GILLAM - FEi

IDC20K
Current generator for testing
railway circuit-breakers
User Guide

Written by : J. Bonardot / K. Flammang

Date

Ref. Doc. :
Revision :

GILLAM - FEi SA

Mont Saint-Martin 58

: (+32) 4/232 95 95 - Fax: (+32) 4/223 42 76

E-mail : info@gillam-fei.be
Internet : www.gillam-fei.be

05/08/2011

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4000 LIEGE
BELGIUM

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HISTORY SHEET

REV.

DATE

SUBJECT

MODIFIED
PAGES

13/04/11

First release

14/04/11

Addition of software part

15/04/11

Revision of software part

05/08/2011

Addition of language configuration (3.7)

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TABLE OF CONTENTS
1.

2.

Introduction ....................................................................................................................... 1
1.1.

Equipment presentation ......................................................................................................1

1.2.

Contents of this user guide ..................................................................................................1

Equipment Description ..................................................................................................... 2

2.1.
2.1.1.
2.1.2.

3.

The ICK20 control module..................................................................................................2

A Man Machine Interface................................................................................................................ 2
A control module situated in a 2U rack........................................................................................... 2

2.2.

IJK20 injection modules ......................................................................................................3

2.3.

Connection ............................................................................................................................3

software Description.......................................................................................................... 5
3.1.

Starting-up ............................................................................................................................5

3.2.

The menu...............................................................................................................................6

3.3.

Injectors status .....................................................................................................................6

3.4.

Current curve loading..........................................................................................................7

3.4.1. Parameterizable function loading .................................................................................................... 7

3.4.2. File loading...................................................................................................................................... 7
3.4.2.1.
Files format............................................................................................................................ 7
3.4.2.2.
File opening ........................................................................................................................... 7

3.5.

Current curve injection .......................................................................................................8

3.6.

Curve saving .........................................................................................................................8

3.7.

Language configuration.......................................................................................................8

3.8.

Curves display configuration ..............................................................................................9

3.9.

Calibration ............................................................................................................................9

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1.

INTRODUCTION

1.1. Equipment presentation

The current injector (IDC20K) is a modular designing equipment aimed at testing circuitbreakers used in high voltage direct current traction networks, or any other intense direct
current equipment.
Tests are performed on insulated devices of the traction network, by injecting by means of
large section cables an arbitrary shape current, with a maximum value of 20000A and a
maximum duration of 500ms.
A standard 230V 16A main supply switch is required for its power supply.

1.2. Contents of this user guide

Equipment description

Sub-assemblies connection instructions

Presentation of the graphical interface

Description of software, functionalities, parameters

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2.

EQUIPMENT DESCRIPTION

The equipment's design is modular and transportable; it is integrated in transportation cases.

It includes among others a control case and maximum five identical injection cases.
The number of injection cases depends on the current required for the test planned,
considering that each injection module is able to supply a maximum current of 2500A.
Each module's connecting cables are included in their respective case.

2.1. The ICK20 control module

This module, located in a case, includes two elements :
2.1.1. A Man Machine Interface
It is composed of a PC located in a 1U high slide drawer.
From the PC screen, you can :

Supervise the operation of each connected injector, especially the good condition of
its electrical connection to the control module and to the main supply, its load state
and a possible failure occurred during an injection.

Create in graphical form the selected instruction current wave to realize the test.

Realize the injection by "left click" with confirmation by "Enter".

View the current shape really injected during the test, upon selection, on a separate
graph or stacked on the instruction; during a circuit-breaker test, the opening time of
this one appears clearly on the return wave.

Store results of tests and various instructions for future use.

2.1.2. A control module situated in a 2U rack

This module is electrically connected on the front panel to 230V main supply by means of
cables. It has a power on switch and eight connectors numbered from 1 to 8 that allow
creating a link by means of a cable specific for each injector used for the test.
This control rack, which is connected by USB link to the PC, realizes in fact a supervision
and control interface electrically insulated between the PC and the injectors.

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2.2. IJK20 injection modules

The injection module has the form of a 3U 19" rack situated in a case.
This case is provided with two front and rear covers; it allows this way storing on the rear
part the two power cables, the connecting cable to the control module and the mains cable.
A 10 points connector is present on the injection module front panel to allow connection to
the control module.
On the front panel, you can also note two power terminals, a red and a black one, that will be
connected to the tested device by means of "push pull" connectors of power cables of
respective colors.
Two connectors, input and output, situated on the front panel allow to chain the power supply
of X modules dedicated to testing. The first injector is connected by means of its input switch
to a mains switch by means of a standard cord; the mains is then chained towards the other
modules by means of the various mains input, output switches and the short, male female
mains cables.
When an injection module is properly connected, on one hand to 230V mains and, on the
other hand, to control module, and when the latter and the PC are under power, a waiting
time of about 10 minutes is required to realize the first load necessary to perform tests. After
a first injection, a maximum reload duration of one minute is required before realizing a new
injection.

2.3. Connection
1)

Injection modules can equally be placed flat, stacked or put vertically, with horizontal
front panel, one next the other, next to the device to be tested.

2)

Power cables are 3 meters long.

Connect, on one hand, power cables marked in red and black to power terminals of
the same colors on each injector module used; a male female foolproofing allows to
avoid polarity reversal.

3)

Connect, on the other hand, other cable ends to the device to be tested by means of
two copper plates (one + one -) especially arranged for the test and equipped one with
terminals and the other with pin-head adapters compatible with the cables and
sufficient in number to connect the quantity of modules required for the test.

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4)

Connect to 50Hz alternating 230V mains the first module by means of a mains cord
usually available in the control case, and then chain all the other injectors at "input"
and "output" mains switches level, by means of "male" and "female" mains cables
present in each injector case.

5)

Connect by means of the multipair linking cable the "control" input of each injector
module to one of the eight "?" outputs of the control module.
There is no connection sequence to follow; for instance the injector module that will
be connected to output "4" shall be considered as being injector n"4" at visual
interface level.

6)

For usability, the control case can be located at about 3 meters far from the injectors
group (length of multipair connecting cables).

7)

Connect also the control rack to 50Hz alternating 230V mains by means of the second
mains cord located in the control case.

8)

Power on the unit through M A switch on the front panel of the control device.

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3.

SOFTWARE DESCRIPTION

3.1. Starting-up
To start the program, the user must execute the IDC.exe file, situated in the installation
folder (ProgramFiles) or use the shortcut on the Desktop .
The software main window is composed of :
A table of LEDs showing injectors status,
Graphs showing sent and received curves,
A tool for generating short-circuit or constant curve on a given maximum intensity,
A panel allowing to select the number of required injectors and to realize the
injections.

The detection and the connection with the control module are carried out automatically at
starting-up or when powering on the control module.
If the control module is not detected, check whether cables, power supply and USB are
properly connected and whether the module is on.

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3.2. The menu

File
Open allows loading a file containing points that show a current curve. The
currently supported file type is .ddl (see 3.4.2).
Save allows saving the resulting curve or the theoretical curve in a file at .ddl
format.
Close closes the program.

Configuration
Graphs allows merging both graphs in a single one.
Log book displays messages on the operating status of the control module.
Language language selection (French, English, Spanish).
Calibration displays a panel allowing to calibrate the control module.

Module
Injection realizes the curve injection (see 3.5).

3.3. Injectors status

Injectors status is represented by the following panel :

This panel displays for each injector the 3

status in which an injector can be :

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Injector connected (green) / not

connected (grey)
Injector charged (green) / discharged
(red)
Error (red on) / no error (grey)

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3.4. Current curve loading

Curve loading can be performed in two ways. Curves can be generated either using a
parameterizable function, simulating a resistant circuit without any train on the line, or
loading the DDL file containing a current curve representation.
3.4.1. Parameterizable function loading
The following panel allows parameterizing a function generating either a short circuit curve
or a constant on a given maximum current intensity.

To generate a short circuit curve, default displayed parameters are the typical values of a 3kV
network (Belgium). These include following parameters :

Voltage of the substation in Volts

Inductance in kilometres of catenary circuit + return by rails and ground
Resistance in kilometres of the same circuit
Fault resistance
Distance in kilometres between fault and substation

The number of injectors required to inject the current curve is then automatically configured.
3.4.2. File loading
3.4.2.1.

Files format

The application allows loading files with a .dll extension.

.dll files are provided by GILLAM-FEi and present on the computer driving the control
module.
3.4.2.2.

File opening

File loading can be realized in several ways :

Through menu File  Open ,
Through icon ,
Selecting the file in Windows and dragging it on the application main window
(Drag and drop).

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3.5. Current curve injection

Max intensity
according
to
injectors
number

To realize an injection, following conditions should be respected :

A curve must be loaded;

The number of connected and ready injectors must be sufficient to provide the
current quantity required to generate the current curve.

When above mentioned conditions are fulfilled, the user is able to realize the injection, either
by clicking on Injection or by following the menu option.
After the injection, the curve of the current really injected is displayed in the second graph.
In case of error during the injection, a restart of control module and software is imperative.

3.6. Curve saving

The software allows saving the result of an injected curve at .ddl format. Recording is
performed through File  Save menu or through
icon.
A curve can be saved as an image. Graph saving in an image format is realized by right-ckick
on the selected curve and by selecting Save image as in the pop-up menu.

3.7. Language configuration

The application can be configured in different languages (French, English, Spanish) through
the language selection panel accessible through the menu.

Records
the
permanently.

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3.8. Curves display configuration

By default, each curve is drawn in a separate area as shown below :

Through the Configuration menu, you can configure curves display to compare both
curves on the same graph; you just have to select Overwritten in the Configuration 
Graphs menu to get the following display :

3.9. Calibration
The calibration
panel,
accessible from
the
Configuration menu, allows to send a 4mA or 20mA
signal on the eight outputs of the control module.

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