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HPBB012 HPB User Manual

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1. C J E E 2 C b 4 2 4 2 C D C 2 C D C 2 C 2 an U UJ m Q gt m U U D m 0 2 JJ m gt lt TOALNOIANYT AMPCONTROL HPB INTEGRATED PROTECTION RELAY 48 ud 7 Termination Unit 2 Dlode 2 Plot 1 3 3 R 3 3 Eartn 1 Stop Verslon 1 0 Y IN Y 38 BE Diode nil nm ype Pilot type relag i u 2 Normal Conectlon for 6 1 Pllot io iralling Cable amp Eartn U Proc ctc amp Earth lt W Q lt c y 1 gt gt uj T 5 Tack 95 108 0 16 25 mm 75 50 mm 108 0 mm 91 00 mm P gt 87 00
2. Software version and serial number HPB Status Operational information from the protection functions e g earth leakage current earth continuity resistance etc System information including the line voltage and current Status of digital inputs and relay outputs Protection trip settings which can be viewed at any time Authorised personnel can modify these settings via the HDM Remote Display Module g Data logging information The 120 most recent events and parameter changes are logged with time and date in a non volatile memory e g power up trip reset close etc e oo 0p NOTE A review of the first few log events is a useful tool for fault finding AMPCONTROL HPB INTEGRATED PROTECTION RELAY The HPB Relay status display is one of the most useful features of the relay s display system and should be viewed as the first step in fault finding This display shows a list of 9 prompts in order of priority indicating what the HPB Relay requires to allow the outlet to close The prompts are listed as follows RUNNING Outlet energised TESTING Performing EFLO Test TRIPPED Trip Condition see HDM LEDs HPB Mem Err HPB Relays non volatile memory is corrupted HTU Mem Err HTU 1 non volatile memory is corrupted HTU STOP Waiting for HTU 1 stop input to be closed ees ber Waiting for HPB stop input to open HPB START Waiting for the HPB Relay s start input to close WAITING Pause between su
3. gt AG 4 1 2 DO 5 6 s P s ADI z K 1 7 6 Pe 1 Data 9 10 1 QCIF 12 6 6 Z 4 dE 2 O 5 E 2 amp o D Rm T C it 38 AMPCONTROL HPB INTEGRATED PROTECTION RELAY 110Vac from HFB Relay 0759 n 052 1 L A Al 140 0 AMPCON I ROL CONB 6 6k HU mmr 7 b tuli A L 4 A mpm 1 nggi ma uuu A GMM Nut Ee eem p CCMB 6 6KV CABLE CONNECTION MODULE gt en G t AMPCONTROL CCMB 22KV DIMENSIONS Drawing HPBAO18 Rev 0 gt gt lt gt lt CC 2 O O LLI O CC a lt CC LLI lt OW HE SQUUNSO CEAOSZ AdONS OV IDS
4. TYPICAL CONNECTION DIAGRAM HPB 6 6kV Drawing HPBEOO6 Rev 0 AMPCONTROL HPB INTEGRATED PROTECTION RELAY Incoming Maximum Short Time 1 Earth Leakage Torold m S Supply Rating of 16 for 3 Ses tane AMPCONTROL EL 500 2 EZL Test Reslstor 5 A 2 Rielt Calculate to give between U 9 9 ih 10095 150 of trip Level 12595 Nominal MCR A GH n EE eg At 2A use 50 Dhms or 2 turns of e CR zie pene aeo m injection wire in toroid with 100 Ohms MC J Coble Connectlon Module Ampcontrol LMB 22kV CBR 4 Over Load CT s CB AMT MEE CB 2006 1 Class 1 0 U V OTHER TRIPS STT Rating LUkA 3 Ser 48Vd c Notes Phasing on Overload C T s Must be as Shown C T amp toroid leads should be Twisted amp Shielded with the shields connected to omer to pin 7 as close as possible to the HPB Outlets Stop Stop 5 RL NOT USED 32 Lock Lolk ii Reset AMPCONTROL Reset amp 2 q O RUN Reset o 41 a srt ied OMF Qptlonal Start High Voltage ly Os 48Vd Start Integrated Protestlon O ac Led Reing 4 O EFLO Relag T B 22kV T Tape 364 Module MC MCI 35 4 O EL MCI 34 R alt po ELT gt M 8 AMPCONTROL Serlal ue a NG 102 10 d LP S I Comms 11 d gt w Serigi Interiote Module C
5. 0 eH Buimeiq S1VLI0 JINGOW LAdLNO Q31 J9IIINIKNILIIASC i mi l mi A ic sindino Edi d oa d 221205 Vd gt 7 mi 0 eH LEOVVd 4 Buiweig IN3IN3ONVHHV TVH3N39 H3GTIOH GHVO 8 god 31 nGON LNdLNO AV T3H god dO ITA CS ON do 007061 N 000 3 i Y HAC OH 9 sod 40 M do ALV d3SVS Ydi OL 12144401 dd 02 A S ss N O Q A O N ON WN OL dd 6 6 6 1 D D IF 2 e w e d gt e VyN i y 3 3 Ou YUS vw00S NE gt 5 oam Go 2 50 552 040
6. 2 O O LLI O a lt am LLI lt OW as VIA FHL OL S329Vd83INI AXZZ GWID FHL x TINIOd HLYVI NIVW H1 OL SI HJIHM j 01 38 GINOHS HLYV4G IVNDIS INIOd JLON HS HidV3 NIVW OL 038 5 550 u 100615 7 310N SN M 39 GINOHS SISSVH 1 5410 S pA87 V ks Alddn DNIWODNI 29 AMPCONTROL HPB INTEGRATED PROTECTION RELAY Position 0 2 3 4 Level PE Ril 0 IN a I gt I 2 HI 9 4 5 fool DATE ME 290898 0848132 8 Nn c t I 9 n t HPB DISPLAY MAP Drawing HPBB004 Rev 1 30 lt A u Q cr S3AHNO 3SH3ANI AYSA LINDYIOD LHOHS LNSAYYND 25 0 m d ge wq wit He DADA AN C 5 5 55 0 e n Pemuni2 22 s 5 BSE 5 93 Fw 2 e x c lt gt c 7 2 EE BI NANA LM LE _ eus 8 _ lt LPR TULL NA NANDA NANA VE 5 CES 1 SS5
7. gt a cm 5 RN lt eu S SS ed aul dps ney S3Auno 3SH3ANI ATSWSYLXS LINDHID LHOHS 9 LNSJYYND H3AO TIME UL TIPIER 075 80mSer 69mSec LOmSer SHORT CIRCUIT Sona m l 139399 c lt ceo C RH PL Y c E 1000 6 5 100 120 amp 160 mSec 800 900 80 100 60 1 8 5 9 0 9 5 10 0 4 5 5 0 5 5 6 0 FaultCurrent Selected Full Load Current Short Circuit Selectable at Times Selected Full Load Current 500 50 ad CURRENT HPB 22kV Range 198 m 2 I time Multiplier 4 0 7 0 7 5 8 0 0 amp 3 0 3 5 Times Selectable at 40 ver 400 Over Current time t sec L 0 Curves r LY T y IIIIIIIIIII Inverse Ircult 0 Short 30 ected Full 200A e 5 SF 100A f H P B Extremely 200 Yo c c c w 15 5 o ei LL STD HPB Range Le gt lt LLI a Z O O LLI
8. lt CC LLI lt OW JE AMPCONTROL 32 lt 0 Q cc 500 8 h ADVYOLS SONILLAS 3 1avLiSsnfrav adi 0 O n 2 x LLI 5 t 2 lt ec oBueu 10 oBueu S SLUUJO07 Jequinw eujuoeg 10 id JequunN eujuoeg m ou oo CCH ou o EE zd el z z koog 1 ol eio LON e nr N E O O O eui epo q 2L 1 n opos Ola aDujnegs og 911810 UON ome oed E E X R I ma JosseooJ oJo gc XY 142 HPB ENCLOSURE DIMENSIONS Drawing HPBMOO5 Rev 0 150 0 mm 151 0 mm 240 0 mm H AMPCONTROL H P B High Voltage Integrated Protection Relay type B AMPCONTROL DM1 MDA Ex 11388 max 190Vac max 100 maximul 66kV 102 Ohms DROP OUT RESISTANCE gt 1 Ohms PILOT CABLE 1C lt 0 2uF L lt 10mH AMPCONTROL AUSTRALIAN MADE
9. ms 400 ms 500 ms 600 ms 800 ms 1 0 1 2 1 5 s and 2 s A maximum setting of 600 ms should be suitable for most installations CAUTION Long time delays should only be used where necessary Consequences of long trip times should be thoroughly assessed from a safety point of view before using the higher values When an Earth Continuity trip occurs the HPB Relay de energises the MCR Relay The EC LED on the display module is illuminated and the open collector output on the relay is switched on to provide remote monitoring if required The Earth Continuity can be set to be latching or non latching See Section 9 User Adjustable Settings 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 For Pilot Fault Finding information see Section 16 1 7 CURRENT RELATED FUNCTIONS 7 1 BASIC OVER CURRENT PROTECTION NOTE The HPB 6 6kV Relay uses 1000 1 CT s HPB 22 amp 11kV Relay uses 2000 1 CT s Two current transformers are used to measure the three line currents The measured currents are used to implement the following protection functions a Over current b Short Circuit Phase AMPCONTROL HPB INTEGRATED PROTECTION RELAY Full load settings cover a range from 7 5 Amps to 464 Amps for the HPB 6 6kV and 15 Amps to 928 Amps for the HPB 22kV
10. to installing or operating this equipment WARNING This equipment generates dangerously high voltage levels Because of the potential risks associated with this equipment it is essential that only appropriately qualified and experienced personnel be permitted to work on or around this equipment AMPCONTROL HPB INTEGRATED PROTECTION RELAY 2 2 SAFE USE OF EQUIPMENT The equipment supplied has been manufactured according to the state of the art and designed to ensure a safe operation The equipment may only be used within the design parameters The instructions within this manual must be observed as an aid towards achieving maximum safety during operation The owner user is responsible for observing the following instructions 2 2 1 Changes to Equipment Changes in the design and modifications to the equipment are not permitted 2 2 2 Equipment Knowledge Experience with or understanding of this equipment is essential for the safe installation and removal of the equipment Therefore in case of a question on how to safely proceed contact Ampcontrol immediately 2 2 8 Manual Handling The transformers supplied with the CCMB 22kV are heavy Care should be taken when transporting and handling these transformers Precautions have been taken to ensure all equipment is safe to handle and free from sharp edges However care should always be taken when handling metal enclosures and gloves should be worn 2 2 4 Installation Correct op
11. 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 over current protection functions The current range is selectable in 4 Amp increments between 60 and 116 Amps The current multiplier is selectable at 1 8 1 4 1 2 1 2 4 times for the HPB 6 6kV and at 1 4 1 2 1 2 4 8 times for the HPB 22kV The selected Range and Multiplier combine to give the basic level Example 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 A selected time multiplier modifies the basic trip time characteristic This multiplier is selected from 0 05 times to 1 0 times The instantaneous current in each of the three phases can be displayed on the display module Level 5 Position 1 The display is expressed as a percentage of the selected full load current and reads between 0 and 999 i e up to 9 99 times full load current When the load current exceeds the full load current level a trip accumulator is incremented at a rate dependant on the current When this accumulator reaches 100 an over current trip Occurs The trip accumulator can be viewed on the HDM Remote Display Module Level 5 Position 2 This may be useful to determine how close an outlet gets to trip condition during start up If the accumulator reaches almost 100 as the load gets away then th
12. m c D 520 go E Roero BA NGANAH NE NANA NAN ANANA NA WV A A A V AR WI LEGI I Mt c L LLLLLIL ee ee ee ee D N ON m Vias iiv ina HEH 8 c lt T HEHHEE B S355 3 ILI amp O wn ns S eee amp do LLL Op F482 mco m 90 S 3 Gros 8 ENEN o A d Y o NN T li T 9 3 gang 2 I E CES y es ni i in 5 u IH gt O Bi LJ lt 2 Q lil I ps So E S E gt 225 7 III IIIOIIIIAIII iii PR a 5 IIIIIIAIIWI II II Ill TE SER LJ LL Nih az e oe Ag y 18 Wil U C Ht qu if isa ll MI Hill EEN m MI pll Un T T a IW Mi ci ae 4 LA E 5 i El N T 3 5 it 4 Wy tj E LU QU ad sail iil 2 e ET e Mr como in o
13. on line or the HTU 1 Module s non volatile memory has been corrupted Combination of faults causing errors 1 and 2 Faulty pilot circuit open or high resistance or shorted to earth Relay is waiting for the HTU 1 Module s Stop input to be closed Outlet was turned off but not by the relay The HBP has no user serviceable parts All repairs must be carried out by Ampcontrol personnel only If afault develops return the HBP to Ampcontrol for repair It is essential that no attempt be made to repair the HBP as any attempt to dismantle or repair the HBP can seriously compromise the safety of the unit The Status page level 0 position 1 should be the first step in troubleshooting This displays what the relay requires to make it operate Also check the first six event logs Hemedy Check there is power to the relay and it is correctly plugged in Relay supplies 15Vd c to the HDM Check cable between HDM and the relay Replace module Check data cable between the relay and the HDM Examine the Group 1 Settings level 8 to check the stored parameters in the non volatile memory One or several settings will show 222 Re program lost settings into the memory Check that the HTU 1 Module is on line level 3 position 1 ie a healthy pilot loop If the HTU 1 Module is on line examine the Group 2 Settings stored in the HTU Settings level 9 One or several other settings will show 222 lost sett
14. or similar 8 AMPCONTROL HPB INTEGRATED PROTECTION RELAY should be installed adjacent to the HPB Relay The earth should be connected to Pin 7 on the relay as directly as possible 4 2 1 Low Voltage Signals Care must be taken to ensure these circuits cannot come into contact with higher voltages e g via insulation breakdown or broken wires etc It is recommended that these circuits be run in a separate loom from the high voltage circuits To ensure that interference is kept to a minimum the following cabling is recommended Low Voltage Signals DUTY Pilot Core Serial Comms Port Remote Display Earth Leakage Toroid Cable Connection Module Current Protection Transformers Local Stop Button digital inpit Lock Switch digital input Reset Switch digital input Start Switch digital input Motor Contactor Aux Contact digital input NOTE 2 SIGNAL Pilot Earth Vsc FIO TXD RDI OV Data Vdm OV EL1 EL2 VcmA VcmB VcmC Earth lal la2 Ic1 Ic2 SpDig SpDig Lock Lock Reset Reset Start Start MCI MCI RECOMMENDED TYPE Single core screened Screen 0V Four core screened Screen 0V Two core screened Screen 0V Two core screened Screen Earth Three core screened Screen Earth Two core screened Screen Earth Two core screened Screen Earth Two core screened Screen Earth Two core screened Screen Earth Tw
15. tests be performed using the HPB with a known resistance e g 50 or a short circuit to earth on the line This should be done on an isolated system high voltage supply disconnected using control power only NOTE The start input must be held closed for the duration of the test including the 3 s delay on HPB 22 kV which is adjustable between 10 and 25 seconds to allow for the charging of cable capacitance Setting the EFLR Test value to off disables the Earth Fault test If this is done and the system is ready to start the MCR Relay closes as soon as the start input is closed 6 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 machine data when a remote HTU HPB Termination Unit is used to achieve machine communication The pilot resistance is measured with a d c signal and communication is achieved by a high frequency a c signal The HPB Relay can be configured to operate in either Resistor or HTU Mode The mode is selected in Pilot Type Level 8 Position 1 and defines the type of termination unit to be connected between the pilot and earth at the machine end of the trailing cable being protected by the HPB Relay The advantage of using the resistor mode is that it uses a simple signal and a robust termination device making the system easy to fault find T
16. to transmit an assigned machine number 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 or extremely inverse over current curves OC t mul Modifies the basic over current time curves to achieve the desired trip times Cur Bal Trp Adjusts the current phase balance trip level SC I trip Sets the short circuit trip level SC Trip Sets the trip time for the short circuit function Pilot Latch Determines whether earth continuity trips are self resetting or not B emf TIME Adjustable time delay to inhibit main contactor fail routine following opening of main contactor Remote Start No function this version 9 2 CHANGING SETTINGS The procedure for adjusting the settings is independent of where the values are stored a Ensure the outlet is stopped b For Group 2 Settings in HTU Mode ensure the HTU 1 Termination Unit is on line C Display the parameter that has to be changed on the HDM Remote Display Module s liquid crystal display Level 8 or 9 d Momentarily operate the lock input A warning message appears 16 AMPCONTROL HPB INTEGRATED PROTECTION RELAY Press the enter button to acknowledge the warning message and to confirm that a change is desired Use the left and right arrows to step through the allowable values until the desired new setting is displayed Press the enter button to indicate that the value shown is the required n
17. true over current trip The status of the timer is displayed adjacent to the Ibal value Level 5 Position 2 on the HDM Remote Display Module A trip condition occurs when the timer reaches 100 8 VOLTAGE RELATED FUNCTIONS 8 1 MAIN CONTACTOR FAIL PROTECTION The Main Contactor Fail MCF protection operates if the Main Contactor fails to function by a 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 provides a Pilot Fail Timer function D Failing to maintain insulation across the contacts when the contactor is open The Cable Connection Module is used to measure the voltage on the load side of the contactor If this exceeds 1096 of the rated line voltage a trip will occur This function is inhibited immediately after the main contactor opens or a cable test is performed to allow for the cable capacitance to discharge The back inhibit time is adjustable from 2 to 40 seconds See Section 9 User Adjustable Settings A main contactor fail trip causes the CBR Relay to de energise which trips the circuit breaker An internal battery backed indication flag in the HPB Relay is also tripped A LED on the front panel of the HPB Relay begins to flash The MCF LED on the Remote Display Module flashes and the open collector output on the HPB is switched on to provide remote monitoring if required To reset
18. 10 3 Open Collector Outputs 10 4 Outlet Control Operational Sequence Event Log Time amp Date Remote Data Communications HPB Equipment Parts List HPB Specifications Trouble Shooting Pilot Fault Finding Information APPENDIX A DRAWINGS APPENDIX B APPROVALS AMPCONTROL HPB INTEGRATED PROTECTION RELAY PAGE AMPCONTROL HPB INTEGRATED PROTECTION RELAY 1 RECEIVING AND STORAGE 1 1 RECEIVING All possible precautions are taken to protect the equipment against damage or losses during shipment however before accepting delivery check all items against the packing list or Bill of Loading If there are shortages or evidence of physical damage notify Ampcontrol immediately Notify Ampcontrol within 7 days maximum in case of shortages or discrepancies according to the packing list This action will help ensure a speedy resolution to any perceived problems Keep a record of all claims and correspondence Photographs are recommended Where practicable do not remove protective covers prior to installation unless there are indications of damage Boxes opened for inspection and inventory should be carefully repacked to ensure protection of the contents or else the parts should be packaged and stored in a safe place Examine all packing boxes wrappings and covers for items attached to them especially if the wrappings are to be discarded 1 2 STORAGE AFTER DELIVERY When the equipment is not to be installed immediately proper st
19. 2 255 mom om cw o oo Bs r es Ov AOL 2 A dd NS gt lt EN LLI cc gt O LLI O CC au m lt LLI lt m a EE AMPCONTROL 42 gt lt gt lt CC 2 O O LLI O CC a lt am LLI lt HE SNOISN3INICI ONILNNOW 9NIMVHG IVOINVHO3M LA LL Sd IOH F WSO ISNV cx LX od q e CFIN i S 1 ASVONODAS E S EE r dvNonado 976 31INVTd3INVN H3AOD tre 43 AMPCONTROL HPB INTEGRATED PROTECTION RELAY APPENDIX B APPROVALS 44 B COCOA lo AM ccu V Nen S K 14 hate Postal Address Business Address P O Box 45 14 Raymond St Boolaroo NSW 2284 Speers PL NSW 2284 Phone 049 586811 Fax 049 586827 A C N 054191347 Mobile 049 018 685252 The Manager Ampcontrol CSM Pty Ltd P O Box 304 WARNERS BAY N S W 2282 OUR REF SA654 FILE REF N C92 0362 DATE 16 02 1995 SUPPLEMENTARY APPROVAL Dear Sir ITEM INTEGRATED PROTECTION RELAY IDENTIFICATION HPB ORIGINAL APPROVAL N2 Ex 11388 ORIGINAL APPROVAL HOLDER AMPCONTROL SWG PREVIOUS APPROVAL N9 EX 11388 SUPPLEMENTARY APPROVAL Ex 11388 DESCRIPTION OF APPROVAL VARIATIONS Modified for use on high voltage systems for open cut coal mine
20. 9 UNPACKING OF EQUIPMENT 2 General safety 2 1 Personnel Safety Warnings 2 2 Safe Use of Equipment 2 2 1 Changes to Equipment 2 2 2 Equipment Knowledge 2 2 3 Manual Handling 2 2 4 Installation 2 2 5 Operation 3 Overview of Equipment 3 1 Introduction 3 2 Remote Display Module HDM 4 Installation and Wiring Instructions 4 1 Installation 4 1 1 Integrated Protection Relay 4 1 2 Remote Display Module HDM 4 1 3 Cable Connection Module 4 1 4 Overload amp Earth Leakage Toroids 4 1 5 Toroid Installation Guide Lines 4 2 Wiring Installation 4 2 1 Low Voltage Signals N O a a a a A A A v 4 2 2 High Voltage Circuits 4 2 3 Earthing 10 5 Machine Communication 10 5 1 HPB Termination Unit HTU 1 10 5 2 Machine Type Codes 10 5 9 Machine Number 5 4 Receiver Sensitivity CONTENTS SECTION DESCRIPTION 10 5 11 12 13 14 15 16 16 1 Eart1 Protection Functions 6 1 Earth Leakage 6 2 Earth Fault Lockout 6 2 1 HPB 6 6kV 6 2 2 HPB 22 kV 6 3 Earth Continuity Current Related Functions 7 1 Basic Over current Protection 7 2 Over current Characteristic 7 3 Short Circuit 7 4 Phase Current Balance Voltage Related Functions 8 1 Main Contactor Fail Protection 8 2 Under Voltage Trip 8 3 Voltage Metering User Adjustable Settings 9 1 Parameter Groups 9 1 1 Group 1 Settings 9 1 2 Group 2 Settings 9 2 Changing Settings System Control 10 1 Digital Inputs 10 2 Output Relays
21. AMPCONTROL USER MANUAL HPB INTEGRATED PROTECTION RELAY 6 6kV 11kV 22 kV VARIANTS Designed and manufactured in Australia by Ampcontrol CSM Pty Ltd Issue R7 July 2014 Document HPBBO12 Part 117829 AMPCONTROL ELECTRONICS Ampcontrol CSM Pty Ltd ABN 35 000 770 141 7 Billbrooke Close CAMERON PARK NSW 2285 Phone 02 4903 4800 Fax 02 4903 4888 electronicsorders ampcontrolgroup co m www ampcontrolgroup com AMPCONTROL HPB INTEGRATED PROTECTION RELAY 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 CSM Pty Ltd 7 Billbrooke Close Cameron Park NSW 2285 Australia DISCLAIMER Ampcontrol CSM 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 Ampcontrol s HPB Integrated Protection Relay WARNING To become completely familiar with this equipment and to ensure correct operation we strongly recommend that you take the time to read and thoroughly understand this user manual AMPCONTROL CSM CONTACT DETAILS 7 Billbrooke Close Camero
22. B 6 6kV which is suitable for 6 6kV systems and the HPB 22kV which is suitable for 11kV and 22kV systems Protection Functions Earth Leakage Section 6 1 Earth Fault Lockout Section 6 2 Earth Continuity Section 6 3 Over current Overload Section 7 1 Short Circuit Section 7 3 Contactor Fail Section 8 1 Protection trips are stored in a non volatile memory requiring a reset function before power can be restored This remains the case even if a power down occurs following a trip condition 3 2 DISPLAY MODULE The Ampcontrol Remote Display Module communicates with the HPB Relay via a three wire connection The Module consists of a two line 16 character alpha numeric liquid crystal display LCD LED status indicators and a tactile keypad The various display pages are arranged on levels with each level having a number of positions The display level is changed with the Up Down arrow keys and the Left Right arrow keys control the display position An Enter key is used when programming the relay The display map shows how the movement is controlled between levels and positions See Drawing HPBBO004 in Appendix A Drawings The healthy LED located top centre of the module flashes at 3Hz three times per second to indicate healthy communications with the relay A flash rate of 1Hz once every second indicates that the module is powered 15Vd c but not receiving data The module displays the following information
23. B INTEGRATED PROTECTION RELAY 46 New South Wales Department of Mineral Resources Accredited Assessing Authority MDA A2507 COAL MINES REGULATION ACT 1982 NOTICE OP SUPPLEMENTARY APPROVAL SUPPLEMENTARY APPROVAL N9 MDA Ex 11388 FILE N9 C92 0362 DATE 16 02 1995 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 6 amp 7A of the Coal Mines Regulation Approval of Items Regulation 1984 This APPROVAL is issued to AMPCONTROL CSM PTY LTD Address of Approval Holder P O BOX 304 WARNERS BAY N S W 2282 Description of Item s INTEGRATED PROTECTION RELAY Item Identification HPB C M R A Approval Clause 27 b EXPLOSION PROTECTED Specific Approval Category PROTECTION Ex This Approval is issued subject to compliance with the requirements of the Occupational Health and Safety Act 1983 with particular reference to Sections 15 to 17 of the said Act as it applies to USERS of Approved Items and to Section 18 of the said Act as it applies to the MANUFACTURERS and or SUPPLIERS of Approved Items The Authority issuing this Approval may for the purposes of the Occupational Health and Safety Act 1983 append a list of recommendation
24. 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 in the symmetry of the cables Nuisance tripping tends to occur when the total current rises such as when a large motor is started To help avoid such problems select the smallest internal diameter CT which will allow the cables to fit through 4 1 5 Toroid Installation Guide Lines a Keep cables as close to the centre of the toroid as possible Do not tie them to one side of the toroid Remember aim at symmetry b 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 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 d Many small cables tend to be worse than for example three large ones Try to position the CT in the circuit with this in mind 4 2 WIRING INSTALLATION The connections to the HPB Relay consist of a mix of low and high voltage supplies and relay contact circuits To reduce induction from high voltages care needs to be taken in the layout of the wiring and the installation When using a 110V HPB a power supply filter e g Schaffner FN612 1106 1A 250Va c chassis mounted filter
25. PB Display Map Very Inverse Over current amp Short Circuit Curves Extremely Inverse Over current amp Short Circuit Curves Adjustable Setting Storage HPB Enclosure Dimensions HPB HTU 1 Termination Unit Enclosure Details Remote Display Module HDM HPB Base Connections HPB 48 V Base Connections CCMB 6 6 kV Cable Connection Module Overall amp Mounting Dimensions CCMB 22 kV Cable Connection Module Overall amp Mounting Dimensions IPA IPB Relay LED Output Module Relay Output Module General Arrangement 22KV VT Mechanical Drawinq And Mountinq Dimensions The drawings appear in the following pages in the same order in which they are listed in the table above 26 incoming Supply A ue 9 9 9 Contro Isolator MCI r3 ns UM to other Outlets MCR 4 lt gt AMPCONTROL PIS High Voltage Integrated Protection Relay Type B AMPCONTROL HPB INTEGRATED PROTECTION RELAY 200 Ohms Cable Connection Module Ampcontrol 66 be as Shown 110Vac S 11 1 qum Tralling Cable 350VI20kA Surge Protectlon M 3 co ee I e 236 ohms Fuse 5 Max Power Supply Filter I Comms 12 oA 0 13 Data 14
26. a cable is inserted into a power outlet The relay can perform an automatic H V Insulation test on the cable prior to the closure of the main contactor The results of the test are displayed on the HPB Display Module HDM 1 and can be remotely monitored The HPB Relay has 5 digital inputs which feed into a microprocessor unit The microprocessor has been programmed to control three output relays Relay MCR for the main contactor and Relay CBR for the circuit breaker RL3 is used to control the supply to the Cable Connection Module enabling it to perform the Earth Fault Lockout test All of the tripping logic and outlet control is performed by the microprocessor so that only minimal external control is required See Typical Connection Diagrams and HPBEO13 in Appendix A Drawings Extensive information display and monitoring features are included to facilitate fault finding and system trending This information can be read locally on the HPB Display Module HDM 1 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 See Drawing 5005 in Appendix A Drawings The Ampcontrol Relay Output Module ROU enables these AMPCONTROL HPB INTEGRATED PROTECTION RELAY indications to be interfaced with a PLC See Drawing IPAAO31 in Appendix A Drawings There are currently two HPB models available the HP
27. ables passing 1 CCMB 22kV da through torati SEE amp C t s to he Insulated to FOR DETAILS Sgstem Voltage ve e Level RL3 u lt 0 350V 20kA Surge Protectlon L P tlrallng Cable gt lt CN CN AMPCONTROL HDM 1 m Ampcontrol 1 o 2 Termination t9 19 59 lt EL EC EF OC SC MCF IT Run Cc m Q 5 lt e Remote Stop HPB Loop O Resistor Mode F io e Connectlon terminate the stop O Pilot Version 1 0 loop Instead of ins ohms this diode Z E Earth See Drawing 013 5 T lt OST Oo G gt gt f 28 WWHOVIG NOILO3NNOO TVOIdAL 3129193234 SSJI WHI 3M40SN3 MIMO4 ONL Td N 38 10NNV3 ALINWI0d OS ONY GO 5531 5I LWHL 390SN3 H3MOd INIA Iddy SUN 01 30199 HLYVI LNIOd 15 AYVWIYd YIWYOISNVY 045 1 310N 44 148 151544 JYNSYINW ONITIVISNE NHHM lNIOd YVLS AYVWidd FHL OL 031 lt J 8 F SI AV 134 AH HI 03 22 8 22 3H1 30 139 AH 035017 ATIVWAON V VIA 3 01 03193 02 NOILV8f1DIJNO nS 43401502 310N HS HlgVi 3SVHd V NI Q31293NNOD 34V SLA SILA X 1 gt lt gt lt CC
28. ating 10 VA Standard AS60044 2 N terminal capable of withstanding 5kV d c test voltage 11 kV Transformers Rated Voltage 11 kV 50Hz Insulation 12 28 75 kV Voltage Factor 1 9 30 sec Ratio 11 kV V3 to 110 N3 Class 0 2 VA Rating 10 VA Standard AS60044 2 N terminal capable of withstanding 5kV d c test voltage NOTE Transformers must be able to withstand 5 kV d c on the primary side 21 AMPCONTROL HPB INTEGRATED PROTECTION RELAY 16 TROUBLE SHOOTING If a problem is experienced with the relay use the following table 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 WARNING and the consequence can be fatal NOTE Symptom Remote Display shows a blank screen The HDM LED indicator located on the top of the HDM module is off Remote Display shows a blank screen The HDM Led flashes at 1 Hz Error Indication 1 level 0 Position 1 Error Indication 2 level 0 Position 1 when in HTU pilot mode Error Indication 3 level 0 position 1 Relay will not close EC fault indicated HPB Status page displays HTU Stop Outlet is off and the log records MC Opened 22 Cause Loss of power to the Display Faulty Display Module Power to HDM is healthy but there is no data Corruption in the Group 1 Settings stored in the relay Either the HTU 1 Module is not
29. ay Module Level 6 Position 1 10 3 OPEN COLLECTOR OUTPUTS The HPB 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 Ampcontrol Relay Output Module ROU enables these indications to be interfaced with a PLC See Drawing IPAA031 in Appendix A Drawings The eight outputs correspond to the LED s on the display module turning on whenever the corresponding LED is flashing The signals are available on the HPB Relay s base pins 35 42 and the common is on pin 34 10 4 OUTLET CONTROL Closing the Start input energises the outlet Both the remote and local stop buttons will turn off the outlet If a remote stop is not required the Stop input must be bridged to earth via a diode at the HTU 1 Termination Module 10 5 OPERATIONAL SEQUENCE Before an outlet can be energised the following conditions must apply a No protection faults present b Local stop input open remote stop loop closed e Local start input closed Once these conditions are obtained a cable fault lock out test is performed automatically The start button must remain closed during the test which may take up to 25 seconds to complete due to the charging of the cable capacitance If the result of this test is satisfactory the HPB Relay goes into the run mode and the MCR Relay picks up The RUN LED on the HDM Rem
30. ay or the MCR Relay This can be achieved by selecting the required relay at the SC Relay selection in the non volatile memory See Section 9 User Adjustable Settings 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 MCR 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 40 to 160mS 14 AMPCONTROL HPB INTEGRATED PROTECTION RELAY 7 4 PHASE CURRENT BALANCE Phase current balance protection is selected via the Cur Bal Trp selection See Section 9 User Adjustable Settings The current balance measurement is displayed on the Remote Display Module and is calculated as Isa x 100 lave Where lave Average of th 3 phase currents MAKA The maximum deviation of a phase current from the average The trip level is selectable at 596 1096 20 5096 and The phase current balance protection is inhibited until the average current exceeds both 2096 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
31. ay settings are stored in the HPB Relay If a load is moved to a different outlet or substation then the HPB Relay s settings need to be checked and updated if necessary HTU Mode When the pilot is set to HTU Mode the trailing cable pilot is terminated with a HTU 1 Termination Module The HPB Relay measures the resistance of the pilot earth loop and assumes that the pilot circuit is healthy if the resistance measured is below the selected trip resistance level If the resistance exceeds the preset level a trip will occur The Event Log will display Trip In mode the relay settings that pertain to the actual load connected are stored in the HTU 1 Termination Module which is installed in the machine If a machine cable is moved to a different outlet or substation then the protection settings for the machine are automatically uploaded to the HPB Relay The earth continuity resistance of the pilot earth loop is displayed in ohms on the Earth Fault Information page level 3 position 1 The leakage SC between the pilot and earth conductors is displayed as OK or Trp The Event Log will display EC Short if a short occurs between pilot and earth when the outlet is energised The Earth Continuity EC Trip resistance for both modes is selectable to 50 75 and 100 ohms Pilot Trip Time is adjustable to allow for operation in noisy electrical environments The following trip times are available 300
32. ccessive Megger Tests An error status indicator is also shown on the status page which is normally zero exceptions are as follows Error fF l Indicates corruption in the Group 1 Settings HPB Mem Error Error 2 Indicates corruption in the Group 2 Settings HTU Mem Error Error 3 Is a combination of faults in both groups For details of Groups see Section 9 1 Parameter Groups 4 INSTALLATION AND WIRING INSTRUCTIONS This manual has been designed to assist users of the HPB Relay with installation and special wiring techniques required to reduce induction from high voltage circuits 4 1 INSTALLATION 4 1 1 Integrated Protection Relay The HPB Relay has a powder coated sheet steel enclosure designed to be mounted into existing enclosures of adequate IP rating The relay is designed to operate when mounted either laid down flat or in a vertical position CAUTION 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 HPB 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 HPB 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 clearly labelled for ease of terminal location and identification 4 1 2 Re
33. cond 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 record shows that an earth leakage 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 recent event Each time a new log is recorded the 120th log is removed from the list and all others move along one The following events are logged Power Up Records the time when the HPB Relay is powered up Pwr Down Records the time when the HPB Relay loses power MCR Close Stopped SEO COO MC Opened 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 HPB Relay EC Trip EC SEL EF trip pine uias RA trip Q E SG SC Trip Ty Dp Setup Mod Pilot Earth continuity loop exceeds the trip level Low resistance between pilot and earth Earth leakage protection tripped Earth Fault test has failed A phase HPB 6 6kV Earth Fault test has failed B phase HPB 6 6kV Earth Fault test has failed C phase HPB 6 6kV Earth Fault test has failed HPB 22 kV Trip condition of short circuit protection Trip
34. condition of over current overload protection Current balance trip condition Records resetting of a protection trip Records that setup data has been modified The log preceding this shows the old and new values Records that voltage was not present on at least one outgoing phase when the main contactor was closed Internal battery backed main contactor fail flag tripped Main Contactor Fail trip due to sensing voltage on the load side of the main contactor when the contactor should be open MCI Fail Main Contactor Input MCI shows the main contactor to be closed when it should be open reset Mem ERROR Internal microprocessor reset Records that the relay s non volatile parameter memory has been corrupted Records that the remote termination unit s non volatile memory has been corrupted or remote termination unit has gone off line while the outlet is running 18 AMPCONTROL HPB INTEGRATED PROTECTION RELAY 12 TIME amp DATE If there is a need to adjust the real time clock carry out the following procedure a 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 150599 09 46 b Press the enter key A v will appear in the top line above the minute section This indicates the number to be changed 6 Use the left and right arrow keys to move the v
35. conventional pilot protection relay such as an Ampcontrol PCA Relay but will NOT operate when connected to an HPB Relay If the remote stop function is not required the stop terminal must be bridged to the diode terminal or the HPB Relay will not energise The status of the Remote Stop input is displayed Online Run or HTU Online and can be viewed on the HDM Module s Pilot and HTU Information page Level 2 Position 1 Also displayed on this page is Off Line Status and pilot information The HTU 1 software version and machine type is displayed on Position 2 The Remote termination settings are programmed via the HDM Remote Display Module Section 9 User Adjustable Settings 5 2 MACHINE TYPE CODES There are 5 selectable machine type codes available for use in the HTU 1 Termination Unit The descriptive code is transmitted to the HPB Relay to identify the type of machine connected to the outlet The codes are selected using the HDM Remote Display Module Level 9 Position 1 Dice lb Drag Line Shy Shovel Dea Drill PSTx Portable Transformer Wpmp Water Pump 10 AMPCONTROL HPB INTEGRATED PROTECTION RELAY 5 3 MACHINE NUMBER Machine numbers 1 to 40 can be assigned to machines 1 to 40 for each machine type These numbers are programmed using the HDM Remote Display Module Level 9 Position 2 5 4 RECEIVER SENSITIVITY The HPB allows the sensitivity of the HTU receiver to be adjusted to suit differen
36. cted to the HPB pin 7 All other earth connections should be run back separately to the main earth point 5 MACHINE COMMUNICATION 5 1 HPB TERMINATION UNIT HTU 1 The HTU 1 Remote Termination Unit is a microprocessor based module that is connected between the pilot and earth at the remote end of the trailing cable to provide machine communication 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 See Drawing HPBMO13 in Appendix A Drawings The HPB Termination Unit HTU 1 provides remote stop of the HPB Relay s controlled outlet by tripping the Earth Continuity function The EC LED on the HDM Remote Display Module is illuminated and the Earth Continuity will need to be reset if Pilot Latch On has been selected Stop switches are connected in series with a diode between the stop and earth terminals Alternately the internal HTU 1 Termination Module s diode can be used to terminate the stop loop Machine stops can be differentiated from other pilot trips in the HPB Relay s Event Log by connecting machine stops into the HTU I Module s Stop input instead of being connected in the pilot loop WARNING Emergency stops must be wired directly into the pilot circuit A transient protected internal diode is connected between the diode terminal and earth When the pilot is connected to the diode terminal the machine can be used with a
37. ed that the relay be returned to Ampcontrol for battery replacement and full testing AA cell installed under the top cover requires replacement is recommended that the relay be returned to Ampcontrol for battery replacement and full testing Check all wiring to the CCMB and earthing 23 AMPCONTROL HPB INTEGRATED PROTECTION RELAY 16 1 PILOT FAULT FINDING INFORMATION To carry out tests on a faulty earth continuity circuit adopt the following procedures Open Circuit Pilot Check the voltage between the pilot and earth at the HPB Relay Pins 6 and 7 The reading should be 30Vd c To determine the location of the fault continue the above test along the pilot until no reading is obtained Current Check Connect a d c ammeter between the pilot and earth at the HPB Relay Pins 6 and 7 The reading should be 45 mA at the HPB Relay or at any point along a continuous pilot Repeat this test at the machine end of the pilot If the voltage is normal 30V d c but the current is less than 45mA then the loop resistance may be too high Tests in Resistor Mode When Resistor Mode has been selected the pilot is terminated with a 2350 resistor The voltage measured across the resistor should be 10 6V d c The voltage measured at the HPB Relay will vary depending on the amount of resistance in the pilot earth loop For example if the loop resistance is 1000 then the voltage at the HPB Relay will increase by 4 5 volts 100 x 0 045
38. eration and safety depend on the HPB and associated equipment being installed correctly Mechanical and or electrical installation and maintenance of plant and equipment must only be carried out by appropriately qualified personnel and must be tested thoroughly prior to operation 2 2 5 Operation As safety depends on the HPB functioning correctly it is highly recommended that all safety functions of the HPB be periodically tested to ensure correct operation 3 OVERVIEW OF EQUIPMENT 2 1 INTRODUCTION The Ampcontrol HPB Integrated Protection Relay is an intelligent protection relay based on microprocessor technology The Relay has been specifically designed to operate with very high interference to the pilot conductor that occurs on cables in open cut mining operations This is more prevalent on a non symmetric position of the pilot and earth conductors The integrated relay provides the necessary functions required for protecting electrical outlets supplying draglines shovels drills etc 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 HPB Relay can provide machine communication through the use of a HPB Termination Unit HTU 1 connected between the pilot and earth at the machine end of the trailing cable Through the use of the HTU 1 Termination Unit the relay parameters are automatically up loaded from a remote machine when
39. esistance is below the preset threshold an Earth Fault Trip occurs At the completion of a test the result is retained in memory until the next test is carried out This can be viewed on the HDM Remote Display Module Level 3 Position 2 An insulation test will yield one of the following results a Hardware Fault The HPB cannot detect the presence of the CCMB Check power supply to the CCMB and all wiring Note An open circuit connection between the CCMB and power circuit cannot be detected and will not display as Hardware Fault lt 10 MQ The resistance between the power circuit and earth is less than 10 MQ value between 10 120 The resistance between the power circuit and earth 10 d gt 120 MO The resistance between the power circuit and earth is greater than 120 MQ WARNING The CCMB generates 5kVd c This high voltage d c is produced and applied to the 3 phase lines even when the high voltage 3 phase supply is not available Care should therefore always be taken when working close to high voltage 3 phase cables bus etc An audible tone is generated whenever the CCMB is active warning of the presence of high voltage d c CAUTION Like all insulation tests a faulty open circuit connection to the power circuit will create the appearance of a high insulation resistance to earth To verify the connection to the power circuit it is recommended that periodic insulation
40. etails 14 HPB EQUIPMENT PARTS LIST Part Description 144069 HPB 6 6 kV Integrated Protection Relay 162922 HPB 22 kV 200mA EL Integrated Protection Relay 142842 HPB 22 kV Integrated Protection Relay 118732 HTU 1 Termination Unit 142848 HPB Base 142845 HPB Base 48V 118542 HDM Remote Display Module Flush Mount 117648 6 6 kV Cable Connection Module 143369 22 kV Cable Connection Kit 144371 11 kV Cable Connection Kit 101503 IPA IPB Relay LED Output Module 117829 HPB User Manual 143911 48Vd c 120W Power Supply AMPCONTROL HPB INTEGRATED PROTECTION RELAY 15 HPB SPECIFICATIONS Note An 11kV system includes the HPB 22KV relay Auxiliary Supply Volts Earth Leakage Protection Earth Continuity Protection Earth Fault Lockout Protection Lockout Resistance Test Time Over current Protection Current Range Current Multiplier Time Multiplier Current Balance Trip Settings Short Circuit Protection Trip Setting Trip Time ms Back EMF Timer Trip Delay Settings Machine Numbers Under Voltage Protection Serial Communication Port Relay Contacts 20 HPB 6 6 110Vac 20 220V A 50Hz 2 Hz HPB 22kV 48Vd c 20 gt 40 W Recommended Power Supply Meanwell DR 120 Ampcontrol Part No 143911 HPB 6 6kV Trip Setting 200 mA to 1000 in 100 mA increments HPB 22kV 200mA EL Trip Setting 200mA to 1000 in 100 mA increments HPB 22kV Trip Settin
41. ew setting Momentarily operate the lock input The display will show a confirming message then return to the viewing level 7079 If the up or down keys are operated during the procedure the HPB Relay aborts the modifying sequence 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 NOTE When the relay has been selected for HTU Mode the HTU Remote Termination Unit must be on line shown at level 2 position 1 on the before Group 2 settings can be adjusted 10 SYSTEM CONTROL 10 1 DIGITAL INPUTS The HPB 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 HDM Remote Display Module Level 6 Positions 2 3 The Lnk input shown in the display is used in tests by Ampcontrol Engineers 10 2 OUTPUT RELAYS The HPB Relay has output relays to control the main contactor and the circuit breaker under voltage control All relays are fail safe with respect to power supply loss and are controlled on the basis of protection functions Relay RL3 operates to initiate the cable fault lockout test There is one spare relay reserved for future development The status of the relays can be displayed on the HDM Remote Displ
42. g 500mA to 2500 in 250mA increments Time Delay Instantaneous 80ms and 150ms to 470ms in 40ms increments Trip Setting 500 750 1000 Shunt Leakage if lt 200 Resistor Mode Operating Time 300ms 400ms 500ms 1 0s 1 2s 1 5s and 2s HPB 6 6kV Selectable at 2 5 10 20 and 50 Meg Ohm and off HPB 22kV Selectable at 15 20 30 50 and 100 Meg Ohm and off Selectable at 10 15 20 and 25 seconds HPB 6 6kV 7 5 to 464 Amps 60 to 116 Amps in 4 Amp increments times current multiplier HPB 22kV 15 to 928 Amps 60 to 116 Amps in 4 Amp increments times current multiplier HPB 6 6kV 1 8 1 4 1 2 1 2 4 times HPB 22 1 4 1 2 1 2 4 8 times 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 5 10 20 50 and OFF 3 0 to 10 0 times in 0 5 increments times full load current 40 60 80 100 120 160 2 5 10 15 20 25 30 35 40 seconds Can be allocated from 1 to 40 Selectable from 30 to 80 in 10 increments or disabled Trip delay 800ms For information on data format and hardware see DNET IP2 Serial Communication System User Manual 118626 MCR CBR 1 N 0 5A 190 Va c 100 VA maximum 1 C 0 5A 190 Va c 100 VA maximum RL3 1 N 0 5A 190Va c 100 VA maximum AMPCONTROL HPB INTEGRATED PROTECTION RELAY 22 kV Transformers Rated Voltage 22 kV 50Hz Insulation 24 50 125 kV Voltage Factor 1 9 30 sec Ratio 22 kV to 110 V3 Class 0 2 VA R
43. he disadvantages are a An incorrect healthy Earth Continuity indication could be produced by a pilot that has faulted to earth with a resistance within the pickup range of the HPB Relay For example if the selected trip level is 5002 then the fault to earth in the range of 2006 to 2850 would be seen as a healthy circuit b The Machine Communication functions of the HPB Relay are not available The advantages of using HTU mode are a Machine communication b Machine stops can be differentiated from Earth Continuity Trips in the HPB Event Log C Increased security in pilot system as the HPB Relay must receive an intelligent signal from the HTU 1 Termination Module in order to deem the pilot circuit healthy The net disadvantage is that the increased complexity in the system may make trouble shooting difficult 12 AMPCONTROL HPB INTEGRATED PROTECTION RELAY Resistor Mode When the pilot is set to Res Mode the trailing cable pilot is terminated with a 235Q resistor to earth 2 x 470Q 5 Watt resistors connected in parallel The HPB Relay measures the resistance of the pilot earth loop and assumes that the pilot circuit is healthy if the resistance measured is between 235 Q and 235 Q RTrip the selected trip resistance If the resistance measured is below 200 short circuit fault between the pilot and earth conductors is assumed and a trip occurs which in turn de energises the MCR Relay In Res mode all of the rel
44. hree phases in parallel CAUTION The CCMB and the HPB Relay must be earthed to the same earth connection as the trailing cable on systems with separate earth grids Ensure that the earth connections are reliably installed as this is the basis of protection for the isolation device CAUTION When installing the CCMB 22 kV measure the resistance between the transformer primary star point and earth before applying power Ensure that it is less than 100 4 1 4 Overload amp Earth Leakage Toroids Current transformers CT are not ideal devices and if correct procedures are not followed during installation nuisance tripping can result using for example 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 is that a small output may be obtained from the CT where none would arise if the device was ideal The size of the error will vary from
45. ings into the HTU 1 memory As outlined above for Errors 1 and 72 Check pilot circuit See detailed fault finding information Section 6 If still faulty replace the relay Ensure HTU 1 Module s stop input is closed through a diode to earth Check main contactor coil or control Circuit Symptom Relay will not remain closed and cycles while the start input is held closed Relay Trips on MCF on power up Time and date incorrect Resets to 1 01 9 on power up HDM Displays Hardware fault Cause The relay s MCI input is not closing level 6 position 2 Relay not receiving voltage feedback on all three outlet phases within 8005 of contactor closing Main contactor fail condition Flat or faulty battery Low battery CCMB has not been detected AMPCONTROL HPB INTEGRATED PROTECTION RELAY Remedy Check that main contactor is closing If not check circuit Check auxiliary contacts and wiring Check system voltage display level 4 position 1 as contactor closes Compare this with the under voltage threshold Check continuity from the relay through the CCMB 6 6 kV to power conductors WARNING Be sure to follow the appropriate high voltage isolation procedures HPB 6 6kV Typical reading CCMB 6 6K 27 Meg Ohm Check main contactor for leakage across terminals on frozen contactor condition AA cell installed under the top cover requires replacement is recommend
46. is may indicate that the over current settings are too low Conversely if the trip accumulator only builds up slightly on a heavy start then the over current settings may be set too high If an over current trip occurs the OC LED flashes and the OC open collector output switches on to provide remote monitoring if required Following an over current trip the following conditions must be met to affect a reset a The trip accumulator must be less than 80 b The HPB Relay s reset input must be closed 7 2 OVER CURRENT CHARACTERISTIC The current time trip characteristics can be selected as either Very Inverse or Extremely Inverse corresponding to the OC Type values of vinv or The drawings Very Inverse Over current Curves HPBBOOS in Appendix A Drawings and Extremely Inverse Over current Curves 001 in Appendix A Drawings show the trip characteristics 7 3 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 When a trip occurs the SC LED on the display module flashes and the open collector output on the HPB Relay is switched on to provide monitoring if required To reset the relay following a short circuit trip it is necessary to hold the lock input closed and then close the reset button The HPB Relay can be programmed so that a short circuit trip will operate either the CBR rel
47. mm i Di 57 i Z AMPCONTROL HDM 1 E E 8 3 e 9 9 Y ES y gt 16 25 mm HDM 1 ENCLOSURE DETAILS Drawing 15 Rev 0 NOTES 1 CUTOUT FOR HDM 91x75 5mm 0 5mm 73 00 mm Vdm Data OV QE ek an 70 UJ z m Q gt m U U O m 0 2 m gt lt TOALNOIANYT AMPCONTROL HPB INTEGRATED PROTECTION RELAY 1 mum on sl s Ld EIN EI p k kt ae ES ams LI T7731 m ii mt I EE BASE HPB INTEGRATED PROT RELAY Drawing HPBMO30 Rev 0 AMPCONTROL HPB INTEGRATED PROTECTION RELAY 17091 rol 002 1 15 2 el lle d 2 15 EL2 Bije 7 limi GB e la Jd 4 18 EE lea a 19 33 Mcr 1 1 Pit el jas 0 T 7 21 Earth 2h 12748 Oa Base Lock Insulation E Test 9 Q B Misc 2 Wg 9 4
48. mote Display Module The Remote Display Module is housed in an IP55 polycarbonate enclosure The Module has been designed to be flush mounted external to the switchgear it is controlling 4 1 3 Cable Connection Module 6 6 kV 6 6kV systems The CCMB 6 6 kV Cable Connection Module type B 6 6 kV is a resistive isolation device which interfaces between the power circuit and the HPB Relay allowing the HPB to measure both the line voltage and the insulation resistance to Earth A 5 AMPCONTROL HPB INTEGRATED PROTECTION RELAY kV d c voltage is generated within the CCMB which under normal operation applies up to 2 5 kV d c between each phase and earth The CCMB 6 6 kV is housed in a polycarbonate enclosure CCMB 22 kV 11kV and 22kV systems The CCMB 22 kV Cable Connection Module type B 22 kV is an isolation device that allows the HPB Relay to interface with the power circuit to measure both the line voltage and the insulation resistance to Earth The CCMB 22 kV connects to the 11kV or 22 kV power circuit via 3 x voltage transformers connected in a phase to earth configuration with the primary star point connected to Earth through the CCMB 22 kV The line voltage is measured on the secondary side of the voltage transformers and an insulation test is performed by lifting the primary star point from earth and applying 5 kV d c to the star point which passes through the primary windings and is applied to all t
49. n Park NSW 2285 P 61 2 4903 4800 F 61 2 4903 4888 EMAIL electronicsorders ampcontrolgroup com WEB www ampcontrolgroup com SAFETY AND WARNINGS WARNING Identifies important safety messages contained within this manual These messages highlight potential risks the occurance of which may result in serious injury or death to personel When you see this symbol pay close attention to the message that follows understand its meaning and ensure other operators are made aware of the risks CAUTION Identifies important technical information contained within this manual Information of this type provides instruction or guidance that will ensure safe installation operation and maintenance This information must be understood and applied in order to reduce the possibility of injury to personel Correct application of these instructions will also reduce the possibility of damage to the products and or connected equipment NOTE Notes contain supplimentary information not directly affecting the safety or integrity of the equipment ENVIRONMENTAL ALERT Information concerning possible impact on the environment along with actions required to reduce environmental risk AMPCONTROL HPB INTEGRATED PROTECTION RELAY CONTENTS SECTION DESCRIPTION PAGE Copyright Notice 1 Disclaimer 1 Before You Begin 1 Ampcontrol CSM Contact details 1 Safety and Warnings 1 1 Receiving and Storage 1 2 RECEIVING 1 2 STORAGE AFTER DELIVERY 1
50. o core screened Screen Earth Two core screened Screen Earth The OV is internally connected to the HPB Relay s earth Pin 7 The screen therefore must NOT be earthed at any other point The HPB Relay s digital inputs could alternatively be run in a screened multicore cable Separate cable for each HPB in multiple installations Where these low voltage circuits need to connect near the power circuits e g current transformers cable connection module main contactor auxiliaries etc care needs to be taken to ensure that the circuits are adequately separated and restrained This ensures that the separation is maintained even if a wire termination becomes loose etc 4 2 2 High Voltage Circuits The high voltage circuits of the HPB are the 110Va c supply 110V version Pins 30 31 only and the relay contacts Apart from keeping these separate from other wiring to the relay there are no special requirements AMPCONTROL HPB INTEGRATED PROTECTION RELAY CAUTION The relay contacts of the HPB Relay must not be used to switch more than 190Va c 5A or 100VA 4 2 3 Earthing The HPB has two earth connections The earth pin 7 is for the communication and pilot circuits The earth on Pin 29 connects to the earth shield of the HPB Relay s internal transformer 110V version only and chassis The CCMB 6 6 kV also has an earth connection and the CCMB 22 kV has two earth connections The CCMB 22 kV signal earth should be conne
51. onal monitoring if required The measured instantaneous leakage current EL is displayed on the HDM Earth Fault Information page as a percentage of the trip level When the leakage reaches 10096 for the selected time delay a trip occurs For the HPB 6 6kV and the HPB 2kV 200mA EL the trip level is adjustable in 100mA increments over the range 200mA 1000mA and for the standard HPB 22 kV the trip level is selectable in 250mA increments over the range 500 2500 The time delay is selectable as instantaneous lt 80mS or adjustable 40mS increments over the range of 150 470 5 6 2 EARTH FAULT LOCKOUT 6 2 1 HPB 6 6kV On 6 6 kV systems the earth fault lockout function tests the resistance of the 3 phase lines to earth by applying a megger test prior to closing the main contactor The test is initiated by closing the start input provided all other starting conditions are met see Section 10 5 Operational Sequence The HPB Relay closes its relay output RL3 which applies 110Va c to the 6 6 kV Cable Connecting Module type B 6 6 kV This is a resistive isolation device used to interface the HPB Relay to the power conductors A 5 kV d c voltage is generated within the CCMB 6 6 kV which under normal operation applies up to 2 5 kV d c between each phase and earth The HPB Relay measures the voltage on the line and calculates the meg ohm resistance to earth of each phase At the end of the test provided the value is ab
52. orage is important to ensure protection of equipment and validity of warranty All equipment should be stored indoors preferably on shelves where practicable and protected from the elements If storing on the ground use wooden blocks to elevate the equipment above the ground and ensure that the storage area is not an area where water will collect When applicable correct handling and fork lift procedures must be in place to ensure that any crates and pallets are moved safely 1 3 UNPACKING OF EGUIPMENT The method of packing used will depend on the size and quantity of the equipment The following cautions should be interpreted as appropriate CAUTION Take care when unpacking crates as the contents may have shifted during transport Make sure that cable drums are securely attached to their shipping pallets before attempting to move them ENVIRONMENTAL The disposal of packaging materials replaced parts or components must comply with environmental restrictions without polluting the soil air or water Ensure that any timber and cardboard used as packaging is disposed of in a safe and environmentally responsible manner Where possible dispose of all waste products i e oils metals plastic and rubber products by using an approved recycling service centre 2 GENERAL SAFETY 2 1 PERSONNEL SAFETY WARNINGS All personnel involved in the installation and operation of this equipment should ensure they are familiar with this manual prior
53. ote Display Module is illuminated and the open collector output on the HPB 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 button is operated while the relay is in run mode the run is cleared and the MCR Relay de energises The event log reads Stopped or HTU Stop depending on which stop button caused the stop condition If a stop button is operated 17 AMPCONTROL HPB INTEGRATED PROTECTION RELAY during a cable fault lockout test then the test is aborted 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 HPB Relay e g open circuited main contactor coil or control supply 11 EVENT LOG A real time clock calendar is included in the HPB Relay This combines with the non volatile memory to provide data logging This log sequentially records the time date and details of the HPB Relay s operations A chronological list of the previous 120 events is stored The event log can be 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 se
54. ove the preset threshold the relay closes allowing the outlet to be energised If the value is below the preset threshold an Earth Fault Trip occurs At the completion of a test the resistance to earth of each phase is retained in memory until the next test is carried out This can be viewed on the HDM Remote Display Module Level 3 Position 2 6 2 2 HPB 22 kV On 11 kV and 22 kV systems the earth fault lockout function tests the resistance of the 3 phase lines to earth by applying a megger test prior to closing the main contactor The test is initiated by closing the start input provided all other starting conditions are met see Section 10 5 Operational Sequence The HPB Relay closes its relay output RL3 which applies 48Vd c to the CCMB 22 kV Cable Connecting Module type B 22 kV The CCMB 22 kV then disconnects the primary windings of its 3 x voltage transformers from earth they are connected to earth at all other times and generates 5 kV d c which is applied to the primary star point resulting in 5 kV d c between all three phases and earth The HPB Relay then measures the current to earth and calculates the resistance of the line insulation to earth of all three phases in parallel Three seconds 3 s after the end of the test if the calculated resistance is above the preset threshold the MCR relay closes 11 AMPCONTROL HPB INTEGRATED PROTECTION RELAY allowing the outlet to be energised If the calculated r
55. resulting in a reading of 15 1 V d c Tests in Mode When HTU Mode has been selected the pilot is terminated with an HTU 1 Termination Module The voltage measured across the Pilot and Earth terminals of the module should be approximately 20V d c The voltage measured at the HPB Relay will vary depending on the amount of resistance in the pilot earth loop For example if the loop resistance is 1000 then the voltage at the HPB Relay will increase by 4 5 volts 100 x 0 045 resulting in a reading of 24 5 V d c 24 2 q gt lt CC 2 O O LLI O a lt am LLI lt OW as 213 084 54015 3 2 5 Sec 30151534 DNILMNIWU 31 INIHJVN suuo 001 TMNDIS NOILVIINNWWO 324151534 319 1014 BOIS AGOW NIH LO lld Cin suu0 001 TMNDIS NOILVJINNWWO J AJN300334 HDIH 300 40151534 1014 324151534 319 1014 A2N300384 HDIH XDW AOE suu0 001 25 AMPCONTROL HPB INTEGRATED PROTECTION RELAY APPENDIX A DRAWINGS Drawing Number HPBE013 HPBE012 HPBB004 HPBB003 HPBB001 IPBB003 HPBM005 HPBM013 HPBM015 HPBM030 HPBM029 HPBM001 HPBA018 IPAS005 IPAA031 Description Typical Connection Diagram HPB 6 6 kV Typical Connection Diagram HPB 22 kV Typical Connection Diagram CCMB 22 kV H
56. 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 1983 The onus is on the Supplier and or User to ensure the Approved Item and any deviation from the list of recommendations in reference to that item is not inferior in any way to the item tested and or assessed this includes the suppiy 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 this Approval Document together with a copy of the recommendations from the Authority issuing the Approval shall be supplied to each user of the approved item Any Maintenance Repair or Overhaul of Approved Items shall be carried out accordance with the requirements of the Coal Mines Regulation Act 1982 A J Weeks Assessing Authority No MDA A2507 FOR THE CHIEF INSPECTOR OF COAL MINES 3 3 Minerals amp Energy House PO Box 536 St Leonards NSW 2065 Australia Telephone 02 901 8888 Facsimile 02 901 8777 AMPCONTROL HPB INTEGRATED PROTECTION RELAY 45
57. s as follows a Change input resistor on E L toroid to give adjustable trips 200ma 1000ma b Trip time adjustable 80 470ms C Status and event log information added and provision for adjusting the trip settings at the remote display module d Provision to use the machine recognition module for auto configuring of machine protection settings e Change name labels to suit Modifications do not effect the actual operating software 1 3 AMPCONTROL HPB INTEGRATED PROTECTION RELAY SUPPLEMENTARY APP Ex 11388 FILE REF 9 92 0362 DATE 16 02 1995 ADDITIONAL APPROVED DRAWINGS HPB Z 001 Rev O Dated 14 02 1995 HPB Z 002 Rev O Dated 14 02 1995 ADDITIONAL RECOMMENDATIONS FOR SUPPLY amp USE 1 The manufacturer shall on his own responsibility carry out such tests and examinations as are necessary to ensure that the HPB module provides satisfactory operation in service 2 No changes shall be made to the software which effect the operational performance of the relay as required by standards Other software parameters may be changed as required by the manufacturer MARKING ON APPARATUS The manufacturers name or mark and the approval number MDA No EX 11388 shall be inscribed in a durable manner in a prominent position on the apparatus Please find enclosed herewith the relevant approval documentation Yours Faithfully A J Weeks Assessing Authority No MDA A2507 2 3 45 AMPCONTROL HP
58. s relates to settings which are linked to the power system rather than the particular load connected to the outlet These are always stored in the HPB Relay 9 1 1 Group 1 Settings Pilot Mode Determines if the pilot is to be terminated with a Resistor or a HTU 1 Termination Unit EL Sens Sets the sensitivity for the Earth Leakage protection trip EL Time Sets the trip time for the Earth Leakage protection EFLR Test Sets the Earth Fault lockout level Eft time Selects the test time for the Earth Fault lockout test to allow for line capacitance U V Trip Selects the under voltage trip threshold as a of line volts SC Relay Selects which HPB output relay is tripped in event of a short circuit trip HTU rx Lev Adjusts the sensitivity of data receiver 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 HPB Relay or the memory in the HTU 1 Termination Unit depending on the Pilot Mode setting If the Resistor Pilot Mode is selected the HPB Relay reads and writes to and from the relay s internal memory for the group 2 settings If the HTU Pilot Mode is selected the settings are sent to and retrieved from the memory in the Remote Termination Unit 9 1 2 Group 2 Settings HTU MC Type Allows the HTU 1 to transmit a descriptive code to identify the machine connected to the outlet HTU MC No Allows the HTU 1
59. t installations For installations where multiple HPBs are located close to each other the sensitivity can be reduced to prevent crosstalk between the pilot signals In installations with long trailing cables the sensitivity can be increased The sensitivity can be adjusted from 1 32 with larger values corresponding to decreased sensitivity For most installations starting with the sensitivity set to 8 should yield good results If the HTU is connected through a long trailing cable and the HTU is not coming online try increasing the sensitivity Alternatively if there are multiple relays installed near each other and they do not behave as expected try decreasing the sensitivity to prevent crosstalk 6 EARTH PROTECTION FUNCTIONS 6 1 EARTH LEAKAGE The earth leakage protection function uses a toroid to measure the earth leakage current A definite time operating characteristic is provided with an adjustable trip sensitivity and 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 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 holding the lock input closed and then closing the reset button When an earth leakage trip occurs the EL LED on the display module flashes and the open collector output on the HPB Relay is switched on to provide additi
60. the flag access to the relay is necessary The reset button is accessible through the front fascia of the relay and must be pressed for 1 second 8 2 UNDER VOLTAGE TRIP Under voltage 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 800ms then the outlet is stopped This is recorded in the event log as uVOLT The trip level is selectable from 3096 to 8096 in 1096 increments or can be set to Off Level 8 Position 6 on the HDM Remote Display Module The Off selection disables the under voltage trip function and is usually used for non 6 6 kV installations AMPCONTROL HPB INTEGRATED PROTECTION RELAY 8 3 VOLTAGE METERING The Cable Connection Module CCMB in addition to enabling the Earth Fault test is used to provide line voltage metering The outgoing line voltages for each of the 3 phases are displayed as a of the nominal line voltage on the HDM Remote Display module Level 4 Position 1 The maximum reading is 140 for the 6 6 kV systems and 120 for the 11 kV and 22 kV systems 9 USER ADJUSTABLE SETTINGS 9 1 PARAMETER GROUPS The HPB Relay has many user adjustable settings which are stored in non volatile memory These can be viewed and modified via the HDM Remote Display Module The settings are split into two groups as outlined below The first group of parameter
61. to the desired position d 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 to a v e Repeat steps c and d until the correct time and date is displayed f With the v showing press the lock push button The v then changes to E This is a prompt to press the enter key g 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 13 REMOTE DATA COMMUNICATIONS The HPB Integrated Protection Relay 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 the Ampcontrol DNET IP2 Serial Communication System transfers data and commands between the Host System and the modules using RS232 RS422 and RS485 protocols Each integrated protection relay is connected to a Serial Interface 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 118626 for further d

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