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CHAPTER 1

INTRODUCTION

This document defines reclamation practices for operating, maintaining, and

testing protective relays and protection circuits. Reclamation protective relays and
associated circuits must be properly maintained and tested to ensure proper protection
of power plants and switchyard equipment and systems. Protective relaying must
function properly to protect the electric power system as well. To test these relays we
need a voltage injection kit.

This is a portable testing kit in one unit suitable for testing protective relay
over current relay earth fault relay protective device, circuit breaker, tripping coils etc.
The set is designed for both laboratory and field use.

1.1 Features of Single Phase Voltage Source

To test voltage sensing relays, we need a voltage injection source. The voltage
injection source has the following features.

 Single phase voltage source consists of auxiliary supply voltages such as 110V
DC, 220V DC, 110V AC and 220V AC. This supply is required by the
measuring circuit of the relay to operate. In a practical protection scheme, this
supply is derived from the station battery. Some electrochemical relays may
not need auxiliary supply.
 Single phase variable AC output voltage (0 to 270V AC) with an output
switch. Either nominal voltage or fault voltage can be chosen by using this
output switch.
 Time interval meter with built in START, STOP inputs and external RESET
input. The timer starts whenever the fault output voltage is switched on by
operating the rotary switch. The NO or NC output contact of the relay under
test has to be connected to the appropriate STOP input terminals of the timer
so that when the relay trips the timer stops. This helps in measuring the
operation time of the relay.
 Voltmeter gives both fault voltage and nominal voltage.

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1.2 Key Specifications of Voltage Injection Kit

 AC voltage output: 0-110V and 0-220V continuous adjustable

 DC voltage output: 0-110V and 0-220V continuous adjustable
 Voltmeter rating voltage: 0-300V AC
 Time counter: 0-9999s
 Time counter resolution: 1ms
 Power supply: 230VAC ± 10%, 50Hz
 Environment temperature: 0-50°C
 Size: 550x410x340mm3
 Weight: 12kg

1.3 Choosing a Suitable Injection Tester

An injection tester is normally used to check the operation and condition of

primary and secondary equipment on the power systems. For this purpose, the
injection tester simulates normal and fault signals which are used to test the specific
equipment under a wide range of system conditions. This involves that the injection
tester be capable of producing and controls the suitable output levels that correspond
to the voltage and/or current levels inputs of the device under test (DUT), with the
suitable phase angle and frequency, including the simulation of power system faults.
The injection tester can include also the capacity to capture and measure specific
responses of the DUT to the specific simulation (e.g. trip signals and trip values, trip
times, logical sequences, turn ratio, etc.) to be able to assess its condition,
characterizing the behavior of the DUT to the expected measured magnitude and
verify its proper and expected performance.

In this way, depending on the type of test, and on the signal level and the type
of response measured, there are different and specific injection testers, which for
easier choice we can classify in two main groups, primary injection tester and
secondary injection tester. Likewise, the user may choose between a specialized
injection tester and a multi-purpose injection tester, according to their needs.

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1.4 Technical features of Voltage Injection Kit:

INPUT: 230Volts 50Hz, Single Phase, AC Supply

OUTPUTS:

1) AC Voltage Output:

a) 110VAC

b) 220VAC

c) Continuously variable 0-270V AC

2) DC Voltage Output:

a) 110VDC

b) 220V DC

3) Time Measurement:

a) Auto ranging: 1 to 9999sec at 0.05% Accuracy

b) Fixed ranges: 9999sec, 9.999sec, 99.99sec, 999.9sec

4) Metering:

a) Digital Voltmeter: Basic Range- 0 to 600V AC at +/- 10% Accuracy of full

range.

5) Voltage circuit

a) Variable auto transformer: For smooth variation of voltage output for AC

& DC 0-250VAC/DC.
b) Isolation transformer of suitable burden is provided for AC/DC output.
c) Metering: Digital Meter, Basic Range: - 0 to 600V AC/DC. Accuracy: -
+/-10% of full range.

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CHAPTER 2

COMPONETS OF VOLTAGE INJECTION KIT

2.1 Autotransformer
This single winding is “tapped” at various points along its length to provide a
percentage of the primary voltage supply across its secondary load.
The autotransformer has the usual magnetic core but only has one winding, which is
common to both the primary and secondary circuits.

Therefore, in an autotransformer the primary and secondary windings are

linked together both electrically and magnetically. The main advantage of this type of
transformer design is that it can be made cheaper for the same VA rating, but the
biggest disadvantage of an autotransformer is that it does not have the
primary/secondary winding isolation of a conventional double wound transformer.

The section of winding designated as the primary part of the winding is

connected to the AC power source with the secondary being part of this primary
winding. An autotransformer can also be used to step the supply voltage up or down
by reversing the connections. If the primary is the total winding and is connected to a
supply, and the secondary circuit is connected across only a portion of the winding,
then the secondary voltage is “stepped-down” as shown.

2.1.1 Autotransformer Design

Fig.2.1: Design of Autotransformer

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When the primary current IP is flowing through the single winding in the
direction of the arrow as shown, the secondary current IS, flows in the opposite
direction. Therefore, in the portion of the winding that generates the secondary
voltage VS the current flowing out of the winding is the difference of IP and IS.

The Autotransformer can also be constructed with more than one single
tapping point. Auto-transformers can be used to provide different voltage points along
its winding or increase its supply voltage with respect to its supply voltage VP as
shown.

2.1.2 The Variable Autotransformer

As well as having a fixed or tapped secondary that produces a voltage output
at a specific level, there is another useful application of the auto transformer type of
arrangement which can be used to produce a variable AC voltage from a fixed voltage
AC supply. This type of Variable Autotransformer is generally used in laboratories
and science labs in schools and colleges and is known more commonly as the Variac.

Fig.2.2: Variable Autotransformer

The construction of a variable autotransformer or Variac, is the same as for the

fixed type. A single primary winding wrapped around a laminated magnetic core is
used as in the auto transformer but instead of being fixed at some predetermined
tapping point, the secondary voltage is tapped through a carbon brush.

This carbon brush is rotated or allowed to slide along an exposed section of

the primary winding, making contact with it as it moves supplying the required
voltage level.

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Then a variable autotransformer contains a variable tap in the form of a carbon

brush that slides up and down the primary winding which controls the secondary
winding length and hence the secondary output voltage is fully variable from the
primary supply voltage value to zero volts.

The variable autotransformer is usually designed with a significant number of

primary windings to produce a secondary voltage which can be adjusted from a few
volts to fractions of a volt per turn. This is achieved because the carbon brush or slider
is always in contact with one or more turns of the primary winding. As the primary
coil turns are evenly spaced along its length. Then the output voltage becomes
proportional to the angular rotation.

Fig.2.3: Circuit Diagram of Variable Autotransformer

We can see that the Variac can adjust the voltage to the load smoothly from
zero to the rated supply voltage. If the supply voltage was tapped at some point along
the primary winding, then potentially the output secondary voltage could be higher
than the actual supply voltage. Variable autotransformer’s can also be used for the
dimming of lights and when used in this type of application, they are sometimes
called “dimmer stats”.

Variacs are also very useful in electrical and electronics workshops and labs as
they can be used to provide a variable AC supply. But caution needs to be taken with
suitable fuse protection to ensure that the higher supply voltage is not present at the
secondary terminals under fault conditions.

The Autotransformer has many advantages over conventional double wound

transformers. They are generally more efficient for the same VA rating, are smaller in
size, and as they require less copper in their construction, their cost is less compared
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to double wound transformers of the same VA rating. Also, their core and copper
losses (I2R) are lower due to less resistance and leakage reactance giving a superior
voltage regulation than the equivalent two winding transformers.

2.2 Time Interval Meter

Fig.2.4: Time Interval Meter

A time interval meter does the measurement of the elapsed time between some
designated START phenomena and a later STOP phenomenon. Time Interval is an
important measurement frequently made with electronic counters. In this role, the
counter makes an elapsed time measurement between two electrical pulses. Minimum
time measurement is much less (to a nanosecond and below) than possible with a
stopwatch. Also, resolution and accuracy are much greater than attainable with a
stopwatch.

With increased speed of the timed object then the time interval becomes
shorter and shorter until the human factor involved in determining when to start and
when to stop the measuring device, a stopwatch or clock for instance begins to
introduce significant error. Mechanical, optical, or electrical transducers or a
combination of all were developed to reduce this error.

A time interval counter can measure electrical delays, pulse widths, and other
time related electrical phenomena required in the development and maintenance of
communications, navigation, television, and other present-day systems.

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2.3 Voltmeter
A voltmeter is an instrument used for measuring electrical potential difference
between two points in an electric circuit. Analog voltmeters move a pointer across a
scale in proportion to the voltage of the circuit; digital voltmeters give a numerical
display of voltage by use of an analog to digital converter. General purpose analog
voltmeters may have an accuracy of a few percent of full scale and are used with
voltages from a fraction of a volt to several thousand volts. Digital meters can be
made with high accuracy, typically better than 1%. Specially calibrated test
instruments have higher accuracies, with laboratory instruments capable of measuring
to accuracies of a few parts per million. Meters using amplifiers can measure tiny
voltages of microvolts or less.

Fig.2.5: Voltmeter

There are three types of Voltmeter:

i. Analog voltmeter

ii. Digital voltmeter

iii. VTVMs voltmeter

2.3.1 Digital Voltmeter

A Digital Voltmeter (DVM) measures an unknown input voltage by
converting the voltage to a digital value and then displays the voltage in numeric
form. DVMs are usually designed around a special type of analog-to-digital
converter called an integrating converter.

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Fig.2.6: Digital Voltmeter

DVM measurement accuracy is affected by many factors, including

temperature, input impedance, and DVM power supply voltage variations. Less
expensive DVMs often have input resistance on the order of 10 MΩ. Precision DVMs
can have input resistances of 1 GΩ or higher for the lower voltage ranges (e.g. less
than 20 V). To ensure that a DVM's accuracy is within the manufacturer's specified
tolerances, it must be periodically calibrated against a voltage standard such as
the Weston cell.

2.4 Potential Transformer

Potential transformer or voltage transformer gets used in electrical power
system for stepping down the system voltage to a safe value which can be fed to low
ratings meters and relays. Commercially available relays and meters used for
protection and metering, are designed for low voltage.

Fig.2.7: Symbol of Potential Transformer

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2.5 Theory of Voltage Transformer

A voltage transformer theory or potential transformer theory is just like a
theory of general purpose step down transformer. Primary of this transformer is
connected across the phase and ground. Just like the transformer used for stepping
down purpose, potential transformer i.e. PT has lower turns winding at its secondary.
The system voltage is applied across the terminals of primary winding of that
transformer, and then proportionate secondary voltage appears across the secondary
terminals of the PT.

Fig.2.8: Voltage Transformer

2.6 Switch
In electrical engineering, a switch is an electrical component that can "make"
or "break" an electrical circuit, interrupting the current or diverting it from one
conductor to another. The mechanism of a switch removes or restores the conducting
path in a circuit when it is operated. It may be operated manually. For example, a light
switch or a keyboard button, may be operated by a moving object such as a door, or
may be operated by some sensing element for pressure, temperature or flow.

2.6.1 Rotary Switch

A rotary switch operates with a twisting motion of the operating handle with at
least two positions. One or more positions of the switch may be momentary (biased
with a spring), requiring the operator to hold the switch in the position. A rotary

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switch may have multiple levels or "decks" in order to allow it to control multiple
circuits.

Fig.2.9: Rotary Switch

2.6.2 Changeover Switch Without Off

A Change over switch is an electrical switch that switches a load between two
sources. Some transfer switches are manual, in that an operator effects the transfer by
throwing a switch, while others are automatic and trigger when they sense one of the
sources has lost or gained power.

Fig.2.10: Changeover Switch Without Off

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Fig.2.11: Connection diagram of Changeover Switch Without Off

2.7 Bridge Rectifier

A Full wave rectifier is a circuit arrangement which makes use of both half
cycles of input alternating current (AC) and converts them to direct current (DC). The
full wave rectifier is much more efficient than a half wave rectifier. This process of
converting both half cycles of the input supply (alternating current) to direct current
(DC) is termed full wave rectification.

Full wave rectifier can be constructed in 2 ways.

 The first method makes use of a center tapped transformer and 2 diodes. This
arrangement is known as Center Tapped Full Wave Rectifier.
 The second method uses a normal transformer with 4 diodes arranged as a
bridge. This arrangement is known as a Bridge Rectifier.

2.7.1 Full Wave Bridge Rectifier

The working & operation of a full wave bridge rectifier is pretty simple. The
circuit diagrams and wave form we have given below will help you understand the
operation of a bridge rectifier perfectly. In the circuit diagram, 4 diodes are arranged
in the form of a bridge. The transformer secondary is connected to two diametrically
opposite points of the bridge at points A & C. The load resistance R (load) is
connected to bridge through points B and D.

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Fig.2.12: Circuit Diagram of Full Wave Bridge Rectifier

2.8 Relay

Fig.2.13: Relay

• A protective Relay is a device that detects the fault and initiates the operation
of circuit breaker to isolate the defective element from the rest of the system.

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The main part of the relay is an electromagnet (a coil of wire that becomes a
temporary magnet when electricity flows through it).
• When a fault occurs at point F on the line the current flowing in the line
increases to a dangerous value this results in heavy current flows through the
relay coil, causing the relay to operate by closing its contacts.
• Thus, in turn closes the trip circuit of the circuit breaker and the circuit breaker
gets open.

Fig.2.14: Circuit of Relay

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CHAPTER-3

SINGLE PHASE VOLTAGE INJECTION KIT

3.1 Block Diagram

Fig.3.1: Block Diagram of Single Phase Voltage Injection Kit

Single phase A.C supply is fed to the voltage injection kit and with the help of
rotary switch, voltage is given to different components. The rotary switch will be
connected to auxiliary PT through auxiliary supply switch which in turn will give ac
or dc voltage for the components of the microcontroller as well as nominal voltage for
the operation of the relay. From that rotary switch, it will be connected to auto
transformer, timer and voltmeter and further connected to rotary switch 2 which will
feed either nominal voltage or fault voltage to the relay. When this rotary switch 2
will be on 1st position, nominal voltage will be fed to the relay but at this time
voltmeter will display only nominal voltage and timer circuit won’t start counting. As
soon as the rotary switch will be rotated to 2nd position, the fault voltage will be set
using an autotransformer which is to be fed to the relay and by this time voltage will
be measured and timer circuit will start counting the time.

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3.2 Wiring Diagram

Fig.3.2: Wiring Diagram of Single Phase Voltage Injection Kit

1) Potential Transformer 1
2) Potential transformer 2
3) Auto transformer

Wiring diagram explanation:

 Single phase AC supply is fed to Rotary Switch 1 through a fuse.

 Auxiliary supply switch is connected in parallel from the output terminals of
Rotary Switch 1.
 Two Auxiliary Potential Transformers are connected in parallel which are
connected to the output terminals of Auxiliary supply switch.
 The output of Potential Transformer 1 is connected to Bridge Rectifier where
AC is converted into DC. This DC supply is given to the components of
microcontroller through DC output terminals.

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 The Potential Transformer 2 is used to produce Nominal voltage for the relay
MV12.
 The phase and neutral terminals of Auto transformer (terminals B & C) and
Timer (terminals 1 & 2) are connected to the output terminals of Rotary switch
1.
 The Nominal voltage is fed to the relay when Rotary Switch 2 is at position 1
between terminal A1 and terminal 2 of rotary switch from Auxiliary supply.
 The fault voltage is fed to the relay when Rotary Switch 2 is at position 2
between terminal A2 and D2 of Rotary switch 2 by using an Autotransformer.
 The timer is connected to the Rotary Switch 2 and when it is turned to 2nd
position, the fault voltage is fed and at that particular time, the timer starts
counting the trip time in seconds.
 A RESET button is used to reset the timer after each operation and it is
connected across terminal 5 and terminal 6 of Timer.
 A NO contact is connected to terminal 2 and terminal 4 of a timer and the
timer stops counting the time when the relayMV12 trips.
 The output is taken from terminal C3 and terminal 4 through a output
terminals.
 A relay is connected inside the kit to protect the kit from abnormal conditions.

3.3 Procedure for the Operation of the Source

 Connect the mains cord provided at the back side of the panel to 230V, 50Hz
single phase power supply through a 5A socket.
 If NC contacts of the trip relay are not used for stopping the time interval
meter then short the external stop (NC) contacts of the voltage source using a
patch cord.
 Select the auxiliary supply voltage as per specifications of the relay under test.
Connect this auxiliary supply to the relay under test using patch cord. In some
electro mechanical relays, auxiliary supply may not be required.
 Reset the relay under test by operating its RESET key and ensure that its trip
indicator is not showing.
 While testing under voltage relays, connect nominal voltage (110V AC or
220V AC depending upon the relay specification) available under auxiliary
supply to the nominal voltage input terminals. After this connection is done,
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the output rotary control switch be operated to output either nominal or fault
voltage.

Note: NO means Normally Open and NC means Normally Closed. A relay is said to
be NO when it has open circuit across its terminals in un-energized state. Similarly, a
relay is said to be NC when it has a short circuit across its terminals in the un-
energized state. When the relay is energized, the NO contact closes whereas the NC
contact opens.

3.4 Voltage Injection Kit Front Panel

Fig.3.3: Voltage Injection Kit Front Panel

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3.5 General Circuit Connections for Testing of

Microcontroller Based UV/OV Relay

Fig.3.4: General Circuit Connections for Testing of Microcontroller Based UV/OV

Relay

 In order to energize or operate the components of microcontroller auxiliary

supply of 110V, 220V DC or 110V, 220V AC is connected to terminal 2 and 3
of the panel.
 Auxiliary 110V AC supply is connected to auxiliary input and this input is
taken through output voltage terminals as a nominal voltage.
 Output voltage terminals are connected to terminals 11 and 12 to give nominal
voltage which acts as a reference voltage.

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 From the same output voltage terminals, fault voltage will be send to the same
terminals for operation of relay after comparing with reference voltage.
 NC terminals are shorted and NO terminals are connected across terminals 5
and 6 which will get closed as soon as relay trips.

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CHAPTER-4

ADVANTAGES, DISADVANTAGES AND

APPLICATIONS OF SINGLE PHASE VOLTAGE
INJECTION KIT

4.1 ADVANTAGES

 Correct operation of the protection scheme

By using secondary voltage injection source, secondary injection tests
are conducted to prove the correct operation of the protection scheme.
 To test different types of relays
With the help of the voltage injection kit we can test different relays
like electromechanical relays, static relays, numerical relays, etc.
 Fault voltage detection
The kit ensures the fault voltage measurement which will trip the relay
coil.
 Accurate tripping time
Accurate tripping time of the relay coil can be known whenever a fault
voltage is fed.
 Portability
The kit is compact in size and is portable to take it from one place to
another.

4.2 DISADVANTAGES

 High cost.
 It does not verify the current sensors, circuit breakers current carrying
components.

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4.3 APPLICATIONS
Protective devices such as relays, overload coils and circuit breakers must be
checked on installation and at regular intervals while in service to ensure that they are
always ready to operate correctly if any fault occur in the equipment’s that they are
protecting. Routine Voltage injection testing will quickly detect fault or incorrect
adjusted protection devices. Also, it will possibly prevent serious damage to plant
equipment and injury to personnel.

The Voltage injection kit is suitable for all these applications and particularly
for testing protective relays, including microcontroller-based relays.

This voltage injection kit can be used in Educational Institutions for

witnessing the operation of relay. It can be used in industries for conducting routine
tests on relay. As it can inject nominal voltage as well as fault voltage, this kit can be
used in substation because substation can control the transmission and distribution of
voltage over a line.

As well as checking that a protective device functions correctly, it is usually

necessary to measure its operating time. This kit has its own built-in timer unit with
the option of control by a remote pushbutton.

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CHAPTER-5

CONCLUSION
A single-phase voltage injection kit has been implemented for the operation of
relay. Certain tests were accounted to test the operation of relay. Single phase
injection kit resembles the operation of numerical relay by giving nominal voltage as
well as fault voltage. It provides voltage for MV12 relay which will fed voltage under
two conditions which are under voltage condition and the other one is over voltage
condition. Fault voltage was set and fed to the microcontroller based under/over
voltage relay. Using auxiliary potential transformers, auxiliary AC or DC supply is
given to the components of microcontroller and AC supply for the relay operating
mechanism.

As this kit is designed for microcontroller based under voltage and over
voltage relay MV12. We can also test different relays based on their operating
voltage. Suppose, a new relay is constructed then tripping characteristics of that relay
can be achieved by using the kit before supplying to the customer.

Through this working environment of members for completing the project, we

came to know about how potential transformers are used for switching of relay
whenever there is an under voltage or over voltage condition.

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REFERENCE

 www.electricalengineeringportal.com
 www.electricalsforu.com
 Switching in Electrical Transmission and Distribution Systems by Rene
Smeets, Lou van der Sluis, Mirsad Kapetanovic, David F. Peelo, Anton
Janssen.

 Protection of Substation Critical Equipment against Intentional

Electromagnetic Threats by Vladimir Gurevich.

SNAPSHOTS

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