IPM V2 user manual
Contents
1. ET ____ IPM V2 USER MANUAL ISSUE 9 0 5 8 5 206603 ON 194 1 130 00 ZWdl ONY NOISN3WIC WLI AJL 90710761 E mm ____ 2 gt gt IPM V2 USER MANUAL ISSUE 9 SOOVZWdl l 8 VL Coe TET 3 NOISN3AIQ 310004 NOLLYNIWY3L 310838 31 14 ONILNNOW SHU 08 13A 31925 LON 00 ae pe ae 1 9 1075 349402 94 40 20 5 1055 0 4200 paanposdas aq 00 mw 1 10222 484 94 23145 30 11839084 50 JNYHIDL JHI 5 ONIMVH SIHL 1V83N39 401 SH 29 IPM V2 USER MANUAL ISSUE 9 204 53113034 y uurg 3X1 1 388012 AV 133 OZLOL N d 40159 31715 LON 00 21 10 60 0000 SNO SN3HIO 8 1 Y 38031 31 104103449 50 la AVINI 103387 11 0001 3X1 2 01 N d 00012. ALM out j j 13 3 Outlet Control The outlet can be energised by local or remote operation depending on the Remote Start option The selection is Yes or No Level 6 Screen 16 If Yes is selected the relay ignores the local start input thus allowing operation of the outlet from the remote machine Both the external and local stop buttons will turn off the outlet If No is selected the local start stop buttons control the outlet 13 4 Start Mode The Start Mode is selected at Level 5 Screen 3 The possible settings are K Ext Ext K amp Ext Modbus and Snore The start stop logic operates as follows e external stop digital input and the front keypad stop button will always stop the relay regardless of the settings for Start Mode In all cases only one of the stop inputs needs to be active to stop the relay K Ext mode Relay can be started with either an external start or the keypad Ext mode Only the external start is used The keypad start is disabled e K amp Ext mode Both the external start and the front panel keypad start button needs to be active to start the relay e Modbus mode Not yet implemented e Snore mode The parameters for Under Current Trip Start Mode and the Snore time delay need to be set for your application Extra protection against accidentally selecting this mode is provided by requiring the external digi
3. Not Active Arming Man Ins Test and Manual Insulat Test The display will show the last measured value 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 The pilot core is also used to transfer data when a Remote Termination Module is used to achieve Machine Data Transfer IPM V2 USER MANUAL ISSUE 9 The IPM relay can be configured to operate in either diode or RTM mode The mode is selected in EC Pilot Mode Level 5 Screen 1 and determines what terminating device the relay is looking for on the pilot Note The Remote Termination Module will only be recognised by an IPM 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 is detected If the pilot earth loop resistance exceeds 45 a trip occurs 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 resistance is less than 45 The selection is either EC Trip Latch On Level 6 Screen 17 To manually reset the relay operate the reset button Eart
4. Under current protection is enabled as soon as the main contactor is closed indicated by closing the MCI input Selecting a Value of none will inhibit this function If any phase drops below the selected trip setting for a period of 4 seconds then the outlet is stopped This raises the Under Current Trip alarm and is recorded in the event log as Und l To reset the relay operate the reset button The trip level is selected via the Under Level setting Level 6 Screen 10 The trip level is selectable at 32 40 48 56 64 72 80 88 and 96 Setting the trip level to None disables this function This function is used when in snore mode and must be set to an appropriate level note that there is a 4 second delay before a trip 5 Voltage Related Functions 51 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 Insulation Test Module ITM is used to measure the voltage on the load side of the contactor If this exceeds 1090 of the rated line voltage a trip will occur This test provides
5. 9 Forward Resistance 10 E C Reverse Resistance 11 Insulat Test Result MOhms 12 Control Keys Up Key Down Key Bit2 Left key Bit3 Right key Bit4 Enter key Bits Esc Key 13 E L Current 0 110 14 A Phase Current 0 1000 15 B Phase Current 0 1000 16 C Phase Current 0 1000 17 Current Balance 0 100 18 Residual Current 0 1000 19 OC Thermal Accum 0 120 20 A Phase Voltage 0 120 21 B Phase Voltage 0 120 22 C Phase Voltage 0 120 23 Phase Voltage Average BCD format 24 Current Average 0 250 25 Unused 26 Unused 27 Unused 28 Unused 29 Unused 30 Unused 31 Unused IPM Software Version where 32 x Top 3 bits Hardware Ver y Bot 5 bits Software Ver 33 Time Sub Second 34 Time Second 35 Time Minute 36 Time Hour 37 Date 38 Month 39 Year 40 Day 41 EC Pilot mode 0 Invalid Data 1 2 Diode 42 0 Invalid Data 1 415V 2 1000 3 Modbus Addr Description 43 Modbus Address 0 Invalid Data Modbus Baud Rate 0 Invalid Data 1 1200 2 12000 3 12003 4 2400 5 24000 6 24003 7 4800 8 48000 9 48003 10 9600 11 96000 12 96003 13 19 2 14 1920 15 19K2N Machine 1 J bo Jumbo 2 Fan 3 Drill 4 lt 5 Hpmp Hydraulic Pump 6 Wpmp Water Pump 7 DCB 8 Bolt Bolter 9 HRMr Hard Rock Miner
6. 10 Belt 11 Winc Winch 12 Crush Crusher 13 DPlug Dummy Plug 14 Spare 46 Machine Number 0 Invalid Data 1 40 47 FLC Setting See OC section 1 32 5 125 10 000A 33 64 10 25 20 00A 65 96 20 5 40 0A 97 128 41 80 129 160 82 160A 161 192 164 320A 193 224 328 640 IPM V2 USER MANUAL ISSUE 9 Modbus Addr Description 48 SC Trip Level xFLC 0 Invalid Data 1 3x 2 3 5x 3 4x 4 4 5x 5 5x 6 5 5x 7 6 8 6 5x 9 7x 10 7 5x 11 8x 12 8 5x 13 9x 14 9 5x 15 10x SC Trip Time 0 Invalid Data 1 20ms 2 40ms 3 60ms 4 80 ms 5 100 ms 6 120 ms 7 160 ms O L Trip Time 6x FLC 0 Invalid Data 1 35 2 45 3 558 4 568 5 75 6 8s 7 10s 8 12s 9 14s 10 16s 11 20s 12 24 13 28 14 32 15 40 S Cool Ratio 0 lt Invalid Data 1510 2 215 3 20 4 25 5 3 0 6 4 0 7 50 Modbus Addr Description 52 O L Reset Level 0 Invalid Data 1 30 40 50 60 70 80 90 A 30 A 40 10 A 5096 11 A 6096 12 A 7096 13 A 8096 14 90 53 54 Current Balance Trip 0 Invalid Data 1 5 2 10 3 2090 4 50 5 Off Under Trip 0 Invalid Data 1 32 2 40 3 48 4 56 5 64 6 72 7 80 8 88 9 9696 10 None 55 Ire
7. Ext External only As per K Ext Start mode K amp Ext Keypad and External As per K Ext Start mode Modbs and Snore These modes will not operate when remote start is set to yes The status display will show Configuration Err Remote start Aux When an appropriate start mode is selected changing the Auxiliary digital input will switch between local keypad or external digital start input or remote RTM digital input It is allowable to change the state of the Auxiliary input while the IPM is running If the RTM input is open and the IPM is running while the Auxiliary input is closed the IPM will immediately stop If the RTM input is closed and the IPM is running while the Auxiliary input is closed the IPM will continue to run Start mode K Ext Ext and K amp Ext The IPM will change between remote start mode and local start mode depending on the state of the Aux digital input When the input is close the IPM will be controlled via the RTM as described in the section above remote start set to yes When the Aux digital input is open the control will revert to local mode The start signal required will depend on the Start mode parameter Start mode Modbs and Snore These modes will not operate when remote start is set to yes The status display will show Configuration Err 11 3 IPM RTM Software Compatibilit
8. Loss of Vacuum Protection This function is inhibited immediately after the main contactor opens to allow for back EMF voltages generated by some motors to dissipate The inbuilt time is selected via the back emf time setting Level 6 Screen 20 The settings are adjustable from 2 to 20 seconds A main contactor fail trip operates the CBR relay which trips the circuit breaker To reset the relay following a main contact failure trip operate the reset key digital input The status of the MCI input can be viewed on the Relay and Keys Screen Level 4 Screen 2 5 2 Undervoltage Trip The Undervoltage protection is enabled as soon as the GZ 0 0 iC 1005 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 800ms then the MCR relay is de energised To reset the relay following an undervoltage trip operate the reset key digital input The trip level is selected via the U V Trp level setting Level 6 Screen 19 and is adjustable from 4090 to 9590 in 10 increments Setting the trip level to off disables this function 5 3 Voltage Metering The Insulation Test Module ITM is also used to provide line voltage metering L2 Displays the line current for each of the 3 phases L3 Displays the line voltages for each of the 3 phases L4 Displays the thermal accumulator and main con
9. 5 Under 7 5 Voltage Related Functions 7 5 1 Main Contactor Fail Protection 7 5 2 Undervoltage 7 5 3 Voltage 7 6 Analogue Output 7 8 7 1 Modbus 5 8 7 2 Modbus Status 8 8 IPM Alarm 8 9 FanControl 8 9 1 Burp Function em et 8 10 The IPM Snore Function 9 10 1 Basic 9 10 2 Setup procedure for Snore Function 9 11 Remote IPM Control Function 10 11 1 Function Overview sessir 10 112 Operation Modes 11 11 3 RTM Software Compatibility 11 IPM V2 USER MANUAL ISSUE 9 12 Adjustable Settings 11 12 1 Parameter 11 12 2 Changing 5 12 13 System Control 12 13 1 Digital Inputs 12 13 2 Output Relays sss 12 13 3 Outlet 13 13 4 Start 13 13 5 Operational Sequence insulation test and Burp Function selected 13 14
10. E N 96000 192000 E N 96000 5 6 Modbus T out 0 5 1 0 2 0 5 0 None 0 5 Sec 5 7 CT Ratio 100 1 and 1000 1 6 Settings Grp2 RTM 6 1 RTM Machine Type J bo Fan Dril Pump Hpmp Wpmp DCB Bolt HRMr Belt Winc Crsh Dplg Spare 62 RTM Mach Num 11040 6 3 100 Current 5 125A 625A 5 125A 6 4 Short Cct Trp Selectable 3 0 to 10 Times FLC 3 0 x 6 5 Short Cct t 20 40 60 80 100 120 160 mSec 20 mSec 6 6 OIL trp t 6x 3 4 5 6 7 8 10 12 14 16 20 24 28 32 40 Sec 3 Sec 6 7 O L cool mult 1 0 to 5 0 ie 2 5 Fan Cooled Mtr 1 0 6 8 OIL Rst Level 30 90 A30 A 90 A Auto Reset 30 6 9 Cur Bal Trip 5 10 20 50 off 5 6 10 Under Level 32 40 48 56 64 72 80 88 96 None 32 6 11 Residual i Trip 10 20 30 40 50 60 80 100 120 150 200 250 10 6 12 Res trip time 100mS 1 2 3 5 Sec 100 mS 6 13 RCD Trp Level 25 50 100 200 500mA 25 mA 6 14 RCD Trp Time 50 100 150mSec 50mSec 6 15 Pilot Trip t 80 120 160 200 300 400 500mSec 120mSec 80mSec 6 16 Remote Start No Yes No 6 17 EC Trip Latch On Off For Reset Operate Reset Button On 6 18 Ins Tst Level 1 2 5 10 20MQ None 1 0 0 6 19 UN Trip level 40 50 60 70 75 80 85 90 95 Off 40 6 20 back emf time 2 5 10 15 20 Sec 2 Sec 6 21 Highlalarm Delay 15 100 600 FLC amp Off 100 6 22 Alarm Lev Delay 25 5096 6096 7096 75 8096 8596 90 95 Alarm Off 5090 6 23 Under Al
11. Event LOG io 13 15 Time amp Date 14 16 IPM Equipment Parts List 15 17 General Notes 15 18 IPM Specifications 16 19 Menu Structure 17 20 IPM Modbus Address Table 18 Drawings Related to Manual IPM2E002 Connection 22 IPM2A013 IPM Display 23 IPM2E008 Motor Overload and Short Circuit Curves sss 24 IPM2A004 Case 25 IPM2A001 IPM Terminal 26 IPM2A002 415V 27 IPM2A003 1kV Module sn 28 IPM2A005 RTM Module 29 CONTENTS IPM V2 USER MANUAL ISSUE 9 IPM2A018 Current Transformer 87mm amp 45mm Profiles ccc seers 30 CONTENTS IPM V2 USER MANUAL ISSUE 9 1 Overview 11 Introduction The Ampcontrol IPM Integrated Protection Relay Version IPM 10 0 is an intelligent protection relay based on microprocessor technology The IPM Integrated Relay provides the necessary functions required for protecting electrical outlets supplying underground mining machinery powered by reeling or trailing cables in the metalliferous industry The relay
12. ISSUE 9 1 Need IPM Start 1 1 Start Status See Trip Status Messages Error Messages Type 2 Enabled amp Cleared Automatically 1 2 1 50 Event Log last 50 events Pwr Up Pwr Down MCR Close Stopped Ext Stop MC Fail Close L2 Event L3 Time Event Fail Trip EC Leak Trip EL trip Burp Done Burp Fail SC Trip L4 Present Time OC bal Trp RESET Set up Mod 2 Earth Leakage 2 1 Current Voltage Overload 22 All Currents E L E L IB Trip Level to 100 Trip Current Balance 3 Earth Continuity 3 1 Earth Continuity When either EC Res or Earth Loop Leakage reaches 100 a trip occurs 3 2 Insulation Test Level 2 10 20MO Alarm 1 5 x Set Value Display shows last measured value 3 3 Status Indicator Remote Input 4 IPM Relays amp Keys 4 1 IPM Relay 8 Keys CBR MCR ALM MCI Str Rst Stp 4 2 IPM Dig Inputs ExtRst ExtStp ExtStr Lock Aux A O 4 0mA 4 3 Modbus Status Address Read Wrt Exc CRC Par NE FE 44 Clock Setup Day Mth Yr Hrs Mins amp Sec Time Stamp Events Log 5 Settings Grp1 IPM 5 1 EC Pilot Mode Diode RTM Earth Loop Resist lt 450 52 ITM Module 415v 1000v 5 3 Start Mode Selects Inputs Reqd For Start Mode 5 4 Modbus Addr 1 31 5 5 Modbus Baud P 12000 24000 E N 48000
13. Level RCD Trp Time Pilot Trip t Remote Start EC Trip Latch Ins Tst Level U V Trp Level Back emf time High alarm O L Alarm Lev Selects the RTM descriptive code transmitted to identify the machine connected to the outlet Selects the assigned machine number to be transmitted by the Remote Termination Module Sets the full load current Combines with OC range to define the full load current Sets the short circuit trip level Sets the trip time for the short circuit function Modifies the basic overcurrent time curves to achieve the desired trip times Allows the cooling rate of the thermal model to be modified Sets the preset level to allow a reset of an O L trip Adjusts current phase balance trip Sets the under current threshold Selects the residual current trip threshold as a of FLC Sets the trip time for the residual current function Sets the sensitivity trip level for the earth leakage protection Sets the trip time for the earth leakage protection Sets the trip time for the earth continuity protection When Yes is selected the IPM Relay ignores the local start input When No is selected the local start stop inputs control the relay Determines whether earth continuity trips are self resetting or not Sets the trip threshold or disables the insulation test function Sets the under voltage threshold Adjustable time delay to inhibit main contactor fail
14. a data logging feature This log sequentially records the time date and details of the most recent event A chronological list of the previous 50 events is stored Event Log 1 Record 01 Power Up 26 07 14 857 13 064 26 07 14558221 The event log can be viewed by using the Right or Left arrow keys to scroll the log A typical display shows L2 Displays the event L3 Indicates the time that the relay powered up on Wednesday 26 July L4 Indicates the present time Log 1 is always the most recent event Each time a new log is recorded the 50th log is removed from the list The following events are logged Power Up The instant that power is applied to the relay Pwr Down Removal of power from the relay MCR Close Closure of the Main Contactor Relay Stopped Stopping of the outlet by operation of the local stop button Ext Stop Stopping of the outlet by operation of the external stop button MC Opened Main Contactor has opened but not initiated by the IPM Relay MC Fail Main Contactor Fail Function Trip CloseFail Indicates that the MCI Input did not close within 5 seconds of closing IPM V2 USER MANUAL ISSUE 9 EC Q Trip EC Leak T EL Trip Burp Done Burp Fail SC Trip OC Trip bal Trp RESET Setup Mod Und l Trp uvolt trp lres trip Tmem Loss T mem Rst Mem ERROR u P reset o l alarm Pilot Ea
15. as the first step in fault finding The Relay Status Page is the default screen on power up and shows the current status of the IPM Protection Relay Status Messages are listed in Table 1 1 IPM V2 USER MANUAL ISSUE 9 Line 1 A one line status message is displayed and if Message and Type Testing Insulation In process of Insulation Test 2 seconds Closing Main Cont MCR closed waiting for MCI feedback 5 Sec max Burp MCR Closed Burp Phase is on MCR closed more than one message is active the display cycles Burp MCR Open Burp phase is active MCR through all active messages at 1 second intervals is open Line 2 IPM Software version appears here while key Outlet Closed held Snore Function Active Line 3 Shows the Load Type and Number from the Snore Close Aux 2 Aux Digital input must be connected RTM unit Closed for Snore to function Line 4 Shows the Load Current 3 average and Load Alar Current Alarm riggered Voltage Average Thermal Trip Alarm 2 Thermal Trip Alarm Through the use of the Modbus communications port Triggered PLC s and SCADA Systems can be configured to display Cur Balance Alarm 2 Current Balance Alam the same messages that appear on the display This precum m Triggered helps t istent information 1 tors elps to provide consistent information to operators Ana 5 Under CEA 14 Status Messages Triggered The following
16. 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 A Burp Function allows for the progressive inflation of ventilation bags tubes by pulsing the motor contactor controlling a ventilation fan several times at start up A Snore Function is available for controlling pumps the Snore function automatically stops the output on detection of low current and restarts the outlet after a fixed or automatically adjustable time delay The IPM Integration Protection Relay has 6 digital inputs which feed into microprocessor unit The microprocessor has been programmed to control three output relays The relays are MCR Main Contactor Relay CBR Circuit Breaker Relay and ALM Alarm Relay All of the tripping logic and outlet control is performed by the microprocessor so that virtually no external control is required See Typical Connection Diagram IPM2 E 002 A four line 20 character backlit LCD display combining with a keypad provides an easy to operate user interface The display provides easy access to all available information A simple procedure allows adjustment of the relay s settings 1 2 Protection Functions The Ampcontrol IPM Integrated Protection Relay provides protection functions for Earth Leakage Section 3 1 Earth Continuity Section 3 3 Overcur
17. j_j PRESSED Aux j A O 20 0mA setting reverts to its previously stored value When changes have been made to the stored values the old value 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 13 System Control 13 1 Digital Inputs The IPM provides six 6 voltage free digital inputs for correct operation To activate an input a connection needs to be made from DiPwr terminal to the respective digital input s terminal L2 Displays the status of the external reset and the lock inputs L3 Displays the status of the external stop and the auxiliary inputs L4 Displays the external start input and the analogue output in mA The function of each input is as follows Lock The lock input needs to be closed while ever changes to the relay settings are being made If the lock input is not closed then the settings cannot be changed The lock input must also be closed to reset the thermal memory to allow an emergency re start To perform a reset the motor must be stopped MCI open and both the reset key and the lock input must be held closed for 1 5 seconds This will reset the Thermal Accumulator and allow the motor to be started immediately Reset The reset digital input performs the same function as the keyboard reset allowing for external remote resetting of trips To reset a trip an open to close transition o
18. on operation of the Start key will cause the relay to proceed through a power on sequence External Start switch When this switch is closed the relay will start a power on sequence on cold boot The Digital input switch must be on if it is open then the relay can t be started in Snore Mode Relay Stop procedure e The relay will be stopped whenever the Stop key or the external Stop is actioned regardless of the Snore process This will reset the delay e the AUX input opens at any time during operation in Snore more then a start is required to restart the snore function The Message Snore Need Aux will be displayed on the screen when in Snore mode with the AUX open This will reset the delay 11 Remote IPM Control The IPM and RTM software have been changed to allow for the RTM digital input to be used to control the IPM This functionality is similar to that of the IPB C D 9 IPM V2 USER MANUAL ISSUE 9 The remote start can be set in two modes In one mode it is always active and in the other mode it is active only when the auxiliary digital input is closed Remote start can also be disabled 11 1 Function Overview There was an existing parameter called remote start This parameter was previously unused but was originally intended to implement the remote start functionality This existing parameter has been used to enable the remote start function Setting it to yes enables remote
19. start Setting it to no will disable remote start Setting it to Aux enables remote start only when the auxiliary digital input is closed The remote input on the RTM is edge sensitive This ensures that if there is an upstream trip the IPM won t restart automatically once the power is restored It also allows the keypad and external digital input stops to work sensibly so that if the IPM is stopped locally it won t restart immediately after any of the stop are released When remote start is active the remote input is closed to start the IPM and must remain closed while the IPM is running The remote input is opened to stop the IPM 11 2 Operating Modes Note that the external digital stop input and the keypad stop will always stop the IPM regardless of the start mode Diode Mode The remote start parameter has no effect when the IPM is set to diode mode RTM Mode The Remote start parameter has three possible options no yes and aux Remote start no The remote input will be ignored Starting the relay will depend on whatever start mode is selected as per the existing operation Remote start yes Start mode K Ext Keypad or External Keypad and External start inputs are ignored Remote input controls the IPM Local stop input will still stop the IPM Local stop inputs will override the remote start if they are held closed while a remote start is signalled Start mode
20. table shows a list of the forty 40 status Earth Leakage Alarm 2 Earth Leakage Alarm messages and the category type of the messages Triggered Messages are cleared according to their message UnderVoltage Alarm 2 Under Voltage Alarm category Triggered Type Insulat Test Alarm 2 Insulation Test Alarm cleared by either pressing the ENT key while on the Status Display Page or by starting a new starting 99 sequence Earth Leakage Trip Earth leakage Function Type 2 Messages are enabled and cleared Tripped automatically Earth Cont Trip 3 Earth Continuity Function Type 3 Messages are triggered by the respective trip Tripped functions and are cleared by resetting the trip function Insulat Fail Trip 3 Insulation Test Function Tripped Message and Type Over Current Trip Over Current Function Tripped No Volts Voltage on load side of Tripped contactor is too low Short Circuit Trip 3 Short Circuit Function Tripped MC Close Fail MCI input did not close Balance Trip Phase Current Balance within 5 Sec of MCR relay Function Tripped closing Residual Cur Trip Residual Current Function External MC Open IPM detected via MCI Tripped input that MC was opened Main Contactor Fail 3 Main Contactor Fail initiated by the IPM Function Tripped relay RTM Offline Trip 3 IPM can t communicate Burp MCI Fail 1 MCI Input fails to follow with RTM MCR relay output during IPM Memory Error Corrupted memory
21. trip Bit11 Overcurrent Trip Bit12 Short Circuit Trip Bit13 Balance trip Bit14 lt Residual Cur Trip Bit15 Main Contactor Fail Bit 0 External Stop Bit RTM Offline Trip Bit2 IPM Memory Error Bit3 RTM Memory Error Bit4 lt Stopped IPM Bit5 Unused Bit Bit6 Unused Bit Bit RTM CT Ratio Error Soft Trip Status and Alarms Bit8 Tripped No Volts Bit9 MC Close Fail Bit10 External MC Open Bit11 Burp MCI Fail Bit12 Under Current Trip Bit13 Unused Bit Bit14 Unused Bit Bit15 Last T Bit 0 High Current Alarm Bit 1 Thermal Trip Alarm Bit2 Unused Bit Bit3 Under Cur Alarm Bit4 Earth Leakage Alarm Bit5 Unused Bit Bit6 Insulation Test Alarm 7 Unused Bit Status Outlet Paused Bit Need IPM Start Bit2 Testing Insulation Bit3 Closing Main Cont Bit4 Burp MC Closed Bit5 Burp MC Open Bit6 Running Bit7 Manual Insulation Test Bit8 Snore Snore Close Aux Bit10 RTM Version Error Bits 0 7 clr when key pressed Digital Inputs and Keys Bit10 Lock Input Bit11 Reset Input Bit12 Aux Input Bit13 Start Input Bit14 Stop Input Bit15 MCI Input 18 IPM V2 USER MANUAL ISSUE 9 Modbus Addr Description 7 cont Stop Key Bit1 Start Key Bit2 Reset Key Bit3 Test Key 8
22. which are recorded sequentially regardless of the date time Date and time data is not used for any control functions 16 IPM Equipment Parts List 143794 121504 121505 143315 101272 101703 141548 IPM 24VAC IPM Integrated Protection Relay ITM 415V Insulation Test Module ITM 1000V Insulation Test Module RTM Remote Termination Module Ver 2 Current Transformers 45mm 1000 1CT Current Transformers 75mm 1000 1CT Current Transformers 45mm 500 5 CT 17 General Notes Torque Setting for Relative Mounting Screws for the Facia assembly 0 8Nm 15 IPM V2 USER MANUAL ISSUE 9 IPM V2 USER MANUAL ISSUE 9 18 IPM Specifications Auxiliary Supply Volts 24VAC DC 20 Power Consumption lt 10W Earth Leakage Protection Trip Setting 25 500mA and off Time Delay Instantaneous lt 80ms 50ms to 150ms Alarm Setting 10 20 30 40 50 60 80 and off Earth Continuity Protection Reset if resistance lt 45 Ohms Trip if resistance gt 45 Ohms Shunt Leakage Trip if 1850 Ohms Operating Time 80 120 160 200 300 400 500ms Insulation Test Lockout Resistance 1 2 5 10 20 Meg ohm and none Test time 2s Alarm Setting Insulation Test Trip setting x 1 5 Overload Protection Current Range 0 5125 to 64 Amps 224 steps 100 1CT Current Range 5 125 to 640 Amps 224 steps 1000 1 CT Trip Time 6xFLC 3 4 5 6 7 8 10 12 14 16 20 24 28 32 40s Cooling Multiplier 1 1 5 2 2 5 3 4 5 times Ov
23. 3 60 7 2 14 4 28 8 57 6 0 9250 1 850 3 70 74 14 8 29 6 59 2 0 9500 1 900 3 80 7 6 15 2 30 4 60 8 0 9750 1 950 3 90 7 8 15 6 31 2 62 4 1 0000 2 000 4 00 8 0 16 0 32 0 64 0 Table 4 1 Current Settings IPM Full Load Current Selection Table Amps 5 125 1025 205 41 82 164 328 5 250 10 50 210 42 84 168 336 5 375 10 75 215 43 86 172 344 5 500 11 00 220 44 88 176 352 5 625 1125 225 45 90 180 360 5 750 11 50 23 0 46 92 184 368 5 875 1175 235 47 94 188 376 6 000 12 00 24 0 48 96 192 384 6 125 1225 245 49 98 196 392 6 250 12 50 25 0 50 100 200 400 6 375 1275 255 51 102 204 408 6 500 13 00 26 0 52 104 208 416 6 625 1325 265 53 106 212 424 6 750 13 50 270 54 108 216 432 6 875 13 75 275 55 110 220 440 7 000 14 00 28 0 56 112 224 448 7 125 1425 285 57 114 228 456 7 250 14 50 290 58 116 232 464 7 375 1475 295 59 118 236 472 7 500 15 00 30 0 60 120 240 480 7 625 15 25 30 5 61 122 244 488 IPM V2 USER MANUAL ISSUE 9 7 750 15 50 31 0 62 124 248 496 7 875 15 75 31 5 63 126 252 504 8 000 16 00 32 0 64 128 256 512 8 250 16 50 33 0 66 132 264 528 8 500 17 00 34 0 68 136 272 544 8 750 17 50 35 0 70 140 280 560 9 000 18 00 36 0 72 144 288 576 9 250 18 50 37 0 74 14
24. 8 296 592 9 500 19 00 38 0 76 152 304 608 9 750 19 50 39 0 78 156 312 624 10 000 20 00 40 0 80 160 320 640 Table 4 2 Current Settings The trip time is selected via the O L Trp t 6x setting Level 6 Screen 6 It is a function of the current and the selected trip time curve Drawing IPM2 E 008 IPM Motor Overload and Short Circuit Trip Times shows the trip time curves The fifteen 15 motor overload curves allow trip settings from 3 to 40 seconds at six 6 times FLC and 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 trip time can be calculated as follows _ 1123849 Trip Time C x 31 53x In 100 I 1 1238 Where C Curve Selected Current FLC 1 A Initial Thermal Accumulator Value Note Cold Start A 0 and on Hot Start A 89 The motor manufacturer s data should always be consulted to select the appropriate settings for the motor being protected Typically the capacity of a cold motor is given at six times its rated current The IPM Relay s trip curves can then be used to select the trip time curve which best suits the motors overload capacity The motor overload trip latches once the thermal accumulator reaches 100 and can only be reset once the thermal accumulator falls below a preset value The p
25. 9 9 a 0 V ZHdi NAVYO d ONIN L 19945 151 EV 160 0L S1 dYW AV1dSIC 138 1231089 031V3931NI 20 30 83101 IVAN 23 IPM V2 USER MANUAL ISSUE 9 5 3 2 INIAN 18085 2 8010 31383 3333 32355 3 28 FIRAR S09 90999 3 A z Lu 14 14 gt 9 E 8 2 5 i Short Circuit Selectable at 3 5 4 5 0 5 5 6 0 6 5 0 4 5 Times Selected Full Load Current 7 0 7 5 8 0 8 5 9 0 9 5 10 0 40 60 80 100 120 amp 160 mSec Trip Times Selectable at 20 in 24 IPM V2 USER MANUAL ISSUE 9 18083 ore whe pn MU 2 2 2 25 IPM V2 USER MANUAL ISSUE 9 19139 01123 02 3 1432 8 WIV WOO Z HOW WOO Z HOW ON Z HOW ON HOW WOO HON WWS ZEL 26 IPM V2 USER MANUAL ISSUE 9 200 V SMO 106603 ON 18 4 1130 NOISN3HIO ASL gt 16 gt 2 90 10 61 avo
26. IPM V2 Integrated Protection Relay User Manual ED E IPM2B003 121549 Issue 9 05 07 12 Designed and Manufactured in Australia by Ampcontrol Pty Limited ACN 000 915 542 Ampcontrol Electronics Phone 02 4903 4800 Fax 02 4903 4888 No Copies of the information or drawings within this manual Shall be made without the prior consent of Ampcontrol AMPCONTROL POWER THROUGH INNOVATION Copyright Notice No part of this publication may reproduced transmitted or transcribed into any language by any means without the express written permission of Ampcontrol Pty Ltd 7 Billbrooke Close Cameron Park NSW 2285 Australia Disclaimer Ampcontrol Pty Ltd will make no 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 IPM 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 IPM V2 USER MANUAL ISSUE 9 CRN 9657 IPM Software Version IPM V03 Initial Release Version IPM V04 Version IPM V05 Prototype only N
27. and displays the Last Trip messages in the Status Message Page Note that the stop trip function also appears in the Event Log Messages that are displayed at Last T Message Comment E C Leakage Trip that provides EC Leak T additional information for E C Trip E C Ohms Trip that provides Trip additional information for E C Trip Main contactor opened opening Opened not initiated by the IPM Relay RTM Off Line IPM can t communicate with RTM Trp Under Current trip caused outlet to stop Stopped IPM Stop Input Tripped Locally Ext Stop IPM Stop Input Tripped Externally Table 1 2 2 Machine Data Transfer 2 1 Remote Termination Module The Remote Termination Module 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 Machine type and machine number are displayed on the Default and Earth Continuity Screens Levels 1 and 3 2 2 Machine Type Codes There are 14 selectable machine type codes available for use in the Remote Termination Module The descriptive code is transmitted to the IPM Relay to identify the type of machine connected to the outlet The codes are programmed at the RTM Mach Type page Level 6 Scr
28. arm Delay 2s 32 40 48 56 64 72 80 88 96 32 6 24 E L Alarm Lev Delay 15 10 20 30 40 50 60 80 Off 10 6 25 Burp Pulses None 1 to 6 None 6 26 Burp On Time 0 6 0 8 1 0 1 2 1 5 2 0 2 5 3 0Sec 0 6 Sec 6 27 Burp Off Time 0 6 0 8 1 0 1 2 1 5 2 0 2 5 3 0Sec 0 6 Sec 6 28 4 20 Ma Output OIL 0 100 lave 0 250 0 100 0 40M O L 6 29 Snore Delay Off 5 10 15 20 8F 15F 20F 30F 60F F Fixed Delay Off EC Leak T Type 2 Tripped No Volts Trip Outlet Paused Snore Close Aux Earth Leakage Trip RTM Off Line Trip MC Close Fail MC Opened Need IPM Start High Current Alarm Earth Cont Trip IPM Memory Error External MC Open RTM Off L Testing Insulation Thermal Trip Alarm Insulat Fail Trip RTM Memory Error Burp MCI Fail Und l Trp Closing Main Cont Cur Balance Alarm Over Current Trip Stopped IPM Under Current Trip Stopped Burp MCR Closed Under Cur Alarm Short Circuit Trip Last Trip Message Ext Stop Burp MCR Open Earth Leakage Alarm Balance Trip Running UnderVoltage Alarm Residual Cur Trip Snore Insulat Test Alarm Main Contactor Fail 17 20 IPM Modbus Address Table Modbus Addr Description 0 3 Unused Address 4 Note Bit set when tripped Note Bit set when tripped Note Bits set when active Trip Status 1 and 2 Bit8 Earth Leakage Trip Bit9 Earth Continuity Trip Bit10 Insulat Fail
29. ay is less than tSnoreSet then tSnoreDelay shall be set to tSnoreSet When in tSnoreDelay mode and if a Start stimulus from e Start key on the relay or e pulse from the External Start is detected then the relay will immediately abort the running tSnoreDelay and proceed through a power on sequence If a power failure occurs when the IPM is operating in Snore Mode it will resume operating in Snore Mode when power is restored If Aux is open or there is an EL fault on Power Up the snore function will wait for up to 15 s to start 10 2 Setup procedure for Snore Function Setup of the Snore Function is done by settings throughout the menu structure The two additional settings that are required to enable the Snore Function to become active e Start Mode must be set to Snore e The Snore Delay parameter must not be set to none e under current trip level must not be set to none The AUX External Digital input must be active Relay Snore Mode starting procedure When Snore start mode is selected see above the relay can be initially started from different sources e Key button button on the relay if and only if Digital input switch is ON e External start button if and only if the Digital input switch is ON The behaviour of each start stimulus is below Key Button Start Regardless of the status of the Snore Function but with the Digital input switch
30. can also be used to provide optimum overload protection of motors used on conveyors pumps fans and compressors 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 IPM Integrated Protection Relay can provide Machine Data Transfer through the use of a Remote Termination Module RTM connected between the pilot and earth at the machine end of the trailing cable Through the use of the RTM Remote Termination Module the relay parameters are automatically up loaded from a remote machine when a cable is inserted into a power outlet The RTM also allows for remote control starting of the IPM output A RS485 Modbus communication port is available that can be connected to Motor Starter PLC s or a central monitoring system for continuous monitoring and fault finding The IPM Relay provides an isolated 4 20mA analogue output to continuously monitor Average Current Overload Earth Leakage and the Insulation level of the relay see Section 6 Page 7 for details An automatic Insulation Test can be initiated once all starting conditions are met A high voltage DC Insulation Test to earth of the cable is carried out If the result of the Insulation Test is above the preset resistance level the IPM s MCR relay energises which in turn closes the main contactor A manual Insulation Test is provided as maintenance
31. creen 3 and is adjustable between 1 and 31 71 lt Modbus Commands The following Modbus commands are supported Modbus CMD Comment 03 Read Holding Registers 06 Store Single Register Table 7 1 Valid read registers are in the range from 1 to 96 An attempt to read a register outside this range will result in an exception scan Currently only the first 78 registers contain valid data Supported Modbus exception responses are Modbus Exception Comment 01 Illegal Function 02 Illegal Data Address 03 Illegal Data Value Table 7 2 12 Modbus Status Status Comment Address The Modbus slave address the IPM is set to Read A solid block when a READ command is received Wrt A solid block when a WRITE command is received Exc A solid block when an unsupported Modbus command is received CRC A solid block when a checksum error is detected Par A solid block when a parity error is detected NE A solid block when noise is detected FE A solid block when a framing error is detected The Modbus Status can be viewed on Level 4 Screen 4 8 IPM Alarm Functions The IPM has several standard alarm functions If any are triggered the Alarm Relay ALM picks up Each has a selectable alarm level and can be disabled Generally the alarms are self resetting once the alarm condition is removed High Current Alarm Is activated by the phase currents exceeding th
32. d Data 1 50 2 60 3 70 4 75 5 80 6 85 7 90 8 95 9 OFF 67 Under Current Alarm 0 Invalid Data 1 32 2 40 3 48 4 56 5 64 6 lt 7200 7 80 8 88 9 96 10 Off IPM V2 USER MANUAL ISSUE 9 68 Earth Leakage Alarm 0 Invalid Data 1 10 2 20 3 30 4 40 5 50 6 60 7 70 8 Off Modbus Addr Description 69 Burp Pulses 0 Invalid Data 1 None NOOO Lu 6 70 0 Invalid Data 1720 68 20 85 321 08 4 128 52158 6 208 T2258 8 308 71 Burp Off Time 0 Invalid Data 120 68 2 088 35 1 05 421 28 55 1 58 6 2 08 72258 8 3 05 72 4 20mA Output 0 Invalid Data 1 2 lave 3 lel 4 73 78 IPM V2 USER MANUAL ISSUE 9 200 J Q31v8931N 26109 1404 8754 298 SUYIN v M QvOH WII 022000 gen paga tied pete Sabio opna prorpexina po pur om apye Pn M 9100 euondo 81 ON d 1 0001 1 0 oseuq 1705 50 IPM V2 USER MANUAL ISSUE
33. e selected threshold It is selected via the Modbus 4 Address 01 Read y 1 1 CRE MEL Parl dm High alarm setting Level 6 Screen 21 and is adjustable from 100 to 600 FLC and off The highest of the three phase currents is used Time delay 1 s Setting the alarm level to off disables this function Overload Alarm 15 activated by thermal accumulator exceeding the selected threshold It is selected via the O L Alarm Lev setting Level 6 Level 22 and is adjustable from 50 to 95 and off Time delay 2 s A motor overload trip overrides this alarm Setting the alarm level to off disables this function Under Cur Alarm Is activated by the phase current falling below the selected threshold It is selected via the Under Alarm setting Level 7 Screen 10 and is adjustable from 32 to 96 and off This alarm is only activated when the motor is running MCI input closed Time delay 2 s Setting the alarm level to off disables this function Earth Leakage Alarm Is activated when the earth leakage current exceeds a set level The alarm level is selected via the E L Alarm Lev setting Level 6 Screen 24 and can be set to 20 50 80 and off The earth leakage alarm has a time delay of 1 second and auto resets when the earth leakage current falls below the selected level Setting the alarm level to Off disables this function Insulat T
34. e time characteristic If the current exceeds the selected level for the pre set time then a trip occurs The short circuit function trips the CBR relay The CBR relay is normally energised and drops out when tripped The short circuit trip level is selected via the Short Cct Trip setting Level 6 Screen 4 and is a multiple of the selected full load current from 3 0 to 10 times FLC in steps of 0 5 The trip time is selected via the Short Cct t setting Level 6 Screen 5 and is adjustable from 20 to 160 ms See Drawing IPM2 E 008 for details To reset the relay following a short circuit trip it is necessary operate the reset key digital input 433 Phase Current Balance The current balance measurement Ib is displayed on the Voltage and Current Information page Level 2 Screen 2 If lave is 10095 the difference between the average current and each phase current is calculated The maximum difference is used as the current balance percentage If lave is gt 100 then the current balance is calculated as x 100 lave lave Average of the 3 phase currents MAX Al The maximum deviation of a phase current from the average Phase current balance protection is selected via the Cur Bal trip setting Level 6 Screen 9 The trip level is selectable at 5 10 20 50 and off The phase current balance protection is inhibited until the average current exceeds both 20 of
35. ected threshold alarm Earth leakage current exceeded the selected threshold RTM Stop In any of the remote start modes the event log will record when the IPM is stopped via the remote digital input 15 Time amp Date Clock Setup 26 07 14259221 If there is a need to adjust the real time clock carry out the following procedure 1 Using the Display s keys select the time and date information page Level 4 Screen 5 to display the Day Month Year Hours and Minutes Press the enter key A v 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 v to the desired position Press the enter key The v now changes to a The right arrow key is used to increment the allowable values once the desired value is obtained press the enter key again The returns toa v Repeat steps 3 and 4 until the correct time and date are displayed With the showing press the reset push button The then changes to E This is a prompt to press the enter key 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 Note The date and time are used only to time stamp the events in the log
36. een 1 J bo Face Boring Machine Fan Ventilation Fan Drill Drill Pump Pump Hpmp Hydraulic Pump Wpmp Water Pump DCB Distribution Control Box Bolt Bolter HRMr Hard Rock Miner Belt Conveyor Belt Winc Winch Crsh Crusher Dplg Dummy plug Spare 2 3 Machine Type Number Machine numbers 1 to 40 can be assigned to machines These numbers are programmed at the RTM Mach Num page Level 6 Screen 2 3 Earth Protection Functions 3 1 Earth Leakage The earth leakage protection function uses a 1000 1 core balance toroid to measure the earth fault current A Residual Current Device RCD operating characteristic is provided with adjustable trip sensitivity and time delay If the earth leakage signal exceeds the trip level for the selected trip time a trip occurs tripping the MCR relay The fault is latched The leakage current is displayed on the Current and Voltage Information page Level 2 Screen 2 as shown as a of the selected trip level When the leakage reaches 100 for the selected time delay a trip OCCUIS To reset the relay following an earth leakage trip operate the reset key digital input The trip level is selected via the Trp Level setting Level 6 Screen 13 and is adjustable between 25 mA and 500 mA and off The time delay is selected via the RCD Trp Time setting Level 6 Screen 14 Settings are Instantaneous and adjustable settings between 50 ms and 150 ms For alarm funct
37. elected via the 100 Current setting Level 6 Screen 2 and can be set between 0 5125A and 640A in 448 steps When the 100 1 CT is selected use Table 4 1 When the 1000 1 CT is selected use Table 4 2 IPM Full Load Current Selection Table Amps 100 1 CT 0 5125 1 025 2 05 4 1 8 2 16 4 32 8 0 5250 1 050 2 10 4 2 8 4 16 8 33 6 0 5375 1 075 2 15 4 3 8 6 17 2 34 4 0 5500 1 100 2 20 4 4 8 8 17 6 35 2 0 5625 1 125 2 25 4 5 9 0 18 0 36 0 0 5750 1 150 2 30 4 6 9 2 18 4 36 8 0 5875 1 175 2 35 4 7 9 4 18 8 37 6 0 6000 1 200 2 40 4 8 9 6 19 2 38 4 0 6125 1 225 2 45 4 9 9 8 19 6 39 2 0 6250 1 250 2 50 5 0 10 0 20 0 40 0 0 6375 1275 2 55 5 1 10 2 20 4 40 8 0 6500 1 300 2 60 5 2 10 4 20 8 41 6 0 6625 1 325 2 65 5 3 10 6 21 2 42 4 0 6750 1 350 2 70 54 10 8 21 6 43 2 0 6875 1 375 2 75 5 5 11 0 22 0 44 0 0 7000 1 400 2 80 5 6 11 2 224 44 8 0 7125 1 425 2 85 5 7 11 4 22 8 45 6 0 7250 1 450 2 90 5 8 11 6 23 2 46 4 0 7375 1 475 2 95 5 9 11 8 23 6 47 2 0 7500 1 500 3 00 6 0 12 0 24 0 48 0 0 7625 1 525 3 05 6 1 12 2 244 48 8 0 7750 1 550 3 10 6 2 12 4 24 8 49 6 0 7875 1 575 3 15 6 3 12 6 25 2 50 4 0 8000 1 600 3 20 6 4 12 8 25 6 51 2 0 8500 1 700 3 40 6 8 13 6 27 2 54 4 0 8750 1 750 3 50 7 0 14 0 28 0 56 0 0 9000 1 800
38. erload Reset Level 30 40 50 60 70 80 90 A 30 A 40 A 50 A 60 A 70 A 80 A 90 Alarm Setting 50 60 70 75 80 85 90 95 and off Current Balance Trip Setting 5 10 20 50 and off Trip Time 2s Under Current Trip Setting 32 40 48 56 64 72 80 88 96 and none Alarm Setting 32 40 48 56 64 and 72 and off High Current Alarm 100 108 120 140 160 200 240 280 320 360 400 500 600 and off Residual Current Trip Setting 10 20 30 40 50 60 80 100 120 150 200 250 and off Trip Time 100ms 200ms 500ms 1s 2s 3s 5s and off Short Circuit Protection Trip Setting 3 0 to 10 0 times in 0 5 increments times full load current Trip Time 20 40 60 80 100 120 160ms Back EMF Timer Delay Settings 2 5 10 15 20s Machine Numbers Can be allocated from 1 to 40 Burp Function Number of Pulses None and 1 to 6 selection of none disables the Burp Function Time On Off Setting 0 6 0 8 1 0 1 2 1 5 2 0 2 5 and 3 0s Snore Mode None 5 10 15 20 8F 15F 20F 30F 60F Time in Minutes F Fixed delay Undervoltage Protection Selectable from 20 to 80 in 10 increments Trip delay 800ms Communications RS485 Slave Modbus Baud Rate 1200 to 19200 Monitoring 4 20mA Analogue Output lave O L MQ Relay Contacts MCR 1 NO 1 C O CBR and ALM 1 C O 5A 190VAC 100VA max 16 19 Menu Structure IPM V2 USER MANUAL
39. est Alarm 15 activated when the meg ohm resistance of each phase to earth as a result of an insulation test equals or falls below the alarm level The alarm level is set at 1 5 times the trip setting The alarm message is displayed until a new test is initiated or the lt ENT gt key is pressed while displaying the alarm message Insulat Test Alarm is also recorded in the Event Log 9 Fan Control 9 1 Burp Function The Burp Function of the IPM relay allows the progressive inflation of ventilation bags tubes by pulsing the motor contactor controlling the ventilation fan several times at start up See Section 12 5 for operational sequence IPM V2 USER MANUAL ISSUE 9 There are three configurable parameters that control the Burp Function at start up Burp Number of Pulses Burp Pulse On Time and Burp Pulse Off Time Selectable Settings Burp Pulses Level 6 Screen 25 Selectable at none and 1 to 6 selection of none disables the Burp Function Burp On Time Level 6 Screen 26 and Burp Off Time Level 6 Screen 27 are selectable at 0 6 0 8 1 0 1 2 1 5 2 0 2 5 and 3 0 seconds 10 IPM Snore Function The purpose of the IPM Snore Function is to optionally add a timed re start the IPM Relay after an undercurrent trip has been detected Please refer to the section above for information on the operation of the undercurrent trip function 10 1 Basic Operat
40. h Continuity be 05 WPump L3 Shows the earth continuity resistance R of the pilot earth loop and the leakage L between the pilot and earth conductors as a of the trip levels When either value reaches 100 a trip occurs The version of the software is also indicated L4 Shows the Load Type and Number from the connected RTM unit Pilot Trip Time is adjustable to allow for operation in noisy electrical environments The trip times can be selected at Pilot Trip Level 6 Screen 15 and can be set to 80 120 160 200 300 400 and 500 ms A setting of 120 ms should be suitable for most installations Long time delays gt 200 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 The leakage trip setting is fixed at 1850 Q 4 Current Related Functions 41 Overload Protection The motor overload function is based on a thermal model of the motor The three phase currents are squared to provide the heating input to the motor model The selected Stopped Cooling Ratio determines the cooling output for the model The state of the thermal model is shown by the Thermal Accumulator which can be viewed on the Current Volts Information level on the display The thermal accumulator represents the motor temperature When it reaches 100 a Motor Overload Trip Occurs The full load current is s
41. in burp phase See Note1 relay s stored settings Need IPM Start Load Pump T Amps V IPM Stop Digital input Under Current Trip Under Current Function RTM Memory Error IPM detected errors in set Tripped See Note 1 up data received from RTM Stopped IPM 3 Outlet 2 IPM waits 5 Sec between activated closed running or testing and re RTM CT Ratio Error 3 the attached RTM was set testing up using a different CT Ratio than that of the IPM in use Need IPM Start Awaiting IPM start digital input IPM V2 USER MANUAL ISSUE 9 Message and Type Comment RTM Version Error 3 the attached RTM does not support 100 1 CT operation Need RTM Start 2 Shown when the digital input is closed but the IPM is stopped Remote Stop Shown whenever RTM s digital input is open Present when Start is set to Modbus In snore mode the delay Configuration Error or undercurrent trip level is not set Also if the remote start is set to yes or aux whilst in snore mode Stopped Ext Stop IPM Stop Digital input externally activated closed Table 1 1 Note1 It is normal to see the IPM Memory Error Message when switching between Diode RTM Mode or when the RTM is first connected to the pilot 1 5 Last Trip Status Messages The IPM Relay has several functions which stop trip the outlet and then self clear The IPM Relay therefore saves the non latched trip codes in a register
42. ion The basic operation of the function is shown by the following scenario Assume a pump is the load device of the relay which pumps a dam When the pump has emptied the dam its load current will drop significantly enough to be detected as an undercurrent trip this level is set in the settings level 6 in Section 18 by the IPM The Snore Function snore Process will operate only after configuration and activation via the IPM menus The snore function will operate after undercurrent is detected and will permit the pump to restart after a time delay tSnoreDelay After this off period the pump will restart During the first 4 second ON period tSnoreOn the pump will run and only if the pump remains in an undercurrent state the IPM will extend tSnoreDelay by 1 5 times and switch off the output relay for the new setting of tSnoreDelay This process will continue until the time reaches a maximum of tSnoreDelay x 8 The initial setting for tSnoreDelay is obtained from a menu configuration setting tSnoreSet The available initial settings are OFF 5 10 15 20 8F 15F 20F 30F 60F minutes the F represents a fixed delay that does not extend tSnoreDelay as described above If a load is detected during tSnoreOn ie no undercurrent is detected the pump will remain on but tSnoreDelay will be reduced to its present setting but not below tSnoreSet this does not apply to the F settings In the case where the new tSnoreDel
43. ions see Alarms Section 8 Page IPM V2 USER MANUAL ISSUE 9 3 2 Insulation Test The IPM Relay can provide an automatic High Voltage Insulation Test A manual Insulation Test is also provided An insulation test module which is a resistive isolation device is used to interface the power conductors to the IPM Relay Modules are selected in the Group 1 Settings ITM Module Level 5 Screen 2 for rated line voltages of 415V and 1000V IPM Insulation Test Modules ITM are the preferred modules and must be used when the Insulation Test function is required When None is selected the IPM Relay does not provide Insulation Test or voltage functions 3 2 1 Automatic Insulation Test If a ITM Module has been selected in the Adjustable Group 1 Settings Section 11 and a trip level has been set in the Adjustable Group 2 settings then an automatic High Voltage DC Insulation Test is initiated by operation of the start button once all starting conditions are met See Section 12 5 The HV DC Insulation Test commences when the IPM Relay applies voltage to the V Test terminal of the relay for a period of 2 seconds This applies 30 VDC to the ITM Module A HV DC voltage is generated in the ITM Module which applies a voltage of 500 V for 415 V operation and 820 V for 1000 V systems between each phase and earth The IPM Relay measures the voltage on the line and calculates the resista
44. n the reset input or reset key is required MCI The Motor Contactor Interlock input provides the IPM Relay with the status of the motor contactor Its status is used by the thermal modelling to activate the Cooling Multiplier and also provides the basis for Motor Contactor Fail MCF monitoring Digital This is an auxiliary digital input Ex Start This input allows the installation of an external start button See Section 11 3 1 Ex Stop This input allows the installation of an external stop button See Section 11 3 1 13 2 Output Relays The IPM provides three relay outputs for correct operation All relay contacts are rated at 5A 190VAC MCR Main Trip Relay This relay energizes when there are no trips and drops out whenever a trip occurs A normally open and a change over set of contacts are provided ALM Alarm Relay This relay energizes whenever there are alarms active and drops out when all alarms are clear One changeover set of contacts is provided CBR CBR Relay This relay is normally energized and drops out if there is a short circuit trip or a motor contactor fail trip One changeover set of contacts is provided L2 Displays the status of the CBR and MCR Relays L3 Displays the status of Alarm Relay the Test key and the Main Contactor input L4 Displays the status of the Start Reset and Stop Keys IPM V2 USER MANUAL ISSUE 9 IPM Relay amp Keys 4 CERE lia Tent
45. nce to earth for all phases At the end of the test the result is stored in the Event Log as It X XMQ 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 3 1 the status message Insulat Test Alarm is displayed on the Status Page Level 1 Screen 1 Ins Tst Level Selection Alarm Level MO MO 1 0 1 5 2 0 3 0 5 0 7 5 10 15 20 30 None None Table 3 1 If the value is less than the preset trip level a trip occurs and is latched and saved in a non volatile memory To reset the relay following an insulation test fail trip operate the reset button Insulation Test Not Active Last Test 8 6M L3 Indicates the status of the insulation test L4 Displays the insulation resistance as a result of the test and is retained in memory until the next test is carried out The trip level is set at Ins Tst Level page Level 6 Screen 18 and is selectable as per Table 3 1 If the Insulation Test is not selected by setting the ITM Module value to None then the MCR Relay closes by operation of the start button 3 2 2 Manual Insulation Test A manual Insulation Test is provided as maintenance fault finding tool The manual test can only be carried out when the load is not energi
46. ot for use Version IPM V06 Snore Function Added Version IPM V07 Modified Under Current Trip Version IPM V08 No Functional Changes Version IPM V09 Added 100 1 Current Transformer Increase relays current range by adding the ability to select either the 100 1 or the 1000 1 CT s Version IPM V10 Added Remote IPM Control 1 07 1 0 2 enne 1 1 1 Introduction 1 1 2 Protection Functions 1 1 3 Basic Display 1 14 Trip Status Messages 2 1 5 Last Trip Status Messages 3 2 Machine Data Transfer 3 2 1 Remote Termination Module 3 22 Machine Type 3 2 3 Machine Type 3 3 Earth Protection Functions 3 3 1 Earth 3 3 2 Insulation 4 3 2 1 Automatic Insulation Test 4 3 2 2 Manual Insulation Test 4 3 3 Earth Continuity sss 4 4 Current Related Functions 5 4 1 Overload Protection 5 42 Short Circuit Protection 6 43 Phase Current 6 44 Residual Current Signal 7 4
47. oup of settings is always stored in the relay and relates to parameters which are linked to the system rather than the particular load connected to the outlet Group 1 Settings EC Pilot Mode Determines if the pilot is to be terminated with a diode or Remote Termination Module ITM Module Selects the Insulation Test Module to be used with the IPM Relay Start Mode Selects the inputs required to initiate a start condition ModBus Address Selects the Modbus Slave Address ModBus Baud P Sets the Modbus baud rate ModBus Timeout Sets ModBus Error timing CT RATIO Selects between 100 1 and 1000 1 toroids 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 IPM Relay or the memory in the Remote Termination Module depending on the Pilot Mode setting Figure 1 Page 9 shows how the memory is switched If a diode pilot mode is selected the IPM Relay reads and writes to and from the relay s internal memory for the group 2 settings If RTM Mode is selected the settings are sent to and retrieved from the memory in the Remote Termination Module Group 2 Settings RTM Mach Type RTM Mach Num 10096 Current OC I mul Short Cct Trp Short Cct t trp t 26x cool mult Rst Level Cur Bal trp Under level Residual i Trp Res Trip time RCD Trp
48. rent Section 4 1 Short Circuit Section 4 2 Under Current Section 4 5 Contactor Fail Section 5 1 Under Voltage Section 52 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 3 Basic Display Operation The facia of the IPM Integrated Protection Relay has a four line 20 character backlit Liquid Crystal Display LCD Status LED and a tactile keypad The layout of the display structure is shown on the IPM Display Map The display level is changed with the Up Down arrow keys and the Left Right arrow keys control the various display screens See drawing IPM Display Map Drawing IPM2 A 013 The ENT and ESC keys are used to modify settings and provide hyper jump access to the display structure The Reset key allows a reset following a trip condition The Test key is used to activate a manual insulation test Start and Stop keys are provided for closing and opening the main contactor supplying power to a machine The Status LED is a single bi coloured LED that can be viewed some distance from the relay Status indication is as follows IPM Status LED Colour LED Flash OK Run Green 4Hz OK Stopped Green 1Hz Alarm Red 4Hz Trip Red 1Hz The IPM status display is one of the most useful features of the relay s display system and should be viewed
49. reset value is selected via the Rst Level setting Level 6 Screen 8 and can be set to 3090 4090 5090 60 70 80 90 A 3096 A 4095 A 50 60 A 70 80 A 90 settings automatically reset a motor overload trip once the thermal accumulator falls below the set value Otherwise the trip has to be reset manually by pressing the keypad RESET button or activating the RESET digital input once the thermal accumulator has fallen below the set value An emergency restart on a hot motor can be achieved by zeroing the thermal accumulator memory This is done by closing the Lock input and Reset key digital input simultaneously for 1 5 seconds Caution Repeated restart attempts in this condition may damage the motor The Stopped Cooling Ratio modifies the cooling output of the thermal model when the motor is stopped This can be used to account for reduced cooling capacity of the motor when it is not running motor run status monitored via MCI digital input The ratio is selected via the O L cool mult setting Level 6 Screen 7 and is adjustable from 1 0 to 5 0 cooling multiplier of 1 means the cooling is independent of whether the motor is running or not eg a water cooled motor Protection for a fan cooled motor is based on a setting of 2 5 however for the best protection consult the motor manufacturer 4 2 Short Circuit Protection The short circuit function has definit
50. rth continuity loop exceeds 45 Ohms Leakage resistance between the pilot and earth is less than 1500 Ohms Earth leakage protection tripped Burp sequence completed Burp sequence failed to complete Trip condition of short circuit protection Trip condition of overload protection Current balance trip condition Records resetting of a protection trip function Records that set up data has been modified Under Current Trip caused outlet to stop Records that voltage was not present on at least one outgoing phase when the main contactor was closed Residual E L Trip condition The thermal memory data has been corrupted Thermal memory has been manually reset to zero Records that the relay s non volatile parameter memory has been corrupted Internal microprocessor reset Records that the Remote Termination Module s non volatile memory has been corrupted Remote Termination Module has gone off line while the outlet is running Records RTM machine code and number when main contactor is closed proceeded by MCR closed This log only appears when in RTM mode Indicates a loss of communications with the RTM Insulation Test failed Records the result of the Insulation Test Result of Insulation Test is equal to or less than the alarm level Thermal accumulator has exceeded the selected threshold L cur alm Phase current has dropped below the selected threshold H cur alm Phase current has exceeded the sel
51. s Trip Level FLC 0 Invalid Data 1 10 2 20 3 30 4 40 5 50 6 60 7 80 8 100 9 120 10 150 11 200 12 250 13 OFF 56 Ires Trip Time 0 Invalid Data 1 100ms 2 200ms 3 500ms 4 1 0 Sec IPM V2 USER MANUAL ISSUE 9 Modbus Addr Description 56 Cont 57 5 2 0 Sec 6 3 0 Sec 7 5 0 Sec RCD Trip Level 0 Invalid Data 1 25mA 2 50 3 100mA 4 150mA 5 Off 58 RCD Time 0 Invalid Data 1 Ins Instantaneous 2 50ms 3 100ms 4 150ms 59 Pilot Trip Time 0 Invalid Data 1 80ms 2 120ms 3 160ms 4 200ms 5 300ms 6 400ms 7 500ms 60 Remote Start 0 lt Invalid Data 1 lt No 2 Yes 61 Pilot Latch 0 Invalid Data 1 25 Off 62 Meg Level 0 Invalid Data 1 1 0M 2 2 0M 3 5 0M 4 10M 5 20M 6 63 Under Voltage Trip Level 0 Invalid Data 1 40 2 50 3 60 4 70 5 75 6 80 7 85 8 90 9 95 10 OFF Modbus Addr Description 64 Back EMF Time 0 Invalid Data 1 2 Sec 2 5 Sec 3 10 Sec 4 15 Sec 5 20 Sec 65 High Current Alarm 0 Invalid Data 1 100 2 108 3 120 4 140 5 160 6 200 7 240 8 280 9 320 10 360 11 400 12 500 13 600 14 66 O L Alarm Level 0 Invali
52. tactor fail timer that counts down when a main contactor fault is detected see section 5 1 Line voltages of 415V and 1000V are configured when the appropriate Insulation Test Module is selected in the Group 1 Settings Level 5 Screen 2 6 Analogue Output IPM Relay provides an isolated 4 20 mA analogue output The output continuously monitors Average Current Overload Earth Leakage and the Insulation Level of the relay The Monitor Output settings can be IPM V2 USER MANUAL ISSUE 9 selected at 4 20mA Output Level 6 Screen 28 Settings available are O L 0 100 lave 0 250 E L 0 100 and 0 40MQ The analogue output status in milliamps is shown on the IPM Relay and Keys Screen Level 4 Screen 2 7 Communications The IPM Relay provides an industry standard RS485 Slave Modbus communication port This allows connection to a PLC or a SCADA system See Section 20 IPM Modbus Address Table for accessible data The baud rate is selected via the Modbus Baud P setting Level 5 Screen 4 and is selectable between 1200 and 19200 Baud with even odd or no parity One stop bit is used in conjunction with parity while two stop bits are used with no parity The half duplex 3 wire RS485 communications interface allows up to 31 devices to be multi dropped onto a single master communication line The IPM s Modbus Slave address is selected via the ModBus setting Level 5 S
53. tal input to be closed before this mode will start 13 5 Operational Sequence Insulation Test and Burp Function selected Before an outlet can be energised there should be no protection faults present Once the start button is operated an insulation test is performed If the result of this test is satisfactory the Burp Phase is initiated When the Burp Phase is completed the IPM Relay goes into the run mode 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 While the main contactor is closed the MCI input is 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 IPM 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 IPM will cycle through the following start sequence testing run stopped pause then repeat the sequence while ever the start input is closed 14 Event Log A real time clock calendar is included in the IPM Relay This combines with the non volatile memory to provide
54. the selected full load current and the selected balance trip level If any phase drops below the selected trip setting for a period of 2 seconds then the outlet is stopped To reset the relay following a current balance trip operate the reset key digital input IPM V2 USER MANUAL ISSUE 9 44 Residual Current Signal The three phase current signals are summed electronically in the IPM to produce a residual current signal that can be used to detect earth fault currents If the residual current signal exceeds the trip level for the selected trip time a trip occurs tripping the MCR relay The fault is latched To reset the relay following a residual current trip operate the reset key digital input L2 Displays the 3 phase currents as a of the FLC L3 Displays the average current and the residual current as Ir L4 Displays the current balance and the of leakage current The trip level is selected via the Residual iTrp setting Level 6 Screen 11 and is adjustable from 10 to 250 FLC and off The trip time is selected via the Res trip time setting Level 6 Screen 12 and is adjustable from 100 ms to 5 seconds Setting the trip level to off disables this function Note that the residual current function can be used even if a core balance toroid is used for earth leakage protection It can be used to provide some detection of wiring CT internal relay faults 45 Under Current Trip
55. ure following opening of main contactor Selects the high current alarm threshold as a of FLC Selects the overload alarm threshold as a 96 of the thermal accumulator IPM V2 USER MANUAL ISSUE 9 Under Alarm Selects the under current alarm threshold as a of FLC E L Alarm Lev Selects the alarm trip level for the earth leakage protection 3t Burp Pulses Sets the burp number of pulses and off Burp on Time Sets the burp pulse on time Burp Off Time Sets the burp pulse off time 4 20mA Output Sets the value to be transmitted Snore Delay Sets the Snore Delay Value 12 2 Changing Settings The procedure for adjusting the settings is independent of where the values are stored The EC 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 2 For Group 2 Settings in RTM Mode ensure RTM is on line 3 Display the parameter that has to be changed 4 Close the lock input 5 Press the enter button to change the current parameter 6 Use the left and right arrows to step through the allowable values until the desired new setting is displayed T Press the enter button to indicate that the value is the required setting 8 Open the lock push input If the ESC key is operated at any stage during the procedure the modifying sequence is aborted and the 4 BRERSE Lock
56. y Note An Old IPM is version 9 or earlier An Old RTM is version 2 or earlier reported as 20 on the IPM display New RTM and New IPM Nothing to consider New RTM and Old IPM The Old IPM will ignore the remote start setting Old RTM and New IPM The new IPM will check the version of the RTM this is transmitted in the pilot protocol If the RTM has the remote start parameter set but the RTM version is too old the IPM will display RTM Version Error Old RTM and Old IPM Nothing to consider IPM V2 USER MANUAL ISSUE 9 11 4 Status Messages There are two new status messages Need RTM Start and Remote Stop When in remote start mode whenever the RTM s digital input is open the display will show Remote Stop If the digital input is closed but the IPM is stopped the display will show Need RTM Start to indicate that the RTM s digital input needs to be opened and then closed to generate a new edge Note This is most likely to happen if the RTM s digital input is closed to allow the IPM to run and then a local stop is used to stop the IPM Because of the edged triggered nature of the RTM digital input the IPM will not automatically restart 12 Adjustable Settings 12 1 Parameter Groups There are two groups of adjustable settings contained in the IPM Relay s non volatile memory Both groups can be viewed and modified via the display and the up down and left right keys The first gr
57. zed A manual insulation test is also prevented when operating in snore mode Before a manual Insulation Test can be performed the following conditions must apply 1 The Insulation Test page being displayed This is located on the Insulation Test screen Level 3 Screen 2 Pilot must be healthy and any previous trips reset Insulation Test function must not be tripped Outlet must not be running Outlet must not be in the process of closing o m Outlet must not be Paused When the above conditions are met the TEST key must be pressed and held for the duration of the test After 3 seconds the manual insulation test is initiated The test voltage is applied to the outgoing feeder while ever the above conditions are held including holding the TEST 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 is completed usually by releasing the TEST key the results are held in memory until another insulation test is commenced either manually or as part of the starting sequence or IPM control power is lost If the ITM Module has been set to None then the manual test will not function The status of the manual insulation test is shown on the Insulation Test Screen Level 3 Screen 2 The three functions shown on the screen are
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