CB.
 TLH 300 + Fixture : For AEG - NGEF 220 kV/ 400 kV SF6 CB.
 LTF 250 C : For CGL make 132 kV/220 kV/400 kV SF6 CB.
 LTF 280 A : For ABB make 220 kV/400 kV SF6 CB (old) .
 LTF 280 A : For ABB make 400 kV SF6 CB (new) .
 NRTF 360 M: For M&G make 400 kV SF6 CB.
 245KV SF6 FXD-14F ALSTOM Make
 420KV SF6 FXD-16&16D ALSTOM Make

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Equipment used ...
Transducers and Fixtures

CB Travel

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Equipment used ...
Transducers and Fixtures

What is most critical ? Important things to


observe
 Proper mounting of fixture.
 Proper position & alignment.  Shocks
 Proper making of variable contact.  Overshoot margin.
 Set up procedure on instrument.
 Rebound margin.
 Care in handling.

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Equipment used ...
Memory Bank : HISAC MB 3.0

Stores the data received from HISAC 2406.


Downloads the same to IBM compatible PC by
using CPLOT 7.01 ( or higher versions ) software.

Features:
 Portable, palm size data bank.
 Operates on 4 No. AA size alkaline cells.

 Interactive menu on 2 line LCD.


 Switchyard compatible.

Built-in battery backed up NV RAM. Storage of results for


years
Reusable memory, can be overwritten.
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Equipment used ...
Memory Bank : HISAC MB 3.0

BENEFITS :
 No longer necessary to carry expensive Laptop in
the field
 Uses easily available 4 x AA size Alkaline
Batteries
 Printouts can be taken latter
 Holds up to 2MB data
 Facilitates transportation of data from site to PC
for further analysis and storage.

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Equipment used ...
PC downloading and analysing software: CPLOT 7.01

 Can be loaded on any IBM compatible Minimum System


Pentium PC or laptop. Configuration
 Can receive data from HISAC 2406 or
 IBM compatible 166 MHz Pentium PC
HISAC MB 3.0.
 Can receive CB data or DCRM data.
 SVGA display adapter with 1 MB RAM
 Can perform all standard calculations & SVGA Colour Monitor with 800 X 600
simply by moving cursors. pixel resolution
 Printouts can be taken on any printer  32 MB RAM, 2 Serial Ports, 1 Parallel
having driver preloaded. Port, 1.44 MB FDD
 Possible to store data on hard disk or
floppy disk.  Windows 95 and MS Office 97 with
 Possible to load data from HDD/FDD Excel & Word installed
 Comparison with historic records  Needs to be installed properly.

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Equipment used ...
PC downloading and analysing software: CPLOT 7.0

BENEFITS :

 Simultaneous analysis of :
 Contact Timings
 Coil Current
 Contact / Mechanism Travel & Velocity between selected points of
travel
 Dynamic Contact Resistance
 View Header, Graph & Footer
 Calculate parameters simply by positioning cursors
 Selectively Enable /disable channels.
 ZOOM a particular portion of a record.
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Equipment used ...
PC downloading and analysing software: CPLOT 7.0

BENEFITS…

 Prints in B/W or in Colour


 Excellent viewing of graphical data
 Neat and clean housekeeping of data
 Easy access to huge data
 Comparison with historical performance and trend
prediction
 Facility of putting values for limit check
 Link to MIS

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Equipment used ...
PC downloading and analysing software: CPLOT 7.0

Now CPLOT 7.0 with net connectivity


 Can easily transmit the data from
 Substations to RHQ
 RHQ to Corporate

over e-mail
• Automatic sorting and storage of files in
logically defined directory structure

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Making connections …
Pre-testing arrangement
Confirm availability of following:
Tool Kit : Breaker Drawing

Millimeter Spare fuses.


Cutter/ Striper/ Pliers/ Suitable table
. Screw driver/ File Distribution box - single phase AC
Spanner set/ Allen key Earthing rods
Insulation Tape/ Polish
Ladder
paper/ Duster cloth.
Safety belt
Looping wire.
Proper stationary

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Making connections ...
HISAC 2406 to CB

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Making connections ...
HISAC 2406 to CB
 Earth CB from both sides.
 Connect master earth of HISAC to earth.
 Connect contact sensing cables to CB, after
cleaning the connection area.
 Make Close/ Trip coil connections to Breaker
Control terminal and Current channels. Ensure
proper polarity.
 Check continuity of transducer element before
connection.

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Making connections ...
HISAC 2406 to CB
 Mount transducer along with fixture. Ensure proper
alignment & firmness of fixture, proper positioning &
contact pressure of moving wiper, tidiness of
connecting wire.
 Keep sufficient margin for overshoot & rebound travel
of CB contact.
 Ensure firmness of TDX connections from TDX to
terminal box and from there to travel channel of
HISAC.
 Remove earthing from both sides of CB.
 Connect AC supply to HISAC.

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Making connections...
DCRM 100 B to CB

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Making connections...
DCRM 100 B to CB
 Earth CB from both sides.
 Connect Master earth terminal of DCRM to earth.
 Check continuity of C+, C-, V+ & V- end to end. Ensure that there is
no continuity of any of above cables with earth terminal of DCRM.
 Connect C+, C-, V+ & V- cables at DCRM end.
 Connect ‘Ck’ clamps on two sides of main contact interrupter as near
to interrupter as possible. Clean the point of connection before this.
 Keep CB in open condition. Now check & ensure the continuity
between C+ & V+ and C- & V-.

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Making connections ...
Contd...

 Connect DCRM resistance output (VAR & 0 V) terminals to


TY channel of HISAC.
 Connect DCRM current output (VAR & 0 V) terminals to TB
channel of HISAC.
 Remove earthing from both sides of CB.
 Keep MCB ‘OFF’
 Connect AC supply to DCRM 100 B.

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Making connections …
Memory Bank : HISAC MB 3.0 to HISAC 2406

Power Connect RS 232 output


P r in t e r P o w e r
port connections of
HISAC 2406 to RS 232
RNXS
TT EC
R RX
T
O NREAOPTIG FMEINST ORYBANUCTI KS

RS PRN
232C D a ta

R e f e r t o in s t r u c t io n m a n u a l b e f o re t e s t in g .
RST NXT REC TRX
port of HISAC MB 3.0.
V e r if y t w ic e t h e f i rm n e s s o f e a r t h in g c o n n e c t io n s . S ELECT A B C D E F G H I
W h e n H IS A C is n o t in u s e f o r a p r o lo n g e d p e r io d , k e e p it
p o w e re d u p f o r 2 4 h o u rs , a t le a s t o n c e a m o n t h .

A B R E A K E R S TA T U S O P E R A T IN G IN S T R U C T IO N S
O N R E AR O F M EM O R Y BAN K
TE S T O P TIO N S

O C CO OC O CO

B D IS P L AY R E S U L T S

Mc T im Ve l
M AX TIM IN G S V E L O C IT Y
CU RR EN TS

C P R IN T R E S U L T S

R G C T V
TO M O VE R EP OR T G RAP H CUR R ENT T IM IN G S V EL O CITY
C URSO R
D U S E R D AT A E N T R Y
TO S E LE C T
ENT O P T IO N
E T E S T S E T T IN G S
P R E V IO U S
ESC MENU
F C U R R EN T S E TTIN G S
O P E N IN G
RST MENU
G T R A V E L S E T T IN G S

H D O W N LO AD TO P C

I S P E C IA L F U N C T IO N S

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Power ‘ON’ the instruments
… and ensure the following.
HISAC 2406:
 Opening selection menu should appear on LCD.
 5 V is appearing between +5 V & 0 V terminals of all travel
channels.
 CB operates after giving command from HISAC.
 After operation of CB proper voltage variation is observed between
VAR & 0 V terminals of travel channel to which TDX is connected.
 Higher voltage should be observed when CB is closed & lower
voltage should be observed when CB is open.
 Proper contact sensing connections by checking contact ON/ OFF
status on LCD.

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Power ‘ON’ the instruments
… and ensure the following.
DCRM 100 B:
 Keep CHARGE/TEST toggle switch in CHARGE mode. Ensure that
battery is charged.
 Put back toggle switch to TEST mode.
 Keep CAL/TEST toggle switch in CAL mode. Check that voltages
across resistance & current outputs of DCRM going to TY & TB
channels of HISAC are more than 4.63 V when CB is in open
condition and test leads are connected.
 Put back toggle switch in TEST mode.

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Power ‘ON’ the instruments
… and ensure the following.
HISAC MB 3.0 :
 After a string of messages display settles down to RECORD
STATUS RECORD NO. 1 EMPTY / FULL
 Before the data transfer from HISAC, the selected location No. on
LCD of HISAC MB 3.0 should not be FULL. If so, go to next
available location.
 If FULL location is selected, the data will be overwritten after
giving suitable warning message.
 Ensure that BATTERY LOW indication is not persistent from more
than one hour. If so immediately replace the batteries.

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HISAC 2406x Opening Menu

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Settings of the instruments...
HISAC 2406
For DCRM
TEST SETTINGS AND USER DATA ENTRY
 By using ‘D’ menu - Enter all historical data.
 By using ‘E’ menu - Select appropriate sampling speed. 10 KC
 Select appropriate time delays ‘tco’ 300 mS &’ toc’.
 Select trigger level ‘ 0’.
 Select appropriate plot length,400 mS
 Enable/Disable ‘Resistor’ (PIR) option depending on CB configuration.

 By using ‘F’ menu - Select appropriate current range on current channels to be used.
 By using ‘G’ menu - Enable Velocity.
 Enter actual mechanism travel or use AUTOPLACE option for finding out travel.
 Enter points P1 & P2 and P3 & P4 for obtaining closing & tripping velocities
respectively.

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Settings of the instruments...
HISAC 2406

TRAVEL SETTINGS If Not used Auto place


 Keep both MIN & MAX pots in fully anti-clockwise direction for all travel channels.
 Keep CB in closed condition.
 After entering the travel and points P1 to P4 for the respective channel to which TDX
is connected AMPLITUDE option will appear.
 When CB is in closed condition set MAX amplitude pot to show count 225 on LCD.
 Take Open operation on CB.
 Set count on LCD to 25 by using MIN amplitude pot without disturbing the MAX pot.
 Two to three such operations may be required to set MIN & MAX counts to steady
values i.e. when CB is closed count should be 225 and when CB is open count
should be 25.

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Settings of the instruments...

DCRM SETTINGS
 DCRM resistance output is to be connected to TY
channel of HISAC.
 DCRM ( for DCRM 100B only ) current output is
to be connected to TB channel of HISAC.
 Go to ‘G’ menu of HISAC. DO NOT enter any
travel in TY or TB channels; and go directly to
AMPLITUDE option.

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Settings of the instruments...

DCRM SETTINGS
 Keep CAL/TEST toggle switch in CAL position.
 By using MAX pot set the count on TY channel to
236. Keep the MIN pot in fully anticlockwise
direction ALWAYS.
 In case of DCRM 100B, by using MAX pot set the
count on TB channel to 236. Keep the MIN pot in
fully anticlockwise direction ALWAYS.
 Keep toggle switch in TEST mode.
 Make MCB ‘ON’.

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And Finally ….

Take operation on CB.

View important test results on display.

Take the printout.

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Troubleshooting ...
OBSERVATION PROBABLE CAUSE

Breaker does not Fuses F2/F3 may be blown.


operate BREAKER CONTROL improperly connected.

Contact connections are loose. Improper place of


connections.
No contact timings, No PIR may be disabled.
PIR timings.

Contact connections may be loose. They may


make/break due to vibrations during breaker
Excessive bounce operation.

No coil current trace. Check polarity of current channel connections.

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Troubleshooting …
Contd...
OBSERVATION PROBABLE CAUSE
No current trace. Range selected is ‘0’.

Spikes on current Connections in current circuit are loose.


channel Auxiliary contacts need to be cleaned.

Velocity may be disabled.


No travel trace
Check firmness of connections and polarity at
TDX and at travel inputs.
Check that HISAC delivers 5 V DC across 0V & 5V
terminals of travel channel as well as at TDX
interface.
TDX element is damaged.

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Troubleshooting ...
contd...
OBSERVATION PROBABLE CAUSE

Travel trace full of spikes and / Check travel TDX and it’s mounting.
or irregularities

Velocity and travel Check value of mechanism travel keyed in with


calculations inaccurate respect to actual travel.
Travel trace has spikes or is irregular.
Datum points selected are too close to the end
position of travel or are too close to each other.
Amplitude pot settings are disturbed.

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Troubleshooting ...
Contd...
OBSERVATION PROBABLE CAUSE

No continuity between C+ & V+ and C- & V- cables


No DCRM trace after connections to CB when it is in open condition.
The voltage across resistance output of DCRM is
less than 4.63 V when CB is in open condition.
One of C+, C-, V+or V- has continuity with earth
terminal.

‘Ck’ clamps are not making proper contact with CB


for some reason, e.g. paint, rust at the point of
connection.

DCRM trace shows only


a straight line at upper
level.

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Troubleshooting ...
Contd...
OBSERVATION PROBABLE CAUSE
1. Resistance between C+ & C- is more than
1. DCRM trace shows only 2000 micro ohms due to improper selection
a straight line at upper of connection points.
level.
2. 2.CB is earthed from either one or both
2. DCRM trace touches sides.
base line. MIN pot of TY channel is not in fully
anticlockwise direction.
3. Excessive spikes at the 3. ‘Ck’ clamp connections are not firm. Loose
beginning of DCRM
connections may make/break due to
trace
vibrations during breaker operation.

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Troubleshooting ...
Contd...
OBSERVATION PROBABLE CAUSE
1. Excessive spikes at 1. Excessive chattering of CB contacts.
the beginning of Pitting of CB contacts.
DCRM trace

2. Either the CB has remained in closed


condition or it is earthed from C+ side.
2. MCB on DCRM 100 B
trips.
3. MB 3.0 is not in RECEIVE mode.
3. Data not uploaded The serial link from HISAC to MB 3.0 is
from HISAC to MB 3.0 not proper.
Battery Low for MB 3.0.

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Troubleshooting ...
Contd...

OBSERVATION PROBABLE CAUSE

 PC not in RECEIVE mode


Data not downloaded
 MB 3.0 not in TRX mode
from MB 3.0 to PC.
 Selected location is empty
 Serial link from MB 3.0 to PC is not proper
 Serial port of PC is not in working
condition.
 Battery Low for MB 3.0

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DOs and DON’Ts
…. Remember !

The DOs :
 Clean the area of connection.
 Ensure firmness of connections.
 Observe proper polarity on current channel.
 Main body, and not only pointed edge; of wiper should slide on the
element of TDX.
 Proper alignment of TDX & firmness of fixture.
 Margin for overshoot & rebound of contact on TDX.
 Correct polarity of connections from TDX to terminal box & from there
to HISAC.
 Remove earthing from both sides CB before operation .

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DOs and DON’Ts
…. Remember !

The DOs :
 Ensure CB is open before taking CO operation for DCRM signature.
 Ensure READY LED on DCRM 100 is glowing before taking operation.
 Ensure that DCRM 100B’s battery is charged and MCB is ON
before taking DCRM signature.
 Switch OFF MCB of DCRM 100B after taking DCRM signature.
 Ensure proper polarity of C+, C- and V+, V- connections.
 Ensure MIN pots of TY & TB are kept fully anticlockwise.

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DOs and DON’Ts
…. Remember !

The DOs :
 Mark points of connections for repeatability in future.
 Power up all instruments for 24 hours, at least once in a month.
 Avoid severe vibrations to the instruments.
 Keep printer away from dust.
 Ensure that the location selected on MB 3.0 for data storage is empty.
 Ensure that location selected on MB 3.0 contains data while downloading to
PC.
 Switch OFF MB 3.0 immediately after use.

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DOs and DON’Ts
…. Remember !

The DON’Ts :
 Do not tighten the ‘Ck’ clamps excessively as it may deform the shape &
affect the measurement.
 Do not enter any travel for TY & TB channels while used with DCRM.
 Do not power ‘ON’ DCRM , if CB is close & ’Ck’ clamps are connected.
 Do not add oil /grease of any make to the threads of ‘Ck’ clamp, as it will
affect the measurement.
 Do not connect the contact sensing cables to the pole on which
DCRM signature is being taken.
 Do not try to open the instrument.

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PC downloading and analysing
software : CPLOT 7.0

MINIMUM SYSTEM CONFIGURATION


Hardware :
 Pentium 166 MHz and above
 SVGA adapter with 1 MB RAM
 SVGA Colour Monitor 600x800 pixel resolution
 HDD with minimum 5 MB free space
 32 MB RAM
 2 Serial & 1 Parallel Port (for printing)
 1 Floppy disk Drive - 1.44 MB
 Any Printer with its driver installed

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PC downloading and analysing
software : CPLOT

MINIMUM SYSTEM CONFIGURATION

Software :

 Operating System Windows 95

 MS Office-97 with WORD & EXCEL installed

 Authorized copy of CPLOT 7.0

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Installing CPLOT
 Close all your programs and applications that are open
& running.
 Insert CPLOT CD in CD drive
 Select ‘Start’\ ‘Run’ and type D:\setup.exe. Press ‘OK’.
( If your CD drive is different replace ‘D’ suitably )
 Follow on-screen instructions to install CPLOT 6.0.
 CPLOT 6.0 will be added to your programs.

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Running CPLOT

 Select ‘Start’\ ‘Programs’\’CPLOT Graphical Analysis


Software’\’CPLOT
 Click to run the program.
 Opening screen will appear with icon of a arrow mark at bottom right
corner of your desktop.
 Click arrow icon to enter into program.
 Now you can run CPLOT

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Downloading test results from
HISAC MB 3.0 to PC

 Connect RS 232 output port of MB 3.0 to RS 232 serial port ( COM 1 or


COM 2 ) of PC.
 Power ON HISAC MB 3.0.
 Select RECEIVE option of CPLOT 6.0 on PC.
 Select the record to be downloaded on MB 3.0.
 Press ‘TRX’ key of MB 3.0.
 The data will be downloaded to PC and appropriate message will be
displayed on PC.

Simple Solution for Difficult


THANK YOU !

Thanks you all very much for being a part


of Workshop on Dynamic Contact
Resistance Measurement.

Simple Solution for Difficult

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