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Elektromotoren und

Gertebau Barleben GmbH

Technical Documentation
Protection Relay for Conservator with
Hydro-Type Compensator (Rubber Sack) Type 80 (CF 38)

Elektromotoren und Gertebau Barleben GmbH

Table of contents
dd
Page
1.

Safety instructions

2.

Installation

2.1.

Installation

2.2.

Filling and bleeding of the protection relay

2.3.

Removal of transport lock

2.4.

Connection of signal lead

3.

Mode of operation

4.

Functional test

4.1.

Testing by means of test key

4.2.

Testing by means of test pump

5.

Maintenance

6.

Technical data

7.

Switching system design options

10

8.

Ordering data/type code

11

9.

Options/special designs and casing colours

13

10.

Additional protection devices for hydro-type compensators


(with rubber sack)

14

Other additional devices

14

11.

1. Safety instructions
Make sure that any person installing, taking into operation and operating the
protection relay type CF 38 (air cell failure relay) for conservator with rubber sack
- is qualified and competent, and
- fully complies with these operating instructions.
Improper operation or misuse might cause danger to
- life and limb,
- the relay and other property of the operator, and
- the relays proper function.

Opening of the device will void your warranty.


________________________________________________________________________________

Safety instructions in this manual are presented in three different forms to


emphasize important information:

Note
This symbol refers to important information on a specific subject.

Caution
This symbol indicates particular risks for the device or any other property of the
operator. Danger to life and limb cannot be excluded.

Warning
This symbol indicates serious danger to life and limb.

Elektromotoren und Gertebau Barleben GmbH

2. Installation
2.1. Installation
The protection relay of type CF 38 (1) is mounted on top of the conservator (2) using four screws
and nuts M10.

A sealing ring (not included in the scope of supply) ensures tight seat.
After mounting and before commissioning open the test valve to drain air from the interior of the
casing (see 2.2.).
Now the circuit can be tested with the help of the test key (see 2.4.).

Alternative 1

Alternative 2

Breathing pipe

R>50

Hydro-type compensator (rubber sack)

Piping to
transformer tank
Figure 1 Installation - sketch

During installation make sure that

gases produced can flow unimpeded to the protection relay;


the flange is stressed evenly when tightening the screws;
the protection relay is installed on or above the conservator,
the pipe has no elbow, and bends are designed preferably with an inside radius of
R > 50 mm.

Make sure during installation that no dirt, moisture or foreign matter


gets into the relay.
The insulating liquid of the transformer must not contain conductive
substances.
2.2. Filling and bleeding of the protection relay
Once the device to be protected is ready for operation and the conservator has been filled with
insulating liquid, bleed the protection relay completely.
Proceed as follows:

Remove the small cap nut (1) from the test valve (2).
Open the test valve (turn anticlockwise), and let the air escape from the protection relay.
Close the test valve as soon as insulating liquid comes out (clockwise rotation).
Fit and tighten the small cap nut on the test valve.
OPEN

CLOSE

Figure 2 Test valve

2.3. Removal of transport lock


Proceed as follows:

Remove the large cap nut (3) from the test key (5).
Take the transport lock (4) out of the
cap nut.
Fit and tighten the large cap nut without
transport lock.

4
5

Figure 3 Removal of transport lock

Elektromotoren und Gertebau Barleben GmbH

Remove the transport lock before taking the protection relay into
operation. If the protection relay has to be transported separately,
reinstall the transport lock.
2.4. Connection of signal lead
Not more than 2 multicore signal leads can be fitted in the protection relay through cable glands.
A conductor cross section of 1.5 mm2 (copper) is recommended.
The maximum cross section that can be clamped is 4 mm2.

Proceed as follows:

Remove screws (1).


Remove cap (2).
Insert the lead through the cable gland (3).
Connect the lead to the terminal studs (4) (max. torque: 3 Nm).
Tighten cable gland (3).
Fit cap (2).
Tighten screws (1) (max. torque: 3 Nm).
2

Connected load of the switching systems:


Voltage:

AC 5 V max. 250 V
DC 5 V max. 250 V

Current:

AC 0.01 A max. 6 A
DC 0.01 A max. 6 A

Switching capacity:

cos 0.5
L/R 40ms

AC max. 1500 VA
DC max. 1250 W

Figure 4 Electrical connection

The inner side of the cap accommodates a plate


with the graphic symbol and the connection
diagram (Figure 5). The switching systems are
shown in their neutral position.
The neutral position is the operating condition when
the protection relay is filled completely with
insulating liquid and the device to be protected
operates without any fault.
Figure 5 Inner side of cap (example)

sklemme

Connect the protective conductor (green-yellow insulation) to the earth


terminal (5) (max. torque: 3 Nm).
6

3. Mode of operation
The protection relay of type CF 38 (air cell failure relay) is normally filled completely with oil. Due
to its boyant force the float is positioned in the upper limit position.
If due to a defective hydro-type compensator (breakage or sealing defect) air gets into the
conservator, it is collected in the protection relay, causes the float to move downwards and
operates a switching contact (magnet contact tube). This produces a signal that can be used for
alarm or shutdown depending on the particular case.
Gas accumulation is visible on the inspection glass.

4. Functional test
The test can be performed with the help of a test key (mechanically) or a special test pump
(pneumatically). Perform the test while the protection relay is filled completely with insulating
liquid.
4.1. Testing by means of test key (Figure 6)
Proceed as follows:
1

Remove the large cap nut (1).


Press the test key (2) down to stop position and keep it
depressed.
2
Obtain verification of correct function from the control room.
Release the test key.
Fit and tighten the large cap nut.

Figure 6 Test key

4.2. Testing by means of test pump (Figure 7)


Proceed as follows:

Remove the small cap nut (1) from the test valve (2).
Fit the adapter (3) of the hose providing the connection to the test pump (4) on the valve
nozzle (5).
Open the test valve (turn anticlockwise).
Pump air into the protection relay until falling of the float causes the magnet contact tube to
operate.
Obtain verification of correct function from the control room.
Close the test valve (turn clockwise).
Remove the adapter from the valve nozzle.
Open the test valve and let the air escape (see 2.2).
Close the test valve as soon as insulating liquid comes out.
Fit and tighten the small cap nut on the test valve.
7

Elektromotoren und Gertebau Barleben GmbH

OPEN

CLOSE

Figure 7 Testing by means of test pump

Use only test pumps with adapter (ball valve) from EMB (ZG 5.1. or ZG 5.2.).

5. Maintenance
Protection relays are insensitive to ambient conditions, provided theses were considered when
selecting the particular design of the protection relay. Therefore, no special maintenance is
required during operation.
Protection relays should be inspected and tested at specified intervals as described in the
maintenance instructions of the plant operator. Make sure that the functional tests described are
performed.
Unless otherwise specified by the operator, EMB recommends operating the test key once a year
in the framework of the scheduled maintenance operations.

When removing the protection relay, make sure that there is no


insulating liquid in the device. On customers request EMB GmbH will
ensure proper disposal of your old relays.

During operation explosive gases are accumulated in the protection


relay. When opening the device make sure that there are no sparks or
open fire in the direct vicinity as they would cause an explosion risk.
Wait for some 10 minutes before starting any work on the relay to allow
the gases to evaporate.

6. Technical data

Type
Internal description

80
(CF 38)

Type of
connection

Flange
4-hole

Pipe diameter
DN
(mm)
d1

38

Flange dimensions
(mm)

Device dimensions
(mm)

d2

d3

d4

h1

75

100

11

10

223

Weight without
packing
(kg)

3.5

Figure 8 Dimensional drawing, type 80

Parameter
Temperature range:
- Ambient temperature

Data

Notes

- 40C to + 55C
- 40F to + 131F

Climatic test acc. to


DIN EN 60068-2-78: 2002-09

- Operating range
* Temperature of insulating liquid

- 40C to + 115C
- 40F to + 239F

Others see p. 13

up to + 135C type code


21 required
* Viscosity of insulating liquid

1 mm2/s to 1100 mm2/s

Insulating liquid

Mineral oil

Resistance to vibration
Resistance to pressure

Vibration: 2-200 Hz, 1 g


Shock: 10 g, 11 ms
0.25 MPa

Resistance to vacuum

< 2.5 kPa

Insensitivity to magnetic fields

25 mT

Response of switching system in


case of:
- gas accumulation

200 cm3 / 300 cm3 / 400


cm3 / tolerance 15%

Type of protection

IP 56
2-component texture paint

Casing colour

Others see p. 13

Static magnetic field of any


direction and polarity
Others on request

Others see p. 13
on polyurethane basis

Elektromotoren und Gertebau Barleben GmbH

7. Switching system design options


Magnet contact tubes are used as switching elements. These are normally-open (NO),
normally-closed (NC) and change-over (CO) contacts. The design of the switching system of the
protection relay can be derived from the last digit of the type code. For coding, see Ordering
data/Type code under section 8., p. 11.

A
3 NO

B
3 NC

C
3 CO

The switching system is shown in its neutral position. The neutral position is the
operating condition when the protection relay is filled completely with insulating liquid.
10

8. Ordering data/type code


For placing orders, please use the following key:

Type 80 (CF 38)

80 X. XX. XX. XX

Type
Cable gland (section 9)
Casing colour (section 9)
options/special designs
Switching point
01 = 200 cm3
02 = 300 cm3
03 = 400 cm3
04 = 200 and 400 cm3
05 = 200 and 300 cm3
06 = 300 and 400 cm3
Sequence, switching contact
1 = 1 switching point
2 = first switching point contact 1; second switching point contact 2
3 = first switching point contact 2; second switching point contact 1
4 = first switching point contact 1 and contact 2;
second switching point contact 3
5 = first switching point contact 1; second switching point contact 2
and contact 3
Contact setting of switching system
Contact 1
Contact 2

Contact 3

NO contact

NC contact

NO contact

NO contact

NC contact

NC contact

NO contact

NC contact

CO contact

CO contact

CO contact

NO contact

CO contact

NC contact

CO contact

NO contact

NO contact

NO contact

NC contact

NC contact

NC contact

CO contact

CO contact

CO contact
11

Elektromotoren und Gertebau Barleben GmbH

Ordering example of protection relay of type 80 (CF 38):


A customer needs to protect the rubber sack in the conservator with a protection relay of
type CF 38 with a cable gland M20 x 1.5.
The switching system should be provided with two switching elements (magnet contact
tubes) designed as NO contacts.
The protective relay should operate at two different switching points, i.e. at gas volumes
of 200 and 400 cm3.
The device colour should be RAL 7033.
According to the data on pages 11 and 13 the type code is as follows:

80 1.25.44. 0423
Explanation:
80

= Protection relay for conservator of type 80 (CF 38))

= M20x1.5: 1 Cable gland with 1 dummy plug

25

= Switching system provided with two magnet contact tubes

44

= Casing colour RAL 7033 (cement-grey)

04

= Switching point at a gas volume of 200 cm3 and 400 cm3

= First switching point = 200 cm3 contact 1


Second switching point = 400 cm3 contact 2

= Contact setting of switching system: Contact 1= NO contact


Contact 2= NO contact

12

9. Options/special designs and casing colours


Explanation
Code
Cable gland *
M20x1.5: 1 Cable gland and 1 dummy plug
M25x1.5: 1 Cable gland and 1 dummy plug
M20x1.5: 2 Cable glands
M25x1.5: 2 Cable glands
M20x1.5: 1 Harting connector and 1 dummy plug
1/2 NPT: 1 Cable gland and 1 dummy plug
1/2 NPT: 2 Cable glands
Cable gland: Special request

1
2
3
4
5
6
7
9

Casing colour *
Casing colour RAL 7001 (silver-grey)
Casing colour RAL 7012 (basal-grey)
Casing colour RAL 7022 (umber-grey)
Casing colour RAL 7033 (cement-grey)
Casing colour RAL 7038 (agate-grey)
Casing colour RAL 7035 (light-grey)
Casing colour RAL 7016 (anthracite-grey)
Casing colour RAL 9002 (grey-white)
Casing colour RAL 7032 (siliceous-grey)

41
42
43
44
45
46
47
48
49

Climate-proof design/type of protection


Climate-proof design (extremely cold open-air conditions below - 40C)
Climate-proof design (offshore)
Type of protection IP 66

34
36
39

Insulating liquid
Insulating liquid: silicone oil
Insulating liquid based on esther

20
21

Casing
Metal nameplate

15

Switching system
Switching system with two magnet contact tubes
Switching system with three magnet contact tubes
Solid float

25
99
16

Special request
Special request (on special agreement with customer)

29

* Mandatory order data, for other mandatory data see section 8, p. 11.

13

Elektromotoren und Gertebau Barleben GmbH

10. Additional protection devices for hydro-type compensators (with


rubber sack)
Other Buchholz relays manufactured by EMB GmbH are also used as protection relays
for the conservator (air cell failure relay).

Single-float Buchholz relay with flanged connection


Type 03 (AF 25/10)

For further information, see our catalogue.

Double-float Buchholz relay with flanged connection


Type 05 (BF 25/6)
Type 06 (BF 25/10)
Type 23 (BF 25/10 S)
For further information, see our catalogue.

11. Other additional devices


Buchholz gas sampler BGS
The Buchholz gas sampler provides a safe method of
taking and transporting gas samples from the Buchholz
relay, protection relay or the gas sampling device. Its
capacity is 100 ml.

14

Buchholz gas tester BGT 3


The Buchholz gas tester is used to measure the
hydrogen concentration of the Buchholz gases. The
measurement can be performed directly where the
sample is taken.

Gas testing device ZG 3.1.


The gas testing device is used to test the gas
accumulated in the protection relay. It can be installed
directly on the test valve of the protection relay or on the
gas outlet tap of the gas sampling device. The gas flows
through two different chemical solutions, and its colour
reactions indicate the nature of the fault.

Reflux lock ZG 4.1.


The reflux lock prevents insulating liquid from flowing into
the gas testing device. It is installed between the
protection relay or the gas sampling device and the gas
testing device.

Test pump ZG 5.1. and ZG 5.2.


The test pump serves to check the function of the upper
switching system (alarm) of the protection relay by
pumping in air. The test can be performed directly on the
protection relay. For that purpose, the test pump is
connected to the test valve of the protection relay. When
the test is performed via the gas sampling device, the
test pump is connected to the gas outlet tap of the gas
sampling device.
- ZG 5.1. manually operated
- ZG 5.2. pedal operated

For further information about the additional devices and other products of EMB GmbH,
please ask for special reference material.
15

Elektromotoren und Gertebau Barleben GmbH

EMB GmbH
Otto-von-Guericke-Allee 12
D-39179 Barleben | Germany
Phone:
Telefax:

+49 39203 790


+49 39203 5330

Email:
Website:

info@emb-online.de
www.emb-online.de
www.buchholzrelay.com

Due to technical improvement of our products the information contained in this catalogue is subject to change without
notice. We further would like to apologize for any printing errors which have not been found despite intensive proofreading. We assume no liability for such errors. Thank you for your understanding.
Edition: Technical Documentation of Protection Relay of Type 80 (CF 38) TD 38/01/14/02 English