INSTALLATION AND OPERATION INSTRUCTION

QJ SERIES GAS RELAY

ISO9001 QUALITY SYSTEM CERTIFIED

SHENYANG SIXING RELAY MANUFACTURE LTD. CHINA

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 INDEX

1. General --------------------------------------------------------------------------------------------------------- 3

2. Structure and working principle ------------------------------------------------------------------------- 3

3. Main technical data ----------------------------------------------------------------------------------------- 4

4. Overall and mounting dimension ------------------------------------------------------------------------- 5

5. Installation and commissioning ------------------------------------------------------------------------- 5

6. Maintenance and repair ------------------------------------------------------------------------------------7

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1. General
1.1. Application
Gas relay is a principal protective device for internal fault inside oil-immersed transformer or oil-immersed
on-load tap changer. Gas relay is mounted in the pipe connecting transformer and oil conservator. In case
of a transformer or on-load tap changer internal fault, which induces oil decomposition into gases or oil
surge, contacts of the gas relay is actuated. Then a control circuit is activated, producing signal or tripping
the transformer.

1.2. Type designation

Q J - 25
Special service environment type
Gas sampling connector ('A is with gas sampling connector)
Pipe through diameter (nominal value)
Type design serial number
Relay
Gas
Note: Special service environment mark
TH: Humid & hot environment; TA: Dry & hot environment; Default: General environment

1.3. Service condition

1.3.1. Service temperature: -30+95

1.3.2. Mounting method: the relay pipe axis shall be parallel to transformer tank top cover. The side
connecting the oil conservator can be slightly higher, but the deflection to horizontal shall not be over 4%.

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2. Structure and working principle
2
2.1. Structure of gas relay
QJ-25 series gas relay has common basic structure. 3 13
The relay switch mechanism is shown in Fig 1 and Fig
12
2. The gas relay structure and working principle is 4
explained below by the example of QJ4-25Its upper 11
5
part, the gas containing device for signaling, consists of 10
(4) weight, (5) float, (11) magnet contact tube and (12) 6
signal magnet. Its lower part, the flowing device for 9
7
tripping, consists of (6) contact, (7) magnet, 8 limit bolt, 8
(9) damper and (10) adjusting bolt. The (1) gas bleeder
on the cover is to remove the gas during installation
1Gasbleeder 2 Probe 3 Spring
and gas sampling during the service. (2) probe is to
4 Weight 5 Float 6 Contact tube
examine the sensitivity and reliability of the tripping
7 Magnet 8 Limit bolt 9 Damper
device.
10 Adjusting bolt 11 Contact tube
12 Magnet 13 Conductor

Fig. 1 Structure of QJ4-25 Series Gas Relay

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2.2. Working principle of relay 1
2.2.1. During normal operation, the gas relay is 13

filled with transformer oil. The float (5) is in the

2
inclined position as in Fig 1. When the
10
transformer has minor internal fault, the
transformer oil is decomposed into gases, which 3

will accumulate in the upper gas chamber of the 9

relay and force the oil level to decrease. Then the 6
float will keep dropping to a certain threshold
8
position, where the magnet contact tube is 7
actuated and trigger the signal circuit, producing
alarming signal. In case the transformer oil level 1 Gas bleeder 2 Probe 3 Spring
6 Contact tube 7 Magnet 8 Limit bolt
drops due to leakage, the same action and 9 Damper 10 Adjusting bolt 13 Conductor
alarming signal will take place.
Fig. 2 Structure of QJ4G-25 & QJ6-25 Series Gas Relay

2.2.2. If there is serious fault occurs inside transformer, the pressure in the transformer tank will
immediately increase and produce oil surge, which goes to oil-conservator and actuates the damper (9).
When the damper moves to a certain threshold position, the magnet will actuates the magnet contact tube
to make, then triggers the control circuit and trips the transformer without any advance alarm. Thus to
protect transformer from escalating damage.

3. Main technical data

3.1. Please refer to table 1 for main technical data
Table 1
Inner Diameter Gas Volume Set oil flow speed range Connection
No. Model Magnet contact tube
(mm) (ml) (m/s) diagram
1 QJ4-25 < 250 Single alarm, single trip 4
2 QJ4G-25 25 1.0 Single trip 5
N/A
3 QJ6-25 Double trip 6
Note: 1. The contact capacity is AC/DC 250V 0.3A. For contact capacity of AC/DC 250V 1A, please specify
when placing the order.
2. For model designating with A at the end, such as QJ-25A, there is a gas collection box equipped to the
relay. Customer can specify when placing the order.

3.2. The power frequency withstand voltage for output terminal to earth and terminal to terminal (when
terminal disconnected) is 2000V/1min, without flashover.

3.3. Free of leakage under 200kPa internal pressure.

3.4. Under vibration with frequency of 4~-20Hz (sin wave) and acceleration of 40m/s2, the tripping contact
will not make.

3.5. With residual pressure of 133pa inside the rely, its free of mechanical damage or permanent
deformation.

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4. Overall and mounting dimension
QJ-25 overall dimension is shown in Fig 3 and table 2
Table 2
Model D0 H L R d
QJ4-25 215 100
QJ4G-25 25 190 200 86 14
QJ6-25 190 86
12 90

M18X1.5
Connect
156.5
H

eR
trac
en
Op
65
35
D0

85
115
d
2 Conservator side
L

Fig. 3 Overall dimension drawing of QJ4-25QJ4G-25QJ6-25 Gas relay

5. Installation and commissioning

5.1. Installation
5.1.1. Before installation and operation of the relay, the inside mechanism must be taken out to check if
the fastener are securely fastened, float and damper can move freely and contact can make and break
reliably.

5.1.2. The relay shall be installed in the pipe connecting the oil transformer and oil conservator. The inner
diameter of the pipe shall be the same as the inner diameter of the relay through passage. The arrow on the
relay shall be directed to the oil conservator. The side of the oil conservator can be slightly higher. But the
pipe axis and horizontal deflection shall be be over 4%. Or a gas bypass pipe can be adopted to allow the
gas easily accumulates in the relay.

5.1.3. The mounting position of the relay shall facility gas sampling, inspection and on-site maintenance. It
should also be fit in the position to allow the inside mechanism to be taken out of the casing. The taken-out
height of QJ4-25 is 130mm.

5.1.4. The electrical connection diagram is shown in Fig 4~6.

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 Airlock Terminal
1 2 3 4

1
2 3
Probe

4
Signal Trip
a) terminal post position diagram b) elementary diagram
Fig 4: QJ4-25 relay connecting diagram

Airlock Terminal
1 3
1

Probe
3

Trip
a) terminal post position diagram b) elementary diagram
Fig 5: QJ4G-25 relay connecting diagram

Airlock Terminal 1 2 3 4
1
2

Probe
3
4

Trip Trip
a) terminal post position diagram b) elementary diagram
Fig 6: QJ6-25 relay connecting diagram

5.2. Testing of relay

The gas relay is a very important protection device for oil-immsersed transformer. Users shall have special
regulations such as before operation, responsible person shall commission, set and sign approval. So the
commissioning and oil flow setting shall comply with certain stipulation.

5.2.1. Adjust air volume

Adjust the air volume by changing the position of the weight in the open cup or changing the position of the
magnet contact tube, fasten the fasteners after the adjustment.

5.2.2. Oil flow setting

Adjust the oil flow speed for the tripping operation contact by adjusting bolt connected to the spring to

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change the pulling force of the damper. fasten the fasteners after the adjustment. The operation oil flow
setting shall be done by special flow calibration device by trained personnel.

5.2.3. The rotation angle adjustment of the damper

Adjust the rotation angle of the damper by the limit bolt, viz. adjust the distance between the magnet and
magnet contact tube (0.5 ~1.0mm), to ensure the reliable make and break of the contact tube.

6. Maintenance and repair

6.1. The gas relay shall perform an annual inspection on the appearance and alarm & tripping signal
reliability.

6.2. For gas relays in service, its cover shall be opened every two years for the inspection of internal
structure and operation reliability.

6.3. For gas relays in service, the power frequency test shall be done every five years.

Shenyang Sixing Relay Manufacturing Co.. Ltd.

Add: Room 3, No.11, Taibaishan Road, Huanggu District, Shenyang, China
Tel: +86 (24) 31203508
Fax: +86 (24) 31203507
Post code: 110036
Web site: http://www.sxrelay.com
Email: sysxrelay@163.com

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