Elektromotoren und

Gerätebau Barleben GmbH

Monitoring Relay
for Tap Changers
Elektromotoren und Gerätebau Barleben GmbH

Table of Contents
Page

Company history 3

1. Preface 4

2. Design features 5

3. Function 6

4. Tests 7

5. Type list 8

6. Switching system design options 9

7. Technical data 10

8. Versions/special designs 11

9. Explanation on code 97 12

10. Use of monitoring relays in combination with Buchholz relays 13

11. Ordering data/type code 14

12. Other products of EMB GmbH 15

12.1. Transformer protection relays (Buchholz principle) 15

12.2. Additional devices for Buchholz relays 16

12.3. Monitoring device for hydro-type compensator 18

12.4. Breathing buffer box 19

2
Company history
Since its foundation the company has passed through an eventful history with regard to
ownership, affiliation and change of name associated with such development.

1863 Foundation of the company as a sugar factory

1921 Invention of the Buchholz relay by Max Buchholz
1943 Branch of SIEMENS Magdeburg
1948 VEB Elektromotorenwerk Barleben; VEM
(state-owned firm)
1951 VEB Starkstromanlagenbau Magdeburg
(state-owned firm)
1951 Start of manufacture of Buchholz relays in Barleben
1965 Start of manufacture of monitoring relays for step changers in Barleben
1970 VEB Elektrotechnik und Gerätebau Magdeburg; EGEM
(state-owned company)
1980 VEB Kombinat Elektromaschinenbau Dresden
VEB Elektromotorenwerk Barleben; VEM; ELMO
(state-owned company)
1990 VEM Antriebstechnik AG Dresden
Elektromotorenwerk Barleben GmbH; VEM; ELMO
(public limited company)
1993 Elektromotoren und Gerätebau Barleben GmbH; EMB
(privately owned company)
2005 Start of manufacture of Buchholz relays of series NM
2009 New premises in Barleben

EMB company building

3
Elektromotoren und Gerätebau Barleben GmbH

1. Preface

More than 1.5 million relays

(Buchholz and monitoring relays)
have been sold worldwide since about 60 years!

The monitoring relay for tap changers, also known as the protection relay for tap changers or oil flow
relay, is a monitoring device for insulating liquid-filled tap changers with conservators. It protects the
tap changer and the transformer from damage. The monitoring relay responds to excessive oil flow in
the direction of the conservator and generates a signal disconnecting the tap changer and the trans-
former immediately from voltage supply.

The monitoring relay is suitable for open-air as well as indoor installation.

Elektromotoren und Gerätebau GmbH (EMB GmbH) provides more than 45 years experience in pro-
ducing monitoring relays and other protection devices for liquid-cooled and liquid-insulated applian-
ces. It ranks among the most distinguished manufacturers of this type of equipment.

EMB monitoring relays feature easy operation, high reliability and a very long life.

Our staff of highly qualified engineers and experienced skilled workers ensures top quality and high-
precision products. The casings are machined on modern CNC controlled machine tools. All products
are subjected to final inspection when all functions are checked using special test equipment.

Profound experience and expertise in this special field are a sound basis for high product quality.
Extensive references from reputed tap changer and transformer manufacturers as well as other users
are proof of the high qualitative level of the products.

EMB GmbH is certified to DIN EN ISO 9001/2008, DIN GOST R, IEC and AEO F.

Figure 1. - Certificates

4
2. Design features

Casing (Figure 2.1.)

The casing is made of weather-resistant cast

aluminium alloy provided with a paint coat.

To check the switching system for proper

function, the casing is provided with sight-
glasses arranged opposite each other and
protected by hinged lids (1).
1

Figure 2.1. - Casing

Cover (Figure 2.2.)

The cover is made of weather-resistant cast

aluminium alloy provided with a paint coat.
The upper section of the cover accommoda-
tes the terminal box (1). The test and reset 7
key covered by a cap nut (2), a screw plug
8
(3) or, alternatively on customer’s request, a
bleeder valve (see section 9. „Explanation on
code 97“) are arranged in front of the terminal
box. In addition a plate (4) with instructions
for actuating the test and reset key is arran-
ged there. The terminal box (1) accommoda- 9
tes the earth terminal (5) and the bushings 5
(6) for the terminals provided in the base of 6
the cover.
1
The terminal box is sealed by an aluminium
cap (7) so that it is safe to touch and protec-
ted against pollution. If the cap is opened the
graphic symbol and the connection diagram
3
(8) are shown. The cable is inserted through
2
the cable gland (9).

Figure 2.2. - Cover with cap removed

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Elektromotoren und Gerätebau Barleben GmbH

Switchgear

The switchgear has the following main components:

- Switching system
- Frame
- Mechanical testing unit.

The switching system consists of the following components:

- Damper
- Permanent magnet(s)
- Magnet contact(s).

The damper is retained in its normal and response positions by a magnet. Via a link the permanent
magnet is firmly connected with the damper and initiates the contact-making process of the magnet
contact tube.

3. Function
The monitoring relay is installed in the pipe between the tap changer and the conservator as close
as possible to the tap changer head.

During normal operation of the tap changer gases are generated which are collected in the gas
dome of the monitoring relay. If the gas volume exceeds the volume of the dome, the gas flows in
the direction of the conservator.
Fault: An incident causes an oil flow in the direction of the conservator.

Response: The liquid flow reaches the damper. If the flow rate exceeds the operating value of the
damper, the latter moves in flow direction.

This movement actuates a switch contact, and the tap changer and the transformer are
disconnected.

Gas

Oil

Figure 3. - Functional principle of damper

6
4. Tests
Each monitoring relay is provided with a works number that is specified on the test certificate and the
name plate. The tests carried out on the monitoring relay are recorded in the test certificate:
- Dielectric strenght test
- Leakage test
- Functional test
- Flow test.
Monitoring relays are delivered in cardboard boxes.
For each relay delivered the following documents in the language
agreed are provided:
- Operating instruction
- Test certificate.

Note: Flange gaskets are not included in the scope of supply!

Exception: Type 16 (ÜRF 25/10-26)

The name plate covers the following information:

Date of manufacture
Type
(week/year)
Type code/
damper setting

Works number switching IP code

6 digits element
S = normally-open
Ö = normally-closed
W = change-over

Figure 4.1. - Functional and leakage test Figure 4.2. - Flow test

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Elektromotoren und Gerätebau Barleben GmbH

5. Type list
Weight
Pipe
Type Flange dimensions Device dimensions without
Type of connection diameter
Internal description (mm, in) (mm) packing
DN (mm)
(kg)

d1 d2 d3 d4 d5 f l h1 h2

12 Flange
(ÜRF 25/10) 4-hole 25 115 85 68 14 16 200 195 62 4.0

15 Flange
(ÜRF 25) 4-hole 25 115 85 - M12 15 160 185 62 3.6

16 Flange l1=200
(ÜRF 25/10-26) 4-hole 28* 115 85 - 14 16
l2=204**
195 62 4.0

170
75
h1
h2

R80
d5

f d1
l d4
d3
Figure 5.1. - Dimensional drawing, type 12 d2

170
75
h1
h2

R 80
d5

f d1
l d3
Figure 5.2. - Dimensional drawing, type 15 d2

170
75
h1

h2

R8
d5

f d1
l1
d3
l2
d2 * Suitable for pipe diameter DN 25 and 26 mm
Figure 5.3. - Dimensional drawing, typ 16 ** l2 = with sealing
l1 = without sealing

8
6. 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 magnet contact tube design can be derived from
the last two digits of the type code. For coding, see Ordering data/type code under Section 11. on
page 14.

...01 ...02 ...03 ...04 ...05 ...06

1 NO 1 NC 1 CO 2 NO 2 NC 1 NO and 1 NC

13 11 1 13 23 11 21 13 11

14 12 2 4 14 24 12 22 14 12

...07 ...08 ...09 ...10 ...11

2 CO 1 NO and 1 CO 1 NC and 1 CO 3 NO 2 NO and 1 NC
21 11 23 11 21 11 13 23 33 13 23 11

22 24 12 14 24 12 14 22 12 14 14 24 34 14 24 12

14 13 24 23 14 13 24 23

34 33 12 11

Explanation of symbols: Example: Coding „...03“

Magnet contact tube design
1

Graphic symbol with terminal marking

1 CO
2 4

Connection diagram in terminal box

The inner side of the cap accommodates a plate with the graphic symbol and the connection
diagram. The schemes show the switching systems in their neutral position. The neutral po-
sition is the operating condition when the device to be protected operates without any fault.

9
Elektromotoren und Gerätebau Barleben GmbH

7. Technische Daten

The technical data in the table apply to all monitoring relays of standard design manufactured by EMB.

Parameter Value/data Remarks

Voltage AC 5 V - max. 250 V Note max.
DC 5 V - max. 250 V switching capacity.
Current AC 0.01 A - max. 6 A Cos φ > 0.5 Note max.
DC 0.01 A - max. 6 A L/R < 40 ms switching capacity.
Switching capacity AC max. 1500 VA
DC max. 1250 W
Dielectric strength AC 2500 V between electric circuit and earth
AC 2000 V (NO, NC) between open contacts
AC 1000 V (CO)
Temperature range:
- Ambient temperature - 40 °C to + 55 °C Climatic test acc. to
- 40 °F to + 131 °F DIN EN 60068-2-78: 2002-09
- Operating range
* Temperature of insulation liquid - 40 °C to + 115 °C Up to + 135 °C requires version 21
- 40 °F to + 239 °F

* Viscosity of insulation liquid 1 mm2/s to 1100 mm2/s

Insulating liquid Mineral oil
Resistance to vibration Vibration: 2-200 Hz, 1 g
Shock: 10 g, 11 ms
Resistence to pressure 0.25 MPa
Resistence to vacuum < 2.5 kPa
Resistence to magnetic fields 25 mT Magnetic balance in any direction and
polarity
Switching system:
- Number of switching contacts 1 See section 6. on page 9
- Switching element Magnet contact tube
- Damper held by magnets

Response time of damper < 0.1 s

Insulation liquid flow For potential data, see order data/ type
Pipe diameter DN: Min. 0.90 to max. 4.00 m/s code under section 11. on page 14.
25 mm oder 26 mm ± 15%
Cable gland M20x1.5; M25x1.5
Nominal installation position 2° to 4° Ascending towards conservator
IP code IP 56
Casing paint 2-component texture paint On polyurethane basis

Other versions and special designs are listed under section 8. on page 11. These additional
versions are provided with a separate code in the ordering data/type code.

Other options are available on request.

10
8. Versions/special designs

Cable gland *
Explanation Code
M20x1.5: 1 cable gland and 1 dummy plug 1
M25x1.5: 1 cable gland and 1 dummy plug 2
M20x1.5: 2 cable glands 3
M20x1.5: 2 cable gland and 1 dummy plug (enclosed) 3B
M25x1.5: 2 cable glands 4
M25x1.5: 2 cable gland and 1 dummy plug (enclosed) 4B
1/2“ NPT: 1 cable gland and 1 dummy plug 6
1/2“ NPT: 2 cable glands 7
Cable gland: on customer’s request 9

Casing colour *
RAL 7001 (silver-grey) 41
RAL 7012 (basalt-grey) 42
RAL 7022 (umber-grey) 43
RAL 7033 (cement-grey) 44
RAL 7038 (agate-grey) 45
RAL 7035 (light-grey) 46
RAL 7016 (anthracite-grey) 47
RAL 9002 (grey-white) 48
RAL 7032 (siliceous-grey) 49

Climate-proof version/IP code

Climate-proof version (extreme frigid open-air conditions below - 40°C) 34
Climate-proof version (offshore) 36
IP 66 39

Insulation liquid
Insulating liquid, silicone oil 20
Insulating liquid on ester basis 21

Casing
Metal name plate 15
With bleeder valve 97
With gasket (ÜRF 25/10-26 only) 98

Switching system (for design options, see section 6. on page 9)

Switching system equipped with two magnet contact tubes 25
Switching system equipped with three magnet contact tubes 99

Customer’s request
Special request (as agreed with customer) 29

* Mandatory ordering data, for other mandatory data see section 11. on page 14

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Elektromotoren und Gerätebau Barleben GmbH

9. Explanations on code 97

Monitoring relays for tap changers with bleeder valve (1) can be vented through the bleeder valve,
if required.

For further information about the construction of the monitoring relay,

see section 2. on page 5.

Figure 9.1. - Monitoring relay with bleeder valve

Figure 9.2. - Changed dimensions compared to standard version

For other dimensions of the monitoring relay, see section 5. on page 8.

12
10. Use of monitoring relays in combination with Buchholz relays

EMB monitoring relays were developed to reliably protect tap changers and transformers from da-
mage. In the event of excessively high oil flows in the direction of the conservator a signal is sent that
immediately disconnects the tap changer and the transformer from voltage supply.

However, monitoring relays do not provide protection from gas accumulation as is required increa-
singly today for the protection of vacuum tap changers. In order to ensure both reliable protection
from excessive oil flows and warning in the case of gas accumulation, EMB monitoring relays of type
16 (ÜRF 25/10-26) can be combined with an EMB Buchholz relay of type 06 (BF 25/10). In this case,
the Buchholz relay also provides protection from loss of insulating liquid.

For that purpose, BF 25/10 is installed in series directly downstream of ÜRF 25/10-26. In the event
of an excessive oil flow, the monitoring relay will disconnect the tap changer from voltage supply. In
order not to affect this reaction, the damper of the Buchholz relay is usually set to a response value
of 3.0 or 4.0 m/s. The Buchholz relay will respond by generating an alarm signal in the event of gas
accumulations, and by disconnection in the event of loss of insulating liquid.

Installation material supplied to

connect monitoring relays and
Buchholz relays
Qty. Description
1 Flange gasket 115 x 40 mm
4 Stud bolt 12 x 60
8 Hexagon nut M 12
8 Spring washer,
corrugated 12 mm
Figure 10. - Combination of monitoring relay and Buchholz relay

Technical data
Parameter Monitoring relay Buchholz relay
Type 16 (ÜRF 25/10-26) Type 06 (BF 25/10)
Voltage AC 5 V - max. 250 V AC 5 V - max. 250 V
DC 5 V - max. 250 V DC 5 V - max. 250 V
Current AC 0.01 A - max. 6 A AC 0.01 A - max. 6 A
DC 0.01 A - max. 6 A DC 0.01 A - max. 6 A
Switching capacity AC max. 1500 VA AC max. 1500 VA
DC max. 1250 W DC max. 1250 W
Dielectric strength:
- between electric circuit and earth AC 2500 V AC 2500 V
- between open contacts AC 2000 V (NO, NC) AC 2000 V (NO, NC)
AC 1000 V (CO) AC 1000 V (CO)
Gas accumulation - 250 ml ± 15 %
Insulation liquid flow 0.90 to max 1.5 m/s ± 15 % 3.00 to max. 4.00 m/s ± 15 %

For further information, please ask for special reference material.

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Elektromotoren und Gerätebau Barleben GmbH

11. Ordering data/type code

For placing orders, please use the following key:

XX X. XX. XX. XX XX
Type (see section 5.)

Cable gland (see section 8.)

Casing colour (see section 8.)

Versions/special designs

Damper setting (m/s)

01 = 0.90 ± 15%
02 = 1.00 ± 15%
03 = 1.20 ± 15%
04 = 1.50 ± 15%
05 = 2.00 ± 15%
06 = 2.50 ± 15%
07 = 3.00 ± 15%
08 = 4.00 ± 15%
09 = 1.30 ± 15%
Contact setting
01 = one NO contact
02 = one NC contact
03 = one CO contact
04 = two NO contact
05 = two NC contacts
06 = one NO and one NC contact
07 = two CO contacts
08 = one NO and one CO contact
09 = one NC and one CO contact
10 = three NO contacts For switch system design options,
11 = two NO and one NC contac see section 6. on page 9.

Ordering example:

A customer needs a monitoring relay of type ÜRF 25/10 with cable gland and a dummy plug M20x1.5.
The damper should respond at a flow rate of 2.00 m/s. The switching system should be equipped
with 2 switching elements (magnet contact tubes). One contact should be normally-closed, the other
one normally-open. The device should be delivered in colour RAL 7033.
(Note: The unit is suitable for use of standard mineral oils and standard degree of protection IP 56)

Based on the above data the relay ordered has the following

Type code: 12-1.25.44.-0506

Explanation: 12 = ÜRF 25/10

1 = M20x1.5: 1 Cable gland and 1 dummy plug
25 = Switching system with two magnet contact tubes
44 = Casing colour RAL 7033 (cement-grey)
05 = Damper setting: 2.00 m/s +/- 15%
06 = Contact setting of switching system: one NO and one NC contact

14
12. Other products of EMB GmbH
Elektromotoren und Gerätebau Barleben GmbH also offers protective and control units for liquid-
insulated transformers and choke coils.

12.1. Transformer protection relays (Buchholz principle)

Single and double float Buchholz relays manufactured to various

norms and standards as well as special requirements.

The Buchholz relay is an important protection and monitoring device for

insu-lating liquid filled transformers with conservator and choke coils. It
also allows separate monitoring of oil-filled bushings or cable terminal
boxes.

Pipe diameter DN: 25 mm (1“), 50 mm (2“), 80 mm (3“) Type of connec-

tion: threaded or flanged

Buchholz relay of type 22 (BB 25)

for use in rail cars
Pipe diameter DN: 25 mm (1“)
Type of connection: threaded

Other Buchholz relay types

for use in rail cars
Type 04 (BG 25)
Type 21 (BG 25 S)
Type 06 (BF 25/10)
Type 08 (BF 50/10) and others

NM series – New generation of Buchholz relays

Buchholz relay with analogue measurement of gas volume

The Buchholz relay of NM series is equipped additionally with a capacitive

sensor. It allows continuous and analogue gas volume measurement so
that gases which have accumulated in the relay are detected at an early
stage, information about the generation of the gases obtained and the
conditions provided for fault analysis at an early stage. Analogue mea-
surement of the gas volume is possible between 50 cm3 and 300 cm3.

Pipe diameter DN: 25 mm (1“), 50 mm (2“), 80 mm (3“)

Type of connection: threaded or flanged

For further information, please ask for special reference material.

15
Elektromotoren und Gerätebau Barleben GmbH

12.2. Additional devices for Buchholz relays

Gas sampling device ZG 1.2.

The gas sampling device is mounted on the transformer and connected

to the Buchholz relay by means of a pipe. It allows sampling of the relay
gas at normal operating level. The length of the pipe can be selected by
the customer. The device can be delivered with a lockable box.

Gas testing devices ZG 3.1. and ZG 3.2.

The gas testing devices are used to test the gas accumulated in the
Buchholz relay. They can be installed either directly on the test valve of
the Buchholz relay or on the gas outlet tap of the gas sampling device.

- ZG 3.1.
The Buchholz gas flows through two different chemical solutions and the
colour reactions indicate the nature of the fault.

Note: Chemical solutions are not included in the scope of supply.

Use of the gas testing device is no substitute for a gas chromatographic

analysis.

- ZG 3.2.
The Buchholz gas flows through two different test tubes, and the colour
reactions allow conclusions about the availability of carbon monoxide and
hydrogen.

Use of the gas testing device is no substitute for a gas chromatographic

analysis.

For further information, please ask for special reference material.

16
 Reflux lock ZG 4.1.

The device prevents insulating liquid from flowing into the gas testing de-
vice. The device is installed between the Buchholz relay or gas sampling
device and the gas testing device.

Test pumps ZG 5.1. and ZG 5.2.

The test pumps check the function of the upper switching system (alarm)
of the Buchholz relay by pumping in air. The test can be performed direct-
ly on the Buchholz relay. For that purpose, the test pump is connected to
the test valve of the Buchholz 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

Oil sampling device ZG 6.1.

The oil sampling device is connected to the Buchholz relay via a pipe and
is used to take oil samples from the Buchholz relay (suitable for use with
Buchholz relays with an oil drain plug). The pipe is supplied to customer’s
specifications.

For further information, please ask for special reference material.

17
Elektromotoren und Gerätebau Barleben GmbH

Buchholz gas sampler BGS

The Buchholz gas sampler provides a safe method of taking and trans-
porting gas samples from the Buchholz relay or the gas sampling device.
Its capacity is 100 ml.

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 at
the place where the sample is taken.

12.3. Monitoring device for hydro-type compensator

Type 80 (CF 38)

This device serves to monitor the hydro-type compensator (air sack,

membrane) in the conservator.
Single and double-float Buchholz relays manufactured by EMB GmbH
are also used as air-cell failure relays.

For further information, please ask for special reference material.

18
12.4. Breathing buffer box

Breathing buffer box G3B

to extend the life of transformers

Aging of the insulation system of a transformer is accelerated by oxygen

dissolved in oil. In open-type transformers the oxygen consumed in this
process is replenished from the atmosphere. This has negative long-term
effects.

The breathing buffer box (G3B) installed in the breathing line of the trans-
former upstream of the desiccant solves this problem. It ensures hermetic
sealing of the transformer.

For further information, please ask for special reference material.

19
 Elektromotoren und
Gerätebau Barleben GmbH

Hamburg

EMB GmbH
Otto-von-Guericke-Allee 12
D-39179 Barleben | Germany Hannover
Barleben Berlin
Magdeburg

Phone: +49 39203 790

Fax: +49 39203 5330 Köln Leipzig

Email: [email protected]
Frankfurt
Website: www.emb-online.de
www.buchholzrelay.com

München

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 proof-reading. We assume no liability for
such errors. Thank you for your understanding.

Edition: Catalogue, monitoring relay KA 07/01/14/02 English