Home

ipc1 user manual issue 8

1. NSO ION Had NOLLO3LOHd CHILVvHOL EN 09 m AS 73 ved OHINOOANY avd Fr tl 1 3 L Uu lu8ni AO JON od x Zumnd o Orid uon 10 ojerido1dde 81125 8 soq Sey porous st sj j1 y nso1 saotAop 9891045 Koo surejuoo se uoZ 9 pedduj pouado oq jou jsnur stu El DNINSVA Wed 109502 sumo AEE lt JICEOWOO 103 VINDO ANE E sumo 01 lt 3 2 2219 0001 VINDO 2840001 suo rv lt STI OINDO 10 SI VW22 ASI anpeA 3uneiodo 1003201 HLAVA 5 1 L WYO HNO09 gt 3 1 H
2. 0 6 8 1 9 S 7 ev S1130 one L gir conr w E pl B 6 88 ONILNNOW 9 LN3I3ONVHSV VAINIO Govone Eu VINNY 9822 MSN E 2S 2B FINGOW ILONIY 60 10 21 HE JOHLN ScIAV Wud ASIMYSHLO 03116 i amp 8 aff 0 0 8 adi WOH sa mm m 8 3iva 3WVN Ald WSO TOHLNOOSdNV Jo Ayedoid Bumeup siu _ PQ 110919 TS uu 016 1589178 urejureu Jo no n2 o y WGu L MA E 2 JON 3 3 S 110 1102 50 2 3 O UI 0 N IA Jeoy UNUNOW DuIMOUS Tog 088 0 8 0 2 d L _ cup 746 o N f uny OS 00 43 OA d d SM9JOS pec 3 V 7 0 80 ZNV 211426 5600181 xq VAW LIF xg TOULNOOdNV 0801 0 6 8 1 9 S 7 27
3. Earth Leakage Toroid Maximum Short Time type AMPCONTROL EL 500 gt Rating of 16 3 Sec In omin 2 Test Resistor ta mSec Suppi 1 ntrinsic Safety may be 6 R eft 200 Ohms compromised if this level a tee needs to produce test current exceded of 100 160 of Trip Level Conti A B Cable Connection Module Supply Control 110Vac Isolator 415V System Ampcontrol 415 MR CR a 1000V System Ampcontrol CCMA 1000 A I 3 3kV System Ampcontrol CCMA 3 3k E MC 415 System Ampcontrol 415 Control m 1000V System Ampcontrol 1 er h 3 3kV System Ampcontrol CCMC 3 3k OTHER TRIPS 110Vac Sec uy LT VN XN XN RLA to AS 3108 1 C Earth Fault Test Resistors LL 022 415 91K Ohms 415 2 4 Ohms mass _ Isolation Chamber 0564 CCMA 1000 220K Ohms 1 2 4M Ohms CENE CCMA 3 3k 680K Ohms CCMC 3k3 7 68M Ohms as Over Load CT s to other rae 1000 1 Class 2M Outlets Sc STC Rating 20kA 3 Sec E Note Phasing on Overload C T s Must 2 be as Shown 47 49 si s s 54 s 56 b 19 Stop K lp g BL PM
4. 01 6 8 4 9 5 H 0 1VH3N39 Pr pode TES 008 Z 19 d D saged 9 80 4 Mida Mec pera anno apy g lt LINN LAdLNO AV 133 IOELNODANG Wad ISIMY3H10 m 50 Vdl 0 9102 w x 3800 een OD are A parody 2 3WVN A11 Ald WSO TOHINOOdNV 00187 o Kyedoid I CI q I 3 00706 aD i s B T L 8 d 5 5 3 Y XI 21 7159579 vd OL J VAO 1 EGO 4 29 535 C NS nr 5 y Id 35 8 alvo Val OL DN ALY IcBSve NO 88599 OL TEHIM A 27 OL 76 SON G D SS EY DIR Tz 1 LIND LL Ted SO SIS SSS I lt Y n m 3 I m 01 6 8 9 5 7 H 34 OL 6 8 9 5 v e E EE E a CV vos ne uoojoguooduie soruomoja 2 X RI GR RUN yole 13965 L 60 L0 1Z 0087 2062 19 id
5. 8 0 mm AMPCONTROL CCMC 1 0k 120 0 mm 140 0 mm 48 0 5 Hc d gt m 2 5 lt n I gd ES e NE xx re QO I 5 LLI La m 1T4 1 D X ul xu d T LL 1 d 5 GIL 1 5 nui 56 EST 812504658 APEERE Zann 4 EA Quoxotg ts zi 2 S 30 y 717140 ONDA4HV AL NOISNSAIO i aj YES Y V NC 3 GAMO VE SHNHVM 3IHYNOOVWN 06 3a fe EE Be JALVHOSLNI eu ARRA a Q ISNSAIC NOMETNI dl OLT Ald TONLNOOdNY DOES V 00 07 j jS e 3 3 3 1 1 1 00 02 99 770103 ME uy qA oec 99 CEMOSHO ANB SENE DO SEE
6. 0L 6 8 2 9 6 v k 30S ne woo joquoodwe sa1uosoa a ETUR 2 e 2 133HS IN3W3ONVHMHV TVH3N39 60 L0 L2 ad bah ant 29 Z soyd seged oy S 2 2 pem s siueluoo sy 10 ajoym u Jo ped 5 lt LINN NOLLVNINYSL SLOWS gdl 60 L0 C V 0303H2 TOHLNOJ2cdIAV 1 GALVLS as su amp zi 5 B LZ0 V gdl 16 10 91 wg NAE NO 18010 340038TII8 SS3INN S3MI3WITIW eg Wl 0L 000 Sc NAV 8 4 7 x o Auedoid eu OMA TONINODANY SINWN GLI Ald WSO TOHLNOOdWV 05 8 091 3 N 3 3 3 3 a 0p m m m m m 1 550 e P O O o 8 v g g 3 d 8 a EZ S z 5 3 ED gt N m Im a OPNS m x jal FA 3 m 3 ER NO RO 5 5 L 83 lt 3 5 O gt u m 8004 2 0 6 8 9 6 v t 26
7. 19315 SS3 INIVIS Q3N3385 HTS AN T3 3SV8 dO 401 SSHOLVW AV T3 40 401 LVHL 3SV8 OLNI ONITIVLSNI N3HM SYNSNA L NDIS3OQ 931905 H30MOd AV T3 ddl ALON IAS 8unind YOR uontejsur 3yeridoidde are saurgos omsu porous st Sururem sm Jt jjnso1 suoripuoo o3e10 s ouo surejuoo jt se uoZ snopiezeH v pouodo aq Jou jsnur pun st so YEE lt X01 lt suog I t lt 9 gt A T HWOI gt T n o gt O gTHVO opoiq 10 TALA T NALA Jonuoodury 2 LINN NOILVNINYAL WYO Gy lt PON aporq Mowry WYO Sh lt opoj 00 10 NLA AE EOD 10 IE E VINDO 10 0001 VINDO STI OINDO 10 STP VINDO anqensny ur 208 52 32323 peddu 4 2810001 284517 sonos 005 Ionuoodury QIOWOL 5 QLy OEE 06E OSE OTE OLT OET 461061 Suigg gt sno uwue sur ojqejoopos ANIL AAL 2 HONVLISISSW LNO dowd SUIYO gt HONVLLSISHS dN Nld 005 Ost OOF OSE 006002051401 3e 2148122195 THAT MAL Surgse woy Ay Sun 195595044 dI VADOT 009 gt WT 009 gt 8 1 TROL 4971 gt O 2180 164 Ionuoodury ToL aN gt 2 2480 t ZH0S 01 224011
8. s N 11 I eene T z ERO 5 58 28 28 8 58 s S 7 S 6 o 3 2 EM 3 Keje4jouogeueuo lt q a S CMT CM 1991102 insu3 sp 523 8 R 01889603 ON Hed x 7 i g TS J o k li li r Y un 1 L 1 e TEM 4 Ng hier j Va lt J X _ A og 2 PEN e B SE 3 8 B o B gt m m gt gt lt F o A _ 1 0 re 28 8 0 mm AMPCONTROL CCMC 415 120 0 mm 140 0 mm Vcma Vcmb RL4 ESI Vcmc Earth 110Vcom gt lt 4 n 2 LU 1 I E 3 EE NE Eu AC 1 LLI 7 a m 5 lI 1 u X ul xu d T LL 1 d 5 lt 5 G ur Fuss x 507235 5 lt lt D guts d S Sonn a EA 5264040 UY uz S EC sep H t dag Era 29
9. ay EEE A Read Write IPB s Non Volatile Group 1 Settings Pilot Mode 4 14 pu o line Mode Mode Line Volts 2 RTU s Non Volatile T Memory Group 2 Settings Group 2 Settings Machine Type Machine Type Machine Number at Machine Number OL Range omms OL Range 2 o uA d Group 2 Setti Figure 1 MC Type Selects the descriptive code transmitted to identify the machine connected to the outlet RTU MC No Selects the assigned machine number to be transmitted by the Remote termination Unit OC I range Sets the basic current range OC I mul Combines with OC range to define the full load current OC Type Selects either very inverse overcurrent or motor overload protection OC t mul Modifies the basic overcurrent time curves to achieve the desired trip times Cool mul Allows the cooling rate of the thermal model to be modified Cur Bal Trp Adjusts current phase balance trip SC I trip Sets the short circuit trip level SC Trip t Sets the trip time for the short circuit function USER MANUAL ISSUE 8 Pilot Latch Determines whether earth continuity trips are self resetting or not B emf TIME Adjustable time delay to inhibit main contactor fail following opening of main contactor Sets the fan current threshold at which other outlets are allowed to run FaniLevel When Yes is selected t
10. AMPCONTROL w o IPC1 Integrated Protection Relay Designed and Manufactured in Australia by Ampcontrol Pty Limited ACN 000 915 542 Phone 02 4903 4800 Fax 02 4903 4888 www ampcontrolgroup com USER MANUAL No copies of the information or drawings within this manual shall be made without the prior consent of Ampcontrol 119051 ISSUE 8 20 3 09 IPC1 Manual Issue 8 119051 200309 pdf Copyright Notice No part of this publication may be reproduced transmitted or transcribed into any language by any means without the express written permission of Ampcontrol Pty Ltd 7 Billbrooke Close Cameron Park N S W 2285 Australia Disclaimer Ampcontrol Pty Ltd will make warranties as to the contents of this documentation and specifically disclaims any implied warranties or fitness for any particular purpose Ampcontrol further reserves the right to alter the specification of the system and or manual without obligation to notify any person or organisation of these changes Before You Begin We would like to take a moment to thank you for purchasing the IPC Integrated Protection Relay To become completely familiar with this advanced protection and control relay system and to ensure correct operation we recommend that you take the time to read this user manual thoroughly IPC1 USER MANUAL ISSUE 8 IPC Software CRN4564 Version V01 Initial Release CRN4902 Version IPC1 V02 2002 12
11. 0 80 ZNV pL I er d 04 OL 35 3ano 01 ININA LEH 3 5191301 31v E38 v NEED SE EU N
12. 2 010 IPC Z 011 222 012 2 013 2008 10 01 IPC Z 014 2008 100 IPC 2 015 IPC Facia Marking DETAILS _ 2009 0216 IPC Z 016 IPC Analog Board Artwork Detail o 2008101 IPC 2 017 IPC Processor Connections o 2008 09 30 IPC 2 018 IPC Processor Inputs _ 20080930 IPC 2 019 1PCProcessorADC _ 200820930 IPC Z 020 IPC Processor CPU 2008 09 30 N JIN N This certificate and schedule shall not be reproduced except in full Page 8 of 9 Australian New Zealand Certification Scheme for EXPLOSION PROTECTED ELECTRICAL EQUIPMENT ANZEx Scheme Certificate of Conformity Certificate No ANZEx 08 4071X Original Issue No 0 Date of Issue 8 March 2009 sumer m re e IPC Z 021 memes 0 1 Processor Batte 1 2008 09 30 IPC Z 022 IPC RDMI Artwork Detail 2008 10 01 IPC Z 023 IPC Earth Leakage Shunt DETAILS EH 2008 10 01 IPC Z 024 IPC 415 CCMC Schematic 2008 09 30 2405 IPC415V CCMC Dimension amp Marking Details 20810011 Pozos IPCRTU 2MARKINGDETALS 20094222 15 7 005 IPSCMARKINGDETAILS APPROVALDRAWING 1 2009 0246 IPSI A 003 SCIENTECHNIC IPSI ISOLATION BOARD PRINTED CIRCUIT ARTWORK 2008 12 03 DETAIL IPSI M 001 SCIENTECHNIC SERIAL INTERFACE MODULE IPSI TRAFFOLYTE 2008 12 03 LABEL DETAILS IPSI S 001 SCIENTECHNIC SERIAL INTERFACE MODULE IPSI CONNECTION 2008 12 03 DIAGRAM IPSI S 002 SCIENTE
13. Ay i o lt M B m S e w S 5 o x 2 S N e 5 E lt M o z n E e 9 2 8 5 S g gt a gt gt m m gt gt gt amp m lt K A 0 re 36 WARING ENGINEERING SERVICES LTD 51 Regal Way Valentine NSW 2280 0249 46 5500 Mobile 0429 331879 gwaring telstra easymail com au j 87 077 639 984 File No C92 0362 AMPCONTROL Pty Ltd 250 Maquarie Road Warners Bay NSW 2282 Attention Mr Darryl Peacock Wednesday September 05 2001 RE Approval of Apparatus for NSW Coal Mines Item Integrated Protection Relay System Type Types IPA IPB and IPC Approval No MDA Ex ia 10035 Thankyou for your application regarding assessment of the above equipment for Supplementary Approval Please find enclosed the following documents in accordance with the DMR directive to AAA approval process Notice of Approval Approval Schedule Stamped Approval Drawings A complete copy of this document has been passed on to the Records Branch of the Dept of Mineral Resources Yours faithfully Gran L Accredited Assessing Authority MDA A2516 Dept File No C92 0362 Doc No d wes appmaster IPC covipc doc
14. Stop o E MCR CBR 29 Se 4 5 OVa fag MEI CoL Ve Lock HoVac i 48 AMPCONTROL 3 ag 7 RUN C 42 Reset x ul Optional 24 a Led Relay OCOS 40 5 1215 Module sc 9604 39 Integrated Protection eu 0603 i oco 26 G Refer Dwg EC 36 27 8005 2 06 01 92 EL OCO0 35 MC e MR 000 34 g MOR S 4 1 ELI F inl eS AMPCONTROL Vsel g 15 Lial gt 8 Comms TXD 10 16 4 E kas Ic gt BDL n Optional Serial Interface Module gt g 4 Vema ves Ha A Cables passin Vemb through toroi 8 4 ANI Ampcontrol B 24 FAN INTERLOCKI vem CCMC a amp Cit s to be 5S ETT Cable Connection Insulated to To Other ed cun FIO Module System Volatge cO M Bam Level imum 100 Ohm IW 2 py TEST Only one for whole loop 12 fir If Interlocking is NOT required Da 7 E 2 10 1 2 FIO 4 13 Vdm 14 6 Pilot gt d LE l 5 Safe Area Amp LAL Hazardous Zone Trailing Cable heilded 2 Core Cable FLP Enclosure FLP Enclosure Ampcontrol 3 RTU2 0v AMPCONTROL RDMI san 5 sun ExialT4 it m Remote Termination Unit Er
15. 20 40 60 80 100 120 160mSec 2 5 10 20 seconds Can be allocated from 1 to 40 32 to 96 in 8 increments of full load current Selectable from 20 to 80 in 10 increments Trip delay 800mSec For information on Protocol and hardware requirements see DNET IP2 Serial Communication System User Manual MCR CBR RL3 RLA 1 N 0 5A 190VAC 100VA maximum 1 C 0 5A 190VAC 100VA maximum 219 USER MANUAL ISSUE 8 15 Troubleshooting If a problem is experienced with the relay use the following tables to fault find the problem Should the fault persist remove the relay and return the relay plus a description of the fault to Ampcontrol for repairs Note Checking the Status page level 0 position 0 should be the first step in troubleshooting This displays what the relay requires to make it operate Also check the first six event logs Remote Display shows a blank screen The RDM Healthy LED indicator located on the top of the RDM module is off Remote Display shows a blank screen The RDM Healthy LED flashes at 1 Hz Status Message IPC Memory Error When in diode pilot mode Status Message IPC Memory Error When in RTU pilot mode Status Message RTU Memory Error Relay will not close EC fault indicated Status Message Need RTU Start or Stopped RTU or Stopped RTU PTC Loss of power to the Display Check there is power to the relay and it is correctly plugged in The Relay supp
16. EV SING SNLLVOO 60 08 f ime ONION 5191301 3157 35 e SUSVOMEN a az Od v EH NOLLOSILOUGI amr RP 55 7 E c uM cl aa QL Ald T091NOOdl V 964 z0 e A RON N Y v 4 CURA B FETT en N oo E N en N ATCP
17. Operation of the remote termination units PTC Thermal memory has been manually reset to zero Mem ERROR P reset Tmem Loss RTU mem E Outlet On RTU OffL Meg Trp IT MQ Insul Alm Records that the relay s non volatile parameter memory has been corrupted Internal microprocessor reset The thermal memory data has been corrupted Records that the remote termination units non volatile memory has been corrupted or remote termination unit has gone off line while the outlet is running Records RTU machine code and number when main contactor is closed proceeded by MCR closed This log only appears when in RTU mode Indicates a loss of communications with the RTU Insulation Test failed Records the result of the Insulation Test Result of Insulation Test is equal to or less than the alarm level 10 Time amp Date If there is a need to adjust the real time clock carry out the following procedure 1 Using the Remote Display Module select the time and date information page Level 7 Position 1 to display the Day Month Year Hours and Minutes MO 150595 09 46 Press the enter key A will appear in the top line above the minute section This indicates the number to be changed Use the left and right arrow keys to move the y to the desired position Press the enter key The now changes to 2 right arrow key is used to increment
18. Range 60 EE D 21 Epe OHO 3150 O SHLO 15 SHISATTIW ISNANG Ti 20 Avedoud ey supp BUME SIUL TIME LTIPIE urrent ri ren Fault Selected Full Lo Time FL elected Full Lc 1107 AF 22 OHO 5551 NI SN SHLO 9174 TV 40 eq eupeuea Dupeeap SIUL In s X ume L Tri ume Time 292 FL elected Full Lc 1107 I 24
19. SIMTARS NI94 0021 Integrated Protection Relay Systems Type A amp B NI95 0023 NI92 005 192 018 SIMTARS 198 0012 Integrated Protection Relay Systems Type A amp B SIMTARS N101 0001 Integrated Protection Relay Systems Type A B amp C SIMTARS 9689A Serial Interface Module for IPA IPSI This certificate and schedule shall not be reproduced except in full Page 4 9 Australian New Zealand Certification Scheme for EXPLOSION PROTECTED ELECTRICAL EQUIPMENT ANZEx Scheme Certificate of Conformity CONDITIONS OF CERTIFICATION The following conditions apply to this certificate Conditions of manufacture 1 In addition to the manufacturer s performance and routine testing it is a requirement of manufacturer that a routine test shall be carried out on each Cable Connection Module to ensure correct operation of the diodes and the value of the current limiting resistance Conditions of safe use 1 When mounted in a cut out in the wall of the enclosure the Remote Display Module RDM 1 Shall be mounted such that the enclosure maintains a degree of protection of at least IP54 2 The equipment shall be installed according to AS NZS 2381 1 amp AS 2381 7 and satisfy the Coal Mining Electrical Rules 3 The equipment shall be connected to systems where the earth fault current is limited to less than 480A and instantaneous peak value for the IPB and IPC relays and 80 for the IPA relay 4 The parameters marked the IPA
20. and IPC units facia plates and respective modules shall be observed Entity parameters for the CCMC are listed below Enti 5 Config 245 os Iu EE UE c ms 42 190 Config A Single CCMC single output channel Earth B Single CCMC all three channels parallel connection earth C Two CCMC all six channels parallel connection earth This certificate and schedule shall not be reproduced except in full Page 5 of 9 Australian New Zealand Certification Scheme for EXPLOSION PROTECTED ELECTRICAL EQUIPMENT ANZEx Scheme Certificate of Conformity Certificate No ANZEx 08 4071X Original Issue No 0 Date of Issue 8 March 2009 5 The RTU 1 Remote Termination Unit RTU 2 Remote Termination Unit RTU CIU1 Communications Interface Module when in a hazardous area shall be installed in a flameproof enclosure and connections thereto shall not be considered intrinsically safe when the power cable is energized 6 The CCMA 110V Cable Connection Module is not to be used for Earth Fault Lockout applications MANUFACTURER S DOCUMENTS mme A1708 0 IPA SCHEMATIC TERMINALS 1992 04 10 E 1 of 8 Al 13 IPA Base Terminal Pin out _A1708 14 IPABloek Diagram 1992 08 06 1708 15___ Typical Connection Diagram a 19920421 _A1708 16__ IPA SERIAL vo PORTS CONNECTIONS _ 19920424 LAUORIT 9908 LAITO2I
21. voltage circuits To ensure that interference is kept to a minimum the following cabling is recommended USER MANUAL ISSUE 8 Duty Signal Recommended Cable Type Two core screened Screen Earth Three core screened Earth Leakage 1 ELI Toroid 2 EL2 Cable Connection Module Screen Earth Two core screened Current Protection Transformers Screen Earth Two core screened Local Stop Button digital input Lock Switch 21 Digital Input 22 Reset Switch 23 Reset Digital Input 24 Reset Start Switch 25 Start Digital Input 26 Start Motor Contactor 27 28 Aux Contact Digital Input The IPC s digital inputs could alternatively be run in a screened multicore cable Separate cable for each IPC Relay in multiple installations Screen Earth Two core screened Screen Earth Two core screened Screen Earth Two core screened Screen Earth MCI Two core MCI screened Screen Earth Lock Lock Where these low voltage circuits need to connect near the power circuits eg current transformers cable connection module main contactor auxiliaries etc care needs to be taken to ensure that the circuits are adequately separated and restrained so that the separation is maintained even if a wire termination comes loose etc C High Voltage Circuits The high voltage circuits of the IPC Relay are the 110VAC supply pins 30 31 and the relay
22. IPA 1000V LINE CONNECTION MODULE CONSTRUCTION DETAILS 2 2008 12 03 LAITOR24 IPA CABLE CONNECTION MODULE 1000V ARTWORK DRAWING 1 2008 12 08 LAITOR2S IPA CABLE CONNECTION MODULE 415V ARTWORK DRAWING 1 2008 12 03 1708 31 IPA REMOTE DISPLAY MODULE ARTWORK amp TERMINAL MARKINGS 1 1992 04 06 1708 44___ IPA INTERFACE CCMA 3 3kV CONSTRUCTION DETAILS 3 2008 12 03 IPA LS Componens 19929729 3 2 3 3 IKAM002 IKA INTERFACE MODULE GENERAL DETAILS 1994 02 11 LIKAINTERFACEMODULESCHEMATIC 3 2008 2243 IKA S 001 IKA INTERFACE MODULE SCHEMATIC 2008 10 01 IKA S 002 IKA Keypad Schematic This certificate and schedule shall not be reproduced except in full Page 6 of 9 Australian New Zealand Certification Scheme for EXPLOSION PROTECTED ELECTRICAL EQUIPMENT ANZEx Scheme Certificate of Conformity Certificate No ANZEx 08 4071X Original Issue No 0 Date of Issue 8 March 2009 2008 12 03 IKA S 004 008 12 03 IKA S 005 008 10 01 IKA Z 001 009 02 16 2 2009 02 04 009 02 16 009 02 16 2008 12 03 2008 12 03 1994 10 24 1994 10 24 1994 10 24 1994 10 24 1994 10 24 1994 10 24 1994 10 24 2008 12 03 2009 01 06 2008 12 01 IPA Z 004 IPA 1 8 Components 2009 01 06 IPB E 003 CIU 1 COMMS INTERFACE MODULE SCHEMATIC IPB Z 001 IPB SCHEMATIC ALNANLOGUE BOARD IPNUTS IPB Z 002 IPB Schema
23. Termination Unit the relay parameters are automatically up loaded from a remote machine when a cable is inserted into a power outlet The earth fault lockout function tests the resistance of the 3 phase lines to earth by applying an intrinsically safe signal prior to the closure of the main contactor in accordance with AS2081 4 1988 The test is initiated once all starting conditions are met If the resistance is above the preset level then an automatic high voltage DC Insulation Test to earth of the cable can be carried out If the result of the Insulation Test is above the preset resistance level the IPC s MCR relay energises which in turn closes the main contactor A manual Insulation Test is provided as a maintenance fault finding tool When this test is performed the MCR relay does not close at completion of a healthy test The Insulation Test allows cable insulation levels to be trended as an aid to preventative maintenance The IPC Relay has 5 Digital inputs which feed into a microprocessor unit The microprocessor has been programmed to control four output relays Relay MCR for the main contactor and Relay CBR for the circuit breaker Relay RL3 can be turned off or configured to follow the Fan Interlock Drive output of the IPC Relay Relay RL4 when closed applies 110V to the CCMC Cable Connecting Module for the Insulation Test All of the tripping logic and outlet control is performed by the microprocessor so that virtu
24. rgencu top Stop SZ stop ina 1 3 Ex 3 pre fi Fy pre 4 Earth s 3 s IPC Diode Mode Pilot Connections LIN IN 23 amm Stop Start ENT i am Pilot o Pilot o EL EC EF OC SC MCF Run Eme e o TA 8 Fk p HOO 2 PT 100 RTD s Remote Control Local Control LS Remote Display Module 1 3 LL 20 a LLI lt ul 2 ks E HR ition N Level Load SCar 182Amr bm 5 Log let On Log Log eset Code SCar 2 N N lt ACHINE MODULE 2 TU Online v 4 tart Sip PT TD S1 4t 1 data 1 4 ok da B ok INFORMATIC achine Scar T 0 0 35 98 d HEP x 4 Es ue t lt G w EARTH FAULT t i R hi 5 c ug X ul x 2 a 2 LTAOE 4 emf Timer 3 E E ENT A E Averages 132Amr E gt 4 2 Z k 2 a lt ELA DIGITAL C ICI START STOP Lock VCFF FD FR F STATI In it st 4 Z N DATE TIVE x 2 5 DISPLA 8 stored Value tored Value tored Value IEW amp MODIFY Type EL Time ins Se kV SETTINGS 9 tored Value tored Value Stored Value VODIF TU MC Type D m
25. the allowable values once the desired value is obtained press the enter key again The 42 returns to a v Repeat steps 3 and 4 until the correct time and date is displayed USER MANUAL ISSUE 8 6 With the showing press the lock push button The then changes to This is a prompt to press the enter key 7 Press the enter key At that instant the seconds are zeroed and the selected time date information is transferred to the internal clock If the battery voltage is low the time will zero and the date will reset to 1st January on power up If the battery is flat or faulty the relay is likely to trip on main contactor fail on power up Note The date and time are used only to time stamp the events in the log which are recorded sequentially regardless of the date time Date and time data is not used for any control functions 11 Remote Data Communications The IPC Integrated Protection Relay has the facility for connecting remote monitoring equipment This can be in the form of either the Remote Display Module or other peripheral equipment such as PLC s For PLC applications each integrated protection relay is connected to a Serial Interface Module IPSI which has its output drop connected to a DNET IP2 Protocol Converter The Protocol Converter provides the communications link to a PLC See User Manual E06510 for further details The Ampcontrol DNET IP2 Serial Communicat
26. 12 02 Change to Relay 3 selection CRN5103 Version IPC1 V03 2004 23 02 04 VOLTS MAX increased to 10 CRN6244 Version IPC1 V04 2007 RTU to Diode Mode Parameters cleared on change CRN7597 Version IPC1 V05 2009 Fan Interlock Delay increased Overview 11 Introduction 1 1 2 Remote Display Module 1 1 2 1 Trip Status Messages 2 1 2 2 Last Trip Status Message 2 Machine Communication 2 1 Remote Termination Unit 3 2 2 Machine Type Codes 3 2 3 Machine Type Number 4 Earth Protection Functions 3 1 Earth 4 3 2 Earth Fault Lockout 4 3 2 1 Intrinsically Safe Test 4 3 2 2 Automatic Insulation Test 4 3 2 3 Manual Insulation Test 5 3 3 Earth Continuity 6 Current Related Functions 4 Basic Overcurrent Protection l kaa ada 6 4 2 Overcurrent Characteristics 6 43 Motor Overload Characteristics 7 4 4 Short Circuit 7 4 5 Phase Current balance 8 Voltage Related Functions 5 1 Main Contactor Fail Protection 8 5 2 Undervoltage Trip 8 5 5 Voltage 8 Fan Control 6 1 Fan Interlocking 9 6 2 In
27. COS TER NOLLVTIVLSNI E x VITWULSNY S822 WS N w Y 8 2 g de 60 00 21 E 7TOH LNOOcdIAV Sud 1 d 8 620 dl 3SV8 AV 1398 Sn ag 36010 300991181 PEN u pue jeves jou g 2dl 8dl Ll 011000 SE NAV NI UU SERVA Pri Sd NOM ENORA WN G11 Ald WSO TOHINOOdNV 1 agimus mp ni ni 3SV8 Odl 8dl aseg onuoodury
28. exceeds both 20 of the selected full load current and the selected balance trip level If the trip level is exceeded a timer is triggered If the imbalance remains above the set level for more than two seconds the relay trips The event log records Ibal to differentiate it from a true overcurrent trip The status of the timer 1s displayed adjacent to the Ibal value Level 5 Position 2 trip condition occurs when the timer reaches 100 5 Voltage Related Functions 5 1 Main Contactor Fail Protection The Main Contactor Fail MCF protection operates if the Main Contactor MC fails to function by either 1 Failing to open when required This is achieved by comparing the state of the main contactor via the Main Contactor Input MCI against the state of the MCR relay output This test provides Frozen Contactor Protection 2 Failing to maintain insulation across the contacts when the contactor is open The Cable Connecting Module is used to measure the voltage on the load side of the contactor If this exceeds 10 of the rated line voltage a trip will occur This test provides Loss of Vacuum Protection This function 15 inhibited immediately after the main contactor opens to allow for back EMF voltages generated by some motors to dissipate The inbuilt time 1s adjustable from 2 to 20 seconds See Section 7 1 A main contactor fail trip causes the CBR relay to de energise which trips the circuit br
29. increments between 60 and 116 Amps The current multiplier is selectable at 1 8 1 4 1 2 1 2 4 times See Section 7 1 Example Overcurrent Setting To obtain a full load current of 152 Amps select a current range of 76 Amps and a multiplier of 2 Two curve types can be selected and a time multiplier modifies the basic trip time characteristic There are eighteen 18 multiplier settings that can be selected ranging from 0 005 times to 1 0 times See Section 7 1 It should be noted that settings 0 005 0 01 0 015 0 02 0 03 and 0 04 are positioned after setting 1 0 in the stored setting s list Level 9 Position 4 USER MANUAL ISSUE 8 The instantaneous current in each of the three phases can be displayed on the RDM Level 5 Position 1 The three phase currents are displayed as a of the overload set current The average current value 15 expressed in Amps and 1 displayed at Level 5 and the Status Page Level 0 Position 0 Following a trip condition the following conditions must be met to achieve a reset a The IPC reset input must be closed b The trip accumulator must be less than 8096 4 2 Overcurrent Characteristic If the selected overcurrent type is then a very inverse overcurrent characteristic set of curves are available for selection See Curves Drawing IPB B 004 Page 22 The three phase currents are compared and the highest current is used to calculate th
30. output can be viewed on the Remote Display Module Relay and Digital Input Status Section Level 6 Position 4 The outlet control in each IPC Relay has been designed so that an outlet will not run unless either a The FIR input is ON or b The Remote Termination Unit connected to that IPC has been programmed with machine type iFan The result of these conditions is reflected in an internal Fan Run Status FRS bit The status of this can be viewed on the Remote Display Module If the FRS is on then the fan interlocking system will allow the associated outlet to run Relay 3 can be selected to be either non functional off or can be configured to follow the Fan Interlock Drive FID or Fan Interlock Read FIR outputs of the Relay For single fan operation select FID or FIR Relay 3 will energises as soon as current is above the preselected threshold If FID is selected for dual fan operation then Relay 3 will energise as soon as current from either fan is above the preselected threshold If FIR is selected Relay 3 will only energise if the current from both fans are above the preselected threshold 6 2 Interlocking Sequence The fan interlocking operates as follows 1 Each IPC powers up with the FID output turned off At this point the FIR input on all IPC Relays will read as off therefore no outlet will run 2 When a machine is plugged into an outlet that has its Remote Termination Unit programmed
31. the IPA relay The parameters marked on the IPA IPB and IPC unit s facia plates and the respective modules shall be observed The RTU 1 Remote Termination Unit RTU 2 Remote Termination Unit and RTU CIU1 Communications Interface Module when in a hazardous area shall be installed in a flameproof enclosure and connections thereto shall not be considered as intrinsically safe when the power cable is energised The CCMA 110V Cable Connection Module is not to be used for Earth Fault Lockout applications 2 In addition to the manufacturers performance and routine testing it is requirement of safe manufacture that a routine test shall be carried out on each completed Cable Connection Module to ensure correct operation of the diodes and value of the current limiting resistance Marking on Apparatus 1 The manufacturers name mark and the approval number MDA ia 10035 shall be inscribed in a durable manner in a prominent position on the apparatus c G L M Waring Accredited Assessing Authority MDA A2516 FOR CHIEF INSPECTOR OF COAL MINES Dept File No 92 0362 Doc d wes appmaster IPC suppschiIPC doc Page 4 of 4 App Holder AMPCONTROL CSM Pty Ltd Minerals and Energy House PO Box 536 St Leonards NSW 2065 Australia Telephone 02 9901 8888 Facsimile 02 9901 8777 Australian New Zealand Certification Scheme for EXPLOSION PROTECTED ELECTRICAL EQUIPMENT ANZEx Scheme Certificate of Confor
32. 12 v Qu c 9 T gv 1 At r u a UBU SJOU uoi SOM JOU 91091007 AA V wt gt LUA L AN 3 3 E L AJ 14 21 407 2 7 We MAS SQ SH TE AU na 90 08 ul 1 0918 09 a d JOL N r ws 100 vd SAILEOIPU jo 1j P o IEDUOOOS m M esne v 4 v z E s dE S 1 E i iN p 4 2 5 Wy y uuA 120 g I woz I y v Aot WE l LA lt y IO18 4 OL 6 8 1 9 S v e L 33
33. App Holder AMPCONTROL CSM Pty Ltd Page 1 of 4 Department of Mineral Resources Accredited Assessing Authority MDA A2516 COAL MINES REGULATION ACT APPROVAL No MDA Ex ia 10035 1982 ISSUE No A2516 01 DATE 5 September 2001 NOTICE OF SUPPLEMENTARY APPROVAL It is hereby notified that the Approved item listed herein has been assessed for compliance with the Coal Mines Regulation Act and appropriate Standards or requirements and is hereby APPROVED in accordance with the requirements of the COAL MINES REGULATION ACT 1982 This approval is issued pursuant to the provisions of Clause 70 and 73 of the Coal Mines General Regulation 1999 This APPROVAL is issued to AMPCONTROL CSM Pty Ltd Address of Approval Holder 250Maquarie Road Warners Bay NSW 2282 Description of Item s amp Variations Integrated Protection Relay Addition of Relay Type IPC including cable connection modules type CCMC 3 3k and CCMC 1 0k to existing range Manufacturer and model type AMPCONTROL CSM Pty Ltd C M R A Regulation i Coal Mines Underground Regulation 1999 Clause 140 1 Specific Approval Category Explosion Protected Intrinsically Safe Ex ia if applicable This Approval is issued subject to compliance with the requirements of the Occupational Health and Safety Act 2000 The Authority issuing this Approval has for the purposes of the Occupational Health and Safety Act 2000 appended a list of conditions recommendation
34. CHNIC PROTOCOL RELAY IPSI OPTO COUPLER BOARD 2008 12 03 SCHEMATIC IPSI Z 001 IPSI OPT110 ARRANGEMENT 2008 12 03 IPSI Z 004 AMPCONTROL IPSI INTERNAL CONSTRUCTION 2008 12 03 This certificate and schedule shall not be reproduced except in full Page 9 of 9
35. F on Main contactor fail Check main contactor for leakage across power up condition terminals on frozen contactor condition Flat or faulty battery AA cell installed under the top cover requires replacement A direct replacement as listed in the approval can be replaced by the owner in a workshop environment It is recommended that the relay be returned to Ampcontrol for battery replacement and full testing Time and date incorrect Low IS battery AA cell installed under the top cover requires replacement A direct replacement as listed in the approval can be replaced by the owner in a workshop environment Resets to 1 01 9 on power up It is recommended that the relay be returned to Ampcontrol for battery replacement and full testing 19 1
36. If the value is less than the preset trip level 0 1 MQ to 15 MQ a trip occurs and is latched and saved in a non volatile memory The EF LED on the Remote Display Module is illuminated and the open collector output on the relay 15 switched on to provide remote monitoring if required An Insulation Trip shares the LED on the Remote Display Module with an EFLO trip but has dedicated trip messages on the Status Page To reset the relay following an insulation test fail trip operate the reset button At the completion of a test the leakage level for each phase is retained in memory until the next test is carried out This can be viewed on the Remote Display Module RDM Level 3 Position 3 If the Insulation Test is not selected by either not selecting CCMC or setting Ins TstT value to None then the MCR Relay closes at the completion of a healthy EFLO Test The accuracy of the insulation test and expected trip ranges are outlined in the table below The results from insulation test should only be used as a guide to confirm that insulation remains above the preset threshold Insulation tests apart from the generated insulation test via the IPC and CCMC should be still carried out on a regular basis for maintenance purposes Actual Fault Resistance MQ Trip Setting Minimum Maximum 0 5 0 4 0 6 1 0 8 1 2 2 1 6 2 4 5 4 0 6 4 Table 2 The values in the expected fault res
37. OLLORLOEG CALVHOSLNI E dl 1 1 211 _ IYL QZZ 000 NOY I SNOENANG 7 Sam died une QL1 ALd TOUINOOdAV uS 0 992 E pem L T L sC J n 27 Ez 21 2 n n n n n 1 1 1 1 1 1 1 1 1 1 1 1 1 J r7 gr c 3 a lt TT MA RC d wp i e o st st st v ue ue e e 5 5 amp 75 iua N lt 67 i 5 E VON 89 ZN D 2 J T J t J fT mE m n T J ft T T j 4 RES gt u o gt N x en z E aS SO cO s S t3 oo 5 ne 15 e 79 c S o O O 0 O g A f 3 3 E x e a e Re S 3 Aejay Jo 4 AQ BA ou A Ne RT ee B A N N A C AA 1094109 eJnsu3 o s s S B S s s epinc uneso d P N T li z k 1 ta 3 2 J 1 li i if LM Ud IM LI L
38. Protection Relay Type IPB in firmware and the Earth Fault Lockout output circuitry Circuit modifications to the remote Display Module RDM 1 Circuit modifications to the keypad IKA Inclusion of alternative relay base connectors PON Compliance Documents d SIMTARS Test Report No NI01 0001 dated 01 06 2001 confirming compliance with AS2380 1 1989 AS2380 7 1987 and AS2081 1988 parts 1 to 4 inclusive 2 Certificate of Conformity AUS Ex 2067 X Issue 6 dated 05 06 2001 Dept File No C92 0362 Doc No d wes appmaster IPC suppschIPC doc Page 3 of 4 App Holder AMPCONTROL CSM Pty Ltd Minerals and Energy House PO Box 536 St Leonards NSW 2065 Australia Telephone 02 9901 8888 Facsimile 02 9901 8777 2 New South Wales Department of Mineral Resources Accredited Assessing Authority MDA A2516 Approved Drawings As per Schedule on listed compliance document AUS Ex 2067 X Issue 6 Conditions of Supply and Use q When mounted cutout in the wall of an enclosure the Remote Display Module RDM 1 shall be mounted such that the enclosure maintains a degree of protection of at least IP54 The equipment shall be installed according to AS 2381 1 and AS 2381 7 and satisfy the relevant Coal Mining Electrical Rules The equipment shall be connected to systems where the earth fault current is limited to less than 480A instantaneous peak value for the IPB and IPC relays and 80A for
39. S STN I SNOISN AIQ TY C LU 15 J ava sw a NT E I Ex la T4 32 0 6 8 1 9 S v e ne uoo joquoodwe sauojoaja o d 0087 06 Z 19 d o 7 VITVULSNY 9982 MSN ipic 28 9 JINON 1 41 G3TAV 133 basia TOH LNOJ2cdIAY Wad 6 10 q31V1S pee i 600 5 261 090 da x 380 E CD 3WVN Gl1 Ald WSO TOHLNOOdNV OOLLSY o uwous ees euo SALIP O 8 EJe es suoneoldae e UJAO gt ES 7 at J
40. UE 8 Status Message Relay 15 waiting for fan If interlocking is not required then a 10k Locked Out Fan interlocking system ohm resistor must be connected between terminals 9 and 12 If fan interlocking is used ensure that the fan is running and the current threshold setting in the fan outlet s RTU 15 correct The Fan Outlet IPC should pick up its FID Fan Interlock Drive signal which causes all other relays to pick up their FIR Fan Interlock Read Check these conditions level 6 position 4 If fan interlocking is not correct check the wiring between the fan relay and other relays terminal 9 Relay displays Outlet The relay s MCI input is Check that main contactor is closing If not Close Fail message after not closing within 5 Sec of check circuit or replace main contactor start is pressed MCR relay pickup level 6 position 2 RDM displays Tripped Relay not receiving lost Check system voltage display level 4 No Volts message voltage feedback on one or position 1 as contactor closes Compare all three outlet phases when this with the under voltage threshold contactor closed Check auxiliary contacts and wiring Check continuity from the relay through the CCMC to power conductors This can be achieved by testing each phase to earth at the outlet provided the circuit is isolated Typical readings CCMC 415 2340k ohm CCMC 1000 2340k ohm CCMC 3 3k 7520k ohm Relay Trips on MC
41. WOI gt 1 006 TA Ionuoodury TIVO opor 10 GIONOL LU LL cna NLA Ionuoodtuy Sw OLb OE 065 OSE LINN NOILVNINYAL OLE OLC OEZ 061 OST WYO SI lt PON ojouioy 1108 gt snoouejuejsu WYO Sp lt IPON 12207 10 NLA 18 9148295 TWIL AONVISISIY LNO dowd 00 OS 00 OSE suyo Sp gt 00 lt 007 OST 001 HONVLSISHY 18 919812915 TAIT AL 5 Aynuguo queg aseyeay 3 way Surmmy 10982904 O P O H 009 gt 31 1 unjo gn 009 gt 3 1 JE ys SH EAGT Hu gt T Hug gt T k mhnO FOL AML T gt 2 221420 OL ANI 20 21980 EE CIL 154 Ionuoodury I GA onuoodury 02 PAO sm mo ST smdmo ST 3 amod 241 amp ejdsiq Jou X44907 xa SAV pL I er xa 9 adh Aey K El poje1doju Le ls TOXNILNOOdWV 2 xm gt LI OV SORS 0 29 0 0S gt 25
42. a problem with the current levels found in flameproof enclosure applications To help avoid problems in other applications select the smallest internal diameter CT to suit the cable size E Toroid Installation Guide Lines 1 Keep cables as close to the centre of the toroid as possible Do not tie them to one side of the toroid Remember to aim at symmetry 2 Do not bring the cables back past the toroid within one diameter of the CT trying to cram cables into a small space reduces symmetry and may lead to problems which are difficult to solve 3 Avoid placing the CT near any device which produces magnetic fields whether it is a transformer or other cables Try to maintain several CT diameters clearance 4 Many small cables tend to be worse than say three large ones Try to position the CT in the circuit with this in mind 12 2 Wiring Installation The connections to the IPC Relay consist of a mix of intrinsically safe circuits through to high voltage supplies and relay contact circuits To ensure the integrity of the intrinsic safety is maintained and to reduce induction from high voltages care needs to be taken in the layout of the wiring and the installation For installations on high voltage systems gt 3 3kV it is advisable to install a power supply filter eg Schaffner FN612 1106 1A 250VAC chassis mounted filter adjacent to the IPC Relay The earth should be connected to Pin 7 on the relay as directly as
43. al test is timing through the enabling period 3 seconds Mt A The manual test is Active The display will show measured values 3 3 Earth Continuity The earth continuity function tests for the continuity of the earthing between the outlet and the machine via the pilot core in the trailing cable This is in accordance with AS2081 2 1988 The pilot core is also used to transfer data when a Remote Termination Unit is used to achieve machine communication The IPC relay can be configured to operate in either diode or RTU mode The mode is selected in Pilot Type Level 8 Position 1 and determines what terminating device the relay 1 looking for on the pilot Note The Remote Termination Unit will only be recognised by an IPC Relay and will not be seen as a diode by other earth continuity devices The relay measures the resistance of the pilot earth loop and the leakage between the pilot and earth conductors The leakage measurement ensures that pilot to earth faults are detected If the pilot earth loop is not healthy a trip occurs See Specifications Page 17 which in turn opens the main contactor control circuit The fault can be configured as latching or non latching This allows the user to determine if the fault is manually or automatically reset once the pilot earth loop is healthy The selection is either Pilot Latch On or Pilot Latch Off Level 9 Position 11 To manually reset the relay operate the
44. ally no external control is required See Typical Connection Diagram IPC E 001 Page 20 Extensive information display and monitoring features are included to facilitate fault finding and system trending This information can be read locally on the Remote Display Module RDM 1K or remotely via a communication link Opto Isolated Outputs are available for connection to optional LED or Relay Modules to provide additional run and trip indications The Ampcontrol Relay Output Module ROU enables these indications to be interfaced with a PLC The protection functions provided by the IPC are Earth Leakage Section 3 1 Earth Fault Lockout Section 3 2 Earth Continuity Section 3 3 Overcurrent Overload Section 4 0 Short Circuit Section 4 4 Contactor Fail Section 5 1 Protection trips are stored in a non volatile memory requiring a reset function before power can be restored to the load This remains the case even if a power down occurs following a trip condition 1 2 Remote Display Module This module Ampcontrol RDM 1K consists of a two line 16 character LCD display LED status indicators and a tactile keypad The display level is changed with the Up Down arrow keys and the Left Right arrow keys control the display position The display map Drawing IPC B 002 21 shows the layout of the various display screens The module is approved to Ex ia Intrinsic Safety Standards so that it can be installed outside of a flamepro
45. and the new value are stored in the event log A separate log immediately proceeds this recording the time and date that the change was made Note 1 While in the diode mode the IPC Relay can be preset with operating values in the Group 2 memory prior to switching to the RTU mode When in this mode the relay uses the Remote Termination Unit settings the Remote Termination Unit is replaced with a diode and the Pilot Mode switched back to diode the settings will revert back to the values preset in the IPC Relay Note 2 When the relay has been selected for RTU Mode the RTU must be on line before the RTU set up mode can be entered 8 System Control 8 1 Digital Inputs The IPC Relay has five digital inputs which are all voltage free contact inputs Shorting the two input terminals together activates them The inputs are MCI start stop lock and reset The status of inputs can be displayed on the Remote Display Module Level 6 Positions 2 and 3 82 Output Relays The IPC Relay has output relays to control the main contactor and the circuit breaker CBR Both relays are fail safe with respect to power supply loss and are controlled on the basis of protection functions Relay 3 has a selective function See section 6 1 RL4 applies 110V for the Insulation Test See section 3 2 2 The status of the relays can be displayed on the Remote Display Module Level 6 Position 1 8 3 Open Collector O
46. contacts Apart from keeping these separate from the other wiring to the relay there are no special requirements In accordance with Australian Standards the relay contacts of the IPC Relay must not be used to switch more than 190VAC 5A or 100VA the intrinsic safety will be compromised if any of these values are exceeded D Earthing The IPC has two earth connections The earth pin 7 is for the intrinsically safe circuits including the pilot circuit The earth on pin 29 connects to the earth shield of the IPC Relay s internal transformer The CCMA also has an earth connection as this is effectively a diode barrier Ideally all of these should be run back separately to the main earth point Note that AS2381 7 requires the earth cable to be a minimum of 4mm 13 IPC Equipment Parts List 118783 Integrated Protection Relay IPC1V01 101504 IPB Remote Termination Unit RTU 2 101182 IPC Base Plate 101500 IPC Remote Display Module RDM 1K 119055 415 Cable Connection Module 101490 CCMC 1000V Cable Connection Module 101491 CCMC 3 3kV Cable Connection Module 101487 110V Cable Connection Module 101503 Relay LED Output Module 101526 IPB Pilot Protection Fuse Holder 101296 IPB Pilot Protection Fuse Holder c w Fuse 117139 Fuse Box of 10 119051 IPCIVOI User Manual 16 14 IPC Specifications Auxiliary Supply Volts Earth Leakage Protection Earth Continuity Protection P
47. d in the Group 1 Settings Level 8 Position 4 the Remote Display Module This parameter 15 also used in determining the cable fault leakage levels 6 Fan Control 6 1 Fan Interlocking A fan interlocking facility can be selected to prevent outlets from being energised until a mine section ventilation fan is operational This facility eliminates the need for dedicated outlets The configuration of the fan interlocking system 18 shown on Drawing IPB B 002 Page 24 Each relay is linked together via the FIO Fan Interlock Input Output Terminal For single fan operation a 100 resistor is connected between this link and earth This causes all relays in the system to default to a Slave mode waiting to receive an interlocking signal before they can run For dual fan operation it is necessary to connect two 1000 resistors in parallel to the FIO Terminal otherwise all FIR Inputs will read as off and the slave outlets will not run When an IPC Relay detects a Remote Termination Unit that has been programmed with the special machine type identifier iFan that particular relay switches to a Master configuration This relay controls the slave outlets allowing them to run when the fan current is above the selected threshold setting Each relay has the ability to read and drive the FIO link via the Fan Input Read FIR processor input and the Fan Interlock Drive FID processor output The status of the input
48. e main contactor is closed the MCI input 18 continuously monitored If it opens the run is cleared and the MCR relay de energises In this case the event log records MC Opened which indicates that the outlet was turned off by something other than the IPC Relay eg open circuited main contactor coil or control supply It should be noted that if the main contactor does not close when the MCR relay closes and the start stop conditions are maintained then the IPC will cycle through the following start sequence testing run stopped pause then repeat the sequence while ever the start input is closed 9 Event Log A real time clock calendar is included in the IPC Relay This combines with the non volatile memory to provide a data logging feature This log sequentially records the time date and details of the most recent event A chronological list of the previous 120 events is stored The event log can be automatically scrolled so as to view the entire log To achieve this press Enter followed by the Right or Left arrow keys to commence the scroll The log will scroll one log per second in the direction of the arrow key pressed Press Enter to stop the scroll at the desired log A typical display shows LOG 10 EL TRIP MO 15 05 09 46 21 This records that an earth leakage fault caused a trip condition on Monday 15 May at 9 46am Log 10 indicates that it is the 10th log in the list Log 1 is always the most rece
49. e open collector output on the relay is switched on to provide monitoring if required To reset the relay following a short circuit trip it is necessary to operate and hold the lock button closed and then close the reset button The relay can be programmed so that a short circuit condition can trip either the CBR relay or the MCR relay This can be achieved by selecting either relay at the SC Relay selection in the non volatile memory Level 8 Position 5 on the Remote Display Module Normally the CBR selection would be used If MCR is selected then the user must ensure that the interrupting device that is operated by the short circuit trip output of the relay has sufficient current interrupting capacity at the system voltage for the situation in which it is installed The short circuit trip level is adjustable from 3 to 10 times full load current in 0 5 increments The trip time is selectable from 20 to 160115 4 5 Phase Current Balance Phase current balance protection 15 selected via the Cur Bal Trp selection See Section 7 1 The current balance measurement is displayed on the Remote Display Module and is calculated as Ibal 100 Iave Iave Average of the 3 phase currents The maximun deviation of a phase current from the average The trip level 1s selectable at 5 10 20 50 and off The phase current balance protection 15 inhibited until the average current
50. e trip time If the current exceeds the selected full load current an overcurrent trip accumulator increases at a rate determined by the current and the selected curve This can be displayed on the RDM Level 5 Position 2 When the current falls below the selected full load current the trip accumulator reduces towards zero rapidly however if the overcurrent condition persists so that the trip accumulator reaches 10096 then a trip occurs If viewed during start up the trip accumulator can help determine if overcurrent settings are correct If a trip occurs the OC LED on the Remote Display Module is illuminated and the open collector output on the relay is switched on to provide remote monitoring if required To reset the relay following an overcurrent trip operate the reset button 4 3 Motor Overload Characteristic The overcurrent type m OL is used when a motor overload characteristic is required See Curves Drawing IPB B 005 Page 23 This characteristic uses a thermal model of the motor to determine the tripping characteristic motor overload curves are shown for both cold and hot conditions The hot curve corresponds to the trip time after the motor has been running at the selected full load current indefinitely The motor manufacturer s data should be consulted to select the time multiplier appropriate for the motor being protected Typically the capacity of a cold motor is given at six times i
51. eaker An internal battery backed flag in the IPC Relay is also tripped A LED on the front panel of the IPC Relay begins to flash The MCF LED on the Remote Display Module is illuminated and the open collector output on the relay is switched on to provide remote monitoring if required To reset the flag access to the relay is necessary In the case of flameproof equipment the power has to be removed in accordance with AS1039 The reset button is accessible through the front fascia of the relay and must be pressed for 1 second USER MANUAL ISSUE 8 5 2 Undervoltage Trip Undervoltage protection is enabled as soon as the main contactor is closed indicated by closing the MCI input If any of the phase voltages drop below the selected trip setting of the nominal line voltage for 800mSec then the outlet is stopped This is recorded in the event log as uVOLT Trp The trip level is selectable from 2096 to 8096 in 10 increments Level 8 Position 4 on the Remote Display Module 5 3 Voltage Metering The cable connecting interface module CCMC CCMA is also used to provide line voltage metering The outgoing line voltages for each of the 3 phases are displayed as a of the selected rated line voltage on the Remote Display Module Level 4 Position 1 The maximum reading is 120 Line voltages from 415V 1000V 3300V or 110V are configured when the appropriate CCMC CCMA Cable Connecting Module is selecte
52. ergy House PO Box 536 St Leonards NSW 2065 Australia Telephone 02 9901 8888 Facsimile 02 9901 8777 Department of Mineral Resources Accredited Assessing Authority MDA A2516 COAL MINES REGULATION ACT APPROVAL No MDA Ex ia 10035 1982 ISSUE No A2516 01 DATE 5 September 2001 SUPPLEMENTARY APPROVAL SCHEDULE Detailed Description of Approved Item s and Variation s The Integrated Protection Relay Type A IPA Type B IPB and Type C IPC with the associated equipment as listed in Table below provide electrical protection functions for electrical power circuits in Coal Mines ASSOCIATED EQUIPMENT Module Type Protection Category 4 Cable Connection Module CCMA 3 3kV 1kV 415V amp 110V Ex ia 2 Optional LED Relay Module 3 Serial Interface Module 1 5 1 4 Remote Termination Units RTU 1 and RTU 2 5 Communications Interface unit RTU CIU1 6 Keypad Interface Keypad IKA Ex ia L E ME Remote Display Module RDM 1 Cable Connection Module CCMC 3 3kV 1 0kV amp 415 Variations 1 Addition of the Integrated Protection Relay Type C IPC and cable connection modules types CCMC 3 3k and CCMC 1 0k The modules enable a meggering function to be performed on the supply cables after the Earth Fault Lockout test is successfully completed The Integrated Protection Relay Type C IPC differs primarily from the Integrated
53. he IPC Relay ignores the local start input When is selected the local start stop inputs control the relay Remote Start Ins TstT Sets the trip threshold or disables the function 7 2 Changing Settings The procedure for adjusting the settings is independent of where the values are stored The pilot mode should be checked prior to making any other adjustments to be certain the changes are made to the desired memory 1 Ensure the outlet is stopped N For Group 2 Settings in RTU Mode ensure RTU is on line Display the parameter that has to be changed on the Remote Display Module s liquid crystal display gt Momentarily operate the lock push button A warning message appears Press the enter button to acknowledge the warning message and to confirm that a change 18 desired Use the left and right arrows to step through the allowable values until the desired new setting 1s displayed If the right arrow key is pressed when viewing the last parameter the display wraps back around to show the first parameter Bi Press the enter button to indicate that the value is the required setting eo Momentarily operate the lock push button The display will show a confirming message then return to the viewing level If the up or down keys are operated during the procedure the IPC Relay aborts the modifying sequence When changes have been made to the stored values the old value
54. hedule EQUIPMENT The Integrated Protection Relay Type A IPA Integrated Protection Relay Type B IPB and Integrated Relay Type C IPC with associated equipment as listed in Table 1 below provide electrical protection functions for electrical power circuits in coal mines Table 1 Associated Equipment Cable Connection Module CCMA 3 3KV 1000V 415V 110 Ex ia Optional LED Relay Module Serial Interface Module I P S I Remote Termination Units RTU 1 and RTU 2 Communications Interface Unit RTU CIUI Keypad Interface IKA Keypad IKA Remote Display Module RDM 1 Cable Connection Module CCMC 3 3kV 1 0kV This certificate and schedule shall not be reproduced except in full Page 3 of 9 Australian New Zealand Certification Scheme for EXPLOSION PROTECTED ELECTRICAL EQUIPMENT ANZEx Scheme Certificate of Conformity Certificate No ANZEx 08 4071X Original Issue No 0 Date of Issue 8 March 2009 TEST REPORTS Test Reports applicable to the product and systems covered by this certificate include Integrated Protection Relay Systems Type A amp B NI92 0106 NI93 0005 NI93 0041 SIMTARS NI94 0021 SIMTARS NI96 0030 Integrated Protection Relay Systems Type A amp B SIMTARS NI97 0006 Integrated Protection Relay Systems Type A amp B 194 0529 SIMTARS NI97 0032 Integrated Protection Relay Systems Type A amp B Test Laboratory Test Report Equipment
55. iFan then that relay will be allowed to run when requested Provided there are no protection trips stops etc preventing its operation 3 When that outlet is running and the current 15 above the preselected current threshold a 5 second time delay is initiated At the completion of this delay that IPC Relay turns on its FID output The fan current threshold is adjustable from 32 to 96 of full load current in 8 increments See Section 7 1 4 Detecting the interlocking signal via their FIR inputs then enables all other IPC Relays on the FIO link USER MANUAL ISSUE 8 5 If at any stage the fan current drops below the threshold or the fan is stopped the master IPC Relay turns off the FID output This causes all slave IPC Relays to stop If fan interlocking is not required the system can be disabled by connecting a 10kQ 1W resistor from the FIO Terminal Terminal 9 to OV Terminal 12 on each relay In this case the FIO Terminals are not interlinked This causes the FIR inputs to read high at all times An auxiliary fan being used in this situation would have its Remote Termination Unit programmed with machine type Fan 7 Adjustable Settings 7 1 Parameter Groups There are two groups of adjustable settings contained in the IPC Relay s non volatile memory Both groups can be viewed and modified via the Remote Display Module The first group of settings 15 always stored in the relay and relates t
56. ilot Cable Parameters Earth Fault Lockout Protection Lockout Resistance IS Test Lockout Resistance Insulation Test Alarm Settings Overcurrent Overload Protection Current Range Current Multiplier Time Multiplier Cooling Multiplier Current Balance Trip Settings Short Circuit Protection Trip Setting Trip Time Back EMF Timer Trip Delay Settings Machine Numbers Fan Current Threshold Level Undervoltage Protection Serial Communications Relay Contacts USER MANUAL ISSUE 8 110vac 10 10VA 50Hz 2 Hz Trip Setting 100 500 mA in 50 mA increments Time Delay Instantaneous 80mS 150mS to 470mS in 40mS increments Reset if resistance 45 Ohms Trip if resistance gt 45 Ohms Shunt Leakage Trip if 1500 Ohms Operating Time 80 120 160 200 300 400 500mS lt 0 3uF L lt 10mH L R lt 600uH Q 415V lt 4 15k Ohms 3 3kV 33k Ohms 1000V 10k Ohms Test Time 1 second Selectable at 0 1 0 2 0 5 1 2 5 10 and 15 and off Test Time 2 seconds Insulation Test Trip setting x 1 5 7 5 to 464 Amps 60 to 116 Amps in 4 Amp increments times current multiplier 1 8 1 4 1 2 1 2 4 times 0 005 0 01 0 015 0 02 0 03 0 04 0 05 0 075 0 1 0 15 0 2 0 3 0 4 0 5 0 6 0 7 0 8 1 0 times 0 2 0 3 0 4 0 5 0 8 1 0 2 0 5 0 10 20 50 times 5 10 20 50 and off 3 0 to 10 0 times 0 5 increments times full load current
57. ings an automatic High Voltage DC Insulation Test is carried out following a successful Intrinsically Safe Earth Fault Lockout Test i e the resistance 15 above the preset level selected in the Group 2 Settings Level 9 Position 15 USER MANUAL ISSUE 8 The HV DC Insulation Test is initiated when the IPC Relay closes its relay output 4 for 2 seconds This applies 110VAC to the CCMC Cable Connecting Module A HV DC voltage is generated in the CCMC Module which applies a voltage approaching the peak system voltage between each phase and earth The IPC Relay measures the voltage on the line and calculates the meg ohm resistance to earth for each phase At the end of the test the result is stored in the Event Log as it MQ If the resistance value is above the preset threshold the MCR Relay picks up allowing the outlet to be energised Additionally if the result is equal to or below an Alarm Level typically 1 5 times the selected trip level see Table 1 the status message Insulation Alarm is displayed on the Status Page level 0 position 0 The alarm message 15 displayed until a new EFLO Test 15 initiated or the lt gt key 18 pressed while displaying the alarm message Insul Alm is also recorded in the Event Log Ins TstT Selection Alarm Level MQ MQ 0 1 0 2 0 2 0 3 0 5 0 8 1 0 1 5 2 0 3 5 0 1D 10 15 15 20 None None Table 1
58. inuous Miner SCar Shuttle Car Bk F Breaker Feeder Crsh Crusher Fan Fan DCB Distribution Control Box BLANK iFan Fan with interlocking AFCm Armoured Face Conveyor Main Gate AFCt Armoured Face Conveyor Tail Gate M BE Mobile Boot End Bolt Bolter HRMr Hard Rock Miner Winc Winch J bo Face Boring Machine Belly Belt Stak Stacker aCar Add Car USER MANUAL ISSUE 8 IGG Inert Gas Generator Transfer belt Dplg Dummy plug 2 3 Machine Type Number Machine numbers 1 to 40 can be assigned to machines These numbers are programmed using the Remote Display Module Level 9 Position 2 3 Earth Protection Functions 3 1 Earth Leakage The earth leakage protection function uses a toroid to measure the earth fault current This function 15 certified to AS2081 3 1988 A definite time operating characteristic 1s provided with adjustable trip sensitivity and an adjustable time delay When a fault occurs and the trip level and time delay are exceeded a trip occurs The trip acts in the Main Contactor Relay MCR logic and is latched An earth leakage trip is treated as a special fault and requires an authorised person to perform the reset function This is achieved by operating and holding the lock button closed and then closing the reset button When a trip occurs the LED on the remote display module is illuminated and the open collector output on the relay is switched on to provide rem
59. ion Repeated restart attempts in this condition may damage the motor Typical fan cooled motor protection is based on a setting of 0 4 however for the best protection consult your motor manufacturer The thermal model continues to simulate the motors thermal behaviour even if the power is removed from the relay When power 15 restored the thermal memory would be at the same level had there been no loss of power The OC Trip Accumulator shows the state of the thermal model 0 Cold 10095 Trip When a trip occurs the IPC Relay cannot be reset by operation of the reset button until the accumulator is less than 80 order that emergency restart on a hot motor can be achieved a reset of the thermal memory 15 possible by selecting Level 5 Position 3 on the Remote Display Module The display shows USER MANUAL ISSUE 8 ZERO THERM MEM LOCK 100 The 100 indicates the current value of the trip accumulator Operating the lock and reset buttons simultaneously while the above display is being shown will zero the OC Trip Accumulator after 1 5 seconds Indication of the trip condition for motor overload is the same that occurs for an overcurrent trip 4 4 Short Circuit The short circuit function has a definite time characteristic If the current exceeds the selected level for the pre set time then a trip occurs The SC LED on the Remote Display Module is illuminated and th
60. ion System transfers data and commands between the Host System and the modules using RS232 RS422 and RS485 protocols 12 Installation amp Wiring Instructions The IPC Integrated Protection Relay is microprocessor based protection relay that has the facility for connecting intrinsically safe remote monitoring equipment This can be in the form of either the Remote Display Module or other peripheral equipment such as PLC s These instructions have been designed to assist users of the IPC Relay with installation and special wiring techniques required maintaining the integrity of the intrinsically safe circuits 12 1 Installation A IPC Integrated Protection Relay The IPC Relay has a powder coated sheet steel enclosure designed to be mounted into existing enclosures ie flameproof equipment or other enclosures of adequate IP rating The relay 15 designed to operate when mounted either laid down flat or in a vertical position Vent holes are provided at both the top and bottom of the relay to assist in the cooling of the electronics inside the relay These vents should not be blocked or restricted in any way When installing the IPC Relay care should be taken to ensure sufficient space is allowed around the relay for the ease of change out during routine maintenance Connections to the IPC Relay are made via a plug in base This base is to be securely fastened to the enclosure in which it is being installed The base is c
61. istance range represent 20 of the nominal value with the exception of the higher end of the 5 range Trip setting values of 10 and 15 aren t specified above but are available for configuration within the software These trip settings of 10 and 15 are not recommended for use by Ampcontrol Note That the start input must be held closed for the duration of the test The recommended trip setting values to be utilised for the insulation test trip settings are to be less than SMO To obtain optimum results the 2MQ trip setting is recommended 3 2 3 Manual Insulation Test A manual Insulation Test is provided as a maintenance fault finding tool The manual test can only be carried out when the load is not energized When this test is performed the MCR relay is prevented from closing at the completion of a healthy test Before a manual Insulation Test can be performed the following conditions must apply 1 The Remote Display Module must be online with the Insulation Test page being displayed This is located on the EARTH FAULT INFORMATION Page level 3 position 2 2 Pilot must be healthy and any previous trips reset EFLO function must not be tripped Insulation Test function must not be tripped Outlet must not be running Outlet must not be in the process of closing Outlet must not Paused The Lock digital input must be closed Qo cJ QN 25 When the above c
62. l the high tension supply and or to provide voltage related functions via 110V PT s In this application the EFLO and Insulation test functions are not provided When CCM None is selected the IPC Relay does not provide an EFLO or Insulation Test or voltage functions Also under voltage checking does not occur Note The CCM None and 10 Modes MUST NOT BE USED in applications where EFLO is required by mining regulations 3 2 1 Intrinsically Safe EFLO Test The initial earth fault lockout function tests the resistance of the 3 phase lines to earth by applying an intrinsically safe signal prior to the closure of the main contactor in accordance with AS2081 4 1988 The test 15 initiated by closure of the start button once all starting conditions are met See Section 8 5 This test takes 1 second If the value 15 less than the preset level See Specifications Page 17 a trip occurs The LED on the Remote Display Module is illuminated and the open collector output on the relay is switched on to provide remote monitoring if required To reset the relay following an earth fault lockout trip operate the reset button The earth fault leakage level EF of the three phases is displayed on the Earth Fault Information page as a of the trip level and relates to the last earth fault lockout test performed 3 2 2 Automatic Insulation Test If a CCMC Mode has been selected in the Group 1 Sett
63. ld be wired direct into the pilot circuit PTC terminals are provided for a semiconductor thermistor connection These terminals are protected in a similar manner to the stop and start circuits If the remote stop start and PTC functions are not required each set of terminals must be bridged or the IPC Relay will not energise Four RTD inputs are provided for PT 100 temperature measuring devices These terminals could also be used with resistor networks to provide digital information back at the IPC Relay TX and terminals are included for the connection of auxiliary devices such as the RTU CIUI These terminals allow the input of data from an RS232 source at the load to be transmitted through the pilot of the cable to the IPC Relay s communication port On Off Line Status machine type machine number software version and input status of the Remote Termination Unit can be examined by selecting Machine Module Information Level 2 Positions 1 2 RTD temperature and CIU data is available Level 2 Position 4 5 2 2 Machine Type Codes There are 26 selectable machine type codes available for use in the Remote Termination Unit The descriptive code is transmitted to the IPC Relay to identify the type of machine connected to the outlet The codes are selected using the Remote Display Module Level 9 Position 1 Belt Conveyor SHRr Shearer S Ld Stage Loader Hpmp Hydraulic Pump Wpmp Water Pump cMnr Cont
64. le of this certificate and the identified documents was found to comply with the following standards AS 2380 1 1989 inc Electrical equipment for explosive atmospheres Amdt No 1 Explosion protection techniques Part 1 General requirements AS 2380 7 1987 Electrical equipment for explosive atmospheres Explosion protection techniques Part 7 Intrinsic Safety This Certificate does not indicate compliance with electrical safety and performance requirements other than those expressly included in the Standard s listed above Attention is drawn to the fact that the above Standards have been superseded ASSESSMENT amp TEST REPORTS The equipment listed has successfully met the assessment and test requirements as recorded in Test Report No and Issuing Body Refer to Schedule Quality Assessment Report No and Issuing Body IECEx AU TSA QAR06 0007 02 File Reference ANZEx 08 4071 8 March 2009 Signed for and on behalf of issuing body Date of Issue Certification Authority Position This certificate and schedule shall not be reproduced except in full This certificate is not transferable and remains the property of the issuing body and must be returned in the event of it being revoked or not renewed Page 2 of 9 Australian New Zealand Certification Scheme for EXPLOSION PROTECTED ELECTRICAL EQUIPMENT ANZEx Scheme Certificate of Conformity Certificate No ANZEx 08 4071X Original Issue No 0 Date of Issue 8 March 2009 Sc
65. learly labelled for ease of terminal location and identification The base sockets are factory adjusted so that they are able to move to assist in alignment when the relay is inserted Do not tighten socket mounting screws For installation mounting see drawing IPBA029 Page 35 B Remote Display Module RDM The Remote Display Module is an intrinsically safe device Ex ia designed to be mounted into the cut out of an 54 enclosure and can therefore be mounted external to the switchgear it is controlling To provide maximum benefit to the operator one RDM is normally used per relay This allows information from several relays to be simultaneously accessed and compared However if space restrictions preclude this a compromise is to use one 1 RDM to monitor and control more than one IPC Relay In these circumstances the following wiring arrangement is recommended The 3 pole change over switch must have sufficient creepage and clearance between IPC Relay channels in accordance with AS2381 7 1989 Section 3 C CCMC Cable Connection Module The Cable Connection Module CCMC is a resistor diode barrier which interfaces between the power circuit and the IPC Relay It also provides an automatic High Voltage DC Insulation Test following a successful Intrinsically Safe Earth Fault Lockout Test The CCMC 18 housed in an encapsulated module USER MANUAL ISSUE 8 Ensure that the earth connections are reliab
66. lies 15v dc to RDM Check cable between RDM and the relay Faulty Display Module Replace module Power to RDM is healthy but there 15 no data Corruption in the Group 1 or 2 Settings stored in the IPC Relay Corruption in the Group 1 Settings in the IPC Relay Either the RTU is not on line or the RTU s non volatile memory has been corrupted Faulty pilot circuit open or high resistance or shorted to earth Relay is waiting for the RTU digital inputs to be closed 18 Check data cable between the relay and the RDM Examine the Group 1 and 2 Settings level 8 and 9 to check the stored parameters in the non volatile memory Machine type and number are irrelevant and should be ignored One or several settings will show 297 Re program lost settings into the memory Examine the Group 1 Settings level 8 to check the stored parameters in the non volatile memory One or several other settings will show 7772 Re program lost settings into the memory Check that the RTU is on line level 3 position 1 ie a healthy pilot loop If the RTU is on line examine the Group 2 Settings stored in the RTU level 9 One or several other settings will show 2297 Re program lost settings into the RTU memory Check pilot circuit eg operate relay with a dummy plug if in diode mode If still faulty replace the relay Check pilot fuse Ensure all three RTU digital inputs are closed USER MANUAL ISS
67. ly installed as this 1s the basis of protection for all barriers including the CCMC D Overload amp Earth Leakage Toroids Current transformers are not ideal devices and if correct procedures are not followed during installation nuisance tripping can result If for example we consider a single phase earth leakage system where active and neutral pass through a toroid then at all times currents in the two wires are equal and opposite so that the net current through the toroid is zero An ideal current transformer would have all the flux from each wire contained in the core and so would accurately add the opposing fluxes to get a net result to zero A real current transformer has leakage fluxes That is a very small proportion of the total flux from each cable is not contained in the core but in the space outside it and as result it may link some turns but not others depending on the positioning of the cables The effect of this 15 that a small output may be obtained from the CT where none would arise if the device were ideal size of the error will vary from CT to CT of the same type because of slight differences in the core and the symmetry of the winding Problems caused in this way become worse as CT sizes increase as currents increase and a decrease occurs in the symmetry of the cables Nuisance tripping tends to occur when the total current rises such as when a large motor 15 started This 15 not normally
68. mity Certificate No ANZEx 08 4071X Original Issue No 0 Date of Issue 8 March 2009 Certificate Holder Ampcontrol CSM Pty Ltd 7 Billbrooke Close Cameron Park NSW 2285 Australia Electrical Apparatus Integrated Protection Relay Systems Types A IPA B IPB and C IPC including equipment as listed in Table 1 Type of Protection IPA IPB and IPC including items 1 to 6 and 9 refer Table 1 ia I Items 7 8 refer Table 1 Ex ia I 150C Marking Code Type of Protection as listed in Table 1 ANZEXx 08 4071X Manufacturing Location s Ampcontrol CSM Pty Ltd 7 Billbrooke Close Cameron Park NSW Australia This certificate and schedule shall not be reproduced except in full Certificate issued by ITACS Pty Ltd uo 4 6 Second Street SA 5007 Australia Accreditation by the Joint PO Box 300 Hindmarsh SA 5007 Australia Accreditation System of Australia and New Zealand ABN 06 098 886 563 Phone 61 8 8346 8680 Fax 61 8 8346 7072 Acc No Z2870404AA Email itacs itacslab com www jas anz com au Page of 9 Australian New Zealand Certification Scheme for EXPLOSION PROTECTED ELECTRICAL EQUIPMENT ANZEx Scheme Certificate of Conformity This certificate is granted subject to the conditions as set out in Standards Australia Standards New Zealand Miscellaneous Publication MP87 2004 STANDARDS The electrical apparatus and any acceptable variations to it specified in the schedu
69. n Stop Fan interlock Stop Current Balance Trip Ibal Trp Differentiates balance trip from basic over current trip Main contactor opened MC Opened opening not initiated by the IPC Relay RTU Memory error RTU mem E Errors in set up data from Off Line IPC ETUR communicate with RTU RTU ptc T RTU PTC input tripped Stopped IPC Stop Input Tripped Under Voltage trip UVOLT Trp voltage on load side too low 2 Machine Communication 2 1 Remote Termination Unit The Remote Termination unit is a microprocessor based fully encapsulated module that replaces the diode at the end of the pilot conductor of the trailing cable It is powered by and communicates via the pilot line Its non volatile memory stores the parameters to configure the outlet as appropriate for that machine terminals are fully shrouded with the pilot and earth terminals being kept segregated from the other terminals See RTU 2 General Case Dimensions Drawing IPB A 021 Page 26 The Remote Termination Unit RTU 2 provides remote stop start facilities of the IPC Relay s controlled outlet The circuitry involved for these functions are self diagnostic and will cause the outlet to turn off if the circuits are earthed or interconnected This reduces the chance of the outlet operating when not required to do so due to wiring faults It should be noted that these functions are operational only and that any emergency stops shou
70. n then the earth continuity will trip at 45 ohms If the MCI is closed the earth continuity trips at 145 ohms It is also necessary to bridge the local start button or start input on the relay on the outlet controlled by this method Both the remote and local stop buttons will turn off the outlet Stop Start functions are operational only Emergency stops should be wired direct into the pilot circuit 8 5 Operational Sequence Before an outlet can be energised the following conditions must apply a No protection faults present b Fan interlocking enabled c Stop input open d Local and remote start inputs closed e RTU stop and PTC inputs closed Once these conditions are obtained a cable fault lock out test 15 performed automatically This takes 1 second If the result of this test is satisfactory the IPC Relay goes into the run mode and the MCR relay picks up The RUN LED on the Remote Display Module is illuminated and the open collector output on the relay is switched on to provide remote monitoring if required A time delay of 5 seconds is allowed for the Main Contactor Interlock MCI to close If it does not close within this time then the run mode is exited If a stop input is closed while the relay is in run mode the run is cleared and the MCR relay de energises The event log reads Stopped stop input 18 closed during a cable fault lockout test then the test is aborted While th
71. nt event Each time a new log 15 recorded the 120th log is removed from the list The following events are logged Power Up The instant that power 1s applied to the relay Pwr Down Removal of power from the relay USER MANUAL ISSUE 8 MCR Close Stopped RTU Stop MC Opened MC Fail CloseFail EC Trip EC Leak T EL Trip EFLR Fail SC Trip OC Trip I bal Trp RESET Setup Mod FanIStp uVOLT Trp RTU ptc T T mem Closure of the Main Contactor Relay Stopping of the outlet by operation of the local stop button Stopping of the outlet by operation of the remote stop button Main Contactor has opened but not initiated by the IPC Relay Main Contactor Fail Function Trip Indicates that the MCI Input did not close within 5 seconds of MCR closing Pilot Earth continuity loop exceeds 45 Ohms Leakage resistance between the pilot and earth is less than 1500 Ohms Earth leakage protection tripped Earth fault lock out test has failed Trip condition of short circuit protection Trip condition of overcurrent or overload protection Current balance trip condition Records resetting of a protection trip function Records that set up data has been modified Outlet stopped by fan interlock Records that voltage was present on at least one outgoing phase when the main contactor was closed Internal battery backed contactor fail trip
72. o parameters which are linked to the system rather than the particular load connected to the outlet Group 1 Settings Pilot Mode Determines if the pilot is to be terminated with a diode or remote termination unit EL Time Sets the trip time for the earth leakage protection EL Sens Sets the sensitivity trip level for the earth leakage protection EFLO Selects the Cable Connection module to be used with the IPC Relay U V Trip Selects the undervoltage trip threshold as of line volts SC Relay Selects which output relay MCR or CBR is tripped in event of a short circuit trip EC Time Sets the trip time for the earth continuity protection Relay 3 Selects off FID or FIR operation of the relay The second group of settings consists of parameters that are related to the load connected to the protected outlet These settings are stored retrieved to from the memory in the IPC Relay or the memory in the Remote Termination Unit depending on the Pilot Mode setting Figure 1 shows how the memory is switched If a diode pilot mode is selected the IPC Relay reads and writes to and from the relay s internal memory for the group 2 settings Ifa RTU Mode is selected the settings are sent to and retrieved from the memory in the Remote Termination Unit IPB RDM Micro Processor Display Module
73. of enclosure The healthy LED located top centre of the module flashes at 3Hz to indicate healthy communications with the relay A flash rate of 1Hz indicates that the module is powered but is not receiving data The module displays the following information 1 IPC Status 2 Software version and serial number 3 Operational information from the protection functions eg earth leakage current earth continuity resistance etc 4 System information including the line voltage and current 5 Status of digital inputs and relay outputs 6 Protection trip settings which can be viewed at any time Authorised personnel can modify these settings via the RDM thus eliminating the need to open the flameproof enclosure 7 Data logging information The 120 most recent events are logged with time and date in a non volatile memory for example power up trip reset close etc A review of the first few log events is a useful tool for fault finding USER MANUAL ISSUE 8 The IPC status display is one of the most useful Message and Type 2 i d e dw Closing MainCont 2 MCR closed waiting for viewed as the first step in fault finding The 5 feedback 5 Sec 2 display is the default screen on power up indicates what the IPC Relay requires in order to Ix allow the outlet to close These messages are useful to EFLO Testing E In process of EFLO Test unskilled pe
74. onditions are met the ENT key must be pressed and held for the duration of the test After 3 seconds the EFLO test will commence If the test result is healthy the manual insulation test is initiated The test voltage is applied to the outgoing feeder while ever the above USER MANUAL ISSUE 8 conditions are held including holding the lt gt key The test results are continuously calculated and displayed The operator should maintain the test at least long enough for the readings to stabilize this being a function of the cable length Once the test 15 completed usually by releasing the ENT key the results are held in memory until another insulation test is commenced either manually or as part of the starting sequence or IPC control power is lost Note that the manual test can be carried out even if the Ins TstT selection is set to none ie the automatic insulation test in the starting sequence 15 turned off If the selection see section 3 2 18 not a CCMC Cable Connecting Module then the manual test will only perform an EFLO test The status of the manual insulation test is shown on the Insulation Test Information Page level 3 position 3 A single letter following indicates the status of the test Mt x Manual Test is blocked by any one or more of the conditions 1 to 8 above Mt e Only the lt ENT gt key is required to initiate the manual test Mt t The manu
75. ote monitoring if required The leakage current EL is displayed on the RDM Earth Fault Information page as a of the trip level When the leakage reaches 100 for the selected time delay a trip occurs The trip level is adjustable in 50 mA increments Range 100 to 500 mA The time delay is adjustable in 40mS increments Range instantaneous lt 80mS to 470mS 3 2 Earth Fault Lockout The IPC Relay can provide a two step insulation test as part of the Earth Fault Lockout protection function The initial test is the mandatory intrinsically safe test and can be followed by an automatic High Voltage Insulation Test A manual Insulation Test is also provided A cable connecting module which is a resistive isolation device is used to interface the power conductors to the IPC Relay Modules are selected in the Group 1 Settings Level 8 Position 3 for rated line voltages of 110V 415V 1000V or 3 3kV IPC Cable Connection Modules CCMC are the preferred modules and must be used when the Insulation Test function 1 required IPA IPB Cable Connecting Modules CCMA are available for the same rated voltages for use with the IPC Relay The use of these modules only allows the normal Intrinsically Safe EFLO Test to be carried out The High Voltage DC Insulation Test is not available with the CCMA Modules An IPA IPB CCMAIIOV Cable Connecting Module is available for use when the relay is installed to contro
76. possible The IPC Relay s approval requires that the relay 15 installed in accordance with the Australian Standard for Intrinsic Safety Installation AS2381 7 Anyone installing IPC Relays should therefore have a good understanding of AS2381 7 A Intrinsically Safe Circuits Signal Recommended Cable Type Pilot Single core screened Earth Screen 0V See note 1 page 15 Serial Four core screened Comms Screen OV 11 RDI 12 OV Remote 13 Data Two core screened Display 14 Vdm Screen OV 12 OV Note 1 That the OV 15 internally connected to the IPC Relay s earth 7 The screen therefore should NOT be earthed at any other point It is recommended that these circuits be separately loomed from all non IS circuits B Low Voltage Signals Although these signals are not IS signals themselves they connect to the low voltage side of the IPC Relay s internal infallible transformer This transformer is designed and certified to comply with section 3 2 2 of AS2380 7 This means that it is not liable to become defective in such a manner as would lower the intrinsic safety of the circuit from definitions section of AS2380 7 Care must therefore be taken to ensure these circuits cannot come into contact with higher voltages eg via insulation breakdown or broken wires etc It is recommended that these circuits be run in a separate loom from both the IS circuits and the high
77. rary Locating Pin and Connection Details 28 CONTENTS Drawings Continued IPC A 013 415V Cable Connecting Module IPC A 005 rens 29 1000V Cable Connecting Module 30 IPC A 008 3 3kV Cable Connecting Module 31 033 110V Cable Connecting Module IPA S 005 IPA IPB Relay LED Output Module IPA A 031 Relay Output Module General Arrangement IPB A 029 Relay Base Installation Drawing 35 IPC A 023 IPC Baseplate Details Including Permanent Locating Pin and Connection Details 17 Approvals NSW MDA Ex ia 10035 ANZEXx 08 4071X IPC1 USER MANUAL ISSUE 8 CONTENTS USER MANUAL ISSUE 8 1 Overview 1 1 Introduction The Ampcontrol IPC Integrated Protection Relay Version IPC1 V5 0 is an intelligent protection relay based on microprocessor technology The integrated relay provides the necessary functions required for protecting electrical outlets supplying underground mining machinery All of the protection functions are combined into a compact plug in unit which can be easily changed out to minimise down time in the event of a problem with the relay The IPC Relay provide machine communication through the use of a Remote Termination Unit RTU 2 connected between the pilot and earth at the machine end of the trailing cable Through the use of the RTU 2 Remote
78. reset button The EC LED on the Remote Display Module is illuminated and the open collector output on the relay is switched on to provide remote monitoring If required The earth continuity resistance ECR of the pilot earth loop and the leakage L between the pilot and earth conductors is displayed on the RDM Earth Fault Information page as a of the trip levels When either value reaches 100 a trip occurs Pilot Trip Time is adjustable to allow for operation in noisy electrical environments The following trip times are available 80 120 160 200 300 400 and 500mS A setting of 120mS should be suitable for most installations Long time delays 2200 ms should only be used where necessary Consequence of long trip times should be thoroughly assessed from a safety point of view before using the higher values 4 Current Related Functions 4 1 Basic Overcurrent Protection Functions Two current transformers are used to measure the three line currents The measured currents are used to implement the following protection functions a Overcurrent or Motor Overload b Short Circuit c Phase Current Balance Full load settings cover a range from 7 5 Amps to 464 Amps A current range and current multiplier are utilised to select and store the full load current value in the non volatile memory This forms the basic reference level for the overcurrent protection functions The current range is selectable in 4 Amp
79. rsonnel If more than one message is 1 second active the display cycles around all active messages Insulat Testing 2 In process of Insulation showing them for 1 second each Test 2 seconds Manual Ins Test 2 In proces of manual Through the use of the serial communications port Insulation Test PLC s and SCADA Systems can be configured to IPC Memory Error 3 Corrupted memory display the same messages that appear on the Remote relay s stored settings Display Module This helps to provide consistent information to operators RTU Memory Error 3 IPC detected errors in set up data received from A RTU 1 2 1 Trip Status Messages Tap RTU OMi 3 m 3 t The following table shows a list of the twenty eight B vill FTU 28 status messages and the category type of the 3 RTU input Tripped open 3 RTU Stop input Tripped open 3 Phase Current Balance Function Tripped 3 Fan interlock system is locking out IPC Type 2 Stopped IPC IPC Stop Digital input Messages are enabled and cleared automatically activated closed messages Messages are cleared according to their Stopped RTU PTC message category Stopped RTU Type 1 PE Messages are cleared by either pressing the ENT key while on the Status Display Page or by starting a new starting sequence 1 e EFLO test started Locked Out Fan I Balance Trip Earth Leak Earth leakage Function Tripped Earth Contin
80. s including drawings documents etc that are applicable to this Approved Item as identified during test and or assessment to assist the Approval Holder and User to comply with the obligations of the Occupational Health and Safety Act 2000 The onus is on the Supplier and or User to ensure the Approved Item and any deviation from the list of conditions recommendations in reference to that Item is not inferior in any way to the Item tested and or assessed this includes the supply installation and continuing use of the Approved Item The Approval Number shall appear in a conspicuous place and in a legible manner on each approved item unless specifically excluded A copy of the Approval Documentation shall be supplied to each user of the approved item and shall comprise the number of pages listed in the footer block together with supplementary documentation as listed in the schedule and in respect to drawings all drawings as listed in the schedule or those specifically nominated for the purposes of repair and maintenance Any Maintenance Repair or Overhaul of Approved Items shall be carried out in accordance with the requirements of the Coal Mines Regulation Act 1982 a Pew 27 7 uthority 2516 Accredited essing Ai FOR CHIEF INSPECTOR OF COAL MINES Dept File No C92 0362 Doc No d wes appmaster IPC suppappIPC doc Page 2 of 4 App Holder AMPCONTROL CSM Pty Ltd Minerals and En
81. terlocking Sequence 9 User Adjustable Settings 7 1 Parameter Groups 9 7 2 Changing Settings 10 System Control 8 1 Digital 11 8 2 Output 11 8 3 Open Collector Outputs 1 8 4 Outlet 11 8 5 Operational Sequence 12 IPC1 USER MANUAL ISSUE 8 9 10 11 12 13 14 15 16 Event Lozg 12 Time amp Date 13 Remote Data Communications 13 Installation amp Wiring Instructions 14 11 1 Installation 14 11 2 Wiring Installation 15 Equipment List 16 IPC Specifications 17 Trouble Shooting 18 Drawings IPC E 001 Typical Connection Diagram 20 IPC B 002 Display ettet enm 21 004 Overcurrent Curves 22 005 Overload Curves 23 IPC B 003 Fan Interlocking System 24 IPC M 013 IPC Enclosure Dimensions 25 IPB A 021 Remote Termination Unit 26 010 Remote Display Module RDM 1K 27 IPC A 010 IPC Baseplate Details Including Tempo
82. tic Analog Board Coms IPA Z 003 110 Construction Details 008 12 03 IPB Z 003 IPB Schematic Processor Board Sheet 1 Inputs IPB Z 004 IPB Proc Board Sheet 2 A D IPB MARKING DETAILS APPROVAL DRAWING 3 IPB Z 014 IPB Typical Connection Diagram 2009 02 16 2009 01 06 2009 01 06 2009 01 06 2009 02 16 2009 01 06 This certificate and schedule shall not be reproduced except in full Page 7 of 9 Australian New Zealand Certification Scheme for EXPLOSION PROTECTED ELECTRICAL EQUIPMENT ANZEx Scheme Certificate of Conformity IPB Z 018 IPB Schematic Remote Termination Unit sheet 2 1994 10 28 IPB Z 019 IPB CIU CASE DETAILS APPROVAL DRAWING 2008 12 03 IPB Z 020 RTU CIUI ARTWORK DETAILS APPROVAL DRAWING L3 2008 12 03 IPB 2 023 _ IPB RTU 2 CONSTRUCTION DETAILS _ 2099216 IPB Z 024 2008 12 03 IPB 2 025 RTUSCHEMATIC SHEET2 0 2008 1203 2 00 IPBRTU2 APPROVALMARKINGDETAUS 2009 02 16 IPB Z 028 RDM Ik REMOTE DISPLAY MODULE GENERAL ARRANGEMENT amp 2009 02 16 MOUNTING DETAILS 2 001 2 002 2 93 IPC Z 004 2 005 IPC Z 006 IPC 1000V CCMC Construction amp Artwork Detail IPC Z 007 IPC Ik CCMC Schematic 2008 09 30 2008 09 30 008 10 01 2008 10 01 008 10 01 008 10 01 008 09 30 008 10 01 008 10 01 2008 09 30 008 09 30 2008 09 30 N N 2 00 IPC 1000 Dimension amp Marking Details 8 IPC Z 009
83. ts rated current The IPC trip curves can be used to select the time multiplier which best suits the motors overload capacity Thermal Model Thermal modeling is based on a thermal time constant of 30 minutes time multiplier setting of 1 0 times The time multiplier can reduce this value to a minimum thermal time constant of 1 5 minutes time multiplier setting of 0 05 times The three measured phase currents are squared and added together to provide the heating input into the thermal model While the main contactor is closed the cooling output from the thermal model is calculated to achieve the necessary time constants When the main contactor is open a Cooling Multiplier is used to modify the basic time constant This can be used to account for the reduced cooling capacity while the motor is not running when applicable This multiplier is selectable at 0 2 0 3 0 4 0 5 0 8 1 0 2 5 10 20 and 50 times A selection of 1 0 times sets the motor off cooling rate equal to motor running cooling rate This selection is appropriate where cooling is maintained even when the motor is stopped eg water cooled motors When 0 2 times is selected the motor off cooling rate is reduced to 20 of the motor running cooling rate A selection of 50 times effectively disables the thermal memory With this selection as soon as the main contactor opens the thermal model resets quickly so that a cold restart 15 achieved Caut
84. uity Function Tripped Earth Fault Lockout Function Tripped Message and Type OverCurrent Trip 1 5 Tripped No Volts 1 Voltage on load side of PP contactor is too low Short Circ Trip Short Circuit Function Type 3 Messages are triggered by the respective trip functions and are cleared by resetting the trip function Earth Cont Trip Tripped MC Close Fail 1 MCI input did not close within 5 Sec of MCR Main Cont Fail 3 Main Contactor Fail External MC Open IPC detected via MCI input that MC was Tripped opened not initiated by Running Amps Outlet Closed shows the IPC relay average of 3 phase currents in amps Shows Last Trip Table 1 1 2 2 Last Trip Status Messages digital input The IPC Relay has several functions which can Awaiting start stop trip the outlet and then self clear The IPC digital input Relay therefore saves the non latched trip codes in Outlet Paused 2 IPC waits 5 Sec between a register and displays the Last Trip messages in em running or testing and the Status Message Page Note that the stop trip re testing function also appears in the Event Log USER MANUAL ISSUE 8 Messages that are displayed at Last T Message Comment E C Leakage Trip that EC Leak T provides additional information for E C Trip E C Ohms Trip that EC Trip provides additional information for E C Trip Fa
85. utputs The IPC Relay has eight open collector outputs which are driven through opto couplers to provide additional indication if required These can be used to drive LED s or additional relays with appropriate drive circuitry The eight outputs correspond to the LED s on the display module turning on whenever the corresponding LED 15 flashing The signals are available on the IPC Relay s base pins 35 42 and the common is on pin 34 USER MANUAL ISSUE 8 Contact Ampcontrol if further information 15 required about these outputs 8 4 Outlet Control The outlet can be energised by local or remote operation depending on the Remote Start option The selection is Yes Level 9 Position 14 RTU Mode If Yes is selected the relay ignores the local start input thus allowing operation of the outlet from the remote machine Both the remote and local stop buttons will turn off the outlet If No is selected the local start stop buttons control the outlet The Remote Termination Unit s start stop and PTC terminals must be bridged to energise the outlet Remote Operation in Diode Mode In this mode the stop start station 1s connected in the pilot See Typical Connection Diagram IPC E 001 Page 20 The pilot has a hysteresis of 100 ohms This is to allow a 100 ohm resistor to be connected across the start button The hysteresis is linked to the main contactor input MCI If MCI is ope

ipc1 user manual issue 8

Contents

Download Pdf Manuals

Related Search

Related Contents