TECHNICAL BROCHURE
July 2008
D.M.C.R.
Detection, Measurement and Control Relay
Protection relay for oil immersed transformers.
In accordance with the EN 50216-3 standard.
1■ THE DMCR RELAY 3
2■ WHAT THE DMCR DOES 3
2■1 Oil level control & gas detection 3
2■2 Pressure control 7
2■3 Temperature control 9
3■ ELECTRICAL CONTACTS 13
4■ ADJUSTMENT RANGE 13
5■ EXTREME CONDITIONS OF USE 14
5■1 Strength test 14
5■2 Endurance test 14
6■ RESISTANCE TO EXTERNAL FACTORS 14
6■1 Anti-U.V. treatment 14
6■2 Protection against mechanical impacts 14
6■3 Waterproof 15
6■4 Saline fog 15
6■5 Temperature 15
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7■ QUALITY CONTROL PROCEDURE 15
7■1 Quality control of the components 15
7■2 Quality control of the finished product 16
7■3 Final control procedure: routine testing 16
8■ PACKING 17
9■ INSTALLATION, USE & MAINTENANCE 18
10■ CONTACT 21
11■ APPENDIX 22
11■1 DMCR Routine testing procedure 22
11■2 Dimensions 28
11■3 Technical datasheet 29
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1■ THE DMCR RELAY
Transformers are essential to the power supply industry.
The DMCR is a protection relay designed for the hermetically sealed oil
immersed transformers without gas cushion.
This device enables complete control of the tank’s internal parameters, i.e.
pressure, temperature, oil level & gas detection.
This protection relay has been designed according to the European standard
EN 50216-3, standard which came into action on the 5th of June 2002.
This specification applies to protection relays for hermetically sealed oil
immersed transformers, (in accordance with the EN 60076 standard) and
induction coils (in accordance with the EN 60289 standard) without gas
cushion for an indoor or outdoor use.
The DMCR relay is an IDEF Systemes design, made in France. It has two
French and one European patents.
2■ WHAT THE DMCR DOES
2■1 Oil level control & gas detection
► Cause
Two separate causes can be responsible for a decline in the oil level inside the
transformer:
- there is a leak in the transformer’s tank: air replaces leaked oil. Once inside,
air comes through to the upper part of the tank, into the relay.
- damage to the coil insulation can result in the triggering of a short circuit
inside the tank, which can in turn provoke a pyrolysis and gas formation. Gas
will then come through to the upper part of the tank into the relay
► Oil level control & gas detection
The DMCR enables to control both the oil level and the presence of gas inside
the transformer’s tank.
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The DMCR body is a small see-through tank fitted onto the transformer’s tank.
Should gas form inside the transformer, it will then accumulate inside the
DMCR and cause the oil level to drop.
● Visual information:
The level drop is first visible through the lowering of the small red float inside
the upper part of the DMCR, followed by the lowering of the main red float.
The 360 degree visibility is a specifically designed and patented
system.
● Electrical information:
A circular magnet is fitted in the main float and it acts upon a magnetic
changeover contact (REED switch) sitting inside the brass tube that runs
through the float. The lowering of the float triggers the activation of an
electrical contact, through the magnet’s motion.
A sampling system facilitates gas collection inside the relay so that one can
analyze it and understand the reason for its presence.
The sampling system has a male G1/8’’ thread, according to the standard.
► Electrical process
For the oil level & gas detection control, the contacts have been chosen in
order to use the REED switch’s working contact when the float is in a high
position. This means that, in such a position, i.e. with a normal oil level and
therefore normal conditions of use, the contact has already switched.
This is a positive security system. With this method, any potential damage
to the switch is immediately spotted.
In addition to this, the magnet is ring-shaped and surrounds the REED switch.
Its powerful magnetic field therefore protects the REED switch from the
external magnetic field created when the transformer is started.
This integrated magnetic protection is a patented design. It is self-sufficient
and suppresses the need for any additional magnetic reinforcement. It can
resist a 25mT magnetic field, according to the standard.
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In normal conditions (the big float is in a high position), contact 1 is closed
while contact 3 is open.
When working (the big float is in a low position), contact 1 is open, while
contact 3 is closed.
The REED switch has no memory. The default state is lost when the DMCR is
back to its normal temperature.
► Gas contact
The numbers below correspond to the numbers & color code used on the wires
of the DMCR’s connecting block.
NO = Normally Open in normal conditions.
NC = Normally Closed in normal conditions.
No oil level default Oil level default
(Float in a high position) (Float in a low position)
NO NC NO NC
Common contact Common contact
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► Visual
The DMCR below is filled in with oil: the main float and the secondary float are
both in high position.
Plug with sampling
system
Secondary float
Main float with
integrated
magnetic protection
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2■2 Pressure control
► Cause
Pressure inside a transformer’s tank can increase significantly when:
- There is a temperature rise due to the transformer charge: oil expands and
pressure increases
- An internal short-circuit occurs and provokes an oil temperature rise.
► Pressure control
An adjustable pressure captor detects overpressure in the transformer’s tank.
It features a changeover contact actuated by a soft membrane which deforms
under pressure.
► Electrical process
In normal conditions, contact 4 is closed and contact 6 is open.
When working, contact 4 is open and contact 6 is closed.
The pressure captor has no memory. The default state is lost when
there is no pressure in the DMCR.
► Adjustment
The pressure adjustment level ranges from 100 to 500mbar.
The standard threshold is 250mbar. However, the transformer manufacturer
can set its own threshold when placing the order.
N.B: Every single DMCR is tested and adjusted on a specially engineered test
bench prior to packing and despatch. In order to be precise, any
adjustment of the pressure captor must be performed on a test bench
with a calibrated main pressure captor.
► Pressure contact
The numbers below correspond to the numbers & color code used on the wires
of the DMCR’s connecting block.
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NO = Normally Open in normal conditions.
NC = Normally Closed in normal conditions.
No pressure default Pressure default
NO NC NO NC
Common contact Common contact
► Visual
The DMCRs pressure captor is accessible from above, once the top removed.
Adjustment knob
Threshold indicator
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Warning: for a correct adjustment, the pressure button must be turned anti-
clockwise until the maximum threshold (500mb), and then turned clockwise
until the required threshold.
2■3 Temperature control
► Cause
Oil temperature generally rises when the transformer is functioning and its
charge is increasing.
► Temperature control
● Visual check:
A needle thermometer indicates the temperature inside the transformer.
● Electrical check:
Two identical adjustable thermostats detect potential over-heating inside the
transformer.
The thermostats feature a changeover contact actuated by a diaphragm
linked by a capillary tube to a temperature probe sitting deep inside the
central brass tube, which is immersed in the transformer’s tank. The capillary
tube and probe are filled in with a liquid which expands proportionally to the
temperature surrounding the probe.
The ALARM thermostat detects a primary temperature threshold.
The TRIPPING thermostat detects a secondary temperature threshold,
superior to the first.
► Electrical process
The “ALARM” changeover contact is generally used to trigger a visual and/or
sound signal.
In normal conditions, contact 7 is closed while contact 9 is open.
When working, contact 7 is open while contact 9 is closed.
The “TRIPPING” changeover contact is generally used to cut the transformer’s
primary or secondary power.
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In normal conditions, contact 9 is closed while contact 12 is open.
When working, contact 12 is open while contact 12 is closed.
The thermostats’ have no memory. The default state is lost when the
DMCR is back to its normal temperature.
The choice of connecting contacts onto the transformer’s primary or
secondary power is entirely up to the installation engineer.
► Adjustment
The temperature adjustment level ranges from 30 to 120°C.
The standard “ALARM” threshold is 80°C.
The standard “TRIPPING” threshold is 90°C.
However, the transformer manufacturer can set its own thresholds when
placing the order.
N.B: Every single DMCR is tested and adjusted on a specially engineered test
bench prior to packing and despatch. In order to be precise, any
thermostat adjustment must be performed on a test bench with a
calibrated temperature captor.
► ALARM: Electrical contact
The numbers below correspond to the numbers & color code used on the wires
of the DMCR’s connecting block.
NO = Normally Open in normal conditions.
NC = Normally Closed in normal conditions.
No temperature fault Temperature fault
NO NC NO NC
Common contact Common contact
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► TRIPPING: Electrical contact
The numbers below correspond to the numbers & color code used on the wires
of the DMCR’s connecting block.
NO = Normally Open in normal conditions.
NC = Normally Closed in normal conditions.
No temperature fault Temperature fault
NO NC NO NC
Common contact Common contact
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► Visual
Adjustment screw for Adjustment screw for
ALARM threshold TRIPPING threshold
Warning: for a precise adjustment of the thermostat, its adjustment screw
must first be turned clockwise until the maximum threshold (120°C), and then
turned anti-clockwise until the required threshold.
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3■ ELECTRICAL CONTACTS
SWITCHING CHARGING
POWER
CURRENT CONDITIONS
ALARM and 240V 50Hz 3A Cosϕ > 0.5
TRIPPING 24V 48V DC 0.1A L/R < 40ms
Contacts
110V DC 0.1A L/R < 40ms
PRESSURE 240V 50Hz 6A Cosϕ > 0.5
Contact 24V 48V DC 2A L/R < 40ms
110V DC 30mA L/R < 40ms
OIL LEVEL/GAS 240V 50Hz 3A Cosϕ > 0.5
Contact 24V 48V DC 3A L/R < 40ms
110V DC 3A L/R < 40ms
4■ ADJUSTMENT RANGE
Alarm temperature: from 30 until 120°C.
Tripping temperature: from 30 until 120°C
Needle thermometer indication: from 30 until 120°C
Pressure: from 100 until 500mbar
Oil level/gas detection: electrical tripping threshold adjusted for a 170 cm3
volume decrease.
The temperature and pressure thresholds are adjusted as specified by the
transformer manufacturers’ requirements.
However, in the absence of any specification from the manufacturer, the
following standard thresholds will be set:
- Temperature alarm: 80°C.
- Temperature tripping: 90°C
- Pressure : 250 mB
Warning:
The user can adjust thresholds with a screwdriver. However, should
he be willing to know the exact values after adjustment, it is
imperative to proceed to a new measurement on a dedicated test
bench.
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5■ EXTREME CONDITIONS OF USE
At the design stage, the DMCR has undergone a battery of tests in order to
verify its solidity and endurance.
5■1 Strength test
For 15 minutes, 1 DMCR was put on a test bench under a 3.5 bar pressure
with a 120°C oil temperature.
During this process, no leak was spotted.
Once the test over and after a thorough analysis, no malfunction was spotted.
5■2 Endurance test
For 1000 hours, 1 DMCR was put on a test bench under a 0.5 bar pressure
with a 100°C oil temperature.
During this process, no leak was spotted.
Once the test over and after a thorough analysis, no malfunction was spotted.
6■ RESISTANCE TO EXTERNAL FACTORS
6■1 Anti-U.V. treatment
The DMCR parts which are subject to potential damage from UV are the plastic
body and top. These parts are made of TROGAMID T 5004 material, an anti-
UV treated see-through thermo-plastic material. It is tinted blue at the
manufacturing stage.
Notice: the TROGAMID T 5004 material is usually yellow. Oil being yellow, its
visibility is then made difficult. The blue tint therefore helps a better visibility
of the oil level inside the protection relay.
The color used has no influence on the quality and properties of the
TROGAMID material.
6■2 Protection against mechanical impacts
According to the C 20 015 standard, the protection factor obtained is IK 07.
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IK 07 reminder: by dropping a 0.5kg load from 40cm above the impact
point, the energy released is 20 joules.
6■3 Waterproof
The DMCR is waterproof according to the IP 56 factor as specified in the EN
60 529 standard.
Reminder: - factor 5: protection against water jets
- factor 6: protection against dust
6■4 Saline fog
The DMCR parts which are subject to potential damage from a saline fog are:
- The base: it is made of Aluminium AS7G0.6, impregnated with a
protection resin.
- The plug system: it is made of brass with a nickel plating.
- The body and top: they are made of TROGAMID T5004, a thermo-
plastic material perfectly resistant to saline fog
6■5 Temperature
The relay is suitable for outdoor use at ambient temperature between -40°C
and +60°C.
7■ QUALITY CONTROL PROCEDURE
7■1 Quality control of the components
All the DMCR components and technical parts are subject to a thorough
quality inspection upon their receipt.
A dedicated control procedure is applied to each category of component,
through a selection of samples picked from each batch received.
For some components, every single one of them is thoroughly controlled.
Once the quality control over, we then accept or return batches.
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7■2 Quality control of the finished product
The assembly line is subject to various manufacturing specifications and
control.
► Tooling specifications
In addition to the strict procedure concerning the assembly process and the
use of tooling and machinery, the screwing machines torque and component
storage are also subject to specifications and control.
Control checks on the finished product
Visual control: detailed check to spot any potential assembly faults or
missing component.
Electrical panel control: every changeover contact is electrically tested.
Should any connectivity problem be spotted, the relay is immediately
withdrawn and the problem solved.
Functioning control: preliminary testing of the safety apparatuses (pressure
captor, thermostat, thermometer, Reed switch) in ambient temperature and
without oil.
Air tightness control: the DMCR is put under an internal 1bar pressure for a
short duration, in order to double check that all gaskets have been fitted
properly, and to spot any potential leak.
Insulation control: to ensure that there is no electrical contact between the
metal body and the 12 connecting points on the connecting block.
7■3 Final control procedure: routine testing
Prior to despatch, every single DMCR is tested in real conditions of use on a
specially-engineered test bench: for 90 minutes, each relay is filled in
with oil, at a 80°C temperature, with a 1 Bar pressure, according to
the EN 50 216-3 specification (see 11.1 of this brochure for further
details).
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Every DMCR function is checked:
- Alarm and tripping threshold
- Pressure threshold
- Oil level threshold
- Sampling system
DMCRs are tested in 10 relay series.
Once this test has been performed:
- Faulty relays are withdrawn. Faulty components are replaced by brand new
ones. The newly-repaired relay is then tested again.
- Each DMCR is numbered
- A test certificate is produced
Finally, every DMCR is rinsed with a solvent (SF 41 B) and dried before
packing and despatch.
8■ PACKING
The DMCR relays are packed in boxes of 6 units, in a polystyrene-free
cardboard box, specially designed to protect them from any damage that
might be caused during transportation.
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9■ INSTALLATION, USE & MAINTENANCE
► Fitting the DMCR
The DMCR is designed to be fitted onto the transformer’s tank. If required, a
fitting kit can be supplied with every relay. It includes:
- 1 Viton gasket (66.04x5.34mm)
- 4 attachment hooks in white zinc-coated steel (stainless steel
available on demand)
- 4 nuts DIN 934 8x125 in white zinc-coated steel (stainless steel
available on demand)
- 4 rings 8x18 in white zinc-coated steel (stainless steel available on
demand)
3 or 4 attachment hooks
rings + nuts
DMCR – TECHNICAL BROCHURE Page 18
► Electrical connecting
The transformer user exploits the DMCR functions by connecting its electrical
connecting block to the control panel he uses to signal malfunctions. Located
on the main body, a cable gland enables the user to run the command cable
into the DMCR. An additional hole in the body allows for a second cable gland
to be fitted in if necessary.
Connecting block
Earth screw
Label indicating the
contacts’ position in normal
conditions
Hole for a second cable gland to
be fitted if necessary (M25 type
for Ø13 to 19mm wires)
PG 21 cable gland (for Ø 12
to 18 mm wires)
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► Cleaning
When cleaning the DMCR, to prevent damage to the body and top, it is
imperative to respect the following condition, as recommended by the
TROGAMID T5004 manufacturer.
DO NOT USE VERY HOT WATER OR ANY ALCOHOL-BASED CLEANING
PRODUCT.
► Settings adjustment
The adjustment method for the pressure captor and thermostat is detailed on
the technical datasheet.
SETTINGS ADJUSTMENT MUST STRICTLY BE MADE ACCORDING TO
CONDITIONS DETAILED IN SECTION 4.
► Sampling system
The DMCR plug enables the user to sample gas that might be found in the
relay, thanks to an open-end spanner.
The sampling process is detailed on the technical datasheet.
► Usage control
The DMCR has 3 lead-sealing points, to check any potential interference.
DMCR – TECHNICAL BROCHURE Page 20
10■ CONTACT
► Address
IDEF SYSTEMES S.A.
Z.A. des Crêts de Viry
B.P. 29
74540 ALBY SUR CHERAN
FRANCE
► Phone
+33 4 50 68 19 00
► Fax
+33 4 50 68 19 01
► E-mail
[email protected]
► Website
www.idefsystemes.com
DMCR – TECHNICAL BROCHURE Page 21
11■ APPENDIX
11■1 Routine testing procedure for each DMCR
Description:
All DMCR relays undergo routine testing during which they are subject to
pressure and temperature endurance tests.
To start with, we check teh DMCR relay waterproofness.
All security functions are monitored, adjusted and tested, in the following
order :
- REED switch tripping level
- Temperature alarm
- Temperature tripping
- Pressure
- Oil level control
Starting conditions :
The test bench is ready to have 10 DMCR relays fitted onto it.
Oil temperature is around 70°C.
There is no pressure inside the bench tank.
Indicator lights and digital displays have been carefully checked, calibrated
and programmed.
Test
STAGE 1 PREPARATION OF THE RELAYS
s
- Visual control of the relays. Gaskets,
screws, 1-A
labels,...
- Control of temperature alarm contacts with an 1-B
electric tester.
- Adjustment of temperature alarm contacts to their
minimum level (30°C).
- Control of temperature tripping contacts with an 1-B’
electric tester.
- Adjustment of temperature tripping contacts to
their minimum level (30°C)
- Graduation labels sticking.
- Detailed check of the plugs and sampling systems, 1-C
especially the gaskets.
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Test
STAGE 2 REED SWITCH TRIPPING TEST
s
- Fitting of a DMCR on the REED switch test bench
(without oil)
- Connection between the DMCR connecting block
and the test bench connecting block.
- Raise and lower the main float several times while 2-A
monitoring (thanks to the indicator lights) that the
REED switch trips only once during the whole course
of the float.
- Proceed to a slow lowering of the main float to 2-B
check whether the REED switch trips within the
tolerated range, indicated in black.
- Remove the test bench connecting block.
- Take the DMCR off the test bench and set on the
adjoining worktop.
Test
STAGE 3 TEST BENCH PREPARATION
s
- Fit the DMCR relays into the designated holes on
the test bench. Small
column and
float on the
right
- Position and tighten the fixing system.
- Screw a plug on each relay.
- Connect the DMCR connecting block to that of the
test bench.
- Switch on the test bench by pushing the
« Validation Banc » button.
- Temperature tripping thresholds are adjusted to
their minimum. Orange lights 3-A
are on
- Temperature alarm thresholds are adjusted to their
minimum. Yellow
lights are 3-B
on
- Pressure is nil.
White lights 3-C
are off
- Check that both floats are in a low position.
Red lights 3-D
are on
DMCR – TECHNICAL BROCHURE Page 23
Test
STAGE 4 TEST START
s
- Set the oil tank of the test bench in a high position.
- Set the bench under a 1000 mbar pressure.
- Check that no DMCR is filling in with oil (if one does, then it has a
leak)
- Proceed to filling in every relay with oil, by opening
the plug’s sampling system. Red lights
4-A
Stop filling when oil level has reached one quarter of are off
the DMCR small column.
- Check that there is no leak (internal or external).
- Reset the pressure to 1000 mbar.
White lights 4-B
are on
OPTION : OIL RENEWAL
When at stage 4, if oil-filling each DMCR is proving difficult, pour
an additional 2 litres of oil in the oil tank of the test bench.
DIALA S MINERAL OIL
- For the whole duration of the test, regular checks are performed
on each DMCR relay, in order to identify any of the following
potential malfunctions/problems:
• Oil is found inside the technical box
• Oil seepage on the aluminium base.
• Any leak on the plug and/or sampling system
• Any malfunction of any of the thermostats
• Any malfunction of the pressure captor
• Any malfunction of the thermometre
• Sinking of any of the floats.
THIS LIST IS NOT EXHAUSTIVE !!!
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STAGE 5 ADJUSTMENT OF THE Test
THERMOSTATS s
- Check the tripping level for each thermostat. 5-A
Bench T° =
95°C
Yellow lights
- Set the tripping threshold of each thermostat on are on
the required value, according to the graduations. Orange lights
are on
89°C<< Bench
< 90°C
T°<
- Adjust the tripping threshold of each tripping
5-B
thermostat . Orange lights
are off
79°C<< Bench
< 80°C
T°<
- Adjust the tripping threshold of each alarm
5-C
thermostat . Yellow lights
are off
STAGE 6 ADJUSTMENT OF THE Test
PRESSURE CAPTORS s
- Set the test bench pressure at the required
threshold. Pressure = 250
mbar
- Adjust the pressure captors by rotating its knob
from 500mbar to 250mbar.
- Lower pressure until 100mbar.
White lights
are on
- Increase pressure very slowly until 250mbar and
monitor the tripping of each pressure captor. <Pressure
248<
<250mbar
6-A
White lights
are off
- Adjust the tripping threshold for each pressure
captor
DMCR – TECHNICAL BROCHURE Page 25
STAGE 7 MONITORING OF THE OIL Test
LEVEL TRIPPING THRESHOLD s
- Depressurize the test bench.
- Set the oil tank of the test bench in a low position.
- Position the oil level benchmarking ruler on a
DMCR.
- Open the DMCR sampling system to lower slowly
the oil level.
- Check the oil level tripping threshold against the 7-A
benchmarking ruler.
- Repeat all three processes for every single DMCR.
Test
STAGE 8 TERMINATION
s
- Remove all plugs from the DMCRs and set them
on the adjoining worktop.
- Switch off the test bench by pushing the
« Validation banc » button.
- Remove the test bench connecting blocks from the
DMCRs.
- Loosen the fixing system.
- Remove all DMCRs from the bench.
- Remove all small floats from the DMCRs and set
them on the adjoining worktop.
- Set all 10 DMCRs on the draining table
DMCRs are
upside down
- Stick a number label on DMCRs which successfully
completed all testing stages.
- Set on the bench 10 new DMCRs which
successfully passed through Stage 1 & Stage 2
- Follow the « CLEANING PROCEDURE »
Note n° 1:
The temperature and pressure thresholds mentioned in the Stage 5 and
Stage 6 are considered as standard settings. Customers are invited to
specify their own settings at time of order.
DMCR – TECHNICAL BROCHURE Page 26
Note n° 2 :
During a whole testing procedure, the DMCR relay is subject to oil at an
average temperature of 90°C and 1 bar internal pressure, for a minimum
duration of 1 hour and 15 minutes.
Note n° 3 :
The test bench allows for every single changeover contact to be validated
in both its positions (open and closed).
Note n° 4 :
Will fail the test any relay with any of the following malfunctions :
- oil is found inside the technical box
- oil seepage on the aluminium base
- leak on the plug and/or sampling system
- malfunction of any of the thermostats
- malfunction of the pressure captor
- malfunction of the thermometre
- sinking of any of the floats
- unsatisfactory oil level tripping threshold (height)
- missing component
Note n° 5 :
For every relay, a test certificate is issued by the test operator.
DMCR – TECHNICAL BROCHURE Page 27
11■1 Dimensions
The 282mm dimension corresponds to the DMCR’s height above the
transformer’s tank, once it is fitted onto it.
18
DMCR – TECHNICAL BROCHURE Page 28
11■2 Technical datasheet
The following document (also available in English, German & Spanish) is
included with every DMCR.
It contains all information relevant to the DMCR installation, use and
maintenance.
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DMCR – TECHNICAL BROCHURE Page 30
