Busbar size and calculation

Busbar

Bus bar

A bus bar (also spelled busbar, buss bar or busbar), is a strip or bar of copper, brass or aluminum
that conducts electricity within a switchboard, distribution board, substation, battery bank or
other electrical apparatus. Its main purpose is to conduct electricity, not to function as a
structural member.
Busbars are typically either flat strips or hollow tubes as these shapes allow heat to dissipate
more efficiently due to their high surface area to cross-sectional area ratio. A hollow section has
higher stiffness than a solid rod of equivalent current-carrying capacity, which allows a greater
span between busbar supports in outdoor switch yards.
A busbar may either be supported on insulators, or else insulation may completely surround it.
Busbars are protected from accidental contact either by a metal earthed enclosure or by elevation
out of normal reach. Power Neutral busbars may also be insulated. Earth (safety grounding)
busbars are typically bare and bolted directly onto any metal chassis of their enclosure. Busbars
may be enclosed in a metal housing, in the form of bus duct or busway, segregated-phase bus, or
isolated-phase bus.
Busbars may be connected to each other and to electrical apparatus by bolted, clamp, or welded
connections. Often joints between high-current bus sections have matching surfaces that are
silver-plated to reduce the contact resistance. At extra-high voltages (more than 300 kV) in
outdoor buses, corona around the connections becomes a source of radio-frequency interference
and power loss, so connection fittings designed for these voltages are used.
Busbars are typically contained inside switchgear, panel boards, or busway. Distribution boards
split the electrical supply into separate circuits at one location. Busways, or bus ducts, are long
busbars with a protective cover. Rather than branching the main supply at one location, they
allow new circuits to branch off anywhere along the route of the busway.
Advantages
Following are some advantages of Bus bar trunking system over normal cabling system:-
1. On-site installation times are reduced compared to hard-wired systems, thus leading to cost
savings.
2. It provides increased flexibility in design and versatility with regard to future modifications.
3. Greater safety and peace of mind for specifiers, contractors and end-users.
4. Because of the simplicity of busbar, it is easy to estimate costs from the design/estimating stage
through to installation on site. This is because the technical characteristics and price of each
component are always known.
5. It is short sighted to compare the cost of busbar against that of a length of cable — and not the
real cost of a cable installation to include multiple runs of cable, tray and fixing, let alone the
protracted time and effort of pulling cables.
6. Distribution busbar distributes power along its length through tap-off points along the busbar at
typically at 0.5 or 1 m centers. Tap-off units are plugged in along the length of the busbar to
supply a load; this could be a sub distribution board or, in a factory, to individual machines. Tap-
offs can normally be added or removed with busbar live, eliminating production down time.
7. Installed vertically the same systems can be used for rising-mains applications, with tap-offs
feeding individual floors. Certified fire barriers are available at points where the busbar passes
through a floor slab. Protection devices such as fuses, switchfuses or circuit breakers are located
along the busbar run, reducing the need for large distribution boards and the large quantities of
distribution cables running to and from installed equipment.
8. Very compact so provides space savings.
9. Where aesthetics have to be considered, busbar trunking can be installed with natural
galvanized, aluminium, or painted finish. Special colours to match switchboards or a specific
colour scheme are also available on request.
10. Busbar trunking has several key advantages over conventional forms of power distribution
including: -
11. (a) Reduced, onsite installation times when compared to hard-wired systems thus leading to cost
savings.
a. Increased flexibility in design and versatility with regard to future modifications.
b. Increased safety features brought about by the use of high quality, manufactured components,
which provide greater safety and peace of mind for specifies, contractors and end-users.
12. Uneven distribution of current takes place where multiple runs of cables are used in parallel.
13. Busbar trunking has tap-off points at regular intervals along each length to allow power to be
taken off and distributed to where it is needed. Because it is fully self-contained it needs only to
be mechanically mounted and electrically connected to be operational.
14. For higher ratings of power distribution we need to have multiple runs of cable. In such
conditions unbalanced distribution of current takes place and causing overheating of some cable.
This is completely avoided in the BTS systems.
15. When multiple runs of cables are used it often leads to improper end connections thereby
causing overheating of contacts, burning of cables ends, and is a major cause of fire. This is
completely avoided in Bus Bar Trunking systems.
Current carrying capacity
The current-carrying capacity of a busbar is usually determined by the maximum temperature at
which the bar is permitted to operate, as defined by national and international standards such as
British Standard BS 159, American Standard ANSI C37.20, etc. These standards give maximum
temperature rises as well as maximum ambient temperatures.
BS 159 stipulates a maximum temperature rise of 50°C above a 24 hour mean ambient
temperature of up to 35°C, and a peak ambient temperature of 40°C.
ANSI C37.20 alternatively permits a temperature rise of 65°C above a maximum ambient of
40°C, provided that silver-plated (or acceptable alternative) bolted terminations are used. If not, a
temperature rise of 30°C is allowed.
A very approximate method of estimating the current carrying capacity of a copper busbar is to
assume a current density of 2 A/mm2 (1250 A/in2) in still air. This method should only be used
to estimate a likely size of busbar, the final size being chosen after consideration has been given
to the calculation methods. Refer catalogue of manufacturers.
The more popular thumb rule being followed in India is to assume current density of 1.0 Amps /
[Link] for Aluminium and 1.6 Amps for Copper for any standard rectangular conductor profile.
Standard size of bus bar
Sr. Application Cable busbar
area
1 Number of One circuit per floor. Just one circuit can cover all floors.
circuits Hence for a 20-floor
building, you need 20
circuits.
2 Main Need 1 outgoing for each Need only 1 outgoing for each riser.
Switchboard circuit. Hence 20 nos. Lower cost and size of main panel.
MCCB outgoings.
Higher cost and larger
space requirement in
electrical room
3 Shaft Size Using 4 core cables, and Typical size of 1600A riser is 185mm x
considering 1 cable per 180mm. Leads to big savings on riser
feeder, you need 20 shaft size, and hence more usable floor
cables on the lowest area on every floor.
floor. Large space
required for cables/ cable
tray.
4 Fire & safety The high concentration The volume of insulating materials used
of insulating materials in trunking is reduced to a minimum so
used in cables and combustive energy is considerably lower
conductors involves a than cables. The insulating materials used
very high level of do not release corrosive or toxic gases in
combustive energy. the event of a fire. Once the source of the
fire is removed, these materials are
extinguished in a few seconds so that the
effect of the fire is minimised
5 Future load on any floor exceeds By providing extra tap off slots on each
expansion initial plan, owner has to floor at the design stage, owner only has
run an additional cable to procure a tap off box and plug it in
from a spare feeder on wherever additional load is required. As
main board to that floor. the plug in can be done live, there is no
shut down required for any of the existing
 clients / circuits. Future Flexibility.
6 Fault Limited by conductor Much higher – typically a 1600 A riser
withstand size of each circuit. has a fault withstand capability of 60 to 70
levels kA. Safer in an electrical fault.
7 Installation Much longer Each riser on a 20-floor building can be
time installed in approximately 2 to 3 days.
8 Voltage drop High impedance if you Much lower impedance. Hence
choose cable size based substantially lower voltage drop.
on each floor current
rating.
Busbars Reduce System Costs
A laminated busbar will lower manufacturing costs by decreasing assembly time as well as
internal material handling costs. Various conductors are terminated at customer specified
locations to eliminate the guesswork usually associated with assembly operating procedures. A
reduced parts count will reduce ordering, material handling and inventory costs.
Bus bars Improve Reliability
Laminated bus bars can help your organization build quality into processes. The reduction of
wiring errors results in fewer reworks, lower service costs and lower quality costs.
Bus bars Increase Capacitance
Increased capacitance results in decreasing characteristic impedance. This will ultimately lead to
greater effective signal suppression and noise elimination. Keeping the dielectrics thin and using
dielectrics with a high relative K factor will increase capacitance.
Eliminate Wiring Errors
By replacing a standard cable harnesses with bus bars, the possibility for miss-wirings is
eliminated. Wiring harnesses have high failure rates relative to bus bars, which have virtually
none. These problems are very costly to repair. Adding bus bars to your systems is effective
insurance.
Bus bars Lower Inductance
Any conductor carrying current will develop an electromagnetic field. The use of thin parallel
conductors with a thin dielectric laminated together minimizes the effect of inductance on
electrical circuits. Magnetic flux cancellation is maximized when opposing potentials are
laminated together. Laminated bus bars have been designed to reduce the proximity effect in
many semiconductor applications as well as applications that involve high electromagnetic
interference (EMI).
Bus bars Lower Impedance
Increasing the capacitance and reducing the inductance is a determining factor in eliminating
noise. Keeping the dielectric thickness to a minimum will accomplish the highly desired low
impedance.
Bus bars Provide Denser Packaging
The use of wide, thin conductors laminated together led to decreased space requirements.
Laminated bus bars have helped decrease total system size and cost.
Bus bars Provide Wider Variety of Interconnection Methods
The flexibility of bus bars has allowed an unlimited number of interconnection styles to choose
from. Bushings, embossments, and fasten tabs are most commonly used.
Bus bars Improve Thermal Characteristics
 The wide, thin conductors are favourable to allowing better airflow in systems. As package sizes
decrease, the cost of removing heat from systems has greatly increased. A bus bar cannot only
reduce the overall size required, but it can also improve airflow with its sleek design.
Material: The copper will be of ETP grade as per DIN 13601-2002 and with oxygen free copper.
Chemical composition: Purity of copper will be as per DIN EN 13601:2002. Copper + Silver
99.90% min.
Typical example
Rating Current: 3200Amp.
System:415Vac, TPN, 50Hz.
Fault Level: 50KA. For 1 Sec.
Operation Temp:40° C rise over 45 ° C ambient.
CONSIDERATION
Enclosure size: 1400 mm. wide X 400mm. height
Bus bar Size: 2:200x10 per Ph., 1:200x10 for Neutral.
Bus bar material: Electrolytic gr. Al. (IS 63401/AA6101)
Short Circuit Rating
-upto 400A rated current: 25KA for 1 sec.
-600 to 1000A rated current: 50KA for 1 sec.
-1250 to 2000A rated current: 65-100KA for 1 sec.
-2500 to 5000A rated current: 100-225KA for 1 sec.
The minimum cross section needed in sqmm for busbar in various common cases can be listed as
below-
Material Fault level Withstand time
(KA)
1 sec. 200 msec. 40 ms. 10 ms.
35 443 198 89 44
Aluminium 50 633 283 127 63
65 823 368 165 82
35 285 127 57 28
Copper 50 407 182 81 41
65 528 236 106 53

Let us select a busbar with an example:

1) Aluminium busbar for 2000A, 35 kA for 1 sec withstand – From the table the minimum
cross-section needed would be 443 mm2. Thus we can select a 100mm x 5mm busbar as the
minimum cross-section. Considering a current density of 1A/ mm2 by considering
temperature as well as skin effect, we shall require 4 x 100mm x 5mm busbars for this case.
2) Copper busbar for 2000A, 35 kA for 1 sec withstand – From the table the minimum cross-
section needed would be 285 mm2. Thus we can select a 60mm x 5mm busbar as the minimum
cross-section. Considering a current density of 1.6A/ mm2 by considering temperature as well as
skin effect, we shall require 4 x 60mm x 5mm busbars for this case.
Thus, by using the above formula and table, we can easily select busbars for our switchboards.
Size in Area Weight/ current carrying capacity in amp ( copper ) at 35 deg.C
mm sqmm km AC ( no. of bus) DC ( no. of bus)
I II III II II I II III II II
12X2 24 0.209 110 200 115 205
15X2 30 0.262 140 200 145 245
15X3 75 0.396 170 300 175 305
20X2 40 0.351 185 315 190 325
20X3 60 0.529 220 380 225 390
20X5 100 0.882 295 500 300 510
25X3 75 0.663 270 460 275 470
25X5 125 1.11 350 600 355 610
30X3 90 0.796 315 540 320 560
30X5 150 1.33 400 700 410 720
40X3 120 1.06 420 710 430 740
40X5 200 1.77 520 900 530 930
40X10 400 3.55 760 1350 1850 2500 770 1400 2000
50X5 250 2.22 630 1100 1650 2100 650 1150 1750
50X10 500 4.44 920 1600 2250 3000 960 1700 2500
60X5 300 2.66 760 1250 1760 2400 780 1300 1900 2500
60X10 600 5.33 1060 1900 2600 3500 1100 2000 2800 3600
80X5 400 3.55 970 1700 2300 3000 1000 1800 2500 3200
80X10 800 7.11 1380 2300 3100 4200 1450 2600 3700 4800
100X5 500 4.44 1200 2050 2850 3500 1250 2250 3150 4050
100X10 1000 8.89 1700 2800 3650 5000 1800 3200 4500 5800
120X10 1200 10.7 2000 3100 4100 5700 2150 3700 5200 6700
160X10 1600 14.2 2500 3900 5300 7300 2800 4800 6900 9000
200X10 2000 17.8 3000 4750 6350 8800 3400 6000 8500 10000
Temperature rise
During the short circuiting, the bus bar should be able to withstand the thermal as well as
mechanical stress. When a sort circuiting takes place, the temperature rise is directly proportional
to the squire of the rms value of the fault current. The duration of short circuiting is very small
i.e. one second till the breakers opens and clears the fault. The heat dissipation through
convection and radiation during this short duration is negligible and all the heat is observed by
the busbar itself. The temperature rise due to the fault can be calculated by applying the
formulae.
T = K (I/A) 2 (1+αθ) 10-2
T=temperature rise per second
A= conductor cross section area
α = temperature coefficient of resistivity at 20 deg.C/deg.C
= 0 .00393 for copper
= 0 .00386 for aluminium
K = constant
=0.52 for copper
 =1.166 for aluminium
θ = temperature of the conductor at the instant at which the temperature rise is being calculated.
Typical calculation
Rated current = 1000A
Fault current = 50KA for 1 sec
Permissible temperature rise= 40 deg.C
Busbar material =aluminium ally E91E
De-rating factor due to material =1
De-rating factor due to temperature rise =0.86
De-rating factor due to enclosure =0.75
Total de-rating factor = 1x0.75x0.86=0.66
Minimum cross section area required to withstand short circuit for 1 sec.
= (Ifc x√t )/0.08
Where, Ifc = fault level current in KA
t= 1 second
Area A = (50x√1 )/0.08 = 625 sqmm
Considering all de-rating factor, A = 625/0.66 =946.97
Say, cross sectional area per phase = 1000 sqmm
For neutral, cross sectional area per phase = 500 sqmm

for more study -refer a practical guide to cable installation and tool box talk
In India -
Ingress Protection

Ingress protection

Electrical equipments used in process areas are protected against the ingress of foreign
particles/water. The classification of ingress protection is given in table.
The protection of enclosures against ingress of dirt or against the ingress of water is
defined in IEC529 (BSEN60529:1991). Conversely, an enclosure which protects
equipment against ingress of particles will also protect a person from potential hazards
within that enclosure, and this degree of protection is also defined as a standard.
The degrees of protection are most commonly expressed as ‘IP’ followed by two
numbers, e.g. IP65, where the numbers define the degree of protection. The first digit
shows the extent to which the equipment is protected against particles, or to which
persons are protected from enclosed hazards. The second digit indicates the extent of
protection against water.
The wording in the table is not exactly as used in the standards document, but the
dimensions are accurate.
 1st charactno. Protection of machine 2ndcharact Protection of machine against
against solid particle no. penetrating of water
0 No protection 0 No protection
1 Particles  50mm 1 Vertically dripping water
2 Particles 12mm 2 Water angled at 75-90deg
3 Particles 2.5mm 3 Sprayed water
4 Particles 1mm 4 Splashed water
5 Dust protected 5 Water jet
6 Ship's deck
7 Effect of immersion
8 Indefinite immersion

IP Degree of Protection according to EN/IEC 60529

Correlations between IP (IEC) and NEMA 250 standards
 IP10 -> NEMA 1
 IP11 -> NEMA 2
 IP54 -> NEMA 3 R
 IP52 -> NEMA 5-12-12 K
 IP54 -> NEMA 3-3 S
 IP56 -> NEMA 4-4 X
 IP67 -> NEMA 6-6 P

Relay test
TESTING OF PROTECTIVE RELAYS

INTRODUCTION

In a given power system, protective relays & relaying systems detect the abnormal conditions & operate the associated switchgear to isolate the faulty
section, this limits the damage at the fault location & prevents the effects of the fault spreading in the system. Hence, the protection system, which
comprises of relays, should be able to recognize an abnormal condition in a power system & take the suitable steps to ensure its isolation with the least
disturbance in the normal operation. The reference standard is “IS 9124 - Maintenance & field testing of electrical relays”.

To ensure the healthiness of relays and the core element of protection system, its testing is done as per the schedule.

Periodic Maintenance Tests

a) The clearance of a fault on the system is correct only if the number of circuit breakers opened is the minimum necessary to remove the fault. A small
number of faults are incorrectly cleared, the main reasons being :
 Limitations in protection design
 Faulty relays
 Defects in the Secondary wiring
 Incorrect connections and
 Incorrect settings

b) The objective of a Relay Testing & Maintenance program is to ensure the integrity of the protection system on a periodic basis after
installation. Calibration testing is required to verify relay testing calibration, configurations and to identify any protection system defect. Functional
testing is required to verify that the intent of the protection system is being carried out.

c) Protection relay evaluation starts with :

 First generation – Electro mechanical Relays
 Second generation – Static relays with Transistors
 Third generation – Static relays with Integrated Circuits
 Fourth generation – Processor based relays

d) Testing features in relays

 Most of the relays of the first, second and third generation relays do not have the capabilities of auto testing of internal circuits or providing an alarm in
case a failure is detected. Electro mechanical relays have a lot of mechanical parts, which may become clogged with dirt or corroded due to
environmental conditions, affecting both operation calibration and movement of the disks.

Static relays generally employ a lot of electronic components made by other manufacturers. Most of the static relays in use have in built power supply
unit and do not have the means to detect the failure of power supply and initiate an alarm. If these electronic components are not tested with rigorous
quality control, the chances of failure of components during relay life time may exist.

The fourth generation processor based relays do have the watchdog feature which facilitates the checking of power supply rails, clock frequencies, and
other patterns. Most of these relays have auto test features, which test the electronic circuit functions.

TESTING OF PROTECTIVE RELAYS

Frequency of Tests & Inspection

The frequency of periodic testing shall depend on the ambience of surroundings in relay room and size & importance of the equipment being protected.

Protective relays shall be tested & inspected as under:

 Before commissioning of the protection system

 Once in a year for critical equipment where the surroundings are clean & dry
 Once in two years for less critical equipment.
 Opportunity testing & maintenance during unit shutdowns.
 For microprocessor-based relays, which are self-monitoring type and regular retrieval and analysis of event records, following system faults verifies
operability. The analog metering digital input/output is verified with functional tests.
 All protective system trip operations should be analysed for cause and corrective action. Testing for cause is required in the event of an incorrect
operation of a protection system.

Tools / Tips for Relay Testing

1. Over current relay should be made to check the minimum pick up current & operating time at current values of approximately. 2, 5 & 10 times of the tap
setting.

2. Instantaneous element in the over current relay should be checked for minimum pick up current.

3. Directional elements in the over current relays should be checked for the minimum pick up voltage on the polarized winding with 5A flowing in the
current winding at 100% power factor & for the phase angle which gives maximum torque.

4. The internal wire terminations relay ligaments & coil ends should be examined for sulphation or green spots caused by electrolysis. If found, it should be
removed by wiping with suitable solvent.

5. Relay targets should operate freely without friction & also reset freely.

6. On draw out type relays, the finger contacts should be examined for sulphation & tracking between the terminals which should be cleaned.

Tests on Relay Circuits

These tests are necessary to check & determine healthiness of the complete protective circuit. The following tests will be carried out for the said
purpose.

1. General: Check for the continuity of circuits, loose terminal connections, open circuits, connections in incorrect phases, incorrect panels, incorrect
circuits & continuity at all disconnecting type links or junction boxes and precise relay flag operation.

2. Primary Injection tests: In this test the required current is applied through the primary terminal of the protected equipment or test points so as to enable
to check the integrity of circuitry as well as the relay operation. Hence the actual conditions of the fault can be simulated & the effectiveness of the
protection circuit can be checked.

3. Secondary injection tests: Where the primary injection is not effective & feasible, there secondary injection is done. Here the current/ voltage is applied
to the required terminals (as per the relay manual) in order to actuate the relays. Precise relay calibration is checked at desired settings preferably.

INSPECTION AND TEST PROCEDURES

The instruction & maintenance manuals issued by the equipment manufacturers and individual testing methods developed should be used as the basic
source of information in testing & maintaining protection systems.

Protective relays

1. Visual and Mechanical specification checks:

1. Compare equipment nameplate data with drawings and specifications.

2. Inspect relays cases for physical damage. Remove shipping restraint material.
3. Tighten case connections. Inspect cover for correct gasket seal. Clean cover glass. Inspect shorting hardware, connection paddles and/or knife
switches. Remove any foreign material from the case. Verify target reset.

4. Inspect relay for foreign material, particularly in disk slots of the damping and electromagnets. Verify disk clearance. Verify contact clearance and
spring bias. Inspect spiral spring convolutions. Inspect disk and contacts for freedom of movement and correct travel. Verify tightness of mounting
hardware and connections. Burnish contacts. Inspect bearings and/or pivots.
5. Set relays in accordance with protection coordination study analysis.

2. Electrical tests
(* - Optional )
1. Perform insulation-resistance test on each circuit-to-frame. Determine from the manufacturer's instructions the allowable procedures for this test for
solid-state and microprocessor-based relays.

2. Inspect targets and indicators.

3. Set contrast for liquid-crystal display read outs.

3. Functional operation checks in relays

1. 62 - Timing relay
1. Determine time delay.
2. Determine instantaneous contacts.

2. 21 – Distance relay
1. Determine maximum reach
2. Determine maximum torque angle
3. Determine offset.
4. *Plot impedance circle

3. 24 - Volts/ Hertz Relay

1. Determine pickup frequency at rated voltage.
2. Determine pickup frequency at a second voltage level.
3. Determine time delay.

4. 25 - Sync check relay

1. Determine closing zone at rated voltage.
2. Determine maximum voltage differential that permits closing at zero degrees.
3. Determine live line, live bus, dead line & dead bus set points.
4. Determine time delay.
5. Verify dead bus/ live line, dead line/ live bus and dead bus/ dead line control functions.

5. 27 - Under voltage relay

1. Determine dropout voltage.
2. Determine time delay.
3. Determine the time delay at a second point on the timing curve for inverse time relays.

6. 32 - Directional Power Relay.

1. Determine minimum pickup at maximum torque angle.
2. Determine closing zone.
3. Determine maximum torque angle
4. Determine time delay
5. Verify the time delay at a second point on the timing curve for inverse time relays.
6. *Plot the operating characteristic.

7. 40 - Loss of Field (Impedance) relay

1. Determine maximum reach
2. Determine maximum torque angle
3. Determine offset
4. *Plot impedance circle

8. 46 - Current balance relay

1. Determine pickup of each unit.
2. Determine percent slope
3. Determine time delay

9. 40N - Negative sequence current relay

1. Relay negative sequence alarm level and trip.
2. Determine negative sequence minimum trip level.
3. Determine maximum time delay.
4. Verify two points on the (I2)2t curve

10. 47- Phase sequence or phase balance voltage relay.

1. Determine positive sequence voltage to close the normally open contact.
2. Determine positive sequence voltage to open the normally closed contact (under voltage trip).
3. Verify negative sequence trip.
4. Determine time delay to close the normally open contact with sudden application of 120 percent of pickup.
5. Determine time delay to close the normally closed contact upon removal of voltage when previously set to rated system voltage.

11. 49R - Thermal replica relay

1. Determine time delay at 300 percent of setting
2. Determine a second point of the operating curve
3. *Determine pickup

12. 49T - Temperature (RTD) relay

1. Determine trip resistance
2. Determine reset resistance
13. 50 - Instantaneous over current relay
1. Determine pickup
2. Determine dropout
3. *Determine time delay.

14. 51 time over current

1. Determine minimum pickup
2. Determine the delays at two points on the time current curve.

15. 55 - Power factor relay

1. Determine tripping angle.
2. Determine time delay

16. 59 - Over voltage relay

1. Determine over voltage pickup
2. Determine time delay to close the contact with sudden application of 120 percent of pickup

17. 60 - Voltage balance relay

1. Determine voltage difference to close the contacts with one source at rated voltage.
2. *Plot the operation curve for the relay.
18. 63 - Transformer sudden pressure relay
1. Determine rate-of-raise or the pickup level of suddenly applied pressure in accordance with manufacturer's specifications.
2. Verify operation of the 63 FPX seal-in circuit.
3. Verify trip circuit to remote breaker.

19. 64 - Ground detector relay

1. Determine maximum impedance to ground causing relay pickup.

20. 67 - Directional Over current relay

1. Determine directional unit minimum pickup at maximum torque angle.
2. Determine closing zone.
3. *Determine maximum torque angle.
4. *Plot operating characteristics
5. Determine over-current unit pickup
6. Determine over current unit time delay at two pints on the time current curve.

21. 79 - Re-closing relay

1. Determine time delay for each programmed re-closing interval.
2. Verify lockout for unsuccessful re-closing.
3. Determine reset time
4. Determine close pulse duration.
5. Verify instantaneous over-current lockout

22. 81 - Frequency relay

1. Verify frequency set points.
2. Determine time delay
3. Determine under-voltage cutoff

23. 85 - Pilot wire Monitor

1. Determine over current pickup
2. Determine undercurrent pickup
3. Determine pilot wire ground pickup level.

24. 87 - Differential Relay

1. Determine operating unit pickup
2. Determine the operation of each restraint unit
3. Determine slope
4. Determine harmonic restraint
5. Determine instantaneous pickup
6. Plot operating characteristics for each restraint.
25. Thermal Relay
1. Pick up value
2. Timing

26. Auxiliary Relays

1. Operation

27. Special Relays & Timers

1. As per manual

4. Control verification

1. Verify that reach of the relay contacts performs its intended function in the control scheme including breaker trip tests, close inhibit tests, 86 lockout
tests and alarm functions.
2. For numerical relays, verify all used inputs, outputs and internal logic.

5. System tests
 After the equipment is initially energized, measure magnitude and phase angle of all inputs and compare with expected values.

6. Test values

1. Use manufacturer's recommended tolerances when other tolerances are not specified.

2. When critical test points are specified, the relay shall be calibrated to those points even though other test points may be out of tolerance.
. Test Procedure of electrical relays
1. Refer Annexure-4 for test procedures and circuits.
2. Refer Annexure-5 for relay testing connection diagram /procedures as per IS-9124. Guide for Maintenance and field testing of electrical relays.
3. Refer Annexure-6 for relay testing of typical English Electric relays using EE relay testing kit.
4. Refer Annexure 6-A for Microprocessor relays.

ANNEXURE – 1

1. Protective Relay Test Procedures and Circuits

The testing of protective relays and associated circuitry can be carried out by following recommendations outlined in manufacturer’s bulletins or the
user’s own test procedures. These procedures should always be updated based upon a review of past relay performance, test equipment evaluation,
and testing method.

The test interval can be adjusted based upon experience. Otherwise, testing of relays on a yearly basis is recommended. The test methods
used for early testing consist of relay functional tests (i.e., relay equipment is separated from power equipment) and only secondary tests are made.
The following general guidelines are recommended for electrical testing of protective relays, associated instrument transformers, and wiring.

a) General Protective relay Calibration and Checklist

i) Perform insulation resistance test on each branch circuit to frame. Do not perform this test on solid- state relays. Check manufacturer’s instructions to
verify if any other precautions are required.

ii) Perform the following tests on the nominal setting specified.

 Minimum pickup parameters on each operating element. A pickup test is conducted to determine the minimum or maximum current, voltage, power or
frequency that causes closure of relay contacts.

 Timing test should be performed at three points on the time dial curve to verify the timing characteristics of the relay.

 Pickup target and seal-in units.

 Special tests as required to check operation of restraint,

directional, and other elements per manufacturer’s instruction manual.

iii)
A zero check test should be conducted on any relay that has a time dial. The purpose is to determine proper time dial position when the relay is fixed
and moving contacts are closed by the manual rotation of the time dial towards zero.
iv) Perform phase angle and magnitude contribution tests on all differential – and directional – type relays after energization to vectorially provide proper
polarity and connection.

2. Relay Test Points and Test Circuits

a) Time Overcurrent Relays – Overcurrent relays are checked for minimum pickup. Check a minimum of three timing points at 2 X tap. 4.5 X tap. and 6
X tap settings. The Periodic inspection pickup tolerance is +/-5% of tap value for nongeared relays and +-7% for geared relays. For new relay the
tolerance is +/-1% of tap value. Pickup is defined a that value of current that will just close the relay contacts. Check the instantaneous unit pickup by
gradually applying the current . Also check the target seal-in unit blocking the main Overcurrent contacts. The testing of Overcurrent relay is done one
phase at a time. The ground relay is tested similarly to the phase relays.
b) Directional Overcurrent Relays – The Overcurrent unit of directional relays should be checked similarly to the Overcurrent relay, with the directional
unit blocked closed. The directional relay should be tested for minimum pickup, maximum torque angle, contact gap, and clutch pressure. If the phase
power supply is not available, the directional unit can be tested by applying single-phase voltage and current in phase. Usually, this will give large
variations in-phase pickup, because of in-phase angle being far different from maximum torque angle.
c) Differential Relays – The test conducted on differential relays is to check minimum pickup values using operating and differential currents. The slope
(Differential characteristic) and harmonic restraint should also be checked. It may also be desirable to trip all circuit breakers from differential relays as
a regular testing procedure.
d) Distance Relays - The distance characteristics of the relay are checked near the fault and load angles. Similar to the directional Overcurrent relays,
the pickup, maximum torque angle, clutch pressure, and contact gap test should be made.
e) Pilot Wire Relays - The Pilot wire relay schemes should be tested for shorts, continuity, and grounds in the pilot wires. The operating values are
checked along with supervisory and alarm relays used in pilot wire schemes.
f)
Plunger-Type Relays – In this type, relays such as PJC,SC, and HFA, are included. These relays are tested for tested for operating pickup and dropout
values by gradually increasing or decreasing the operating current or voltage.
g) Current Balance Relays – Check pickup of each coil as explained under section on Overcurrent relays. Check for no-trip condition by applying equal
amounts of current to opposing coils. Also check operation of the target indicator coil in a manner similar to Overcurrent relay.
h) Overvoltage Relay – Check minimum pickup of overvoltage coil similar to overcurrent relays. Select three timing points on the specified time dial.
Pickup and timing points should be within + / -1% for new installations and within +/ -5% on existing installations. Check the instantaneous (if
applicable) pickup and target indicator coil.
i) Undervoltage Relay – Check dropout of relay and time relay trip when voltage is suddenly reduced from rated voltage to dropout voltage setting or to
zero. Select three timing points on the specified time dial. Dropout and timing points should be within +/-1% for new installations and within +/- 5% for
existing installations. The instantaneous unit should be checked for dropout and target indicator coil.
j) Thermal Overload Relays. The thermal overload relays minimum pickup value should be checked using some convenient multiple of tap setting.
Because of long time characteristics, the relay pickup point below 200% of tap setting may take a considerable time. Therefore, for test purposes,
check pickup at about 200 to 400% of tap setting.
k) Voltage Restrained o voltage Controlled Overcurrent Relays – The overcurrent unit is checked and calibrated much the same as a simple time
overcurrent relay. In the case of a voltage restrained relay, the current pickup of the relay will change with the voltage applied to the voltage sensing
coil. In the case of the voltage or torque controlled relay, the overcurrent element will not function at all unless the voltage element drops out.
l) Under-Over Frequency Relays – The relays generally require three calibration function: 1) Voltage cutoff or drop out ; 2) Over or under frequency
pickup points; 3) Time delay before trip after frequency set point has been sensed. The delay times are not necessarily equal.
m)
Synchronism Check Relays - Setting and calibrating these relays requires test equipment similar to that used in distance relaying. The permissible
“window” of the angle between the “Bus” and “line” voltages must be accurately determined during the calibrating or maintenance test. These relays
generally have delay times associated with the angle pickup point.