GCM52 User Manual
Contents
1. eg lt He 150 5 90 B Es TI E switching sy stems aad ENGINEERS Q E Gi GCM Earth Continuity Monitor A Protection Filter b SE Model GCM PF1 Pilot Earth Pilot Line Monitor ZK 11213 SS Gd lala Note 1 Dimension units ejje 1 Without brackets are in mm With brackets are in inches Fig 10 Dimensions of the GCM PF1 Protection Filter in mm Pen Page 14 GCM 52 User Manual Notes GCM 52 Page 15 User Manual Earth Continuity Monitor For Model GCM 52 Transformer e Control Voltage Neutral Earthing cl Resistor ad Switchgear Main Earth oo 1 Protection Filter 3 Breaker Earth Leakage A typical Earth Continuity Monitor connection diagram switc h j n g PO Box 33457 Jeppestown 2043 Republic of South Africa syste ms Tel 27 0 11 624 3317 Fax 27 0 11 624 2382 ELECTRONIC ENGINEERS e mail info switchingsystems co za Doc Ref 3701 002 Rev 1 2 7 July 2005 LPW2. 50Q 0 12 200Q 180ms 20sec 20sec 2 Potential free c o contacts 5A 220V AC See Fig 7 Surface mounting enclosure see Fig 7 Prewired Molex plug socket with colour coded condctor harness wire length 2m SABS Intrinsically safe Ex ib I Ilc 1sec MODEL GCM 51PF1 Protection Filter Current rating Non repeditive peak KE Surge Voltage Insulation voltage Line resistance Clamping voltage Mass Ordering Stock 5001 050 5001 053 5001 070 5001 058 5001 057 Page 10 39A rms 580A 1400A sec 5kV at 5 Joules 2 5kV 0 4Q max 55v peak 1kg Description GCM Remote Module GCM 52 Connection Leads GCM 52 Earth Continuity Monitor plastic case GCM PF1 Protection Filter Conversion of GCM 110 to GCM 52 1D GCM 52 User Manual Installation guide It is essential that the GCM Earth Continuity Monitor be installed in such a way that the generated signal must travel via the fully insulated pilot conductor direct to the Remote Module The latter must be situated remotely from the GCM Monitor as shown in Fig 6 below The main earth conductor must form the return path to the GCM Monitor via the equipment frame at each end and at intermediate points where applicable The pilot and earth conductors plus the remote module thus comprise the monitored loop On completion of the installation and connection of the wireing harness to the pilot and earth conductors the following tests should be made before connecti
3. O o ive Po Leakage oO Protection Filter en Cable oO Lu Load GCM PF1 9 Main Earth Earth M12 Fig 2 Earth Continuity Monitor Connection Diagram Remote Module GCM 52 User Manual Front panel controls The GCM 52 front panel is shown below together with descriptions of the controls and control functions switching systems ELECTRONIC ENGINEERS LCD Display 2x12 dl Earth Continuity Monitor GCM 52 Next key A p Navigate to the various menus and Up Next select the digit to be adjusted Up key a e S Adjust the selected digit value press y e e once to increment by 1 press amp hold to cycle through all digit values 0 9 automatically Fig 3 i Front panel controls Operation Switch on When the GCM 52 Monitor is switched on it performs a self test amp calibration routine When the routine is completed successfully the display shows the Trip level amp the Loop resistance The start up display sequence is shown below The Trip figure displays the currently set Trip level in Ohms The Loop figure displays the actual measured Loop resistance in Ohms On the right of the Trip figure is a navigation arrow that indicates which key to press to reach the adjustment menus GCM 52 Page 5 User Manual Set Password T
4. Press the Next key gt to navigate to the password entry screen shown below the left most digit will flash Uses the Up key to increment the flashing digit to the required value 0 9 Use the Next key gt to select the next digit to adjust the digit will flash to indicate that it is selected Set the four digits to match the password After the fourth digit is set press the Next key gt Page 6 GCM 52 User Manual GCM 52 If the password is incorrect the screen will display and automatically return the Trip Loop display If this happens start over and enter the correct password If the password is correct the Trip Level adjust screen is displayed The left most digit will flash to indicate that it is selected Use the Up and Next keys to set the Trip level value When the right hand digit is set press the Next key gt to return to the Trip Loop display The Trip value will indicate the new setting Cable fault conditions Loop resistance exceeds Trip setting If this condition occurs the display will show If the fault condition lasts for more than 20 seconds the Monitor will trip relay A is energized relay B is de energized and an audible alarm sounds The display will freeze showing To reset the Monitor press the Next key gt Cable short circuit pilot to earth If this condition occurs the display will show If t
5. User Manual Earth Continuity Monitor For Model GCM 52 KE ELECTRONIC ENGINEERS GCM Earth Continuity Monitor Protection Filter Model GCM PF1 s SPIP SS systems j ECTRO NEERS Pilot Earth Pilot Line Monitor ar 1 switching Leaders in systems Voltage Dip Proofing ELECTRONIC ENGINEERS Earth Continuity Monitoring User Manual Contents deii ele Wegen EE 3 Theory eeler 3 Reide lee EE 4 Front er E ee dE 5 HEIEREN 5 R lay te e E 9 Specifications amp Ordering EE 10 Installation ele TTT 11 RE E 11 Mechanical outlines A CONNECTIONS 0000 eet teeeeeee errr eeeeeeeeeaaaaeeeneeeeees 13 Page 2 GCM 52 User Manual Introduction Earth leakage relays perform two main functions on mining installations to protect machinery from damage and to make the installation safer for personnel In the typical distribution circuit shown in Fig 1 an earth leakage relay provides protection against leakage to earth and earth faults The principle of this method is that all the current flowing to the load must return from the load If current leaks to the frame of the motor and returns via the earth bond back to the star point of the supply transformer then this difference is detected by the earth leakage relay which triggers the breaker thus disconnecting the load It becomes apparent that the earthing must be solid and reliable for electrical installations to be safe For this reason machinery is
6. e Monitor will measure accurately with a DC offset of up to 2V present on the pilot When the DC offset exceeds 2V loop measurement is suspended the symbol appears next to the Loop value and the display is frozen Under these conditions Open circuit detection continues to function normally Immunity to supply disturbances The Monitor is immune to momentary supply voltage sags and interruptions The Monitor will operate normally for events of up to 1 second in duration In addition it will function normally for extended periods under supply voltage sag conditions down to 60 66V of nominal supply voltage i Page 8 GCM 52 User Manual Relay truth table Conditi Supply Off Supply On Supply On SEN PILOT IRRELEVANT PILOT HEALTHY PILOT FAULTY De Energised De Energised Energised Relay A ji il 5A 6A 9A 5A 6A 9A 5A 6A 9A De Energised Energised De Energised Relay B d j 3A 1A 2A 3A 1A 2A 3A 1A 2A Fig 5 Relay truth table GCM 52 Page 9 User Manual Specifications amp Ordering MODELS GCM 52 Control voltage Voltage variation Relay burden Operational accuracy Measurement limit Resolution Open circuit fault Open circuit response time Short circuit response time High resistance response time Output contact Contact arrangement GCM 52 Mounting GCM 52 Connections GCM 52 Compliance standard Voltage dip immunity 110V AC Sinusoidal 50Hz 40 10 15VA 0 5Q
7. earthed via the supply cable using either a copper conductor of the cable or the armour The ground on which the machinery stands is normally not considered a reliable earth Mechanical damage to the earth bond corrosion of the armour or bad workmanship may result in a high resistance point in the earth return If an earth fault occurs voltage will be developed across the high resistance region This voltage poses a potential hazard to any personel who may be exposed to it Depending on the resistance value the current flowing and the reaction time of the earth leakage relay this could be fatal It is obvious that continuous Bus monitoring of the earth bond is imperative if safety standards are to Do be maintained Supply Transformer Main Earth Neutra Earthing Resistor SWITCHING SYSTEMS range of EARTH CONTINUITY breake D V S i RELAYS provides a cost effective solution to the problem fe Te Te Theory of operation i SIE 3 v Eart To continuouslymonitor the resistance of the earth bond an electrical Leakage measuring signal is fed into the earth conductor via a separate pilot S wire To cater for the possibility of a short between this pilot and the lt earth a remote module must be employed Contactor with Overload A loop now exists consisting of the pilot wire the remote module and the ear
8. he GCM52 is supplied with the password preset to 0000 The password is used to prevent unauthorized adjustment of the Trip Level It should be set by and known only to the person responsible for the electrical installation If the password is lost or forgotten call Switching Systems for assistance in retrieving it To set the password start at the Trip Loop display press the Next key to display Press the Up key to display If this is the first time the password has been set the old password will be the default value of 0000 in this case press the Next key gt four times to accept the default value After the fourth key press the display will show The left most digit will flash indicting that it is selected use the Up key to set the digit to the desired value then press the Next key gt to select the next digit to adjust Proceed until all four digits have been set make a note of the new password After setting the last digit press the Next Key to go back to the Trip Loop display To change an existing password other than the default the old password must be entered using the Up amp Next gt keys as described above Set Trip Level The GCM52 is supplied with the Trip Level preset to 30 02 To set the Trip level to a new value start from the Trip Loop display and press the Next key gt Is displayed the Next key navigation arrow gt is flashing
9. he fault condition lasts for more than 20 seconds the Monitor will trip relay A is energized relay B is de energized and an audible alarm sounds The display will freeze showing To reset the Monitor press the Next key gt The Monitor will perform a self test routine before returning to the Trip Loop display During self test the display will show Page 7 User Manual Open circuit cable If this condition occurs the display will show The Monitor will trip within 180ms relay A is energized relay B is de energized and an audible alarm sounds The display will freeze showing To reset the Monitor press the Next key gt The Monitor will perform a self test routine before returning to the Trip Loop display During self test the display will show Monitor self test failure If the self test routine detects an internal system failure the display will show This message can occur when Monitor is switched on Monitor is reset after an open circuit fault Monitor is reset after a short circuit fault Noise Immunity AC noise The Monitor will measure accurately with noise levels up to 15Vac present on the pilot When noise levels exceed 15Vac loop measurement is suspended the symbol appears next to the Loop value and the display is frozen Under these conditions Open circuit detection continues to function normally DC offset Th
10. inals for the supply voltage three terminals each for the two potential free change over contacts plug A and one each for the pilot and earth connections plug B The truth table for the operation of the two changeover contacts is shown in Fig 5 This configuration was chosen to provide a no power on unit indication The dimensions and connection diagram are shown in Fig 7 on page 13 The Remote Module consists of a 1009 1 30 watt calibrated resistor terminated with a M12 and M8 brass bolt for connection to Earth and Pilot respectively For physical dimensions see Fig 9 on page 14 The Protection Filter prevents damage to the monitor due to phase to earth and phase to pilot faults The monitor filter can continuously withstand faults on restricted neutral systems up to 300A without damage to the filter or monitor It is recommended that a protection filter should be pur chased together with anew GCM monitor and consideration should be given to installing a protection filter to to protect the monitor in existing installations Electrical amp mechanical specifications appear on pages 7 amp 10 respectively Page 4 Supply Transformer Earth Main 7A 8a Control Voltage Neutral T Bus Bars Earthing Gei Resistor da 2 Earth Continuity Monitor Qi Breaker wo Earth
11. on to the 110 volt ac supply to the monitor Supply cable to load center Supply cable from switchgear a Main Earth Q Monitor Pilot black Supply from circuit breaker Main Earth 5A Brown IN 6A Purple Relay A 9A Red 3 G 2 3A Orange 1A White Relay B 2 2A cay ge Pilot M8 7A Blue 110V Suppl Remot GCM 51 monitor BA Blue 110V Supply Module 1B Green Earth Load 2B Black Pilot 7 Earth M12 Switchgear frame Load centre frame Fig 6 GCM 52 connection Test schedule 1 With remote module disconnected check the insulation of the pilot and earth Test should read infinity 2 Connect the remote module with the M12 bolt fastened to the load centre frame earth and the pilot conductor connected to the M8 bolt 3 Measure the total loop resistance between pilot and earth This reading should bea minimum of 1009 and a maximum of 1509 Pilot re e R pilot Black M8 R total R pilot R earth R module z The resistance displayed by the Monitor will be o o 2 R display R total R module R total 100 2 2 a S Thus the Monitor only displays the resistance of o e the pilot conductor plus the earth conductor S M12 3 Green J GE gt gt e R earth Earth GCM 52 Page 11 User Manual 4 Plug the 9 pin and 4 pin plugs into their sockets at the rear of
12. th wire in the cable An intrinsically safe signal is injected into the loop and by interpreting the voltage and the current flowing the resistance can be monitored see Fig 2 The energy level Cable of an intrinsically safe signal is so low that dangerous gases like hydrogen or methane cannot be ignited by it Depending on factors such as the length of the supply cable the nature of the load variable speed drives or heavy load switching and the location of the installation near a pipeline with cathodic Load protection or a DC railway line a range of noise signals can be induced or injected into the loop the signals can vary from high 27 frequency generated by thyristor switching to 50Hz and DC Noise signals can have an amplitude of up to 100V The relatively low level Fig1 of the intrinsically safe measuring signal and the high electrical noise 4 typical distribution necessitated the development of specialised measuring circuitry circuit GCM 52 Page 3 User Manual Description The earth continuity monitoring system consists of a monitor remote module and monitor protection filter Moni tors are available in two types of enclosure as described below The GCM 52 monitor is mounted in a compact plastic case and is connected via two Molex plugs This is the preferred model forall new installations Atypical application circuit is shown in Fig 2 The external connections consist of two term
13. the GCM 52 Monitor and switch on the 110v ac supply The monitor will run a self test and calibration routine then display the Loop Trip readings The startup display sequence is shown below When the self test and calibration routine has run successfully and the trip and loop values are displayed the GCM 52 monitor is fully operational and ready for service If the password and trip level have not been set this should be done now Refer to page 6 for instructions Page 12 GCM 52 User Manual Mechanical outlines amp connections 72 53 218 68 O ro O ZS 2 2A 3A 6A 9A oS 2B L N of 8A 218 1B x 1A 5A 7A L 0 y Connection lead colour codes length 2M Socket B Socket A L 5A Brown 7A Blue 110V Supply Sockets A amp B exit enclosure 6A Purple Relay A 8A Blue 110V Supply via flying leads 100mm long La 9A Red Con 3A Orange oo 1A White Relay B 4B Green Earth Panel cutout size L o 2AGrey 2B Black Pilot 69mm x 139mm Fig 7 Dimensions of the GCM 52 in mm GCM 52 Page 13 User Manual Earth a 48 Bi 35 r M12 Fig 9 Dimensions of the GCM Remote Module in mm
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