CONTENTS

1. INTRODUCTION

2. GENERAL DESCRIPTION

3. SPECIFICATION

4. COMMISIONING

4.1 GENERAL INSPECTION

4.2 WIRING CHECK

4.3 INSULATION TEST

4.4 CURRENT TRANSFORMER CHECKS

4.5 SECONDARY INJECTION TESTS

4.6 TRIP AND ALARM CIRCUITS CHECK

4.7 PRIMARY FAULT SETTING STABILITY TESTS

4.8 LOAD TESTS

5. CURRENT TRANSFORMERS REQUIRMENTS

6. SETTING CALCULATIONS

7. ANNUAL TESTING

8. ILLUSTRATIONS

8.1 COMMISSIONING TESTS SCHEDULE

8.2 CT POLARITY CHECK

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8.3 PRIMARY INJECTION TEST SET

8.4 CT RATIO CHECK

8.5 CONNECTIONS FOR TESTING THE RELAYS

8.6 PRIMARY FAULT SETTING TEST

8.7 STABILITY TEST

1. INTRODUCTION

This manual covers the commissioning and maintenance instructions for static modular
high impedance Differential relay Type FAC.

The working principle of this relay is based on high impedance protection which is
unaffected by the harmonics as the relay is tuned to 50HZ.

Type FAC relays are recommended for balanced and restricted earth fault, phase
and earth fault and certain forms of differential protection of generators, reactors,
Bus-bars and motors. Types FAC14 and FAC34 are single and triple pole relays
respectively. A shunt connected “metrosil” unit is supplied which will limit the peak
voltage under fault conditions to approximately 900 volts

2. DESCRIPTION:

A number of “metrosil” resistors connected in series with the unit-

operating coil varies the relay setting and is determined by a seven-way plug
setting bridge. The non-linear characteristic of these resistor results in short
relay-operating times when the voltage setting is exceed.

A capacitor is connected in series with the operating coil to make the relay
insensitive to the d.c component of fault current. The setting voltage can thus be calculated
in terms of r.m.s alternating quantities without regard to the degree of offset produced by
the point-on-wave at which the fault occurs

An external nonlinear device, Metrosil is connected across the relay phase to neutral
terminals (i.e. across the differential pilots) to limit the peak voltages during internal faults.
Each phase is provided with an external Metrosil.

Operation
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The application diagram of the relay is shown in Figure B wherein the FAC relay is
connected to differential circuit of generator current transformers. During an external
fault, since the currents circulate among the CTs, no current flows through the relay. Also
the high impedance of the relay restricts the spill current, if any, flowing through it, making
the relay stable. The voltage setting of the relay is calculated to achieve throughfault
stability even with one CT completely saturated and the other healthy under the most
severe external fault condition. The voltage setting is expressed as follows.
25 to 175/50 to 350 volts adjustable in seven equal 25/50 volt steps. The required
voltage setting (Vs) of a type FAC relay is calculated by the

Vs = IF ( Rct + 2Rw) Volts

Following formula where

IF = Maximum through fault current for which stability is required (amps

r.m.s)

N = Current transformer turns ratio

Rct = Secondary resistance (ohms)

Rw = Total lead resistance between one C.T and relay

In practice, the setting Vs actual equal to or nearest above the calculated value of Vs is
selected for an internal fault, the current flows through the relay and the relay operates.
The operating current of the relay does not exceed 22 mA at any setting; hence the relay
maintains sensitivity for internal faults.

3. SPECIFICATION

TECHNICAL DATA

Setting Ranges : A)25-175 V

B)50-350V .
Contacts : Two normally open, self reset contacts
for each differential element. Operation
Indication : Flag indications are provided for each differential
element.
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4. COMMISSIONING:

The following tests are recommended for the initial commissioning of FAC Relay:
1) General inspection.
2) Wiring check.
3) Insulation tests.
4) Current Transformer checks.
5) Secondary injection tests.
6) Trip and alarm circuits check.
7) Primary fault setting and stability tests.
8) Load tests

A record of the Commissioning test results should be complied in accordance with the
specimen copy shown. By comparing the subsequent test results, the behaviour of relays
can be noted. During most of these tests auxiliary supplies are isolated, the trip intertrip
and alarm circuits isolating links etc. are removed. It should be ensured that secondary
winding of a current transformer is not open-circuited while current is flowing in the
primary. When making Secondary injection tests ensure that the circuit is earthed at only
one point.

4.1 General Inspection:

Wipe away any dust that has collected on the outside of the relay before opening the
cover. Make a general inspection of the relay to ensure that any moving parts if fitted are
free to move and that there are no signs of damage anywhere. Check that there are no
loose connections or terminals and that the equipment is clean and free from dust.

4.2 Wiring Check :

Make a through check of the internal and external wiring of the relay. The internal wiring
can be checked by reference to the relay-wiring diagram, which is supplied for each relay.
The external wiring should be checked with the help of schematic diagrams (Showing
reference number of interconnecting wires, relay terminal nos. etc.) supplied by the relay
panel manufacturers. Make ensure there should not be multiple earthing in CT circuits.

4.3 Insulation Test:

Insulation resistance tests at 1000v DC are to be carried out on all AC and DC circuits to
ensure that the wiring is in satisfactory condition. Tests should be carried out as follows.

1) Insulation resistance to earth of CT circuits.

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2) Insulation resistance to earth of DC circuits.

3) Insulation resistance between DC and CT circuits.
4) Insulation resistance between DC circuits.

When measuring the insulation resistance to earth an individual circuit, all the other
circuits should be normal e.g. earth links closed and DC circuit normal. This will ensure that
the insulation of this circuit is satisfactory, both to earth and to all other circuits.

The readings should be recorded and compared with readings obtained during subsequent
tests to check any deterioration of insulation.

4.4 Current Transformer Checks:

CT Checks:
Polarity and ratio checks on each current transformer are recommended.

Polarity Checks:
Each current transformer should be individually tested to verify the polarity markings on
the primary and secondary windings are correct. Figure-2 indicates the test circuit for this
test. The ammeter ‘A’ is a robust, moving coil, permanent magnet, centre zero type
instrument. A low voltage battery is used via a single pole push button to energise the
primary winding. On closing the push button, the Dc ammeter ‘A’ should indicate a positive
flick and on opening, a negative flick.

CT primary check can also be carried out by using primary injection test set mentioned
below:

Ratio Check:

This check is carried out during primary injection tests. The test apparatus normally
comprises a portable injection transformer arranged to operate from the local mains
supply and having several low voltage heavy current windings which may be connected in
series or parallel, depending on the current required and resistance of the primary circuit.
The injection transformer is usually of about 10KVA rating with a typical ratio of
250/10+10+10+10Volts. This permits current upto about 1000 amperes to be obtained
with the four secondary windings in parallel and upto about 250 amperes with the
windings in series. The injection transformer current can be controlled by a heavy current
(about 40 amperes). Variable auto-
transformer as shown in Fig-3. If the main current transformers are fitted with test
windings, these can be used in place of the primary windings for primary injection test. The
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current required for primary injection is the greatly reduced and can be obtained from less
cumbersome equipment. However, these test windings are not always provided on the
current transformers due to space limitation factor.

For carrying out the ratio check on current transformers, the test circuit shown in Fig-4 is
used. Current is passed through the primary conductors and measured on the test
ammeter A1. The current transformer secondary current is measured on ammeter A2 and
the ratio A1/A2 should approximate to the ratio marked on the current transformer name-
plate.

4.5 Secondary Injection Tets:

Set the relay for the required setting and connect a single phase variac across 9 and 10, (B-
Phase) as shown in Fig-5. Gradually increase the voltage and note the pickup value of the
relay. The value should be within +or- 10% of the setting. Reduce the voltage till relay
resets and note the reset value. Similarly, repeat the procedure for and 8 (Y-phase), 5 and
6 (R-Phase). Check the corresponding element operations and trip/Alarm contacts
operation.

4.6 Trip and Alarm Circuit Checks:

It is essential that on completion of the above tests, the tripping, intertripping and alarm
circuits are checked.

4.7 Primary Fault setting and Stability Test:

In practicable, by primary injection test set, primary fault settings of FAC relays can be
determined as shown in figure 6. While carrying out this test it is advisable to measure the
voltage across the relay coil and check the approximate voltage developed by the main
transformer to cause relay operation.
Sensitivity of the FAC scheme can also be checked by injecting current through the neutral
current transformer each phase current transformer as shown in figure 6.
Stability of the FAC163 scheme can also be checked by injecting current as shown
in figure 7.
4.8 Load Test:

After all the tests are complete, energise the protected apparatus and check that the
correct secondary currents are flowing. This can be done by using an ammeter connected
to a split-Plug or Tong testers. This test should be carried out on all the three phases of the
system so that, if the primary currents are balanced in all the three phases the secondary
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currents will also be balanced and this can be verified by measuring voltage across relay
terminals. When a differential protection earthfault protection is used, the relays should
have negligible current under healthy balanced load conditions and this can be verified by
inserting the Split-Plug or Tong Tester in the differential relay. If the current is zero or
negligible, the correctness of the residual differential circuit will be proved. If the AC
voltage across differential relay terminal; zero or negligible, to the correctness of the
differential circuit will be proves. The differential current 80mA at the maximum setting will
operate the relay. If there is a measurable voltage persists across the relay terminal, there
will be possibilities of

1) CT ratio mismatching.
2) CT reversal
3) Wrong sequence in one side.

5. CURRENT TRANSFORMER REQUIREMENTS

Relay Type = FAC34/14

Minimum knee point Voltage(V)=2If (Rs+Rp).
Maximum Exciting Current =Is-Ir/4 at V/2 Volts.

If = Equivalent Secondary pilot current of maximum through fault current.

Is = Effective fault setting expressed in secondary amperes.

Ir = Relay operating current.

Rs = Current transformer secondary winding resistance.

Rp = 2 X Maximum lead resistance between the relay circuit and any CT.

*** Stabilizing Resistor are built in the relay.

6. SETTING CALCULATIONs:

FAC34 used as a differential relay for 220KV has with maximum fault level=25KA;
CTR=2000/1.
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Maximum through fault current = 25KA(pri)

If = 12.5A (sec).
Rs = 5 Ohms.
Rp = 3 Ohms.

Voltage setting Vs = IF (Rs+Rp).

= 12.5(5+3).
= 100V.
Therefore setting of the relay = 100V.

7. ANNUAL TESTING

The following test should be carried out at least once a year.

1) A general check of connections and inspection of trip circuit fuselinks.
2) Carry out the insulation resistance test.
3) Operate the relays and see that trip circuit, inter-trip and alarm circuits are
energized and operation indication operate.
4) Check the pick-up value at the setting being used.

8. ILLUSTRATIONS

Figure 2 –Current transformer polarity check

Figure 3 – Primary injection test set
Figure 4 – Current transformer ratio check
Figure 5 – Injection test circuit for current operated relays
Figure 6 – Sensitivity check of restricted earth fault protection
Figure 7 – Stability check of restricted earth fault protection

8.1 COMMISSIONING TEST SCHEDULE FOR STATIC HIGH IMPEDANCE DIFFERENTIAL

TYPE FAC

LOCATION :

OWN ING AUTHORITY :

SYSTEM VOLTAGE :
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CIRCUIT DESIGNATION :

AUXILIARY SUPPLY VOLTAGE :

DATE OF TEST :

TESTED BY :

ACCEPTED BY :

1. Relay Details :

2. Current Transformer Details :

Phase Type & Serial CT Accuracy Rated Rated Accuracy

make No. Ratio class Burden Limit factor
Red

Yellow

Blue

Earthfault

3. General Inspection :

3.1 Wiring Check

Wiring checked to a. Wiring diagram No.

b. Schematic diagram No.

3.2 Current Transformer Checks

a. Polarity:
A B C N (if provided)

b. Ratio:
Phase Primary Secondary Measuring point & Remarks
Injected Current current phases measured
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A
B
C
N
(if provided)

c. Secondary Injection Tests:

Phase Setting Pick up voltage Drop off voltage
A
B
C
N

3.3 Trip and Alarm circuit checks

a. Alarms correctly initiated:

b. Correct circuit breaker tripped:

3.4 Primary fault setting and stability check

a. Primary current passed
Current through relay coil
Voltage across the relay
Coil and stability resistor
b. Check for the stability of protection:
A-N B-N C-N
Primary current passed:

Voltage across relay terminal:

3.5 Load Tests:
Load current
Equivalent CT secondary current:
Phase Measured Current
A

C
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Fig-B 111

Fig 2: Current Transformer Polarity Check

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Fig 3: Primary Inject Test Set

Fig 4: Current Transformer Ratio Check

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Fig 6: Sensitivity Check

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Fig 7: Stability Check