OVERCURRENT RELAY TEST KIT

Type: SI-CV100

Operation Manual

SUDHARSAN INSULATIONS
91-92, Industrial Estate, Perungudi, Chennai - 600 096

Tel: 91-44-24961392 Telefax: 91-44-42123327

E-mail: si@sudharsaninsu.com sprajah@gmail.com
sudharsaninsulations@gmail.com
Web site: www.sudharsaninsu.com
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OPERATING INSTRUCTIONS
1. SI CV100 - has been designed generally for ON SITE TESTING of overcurrent relays and
specifically for Electromagnetic Inverse Type Overcurrent Relays (3 VA Burden) where a steady
and controlled alternating current of undistorted wave form is essential. The SI CV100 gives you
an added advantage by offering variable A.C and D.C Voltages as auxiliary outputs.

2. Features
Portable, yet sturdy design
Simultaneous availability of injection current and auxiliary A.C / D.C outputs
Overload Protection for the test kit with 10A MCB
Overload Protection for auxiliary outputs with 0.5Amp glass cartridge fuse
Digital Panel meters for Volts/Amps/Time
Undistorted sine wave injection current.
Front Panel equipment protected against mechanical damage with tamperproof lockable
cover
Extra feature to test the relays with NO and NC trip contacts.

Overall Dimensions: 500 X 450 X 325 mm approx.

Weight of the Unit: 35 Kg. Approx.

3. Specification
Rated Input: 220 250 V, 50Hz, 10 Amps
Outputs
I. AC Injection current Isolated from Mains 60/90 Secs. Rating.
Continuously adjustable from 0.01 100 Amps on 3 VA burden relays.
II Auxiliary outputs Continuously rated and non-isolated from mains
0 250 V, 0.75 Amps AC
0 300 V, 0.50 Amps DC

4. General
If the test voltage is applied directly to the relay coil, due to magnetic saturation, the non linear
characteristics of Inverse Time Electromagnetic Overcurrent Relays cause undesirable waveform
distortions and harmonics in the test currents. Calibration of any protective relay has to be done
under standard reference conditions i.e., pure sinusoidal input test current.

Test kit SI CV100 gives an undistorted sine wave form for the entire range of current outputs
with the least power dissipation. This offers the utmost reliability for periodic checking/calibrations
of any type of overcurrent relays.

5. Construction
Test Kit SI CV100 has a powder coated mild steel enclosure with an easy accessibility for all
components for effortless and easy maintenance.
The detachable powder coated mild steel front panel cover protects all the front panel fittings and
meters while the kit is transported to the site.
The front panel is fitted with Digital Voltmeter, Ammeter, Timer, Variacs for current injection and
auxiliary outputs, heavy duty rotary switches for current selection and output terminal shorting,
push buttons for start, stop/reset, output terminals etc.
The main contactor, current control choke, injection transformer, a multi range CT etc are mounted
inside. The trip control circuit with 18 V DC relay is fitted as a detachable module assembly. A pair
of foldable metal lifting handles is provided for easy handling. The 3 core input mains chord and
spare 1A fuses are kept inside the detachable cover of the front panel
For better thermal rating of the equipment, it is recommended that the kit be used with the front
panel in vertical position.
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6. Operation
th
Refer the circuit diagrams SI CV100 / Rev 5 dated 30 Sept 2003 / Sheets 01 and 02
Detach the front panel cover from the kit and check the following initial conditions.
10 Amp MCB is in off state.
Both variacs are in 0 position.
Auxiliary A.C / D.C main switch SW-1 is in off position.
To Relay coil output terminals are shorted by external leads.
Rotary Switch RS-1- in any selected position.
Rotary Switch RS-2 (shorting switch) in short position
Toggle switch SW3 of relay trip contact selector in NO or NC mode

Plug in the 3 wire mains chord into the test kit socket and the mains socket.
Caution 1 : Ensure the mains supply is 220 V, 50 Hz A.C from a 3 pin socket outlet with its
earth pit effectively grounded.

By Switching on the MCB of the Test Kit, the digital panel meters display is illuminated. Now the
equipment is ready for either for current injection or auxiliary AC/DC output or both.

6.1. Auxiliary AC/DC outputs

6.1.1. Auxiliary AC output
Switch on SW1 the illuminated rocker switch located below the AC/DC voltmeter. Variac TR1 is
connected to the mains through 0.75/1.0A glass cartridge fuse. This delivers the continuously
variable AC voltage at AC Volt terminals. The voltage across AC Volt terminals is indicated by
the digital voltmeter by selecting the meters selector switch SW2 to AC measurement. This AC
output is continuously rated for 0.75 Amps.

6.1.2. Auxiliary DC Output

A diode bridge rectifies the AC output from Variac TR1 and the DC output is made available at
DC Voltage output terminals. DC output is continuously variable from 0 300 VDC with 0.5 amp
continuous rating. The same digital voltmeter is used to read the DC output by selecting the meter
selector switch SW2 to DC position. The DC output available at DC terminals is not ripple
smoothened DC.

For the DC output with ripple smoothened to about 5%, it is recommended to use AC to DC
converter module available with us as an add-on accessory at a nominal cost. This handy module
consists of input AC and output DC terminals, input AC fuse/Input neon lamp/ output DC selector
switch for 100V or 250VDC, but with no built-in DC voltmeter and variac. For load current within
0.5 amps DC, this AC to DC converter module can be fed from auxiliary AC output terminals of
the test kit SI-CV100. However the output DC is to be measured with a separate DC voltmeter
only.

Caution 2: Though AC and DC voltages are both simultaneously available at auxiliary

output terminals, only one of them should be used at a time.

Switch off the illuminated rocker switch SW1 when the auxiliary AC/DC outputs are no longer
required.

6.2. Current Injection

Ensure the following:
MCB is in ON position and digital meters display illuminated.
Current injection variacTR2 is in 0 position.
The external short at To relay coil is removed.
Over current relay under test is connected.
N.O contacts of the relay under test is connected to Relay contact terminals of the test kit
Select the appropriate test current among the six available test currents (2/5/10/20/50/100
Amps) using the rotary switch RS1.
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Rotary switch RS2 (shorting switch) is set at short position. This switch enables the
preliminary current setting to be obtained without overheating the relay coil or causing its
operation unnecessarily.

6.2.1. Procedure

Current is injected by pressing start push button PB1. Stop/Reset push button PB2 stops the
current injection. Both these push buttons are at the bottom of the front panel.

Pressing the start push button, contactor K gets energized and held on. Neon lamp L2 glows
indicating the current injection is initiated.

Variac VR2 gets the power through contactor K. Adjusting the variac VR2, variable supply is
applied to the primary of injection transformer TR3 which is in effect an impedance matching unit.

The isolated secondary of TR3 is tapped for different current ratios and can be selected by means
of current range selector rotary switch RS1.

A multi range current transformer (for measurement) of appropriate current ratios is provided at the
secondary side of the injection transformer and is automatically selected by RS1 while choosing
the current range.

Current output is read as the reading indicated by 1Amp digital AC ammeter multiplied by the
current multiplier selected with selector switch RS1

Selecting the current with the rotary selector switch RS1 while RS2 is in short position and
pressing the start push button PB1 initiates the current injection.

Adjust the variac TR2 to the desired test current.

(Actual output current = Meter reading x current range selector switch setting)

Note that the relay under test will not receive the injection current since the output terminals are
shorted internally by the shorting switch RS2.

Set the shorting switch RS2 to open position. Current is then injected into the relay under test. In
the event of any marginal current dip, due to the test relay coil impedance, variac TR2 is adjusted
to correct the current dip.

The open position of RS2 also initiates the time interval meter. The eventual closing of N.O
contact of the relay under test will instantly interrupt the flow of test current to the relay and
simultaneously stops the timer.

Timer display indicates the time duration from the instant of current injection to the tripping of the
relay under test. Timer display can be reset to zero by pressing the reset button on the timer. Neon
indication for the current injection also turns off while tripping.

In the event of tripping during the current injection, the test can be repeated only after pressing the
stop/reset push button PB2.

Caution 3 : The test kit is designed for short time rating of 60 Sec of current injection. It is
necessary to give sufficient cooling period between two injections for longer life of the test
equipment.
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PORTABLE OVERCURRENT RELAY TEST KIT

Type SI CV100

Serial No: ...../.....

Customer: .................................................................................

.................................................................................

.................................................................................

Purchase Order: .................................................dated.....................

PART MAKE Sl. No.

Injection Transformer Sudharsan

Current Limit Choke Sudharsan

Current Transformer Sudharsan

Control Circuit Transformer Sudharsan

Variac 4 Amps AE

Variac 0.75 Amps AE

Rotary Switches Kaycee

AC/DC Voltmeter Meco

AC Ammeter Meco

Timer Sudharsan/PLA

Front panel lock Godrej/

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TEST REPORT
PORTABLE OVERCURRENT RELAY TEST KIT
Type SI CV100 Serial No: ...../.....

1. Insulation Resistance: (with 1000 V meggar)

All input and output terminals to earth ....................Megohms.

2. Auxiliary Outputs:

AC Output DC Output

Test Kit Avo meter Test Kit Avo meter

Reading Reading Reading Reading

50 V ............V 50 V ............V
100 V ............V 100 V ............V
150 V ............V 150 V ............V
200 V ............V 200 V ............V
250 V ............V 250 V ............V
300 V ............V 300 V ............V

3. Over current Tests

(With Alstoms CDG11 Overcurrent Relay Rating 2.5 to 10 Amps)

a. Plug setting: 2.5 Amps, TMS 1.0

Injection Current Trip time

Times current setting Amps As per graph Actual time

X2 5.0 A 10.0 Sec .............

X3 7.5 A 6.4 Sec .............
X5 12.5 A 4.4 Sec .............
X7 17.5 A 3.6 Sec .............
X10 25.0 A 3.0 Sec .............

b. Plug setting changed to 5 Amps, repeated the above tests and confirmed the timings as
per the graph.

(Sudharsan Insulations) (Customer)

Date: ..................................
 MCB-1 3C 3E
TR-2
3Y K 4 CH 6
3 VARIAC 5 32
L TR-3 2A
3L2 4T2 D 5A 2
RS-1 To O/C relay
3H
3Z P1 RS-2
10A COIL
20A B2
230 V AC E RS-2
50A
0C 0E A
P2 31
100A
0A 0B 0H 0Z 0Y K 2T1
N 1T1 10 10

100A

2A
L2 COM 30
K
PB-1 START RL-1
E SW-1 12 TR-4
CT
14 11 PB-2
8 7
L1 F1-1A STOP/
TR-1 RESET 33 34
15 A
RL-2
1 amp 0E/3E Mains
6 26
21 TR-5 3C
0 0 1
AC o/p Rect-II
DPM 22
0-250V 24A 24 23
16 16
SW-3 4
RL-1
To relay 10 9
C1
Volt meter

2
Yellow 54 Contact 28 27
0C
~
AC/DC

18 20
18 RL-2 RL-1
DC+ Red 55 +
25
Grey 53 5 25 LEGEND
Ext.Short Grey 52 DC o/p
0-300V PB-1 Push Button (Start)
Black Rect-1
17 RS-2 PB-2 Push Button (Stop/Reset)
Com 17 1 A1
m. 51 AC K Main contactor
DC - 40 CLOSE TO
START RL-2 18 / 12 V DC relay 2C/O
TIMER RL-1 18 / 12 V DC relay 2C/O
0E 3E 5L3 41 OPEN TO Rect-1 18V Bridge Rectifier
K STOP Rect-2 300V Bridge Rectifier
6T3
LEGEND V AC/DC Digital Voltmeter
42
A 1A, AC Digital Ammeter
T Digital Timer
MCB-1 Double pole, 10 A MCB F1 Glass Fuse 1A
Sw-1/L1 Rocker switch (illuminated) 230 v/3A 230 V AC
SW-2 AC/DC Meter Selector switch 3 pole, 2way 0E / 3E
SW-3 2 Pole, 2 way No off (NO / NC relay contact selector)
RS-1 Rotary switch 25A, 2 pole 6 way, injection current selector
RS-2 Rotary switch 40A, 2 pole 2 way, Shorting Switch
TR-1 Variac 0.75A
TR-2 Variac 4A (for 100A unit)
SUDHARSAN INSULATIONS , CHENNAI - 96
TR-3 Injection Transformer
TR-4 Measuring C.T.
TR-5 Trip control circuit Transformer 230 / 18 /12V RELAY TEST KIT - CV-100
L1 Rocker switch lamp Schematic Diagram
L2 Current injection ON

DATE : Jan 2008 Sheet 1 of 2

 PCB -1 300V DC Rectifier Circuit PCB
TR-5 20 ~ ~
Rect -1
20
22 0 16
18
+

C1 RL1 RL2
21

18K/6W
10mfd
25 450v

-
17

RL2 RL1

20 RL1

0C 3C 23 25 26 10 12 27 28

1 2 4 5 6 7 8 9 10 11 12

230 v AC TO PB To Relay To Toggle

STOP/RESET Contact Sw-3
Contactor K To Toggle
Holding CKT. Sw-3
TRIP CONTROL CIRCUIT MODULE

MOLEX CONNECTORS LAYOUT ON TRIP CONTROL PCB

8 pin molex
2 pin molex
10 9 8 7 6 5 4 3

O O OO OO OO OO OO O O X O
O O
Y O SUDHARSAN INSULATIONS , CHENNAI - 96

RELAY TEST KIT - CV-100

28 27 12 10 26 25 23
21 20 Trip Module Circuit

DATE : Jan 2008 Sheet 2 of 2

To Sy.18V of PCB control Tr