DCEFL Manaul631 P Series

DC - Earth Fault Locator System

DIGITRACE DC - 631 P SERIES

‘DIGITRACE’

TECHNICAL MANUAL

‘DIGITRACE’ DC Portable DC - Earth Fault Locator

Corporate Office: No. 26, “Mahadimane”, 12th Main, 1st Block, Rajajinagar Bangalore - 560 010, INDIA.

Te l : + 9 1 8 0 2 3 0 1 2 3 0 1 , F a x : 2 3 3 2 7 7 3 6 , E m a i l : i n f o @ t a u r u s p o w e r t r o n i c s . c o m .

Sales & Service Office: No.648/54, KLE College Road, 2nd Block Rajajinagar, Bangalore - 560010, INDIA.

Tel: +91 80 2352 2136 / 174, Email: [email protected]

Web: www.tauruspowertronics.com

TAURUS POWERTRONICS SYSTEMS

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ContentsPg. No.

1.0 INTRODUCTION 5

2.0 TAURUS DC EARTH FAULT LOCATOR SYSTEM CONFIGURATION 6

3.0 DC 631 - P SERIES - INTRODUCTION 8

4.0 DC 631 - P SERIES - TRANSMITTER UNIT 9

5.0 DC 631 - P SERIES - RECEIVER UNIT 10

6.0 DC 631 - P SERIES - DESCRIPTION 11

7.0 DC 631 - P SERIES - TRANSMITTER ACCESSORIES 13

8.0 DC 631 - P SERIES - RECEIVER ACCESSORIES 14

9.0 DC 631 - P SERIES - CONNECTING PROCEDURE 15

10.0 DC 631 - P SERIES - PRINCIPLE OF OPERATION 16

11.0 DC 631 - P SERIES - SCHEMATIC DIAGRAM 17

12.0 DC 631 - P SERIES - OPERATING PROCEDURE 18

13.0 TIPS IN FAULT FINDING 19

14.0 DC 631 - P SERIES - ADVANTAGES 20

15.0 DC 631 - P - SPECIFICATION 21

16.0 DC 631 - PX - SPECIFICATION 22

17.0 MAINTANANCE & HANDLING 23

18.0 WARRANTY 24

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1.0 Introduction

ower stations and several process industries like refineries, pharmaceuticals and etc. employ a

floating DC source comprising of battery banks to provide electrical power to their equipments. This is Pdone to greatly improve the reliability of the control system and to guarantee foolproof operation. The

DC source usually consists of a bank of lead acid batteries connected in series to obtain the required voltage.

The floating DC source supplies power to the control equipments through suitable cables, which consists of a

single core, one for positive line and other for the negative. Any floating system has a redundancy of 50% as

it continues to work without disruption even if one of the lines gets earthed in the course of time. Where as in

an earthed system, the system bus gets short-circuited in case of an earth fault with opposite polarity core.

The entire control system consisting of the DC source, connecting cables and various control equipment

forms a floating circuit with respect to earth i.e. no point of the control system is electrically connected with

the earth. In such a system, even if any one of the cores, either positive or negative happens to develop an

earth fault, either by a short circuit or through a low resistance path due to insulation failure or cable damage,

the control function will not be disturbed as the system being a floating one. However, in course of time,

another core of opposite polarity were also to develop an earth fault will result in a short circuit across the DC

source causing overloading of the DC source, cable burning and disruption of power to control equipments.

The protection of Control System is as important as its Generation & Transmission. To avoid heavy loss to

equipment & industry the power engineers always endeavors to have normal operation of control system

with out electrical failures.

The task of identifying the faulty cores and isolating them from the source consume great deal of time and

effort, as no easy and well-established techniques are available at present.

It is here where the TAURUS DC EARTH FAULT LOCATOR SYSTEM provides you quick and complete

solution to all such problems. Like all TAURUS products, the TAURUS DC EARTH FAULT LOCATOR

SYSTEM is a technically superior product from our R&D lab. The TAURUS DC EARTH FAULT LOCATOR

SYSTEM has been designed not only to immediately & accurately identify the faulty cable, but also to pin

point the fault at the exact spot. Technically superior in design, concept and hardware, the TAURUS DC

EARTH FAULT LOCATOR SYSTEM can accurately pinpoint fault upto a resistance of 400 kilo ohms optional

100kW on both positive and negative and upto a distance of 1km optional 3km . Now with this technically

superior product from the house of TAURUS, DC Earth faults occurring in power generating and power

receiving stations need not be a cause of prolonged uncertainty in eliminating leakage currents that can

eventually lead to serious malfunctions that could trip the entire station.

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2.0 TAURUS DC EARTH FAULT LOCATOR SYSTEM

CONFIGURATIONS:

1. TAURUS Model DC - 415M

2. TAURUS Model DC - 631 P series

Model DC - 415 M is a dedicated system connected on-line and instantaneously identifies and indicates the

faulty cable. The portable handy fault pin pointer is used to then identify the exact point on the faulty cable.

DC - 415 M comprises of a Monitoring unit (consisting of the Main unit and a dedicated on line monitoring

module) and a portable Fault Pin Pointer.

Model DC - 631 P series are portable systems that are connected to the DC bus when required. Using the

portable handy fault pin pointer & individually connecting to all terminals, the faulty cable is identified. The

portable handy fault pin pointer is then used to identify the exact point on the faulty cable. Model DC - 631 P

series comprises of a Main unit and a portable Fault Pin Pointer.

Following variations are available in model DC - 631 P Series

1) DC-631P (Range upto 400kW)

2) DC-631PX (Range upto 100kW)

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TAURUS DIGITRACEMODEL - DC 631 P SERIES

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3.0 Introduction to Model DC - 631 P series

This equipment comprises of 2 units.

-the Main Unit (with Transmitter)

-the Portable Fault Pinpointer.

1.The Main unit consists of two Analog voltmeter on th left and right side of the front panel indicating positive

to the ground and the other from the negative to the ground respectively. Both these meters indicate the

presence of fault on the DC System. If both the meters indicate half the reading of the system voltage, then

the system is considered to be healthy. Depending on the fault resistance, these two readings vary. The

voltage reading lower of the two is indicative of the faulty cable. By noting the polarity, the fault can be traced

to the positive or negative side.

An in-built transmitter with low frequency output, is connected to the Positive and Negative of the battery

and to the ground of the station as per procedure described in "Connecting to DCDB".

This unit is normally placed in the near Dc distribution board so that the DC system can be monitored

regularly.

Mains & battery operated, this unit works on 230 volts single phase AC.

2.Portable Fault Pinpointer: This is a portable small lightweight unit that can be slung around and carried

in a shoulder bag. It has an in-built battery and battery charger. It is provided with a very compact probe,

which can be easily temporarily affixed over any cable in the DC System. This instrument is put at various

points on the faulty feeder to pin point the fault. It is provided with a LED lamp and a Buzzer. Upto the faulty

point the fault signal would persist; beyond that there will be no fault signal.

The receiver can detect faults from a resistance of 0 ohms to 400 kilo ohms(optional 100 Kilo Ohms) . No

circuit contact is necessary. The portable mini probe has to be simply used over the cable for detection of

faults in the cable upto a fault resistance of 400 kilo ohms (optional 100 Kilo Ohms).

In the TAURUS DC - 631 P series , no in-circuit contact is necessary and the instrument takes care of the

cable capacitance automatically upto a cable length of 1 km optional 3 km.

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4.0 The Transmitter Unit

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Positive Protection Fuse

Negative Protection Fuse

Positive Voltmeter

Negative Voltmeter

Main Socket

Battery Status LEDTransportation Fuse

Main Switch

MainsFuse

PowerSwitch

TransmitterPulse

Indicator

Transmitter OutputSocket to DCDB

Earth Terminal


5.0 The Receiver Unit

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Power On Switch

Fault Sensitivity Selector Switch

Battery Status Indicator

High Sense Pot Output to SensorProbe

Fault Count LCD

Fault Indicator LED

Sensitivity Potentiometer

DIGITRACE 631P


6.0 Description of DC Earth Fault Locator P series:

A) TRANSMITTER UNIT:

1.MAINS ON/OFF SWITCH:

To Charge the battery, connect the mains power chord to 230 V Socket and switch on the 'MAINS' switch and

check whether 'Charging led' is glowing. When fully charged, the 'charging led' will go dim.

2.POWER ON SWITCH:

Switch ON the 'Power on' to operate the equipment and ensure 'Charged LED' and Transmitter Pulse LED

is glowing and 'Discharged LED' is not glowing.

3.FUSE:

1.Mains fuse is provided to protect the equipment from mains supply.

2.Positive & Negative fuse is provided to protect the equipment from Positive & Negative DC busbar.

3.The transportation fuse is provided to dis-engage / disconnect the battery for transportationpurpose.

4.TRANSMITTER OUTPUT SOCKET:

This output is connected to DCDB Positive & Negative bus using the cables given.

5.BATTERY:

CHARGED / DISCHARGED / CHARGING LED's indicate the status of the battery.

6.TRANSMITTER PULSE LED:

This LED indicates that the transmitter unit is switched on and the pulse is being sent. This LED will blink on &

off when the transmitter unit is switched on.

7.VOLTMETER:

Positive to ground & negative to ground voltmeter indicate the voltage of the respective bus with respect to

ground.

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B) RECEIVER UNIT:

1.POWER ON SWITCH: This switch is used to switch on the receiver.

2.FAULT SENSITIVITY SELECTOR SWITCH: This switch indicates the severity of the fault, H2/H1 - High

resistance fault, M2/M1 - Medium resistance faults, L2/L1 - Low resistance faults.

3)HIGH SENSE POT:

HIGH SENSE MODE: The potentiometer dial is kept at ‘0’ position (fully anti clock wise) and the kit sensitivity is

maximum i.e Fault sensitivity selector switch when kept in ’ H2’ will read all faults <= Maximum sensitivity of kit*

* Maximum sensitivity of kit (400 kW for model 631P)

(100 kW for model 631PX)

H1 <= H2/2, M2<= H1/2, M1 <= M2/2, L2 <= M1/2, L1 <= L2/2

LOW SENSE MODE: The potentiometer dial is kept at ‘0’ position (fully clock wise) and the kit sensitivity is

minimum i.e Fault sensitivity selector switch when kept in ’ H2’ will read all faults <= half of Maximum sensitivity

of kit*

* half of Maximum sensitivity of kit (200 kW for model 631P)


H1 <= H2/2, M2<= H1/2, M1 <= M2/2, L2 <= M1/2, L1 <= L2/2

Recommended setting: For 631PX the potentiometer is kept at ‘0’ position and for 631P potentiometer is kept at

‘10’ position

Note: There is a lock provided on the potentiometer dial. This has to be unlocked for adjusting the

potentiometer. When the potentiometer is increased in clockwise direction the sensitivity of the relatively

decreased. When the potentiometer is set at 10 turns the receivers each position of the fault sensitivity selector

switch is reduced by half.

4.FAULT COUNT LCD: This is a count proportional to fault current in that particular feeder. Lower the resistance

' higher the fault current' bigger the fault' bigger the count. In case there are two high resistance fault say H2

category, the fault with bigger count shall be concentrated first.

5.CHARGING SOCKET: The external charging Adaptor is connected to this socket on the back panel of the

receiver unit.

6.BATTERY Status LED: LOW BAT. LED indicates status of the battery.

7.FAULT INDICATOR: This LED indicates the presence of Fault. This LED blinks on & off with audio visual beep

when there is a fault in the DC system.

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7.0 Accessories - Transmitter

Two Core Transmitter

Positive and Negative Cable

Flexible Earthing Cable

with Crocodile clip

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8.0 Accessories - Receiver

Receiver Charger Adapter

-used for charging the receiver unit.

Fault Guide (Big)

-used to clamp on the feeders from DCDB

Fault Guide (Small)

-used to clamp on the outgoing feeders from DCDB

Two core male jack

-used to connect receiver unit & fault guide probe

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9.0 Connecting to DCDB:

1)Take the equipment near Main DC Distribution Board (DCDB).

2)Connect the Earth terminal on the side of the Transmitter Unit to the Station Earth using the Black cable

provided.

3)Connect the unique twist lock connecting plug to the Transmitter unit's DCDB socket. The grooves of the

connecting plug should match the corresponding grooves in the Main Unit, press the connector plug and turn

it anticlockwise direction for locking & check for firm connection. To unlock press & turn the connector

clockwise.

4)Connect the other end of the cable with crocodile clip to the DCDB. Connect RED wire to Positive bus-bar

and Blue wire to Negative bus-bar of DCDB.

5)Inter connect the Receiver unit and sensor using the provided two core cable with male jack on both sides.

NOTE:

1) Do not come in contact with bare crocodile terminals. Use the rubber insulation provided on the crocodile

clip.

2) After removing the DCDB connection, do not touch the bare portion of crocodile clip as the capacitive

voltage on the crocodile clip may harm the personal. Please discharge the capacitive voltage to ground

before touching the same with bare hands.

3) It is recommended not to connect the mains chord to 230 V socket during fault finding.

4) The earthing of the kit to be removed at the last.

5) It is recommended that after removing the positive & negative cables the same shall be discharged to

earth before touching the bare terminals.

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10.0 Principle of Operation:

The TAURUS Digitrace DC Earth Fault Locator DC 631 P series incorporate sophisticated circuitry that

empowers the equipment to function effectively & trace any Earth fault either low resistance or high

resistance up to a length of 1 km optional 3km from the point of testing. Unlike other conventional

instruments available, the TAURUS Digitrace DC Earth Fault Locator DC 631 P series has advanced

signal generator circuits that generate low frequency Pulse coded signal and leaves no scope for any elusive

fault to be untraced. The system not only uses the advantages of CW sinusoidal signals but also transmits &

evaluates using PW signals, thus enabling the Digitrace to provide you a fool proof diagnostics. When the

power on switch is switched on, the Transmitter sends desired pulse in all the DC feeders through Positive &

negative bus.

When there is an earth fault as indicated in the diagram, our pulse gets the return path through the

equipment earth. Hence the pulse travels through the closed path and the pulses are detected through the

Receiver unit. TAURUS Digitrace DC Earth Fault Locator DC 631 P series is equipped with advanced

signal processing circuitry, which enables the Receiver to capture the transmitted signal and reject all

unwanted frequencies (noises). TAURUS Digitrace DC Earth Fault Locator DC 631 P series is

specially designed to work under the substation environment. When the sensor is placed before the fault

point as indicated in the diagram and an Audio Visual alarm will be indicated in the Receiver unit.

When the 'sensor' is placed after the fault point, the Receiver unit will not sense the transmitted signal as the

pulse travel to the least resistance path i.e. through ground and the pulse do not travel to the point up to the

sensor.

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11.0 SCHEMATIC DIAGRAM

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MAINS

230V AC

FUSE

180 20 21 4 00 6 3 00 0

180 20 21 4 00 6 3 00 0

BATTERYBANK

CHARGER

+VE BUS

-VE BUS

DCDB

Relay Coil

Receiver Unit

Transmitter Unit


12.0 OPERATING PROCEDURE:

Step1:

Set the controls as follows:

Transmitter Unit

POWER ON switch OFF Position

Receiver Unit

POWER ON switch OFF position

LEAKAGE RESISTANCE SELECTOR SWITCH. H2 position

HIGH SENSE POT 0 turns (maximum clock wise direction)

Connect the Black wire 'O' type lug to equipment earth on the side of the transmitter unit panel and the other

end (crocodile clip) to the station earth. Connect the unique twist lock plug to the transmitter unit. Then

connect the RED wire to Positive bus of the DCDB and BLUE wire to negative bus of DCDB.

Step2:

Switch the POWER ON switch on the Transmitter unit and see the transmitter pulse signal on the

Transmitter pulse indicator LED.

Step3:

Clamp the sensor on the outgoing positive or negative feeders independently and switch on the Receiver unit

and wait for the first beep.

Step4:

After the first beep, verify whether the same pulse characteristics as on the Transmitter unit is repeated on

the Receiver unit's FAULT Indicator LED. If the pulse characteristic repeats on the Receiver unit there is a

Fault and to find the intensity of the fault, switch off the Receiver & go to step 5. If same signal doesn't appear

on the Receiver unit then switch off Receiver unit redo step3 to check another feeder.

Step5:

Select the 'Fault sensitivity selector switch' one step below (i.e., to H1 position from H2 position in this case)

then switch on the Receiver unit & repeat step 4.

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13.0 TIPS in FAULT FINDING

1)After connecting the transmitter to the DCDB, the positive to ground Voltmeter & Negative to ground

Voltmeter will show the corresponding voltages of your station bus. If positive to ground voltmeter is showing

less value, you can prioritize your check in positive feeders. If Negative to ground voltmeter is showing less

value, you can prioritize your check in Negative feeders.

2)For finding High resistance faults you may keep the Receiver unit's 'Leakage resistance' selector switch in

H2/H1 position.

3)For finding Medium/Low resistance faults you may start with M2/L2 position respectively in the Receiver

unit.

4)HIGH SENSE POT:

HIGH SENSE MODE: The potentiometer dial is kept at ‘0’ position (fully anti clock wise) and the kit sensitivity

is maximum i.e

Fault sensitivity selector switch when kept in ’ H2’ will read all faults <= Maximum sensitivity of kit*

* Maximum sensitivity of kit (400 kW for model 631P)


H1 <= H2/2, M2<= H1/2, M1 <= M2/2, L2 <= M1/2, L1 <= L2/2

LOW SENSE MODE: The potentiometer dial is kept at ‘10’ position (fully clock wise) and the kit sensitivity is

minimum i.e

Fault sensitivity selector switch when kept in ’ H2’ will read all faults <= half of Maximum sensitivity of kit*

* half of Maximum sensitivity of kit (200 kW for model 631P)


H1 <= H2/2, M2<= H1/2, M1 <= M2/2, L2 <= M1/2, L1 <= L2/2

Recommended setting: For 631PX the potentiometer is kept at ‘0’ position and for 631P potentiometer is kept

at ‘10’ position

5)In finding faults sometimes you may find some external noise signal coming in the Receiver unit that is

having different characteristics/pattern when compared to Transmitter units signal. At this time you may put

the sensor clamp to both positive & negative feeder together & check for the fault signal in the Receiver unit.

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14.0 Advantages of the TAURUS DC - 631 P series

1.Convenient portable system designed to use as and when required or during routine maintenance checks.

2.Fault sensing is immediate on connection. The earth fault will be instantaneously indicated.

3.Earth faults from 0 to 400 kW optional: 100 k are immediately detected

4.Separate meters indicate whether the faults are on the +ve or -ve of the cable.

5.Ground faults anywhere along the cable will be detected up to a length of 1 km. Optional: 3 km.

6.Once the fault is indicated on the Transmitter unit, the portable Pin Pointer will guide you exactly to the point of

fault.

7.Clear, noise/interference free performance. Complete immunity to 50 Hz interference (15 amps).

8.The Transmitter unit does not required to be connected at various points along the faulty cable for detecting

faults.

9.No balancing control is required to be adjusted to attain cable capacitance during the test.

10.A handy system conceptionalised to give you complete fault sensing, identification and tracking.

W

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15.0 SPECIFICATIONS for DC - P

1. Equipment Type : TAURUS DC Earth Fault Locator System - Model TAURUS

DC - 631 P Portable System.

2. Operating Voltage : 230 V, 50 Hz, Single Phase AC Optional: Battery back up.

3. Power consumption : 10 watts.

4. Range of fault resistance Detection : up to 400 KW on both positive and negative

5. Distance of detection : 3 km.

6. Accuracy of pinpointing : Exact spot.

7. Output : Low frequency coded pulse.

8. Noise immunity : Immune to 50 Hz noise. Fault finding free from 50 Hz

disturbance (15 amps).

9. Mechanical : Particulars Weight

- Transmitter unit 12 kg

- Receiver unit 3 kg

631

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16.0 SPECIFICATIONS for DC - 631 Px

1. Equipment Type : TAURUS DC Earth Fault Locator System - Model

TAURUS DC - 631 PX Portable System.

2. Operating Voltage : 230 V, 50 Hz, Single Phase AC Optional: Battery back

up.

3. Power consumption : 10 watts.

4. Range of fault resistance Detection : up to 100 KW on both positive and negative

5. Distance of detection : 3 km.

6. Accuracy of pinpointing : Exact spot.

7. Output : Low frequency coded pulse.

8. Noise immunity : Immune to 50 Hz noise. Fault finding free from 50 Hz

disturbance (15 amps).

9. Mechanical : Particulars Weight

- Transmitter unit 12 kg

- Receiver unit 3 kg

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17.0 MAINTANCE & HANDLING OF 'DC EARTH FAULT

LOCATOR’

BATTERY CHARGING PROCEDURE:

1) Transmitter Unit: Insert the power chord's 3-pin plug coming from Transmitter unit to 230V AC mains,

switch on the Mains On Switch provided in the transmitter unit, Charge continuously for 8hrs. After full

charging the charging led will go dim.

2) Receiver Unit: Connect the pin of external 12V power supply supplied to DC input socket provided at the

backside of pinpointer & connect the 2-pin plug's other end to 230V AC mains.

BATTERY MAINTENANCE: Battery has to be charged for 8hrs every fortnight (15days) & 8hrs same day

after the equipment is used.

TRANSPORTATION: In the event of equipment needs to be transported, it has to be properly housed in

the suitcase & cushion cover provided & necessary care to be taken like keeping the suitcase in upright

position. If the equipment is to be transported by air the transportation fuse has to be removed.

0 0STORAGE: The equipment should be stored in clean dry place & temperature between -5 C to 55 C

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18.0 W A R R A N T Y

The system is warranted against any manufacturing defects for a period of 12 months from the date of

installation.

Parts like the LED's, carry case do not come under this warranty clause. Replacement for such components

would be charged, however no service charges will be levied during the warranty period.

Please ensure the batteries are regularly kept in fully charged conditions. Batteries that may need

replacement will be charged extra if falling outside the warranty period specified by its manufactured.

The suitcases of the equipments are just carrying cases for carrying the equipment within the station only. If

the equipment has to be transported it should be taken with proper packing and protection. Damages due to

transportation are not covered under the warranty and repair due to transportation will be charged for.

For any service requirements please call us at:

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Corporate Office: No. 26, “Mahadimane”, 12th Main, 1st Block, Rajajinagar Bangalore - 560 010, INDIA.

Te l : + 9 1 8 0 2 3 0 1 2 3 0 1 , F a x : 2 3 3 2 7 7 3 6 , E m a i l : i n f o @ t a u r u s p o w e r t r o n i c s . c o m .

Sales & Service Office: No.648/54, KLE College Road, 2nd Block Rajajinagar, Bangalore - 560010, INDIA.

Tel: +91 80 2352 2136 / 174, Email: [email protected]

Web: www.tauruspowertronics.com

TAURUS POWERTRONICS SYSTEMS

DCEFL Manaul631 P Series

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