hpb6 v04 user manual issue 1
Contents
1. A 26 1 i 1E8 v YdI lWzONVHUV HARD Y30704 0990 God LINN ifdlno v 2 Mal CNS C6 1 8 C SOESVdI ONLMYHO ivAOMHddV YOW OL 953584 E 00 ABSI SWH 98 ABET SIOVAINDO AY aH ON Nid HSYE SALYOIONI SE NOILONDZ SALVOIONT 0000150 8090 Vgl L OWIHIA ZO ALY daSve YA 53598 01 X034 Suv 01 SON UNDA TIVE NIG ESL NO LIND AV m8 INDOW T SALON 3 804 JO 015 SS wu 00061 SES Cad pos A SS 5 DIL Dur PTS F Iml 595 5755875 5585 696 SPE 238 LL tl Lid Qua 27 o4 a3 Postal Address P O Box 45 Boolaroo NSW 2284 A C N 054191347 The Manager Ampcontrol CSM Pty Ltd Box 304 WARNERS BAY N S W 2282 DATE 16 02 1995 d o FN Business Address 14 Raymond St Speers NSW 2284 Phone 049 586811 Fax 049 586827 Mobile 049 O18 685252 OUR REF 54654 FILE REF N C92 0362 SUPPLEMENTARY APPROVAL Dear Sir ITEM IDENTIFICATION ORIGINAL APPROVAL2. 9 11 2 Wiring Installation 10 HPB Equipment List 11 HPB Specifications 12 Trouble Shooting 13 Drawings HPB E 006 Typical Connection Diagram 16 HPB B 004 Display 17 HPB B 003 Very Inverse Overcurrent Curves 18 HPB B 001 Extremely Inverse Overload Curves 19 IPB B 003 Adjustable Setting Storage 20 HPB M 005 HPB Enclosure Dimensions 21 HPB M 013 HTU 1 Termination Unit 22 HPB M 015 Remote Display Module HDM 23 IPB A 009 IPB Base Connections 24 HPB M 001 CCMB 6 6kV Cable Connection Module rtp ette 25 5005 IPA IPB Relay LED Output Module 26 IPA A 031 Relay Output Module General Arrangement 27 Approvals NSW MDA Ex 11388 CONTENTS HPB6 V04 USER MANUAL ISSUE 1 1 Overview 1 1 Introduction The Ampcontrol HPB Integrated Protection Relay Version HPB6V02 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 p
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4. 4 OY IN COE O NIN clon e cn Co ET ESI se BRS 4 ONES S Ps eo E SR Je eS ec let Ier er er Lar c er ox per echt ect aloo x EE 92 60 OEE fas col CI d Ed Ed i es Pleo akon Ss 200 X of Selected Full Load CURRENT Cur Mut 1n 9 E 771 HPB Very Inverse Over Current 8 Short Circuit Curves vex vx 172 22 7 eB LL c i ur c E d m a d a a 2 EA 5 E Ug 3 8 BRB BF 8 rs dan N Qh SR 8 B 5 S 8 amp mo v odds ds Ei d eg S e 88 id 58 5 8 5 C Z 1 8 25 a Trio Time C 98 a 98 95 84 Gb HPB Extremely Inverse Over Current amp Short Circuit Curves Bears 16 mSec T28moec 1aamSec Bamses 40 SHORT CIRCUIT 280 300 400 500 600 788 800900 1090 of Selected Full Load CURRENT Selected Full Load Current SFLC Over Current Trip Time i Cur Mut 198 m eec USE 88A 73A 38 m time Multipiter D Fault Current Selected Full Load Current Short Circuit Selectable at 17 38 35 48 45 58 55 88 65 78 75 80 85 88 95 108 Times Selected F
5. H P B High Voltage integrated Pratectlon Relay Type Ampcontral HTU 1 e HPB Terninotion Unit HPB Resistor Mode Connection Earth Leakage i type AMPCONTROL EL 900 Test Resistor R gett 200 C needs to produce test current of 100 1607 of Trip Level gt 1 nnectlon le t Anpcontrol CCHE 6 6 7S or 1000 1 Class 2M STE Rating 20kA 3 Sec Phasing on Bverload Must be as Shown C T amp Toroid leads should be Twisted amp Shelded with the shellds connected to pin 7 as close as posslkle to the HPB li Voc Earth E cp Om Owr Led Reloy ox Module O Omn Refer Deg 060792 m AMPCONTROL IPSI FK Gees AdO2 TYPICAL CONNECTION DIAGRAM INTERFACE MBDULES GP Pica arl ruh 296 i6 PAP DF ROW OF CONTENTS get wea vee Status ERI 826 4887 Ruming EMNTLOG 1 Logi MGOsed Log2 RESET s 1003 Tipped fa INFORMATION SUF 95 817 a 5029 98 084300 E Qnaedg7 i t EC A SOK Machine Drgi 1 KTU Onlne Run HTU S W Ver 1 eee i i H PLOF amp HTU 2 EARTHFAULT 8 EL 9 a A B ECRAN p 52 49 60M i 1 E SYSTEM VOLTAGE 4 103 Bite C
6. AMPCONTROL 4 gt HPB Integrated Protection Relay Version HPB6 V04 Designed and Manufactured in Australia by No copies of the information or drawings Ampcontrol Pty Limited ACN 000 915 542 within this manual shall be made without the Phone 02 4956 5899 Fax 02 4956 5985 prior consent of Ampcontrol USER MANUAL E05296 ISSUE 1 6 12 99 HPB6 V04 USER MANUAL ISSUE 1 HPB Software Version Copyright Nouce HPB6 V02 March 1999 Initial No part of this publication may be Release reproduced transmitted or transcribed into any language by any means HPB6 V03 7 June 1999 without the express written permission of Ampcontrol Pty Ltd 250 Macquarie Road Warners NSW 2282 HPB6 V04 2 December 1999 Australia Disclaimer Ampcontrol Pty Ltd will make no watranties as to the contents of this documentation and specifically disclaims any implied warranties or fitness for any particular purpose Ampcontrol further reserves the right to alter the specification of the system and or manual without obligation to notify any person or organisation of these changes Before You Begin We would like to take a moment to thank you for purchasing the HPB Integrated Protection Relay To become completely familiar with this advanced protection and control relay and to ensure many years of trouble free operation we recommend that you take the time to read this user manual thoroughly 10 11 HPB6 V04 USER MANUA
7. 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 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 Group 2 Settings HTU MC Type Allows the HTU 1 to transmit a descriptive code to identify the machine connected to the outlet MC No Allows the HTU 1 to transmit an assigned machine number HPB6 V04 USER MANUAL ISSUE 1 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 overcurrent curves OC t mul Modifies the basic overcurrent 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 leve
8. 400mS 500mS 600mS 800mS 1 0 Sec 1 2 Sec 1 5 Sec and 2 Sec A maximum setting of 600mS should be suitable for most installations 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 6 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 page 15 4 Current Related Functions 4 1 Basic Overcurrent Protection Two current transformers are used to measure the three line currents The measured currents are used to implement the following protection functions a Overcurrent b Short Circuit c Phase Current Balance Full load settings cover a range from 7 5 Amps to 464 Amps A current range and current multiplier are utilised to select and store the full load current value in the non volatile memory This forms the basic reference level for the overcurrent protection functions The current range is selectable in 4 Amp incr
9. 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 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 eg open circuited main contactor coil or control supply 8 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 second in the direction of the arrow key pressed Press Enter to stop the scroll at the desired log A typical display shows LOG 10 EL TRIP MO 15 05 09 46 21 This records that an earth leakage caused a trip condition on Monday 15 May at 9 46amLog 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
10. psey 405580044 0401 Seg N amp dH FYNSOTONA eJnsoiouz NN CONOM BOZ SMENOMEN BOT GVH 24 CIG 980 NOV 41d ior RENEE E WERE CE RE AO PO ANGLUS d aT _ f FIR L X arc E edly Rop YBH 03134304 HTU 1 H Termination Unit Version 18 Use this connection for Diode _ Type Pilot typo relay eg 7 Normal for X To Trailing Cable Pilot amp Earth Pilot Remote Stop Start Loop only N A If Diode type Pilot Relay e 8 b ult S ISO HBC NS 5 N 844 s Tx SAA WWG GAS 100100 71 SALON ez gt uni gg 9 p uu SARL WML Sze OO LE ta unu po L6 gt 80 mmm er 0962 una qaot QL 6 8 IPB 993 AMPCONTROL DWG C 201 Data A CD MCI OD P ge ASOD CU VOR LNG T ie orem oe
11. Contactor Input MCI shows the main contactor to be closed when it should be open u P reset Internal microprocessor reset Mem ERROR Records that the relay s non volatile parameter memory has been corrupted HTU mem E 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 9 Time amp Date If there is a need to adjust the real time clock carry out the following procedure 1 Using the Remote Display Module select the time and date information page Level 7 Position 1 to display the Day Month Year Hours and Minutes MO 150595 09 46 2 Press the enter key A v will appear in the top line above the minute section This indicates the number to be changed 3 Use the left and right arrow keys to move the to the desired position 4 Press the enter key The v now changes to 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 5 Repeat steps 3 and 4 until the correct time and date is displayed 6 With the v showing press the lock push button The then changes to This is a prompt to press the enter key 7 Press enter key At that instant the seconds are zeroed and the selected time date information is transferred to the internal clock If t
12. Ne ORIGINAL APPROVAL HOLDER PREVIOUS APPROVAL SUPPLEMENTARY APPROVAL INTEGRATED PROTECTION RELAY HPS Ex 11388 AMPCONTROL SWG Ex 11388 Ex 11388 DESCRIPTION OF APPROVAL VARIATTONS Modified for use on high voltage systems for open cut coal mines as follows a Change input resistor on E L toroid to give adjustable trips 200ma 1000ma b Trip time adjustable 80 470ns 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 SUPPLEMENTARY APP N2 Ex 11388 FILE C92 0362 DATE 16 02 1995 ADDITIONAL APPROVED DRAWINGS HPB 2 001 Rev O Dated 14 02 1995 2 002 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 moduie 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 E
13. Position 1 DrgL Drag Line Shvl Shovel Dril Drill PSTx Portable Transformer Wpmp Water Pump 2 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 HPB6 V04 USER MANUAL ISSUE 1 3 Earth Protection Functions 3 1 Earth Leakage The earth leakage protection function uses a toroid to measure the earth leakage current This function is certified in approval MDA Ex 11388 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 MCR logic and is latched An earth leakage trip is treated as a special fault and requires an authorised person to perform the reset function This is achieved by holding the lock input closed and then closing the reset button When an earth leakage trip occurs the LED on the display module flashes and the open collector output on the HPB Relay is switched on to provide additional monitoring if required The measured instantaneous leakage current EL is displayed on the HDM Earth Fault Information page as a of the trip level When the leakage reaches 100 for the selected time delay a trip occurs The trip level is adjustable in 100mA increments over the ra
14. 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 Closure of the Main Contactor Relay Stopped Stopping of the outlet by operation of the local stop button HTU Stop Stopping of the outlet by operation of the remote stop button MC Opened Main Contactor has opened but not initiated by the HPB Relay EC Trip Pilot Earth continuity loop exceeds the trip level EC Short Low resistance between pilot and earth EL Trip Earth leakage protection tripped EF trip A Earth Fault test has failed A phase EF trip B Earth Fault test has failed B phase EF trip C Earth Fault test has failed C phase SC Trip Trip condition of short circuit protection OC Trip Trip condition of overcurrent overload protection I bal Trp Current balance trip condition HPB6 V04 USER MANUAL ISSUE 1 RESET Records resetting of a protection trip Setup Mod Records that setup data has been modified The log preceding this shows the old and new values uVOLT Trp Records that voltage was not present on at least one outgoing phase when the main contactor was closed MCF F Trp Internal battery backed main contactor fail flag tripped MCF V trp 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
15. as close to the centre of the toroid as possible Do not tie them to one side of the toroid Remember aim at symmetry 27 Do not bring the cables back past the toroid within one diameter of the CT trying to cram cables into a small space reduces symmetry and may lead to problems which are difficult to solve 3 Avoid placing the CT near any device which produces magnetic fields whether it be a transformer or other cables Try to maintain several CT diameters clearance 4 Many small cables tend to be worse than say three large ones Try to position the CT in the circuit with this in mind 11 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 A power supply filter eg Schaffner FN612 1106 1A 250VAC chassis mounted filter should be installed adjacent to the HPB Relay The earth should be connected to Pin 7 on the relay as directly as possible A Low Voltage Signals These signals are connected to the low voltage side of the HPB Relay s internal transformer Care must be taken to ensure these circuits cannot come into contact with higher voltages eg via insulation breakdown or broken wires etc It is recommended that these circuits be run in a separate loom from the high voltage circuits To ensure that interference is
16. transformers are not ideal devices and if correct procedures are not followed during installation nuisance tripping can result If for example we consider a single phase earth leakage system where active and neutral pass through a toroid then at all times currents in the two wires are equal and opposite so that the net current through the toroid is zero An ideal current transformer would have all the flux from each wire contained in the core and so would accurately add the opposing fluxes to get a net result to zero A real current transformer has leakage fluxes That is a very small proportion of the total flux from each cable is not contained in the core but in the space outside it and as result it may link some turns but not others depending on the positioning of the cables The effect of this 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 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 E Toroid Installation Guide Lines 1 Keep cables
17. was made Note When the relay has been selected for HTU Mode the HTU Remote Termination Unit must be on line before Level 9 on the HDM Remote Display module can be entered 7 System Control 7 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 7 2 Output Relays The HPB Relay has output relays to control the main contactor and the circuit breaker under voltage control 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 Display Module Level 6 Position 1 7 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 enables these indications to be interfaced with a PLC See Drawing IPA A 031 Page 27 The eight outputs
18. 183 B ernf Timer 9 t Y la b ic OG Trip 0856 85 8596 85 te E 5 amp 6 EM CBA RELA MCISTART Lok Ret Link OF oo oo Ast DATE THE 7 230808 08 48 32 Tha err ot nien ird CR IR tart OF ln hola ar a conscia thed partim ieu pror etn Porh 17 SANYO ISHAANI AMSA ABL pyd NCE Dun CJ a Es F PEMA DO AID JO POU UL do ipd g 6048 peung KAATAHI ur yx pus Toma 8 ddH EE NAYEU aj Pug ON DAT TOUINODGHY zio jiswa fada nu iu UE 388 BE KR a Bu p 5 55 hs bgg 3ecnn oo N3 5 8 BANS 8 OY d 7 sss TG c c as S co t3 5 t 2 558 gs gest 6 o P fina st Bogs 8 e Ele Ses m PS Gor g S de Bae Bras 2 e 3 ES aS 8 2E Tas b Se 8 3 A in T amp 1 7159 LEG E m OMNE 5 Q Z b D c e c e 2 368 x jer ecce en acl ec Prete e ie EX RES RSS IS
19. L ISSUE 1 Overview 1 1 Introduction esssss 1 1 2 Remote Display Module 1 Machine Communication 2 1 HPB Termination Unit HTU 1 2 2 2 Machine Type Codes 2 2 3 Machine Type Number 3 Earth Protection Functions 3 1 Earth 3 3 2 Barth Fault Lockout 3 3 3 Earth Continuity 3 Current Related Functions 4 1 Basic Overcurrent Protection Function sese es 4 4 2 Overcurrent Characteristics 4 4 3 Short Circuit 5 4 4 Phase Current balance 5 Voltage Related Functions 5 1 Main Contactor Fail Protection 5 5 2 Under Voltage Trip 5 5 3 Voltage Metering 6 User Adjustable Settings 6 1 Parameter Groups 6 6 2 Changing Settings 6 System Control 7 1 Digital eee 7 7 2 Output Relays 7 7 3 Open Collector Outputs 7 7 4 Outlet Control 7 7 5 Operational Sequence 7 Event Log 8 Time amp Date 8 Remote Data Communications 9 Installation amp Wiring Instructions 12 13 14 15 15 11 1 Installation
20. TU 1 non volatile memory is corrupted HTU STOP Waiting for HTU 1 stop input to be closed HPB STOP Waiting for HPB stop input to open HPB START Waiting for the HPB Relay s start input to close WAITING Pause between successive Megger Tests An error status indicator is also shown on the status page which is normally zero Error 1 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 6 Page 6 2 Machine Communication 2 1 HPB Termination Unit HTU 1 The HTU 1 Remote Termination Unit is 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 HPB M 013 Page 23 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 c
21. X 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 14 A J Weeks Assessing Authority No MDA A2507 New South Wales Department of Mineral Resources Accredited Assessing Authority MDA A2507 COAL MINES REGULATION ACT 1982 NOTICE OF SUPPLEMENTARY APPROVAL SUPPLEMENTARY APPROVAL MDA Ex 11388 FILE C92 0352 DATE 16 02 1995 It is hereby notified that the Approved Item listed herein has heen 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 5 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 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 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
22. an 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 Emergency stops should be wired direct 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 conventional pilot protection relay such as an Ampcontrol PCA Relay but will not operate when connected to a 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 HTU Online Run or HTU Online Stp 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 See Section 6 Page 6 2 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
23. ay 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 selectable from 40 to 160mS 4 4 Phase Current Balance Phase current balance protection is selected via the Cur Bal Trp selection See Section 6 The current balance measurement is displayed on the Remote Display Module and is calculated as Ibal MAX AIx 100 Iave Iave Average of the 3 phase currents The maximum deviation of a phase current from the average The trip level 15 selectable at 596 1096 2096 50 and off The phase current balance protection is inhibited until the average current exceeds both 20 of the selected full load current and the selected balance trip level If the trip level is exceeded a timer is triggered If the imbalance remains above the set level for more than two seconds the relay trips The event log records Ibal to differentiate it from a true overcurrent trip The status of the timer is displayed adjacent to the bal value Level 5 Position 2 on the HDM Remote Display Module trip condition occurs when the timer reaches 100 5 Voltage Related Functions 5 1 Main Contactor Fail Protection The Main Contactor Fail MCF protection operates if the Main Contactor fails to function by 1 Failing to open when required This is ac
24. contactor fail Check main contactor for leakage across power up condition terminals on frozen contactor condition Flat or faulty battery AA cell installed under the top cover requires replacement The owner in workshop environment can replace a direct replacement battery It is recommended that the relay be returned to Ampcontrol for battery replacement and full testing Time and date incorrect Low battery AA cell installed under the top cover requires replacement The owner in Resets to 1 01 9 on power workshop environment can replace a direct up replacement battery It is recommended that the relay be returned to Ampcontrol for battery replacement and full testing 14 HPB6 V04 USER MANUAL ISSUE 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 30VDC To determine the location of the fault continue the above test along the pilot until no reading is obtained Current check Connect a DC 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 DC but the current is less than 45mA then the loop resistance may be too high Tests in Re
25. cooling of the electronics HPB6 V04 USER MANUAL ISSUE 1 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 B Remote Display Module HDM 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 C Cable Connection Module The Cable Connection Module CCMB 6 6kV is a resistive isolation device which interfaces between the power circuit and the HPB Relay 5kV DC voltage is generated in the Cable Connection Module which under normal operation applies up to 2 5kV DC between each phase and earth The CCMB 6 6kV Cable Connection Module is housed in a polycarbonate enclosure The CCMB 6 6kV Cable Connection Module 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 D Overload amp Earth Leakage Toroids Current
26. 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 7 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 HPB6 V04 USER MANUAL ISSUE 1 input must be bridged to earth via a diode at the HTU 1 Termination Module 7 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 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 Remote 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
27. ements between 60 and 116 Amps The current multiplier is selectable at 1 8 1 4 1 2 1 2 4 times 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 HPB6 V04 USER MANUAL ISSUE 1 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 ie 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 overcurrent 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 gets almost to 100 as the load gets away then this may indicate that the overcurrent settings are too low Conversely if the trip accumulator only builds up slightly on a heavy start then the overcurrent settings may be set too high If an overcurrent trip occurs the LED flashes and the OC open collector o
28. he 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 10 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 E06510 for further details 11 Installation amp 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 11 1 Installation A 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 Vent holes are provided at both the top and bottom of the relay to assist in the
29. hieved 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 HPB6 V04 USER MANUAL ISSUE 1 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 EMF inhibit time is adjustable from 2 to 40 seconds See Section 6 Page 6 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 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 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 5 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 nom
30. hy LED located top centre of the module flashes at 3Hz to indicate healthy communications with the relay A flash rate of 1Hz indicates that the module is powered 15VDC but not receiving data The module displays the following information 1 Software version and serial number 2 HPB Status 3 Operational information from the protection functions eg earth leakage current earth continuity resistance etc 4 System information including the line voltage and current 5 Status of digital inputs and relay outputs 6 Protection trip settings which can be viewed at any time Authorised personnel can modify these settings via the HDM Remote Display Module 7 Data logging information The 120 most recent events and parameter changes are logged with time and date in a non volatile memory eg power up trip reset close etc HPB6 V04 USER MANUAL ISSUE 1 A review of the first few log events is a useful tool for fault finding 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 H
31. inal line voltage for 800mSec then the outlet is stopped This is recorded in the event log as uVOLT Trp The trip level is selectable from 3096 to 8096 in 10 increments can be set to Off Level 8 Position 6 on the HDM Remote Display Module The selection disables the under voltage trip function and is usually used for non 6 6kV installations 5 3 Voltage Metering The Cable Connection Module in addition to providing the Earth Fault test is also used to provide line voltage metering The outgoing line voltages for each of the 3 phases are displayed as a 96 of the nominal 6 6kV line voltage on the display module Level 4 Position 1 on the HDM Remote Display module The maximum reading is 140 6 User Adjustable Settings 6 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 parameters 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 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
32. kept to a minimum the following cabling is recommended HPB6 V04 USER MANUAL ISSUE 1 Low Voltage Signals Recommended o sem 6 Single core Pilot Core screened Screen Four core screened Screen 0V Serial Comms Port Two core Remote screened Display Screen Earth Two core Leakage screened Toroid Screen Earth Three core Cable screened Connection Screen Earth Two core Current screened Protection Transformers Screen Earth Two core Local Stop Button screened digital input Screen Earth Two core screened Screen Earth Two core Reset Reset screened Screen Earth Two core Start Start screened Screen Earth Motor ok Contactor MCI Two core Aux MCI screened Contact Screen Earth digital input Notes That the OV is internally connected to the HPB Relay s earth Pin 7 The screen therefore should NOT be earthed at any other point Lock Switch digital input Reset Switch digital input Start Switch digital input 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 eg current transformers cable connection module main contactor auxiliaries etc care needs to be taken to ensure that the circuits are adequately separa
33. l SC Trip t 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 following opening of main contactor Remote Start No function this version 6 2 Changing Settings The procedure for adjusting the settings is independent of where the values are stored 1 Ensure the outlet is stopped 2 For Group 2 Settings in HTU Mode ensure the HTU 1 Termination Unit is on line d Display the parameter that has to be changed on the HDM Remote Display Module s liquid crystal display Level 8 or 9 Momentarily operate the lock input A warning message appears e 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 zi Press the enter button to indicate that the value shown is the required new setting oo Momentarily operate the lock input The display will show a confirming message then return to the viewing level If the up or down keys are operated during the procedure the 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
34. nge 200mA 1000mA The time delay is selectable at instantaneous lt 80mS or adjustable in 40mS increments over the range of 150mS 470mS 3 2 Earth Fault Lockout On 6 6kV systems an earth fault lockout function tests the resistance of the 3 phase lines to earth by applying a megger test prior to the closure of the main contactor The test is initiated by the closure of the start button provided all other starting conditions are met see Section 7 5 Page 7 The HPB Relay closes its relay output RL3 that applies 110VAC to the CCMB 6 6kV Cable Connecting Module This is a resistive isolation device used to interface to the power conductors A 5kV DC voltage is generated in the CCMB 6 6kV Cable Connecting Module which under normal operation applies up to 2 5kV DC between each phase and earth The HPB Relay measures the voltage on the line and calculates the meg ohm resistance to earth for each phase At the end of the test provided the value is above the preset threshold the MCR Relay picks up allowing the outlet to be energised If the value is below the threshold an Earth Fault Trip occurs At the completion of a test the leakage level for each phase is retained in memory until the next test is carried out This can be viewed on the Remote Display Module HDM Level 3 Position 2 The test time is adjustable between 10 and 25 seconds to allow for the charging of cable capacitance The CCMB 6 6kV Cable Connection module prod
35. ngs 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 EC Trip In HTU mode the relay settings that pertain to the actual load connected are stored in the HTU I 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 ECR of the pilot earth loop is displayed in ohms on the HDM 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 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 300mS
36. on 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 IPASO05 Page 25 The Ampcontrol Relay Output Module ROU enables these indications to be interfaced with a PLC See Drawing IPA A 031 Page 27 Protection Functions Earth Leakage Section 3 1 Earth Fault Lockout Section 3 2 Earth Continuity Section 3 3 Overcurrent Overload Section 4 0 Short Circuit Section 4 3 Contactor Fail Section 5 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 1 2 Remote Display Module HDM 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 HPB B 004 Page 17 The healt
37. rotecting electrical outlets supplying draglines shovels drills etc 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 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 a cable is inserted into a power outlet The relay can perform an automatic Megger 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 110 volt supply to the Cable Connection Module enabling it to perform the Earth Fault Lockout test of the tripping logic and outlet control is performed by the microprocessor so that virtually no external control is required See Typical Connection Diagram HPB E 006 Page 15 Extensive information display and monitoring features are included to facilitate fault finding and system trending This informati
38. sistor 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 DC 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 15 1 V DC Tests in HTU 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 DC 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 DC HPB MACHINE PILOT PILOT CABLE RESISTANCE 100 Ohms 45mA V 30V Max HPB PILOT RESISTOR MODE HPB HTU TERMINATING RESISTOR 235 Ohms HIGH FREQUENCY COMMUNICATION SIGNAL G 100 Ohms 100 Ohms MACHINE STOPS HIGH FREQUENCY COMMUNICATION SIGNAL PILOT CABLE RESISTANCE PILOT HPB PILOT HTU MODE 15 Inconing Supply dating of ik for 9 Isolator Contrai Tronsfarner _ li vac Sec OTHER TRIPS AS 3008 or AR 3126 x to other lutiets
39. st settings into the HTU 1 memory Error Indication 43 level Combination of faults As outlined above for Errors 1 and 2 0 position 1 causing errors 1 and 2 Relay will not close EC Faulty pilot circuit open or Check pilot circuit See detailed fault fault indicated high resistance or shorted finding information page 15 to earth If still faulty replace the relay HPB Status page displays Relay is waiting for the Ensure HTU 1 Module s stop input is HTU 1 Module s Stop closed through a diode to earth HTU Stop input to be closed Outlet is off and the log Outlet was turned off but Check main contactor coil or control records MC Opened not by the relay circuit 13 HPB6 V04 USER MANUAL ISSUE 1 Relay will not remain The relay s MCI input is Check that main contactor is closing If not closed and cycles while the not closing level 6 check circuit start input is held closed position 2 Check auxiliary contacts and wiring Relay not receiving voltage Check system voltage display level 4 feedback on all three outlet position 1 as contactor closes Compare phases within 800mS of this with the under voltage threshold contactor closing Check continuity from the relay through the CCMB Cable Connection Module to power conductors after following the appropriate high voltage isolation procedures Typical reading CCMB 6 6K 27 Meg ohm Relay Trips on MCF on Main
40. ted and restrained This ensures that the separation is maintained even if a wire termination becomes loose etc B High Voltage Circuits The high voltage circuits of the HPB are the 110VAC supply Pins 30 31 and the relay contacts Apart from keeping these separate from the other wiring to the relay there are no special requirements The relay contacts of the HPB Relay must not be used to switch more than 190VAC 5A or 100VA C 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 The CCMB 6 6kV Cable Connection Module also has an earth connection as this is effectively a diode barrier Ideally all of these should be run back separately to the main earth point 12 HPB Equipment Parts List E06629 HPB6V0 2 Integrated Protection Relay E06407 HTU 1 Termination Unit E04909 HPB Base Plate E06408 HDM Remote Display Module Flush Mount EO5061 6 6kV Cable Connection Module E04801 IPA IPB Relay LED Output Module E05296 HPB User Manual HPB6 V04 USER MANUAL ISSUE 1 13 HPB Specifications Auxiliary Supply Volts Earth Leakage Protection Earth Continuity Protection Earth Fault Lockout Protection Lockout Resistance Test Time Overcurrent Protection Current Range Current Multiplier Time Multiplier Current Balance Trip Settings Short Circ
41. to the MANUFACTURERS and or SUPPLIERS of Approved Items The Authority issuing this Approval may ffor the purposes of the Occupational Health and Safety Act 1983 append a list of recommendations 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 supply installation and continuing use of the approved item The Approval Number shall appear in a conspicuous place and in a legible manner on each approved item unless specifically excluded 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 in 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
42. uces an audible tone to indicate a test is in progress warning of the presence of high DC voltage The High DC Voltage can still be produced even when the 6 6kV supply is not available Care should therefore always be taken when working close to 6 6kV cables bus etc Note That the start input must be held closed for the duration of the test 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 picks up as soon as the start input is closed This is the normal configuration for systems other than 6 6kV 3 3 Earth Continuity The earth continuity function tests for the continuity of the earthing between the outlet and the machine via the pilot core in the trailing cable The pilot core is also used to transfer machine data when a remote HTU Termination Unit is used to achieve machine communication The pilot resistance is measured by a DC signal and communication is achieved by a high frequency AC 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 used to connect between 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 The disad
43. uit Protection Trip Setting Trip Time Back EMF Timer Trip Delay Settings Machine Numbers Under Voltage Protection Serial Communication Port Relay Contacts 110vac 20 10VA 50Hz 2 Hz Trip Setting 200mA to 1000mA in 100mA increments Time Delay Instantaneous 80mSec 150mSec to 470mSec in 40mSec increments Trip Setting 500 750 and 1000 Shunt Leakage Trip if lt 2000 Resistor Mode Operating Time 300mS 400mS 500mS 1 0 Sec 1 2 Sec 1 5 Sec and 2 Sec Selectable at 2 5 10 20 and 50 Meg ohm and off Selectable at 10 15 20 and 25 seconds 7 5 to 464 Amps 60 to 116 Amps in 4 Amp increments times current multiplier 1 8 1 4 1 2 1 2 4 times 0 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 160mSec 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 800mSec For information on data format and hardware see DNET IP2 Serial Communication System User Manual E06510 MCR CBR 1 5A 190V AC 100VA maximum 1 C 0 5A 190VAC 100VA maximum RL3 1 5A 190V AC 100VA maximum 12 HPB6 V04 USER MANUAL ISSUE 1 14 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 rela
44. ull Load Current 60 88 188 B Times Selectable at s 8 120 29 3 i cn gt Ed Ti SRS or re DIO h 100 DIDI ASO S J gt gt ER mene NOBILIS AIR ee oe 3 gt gt EN Nada al IND Pe en ps i a eor Ie ww REFCORRGL DWG tor HPB B 01 Curves EXTREMELY INVERSE CURVE HPB Over Currant amp Short Circuli APPROVED d 8165 ME WS J Ts dming Cialis TD of Amecontrol Pty Lfd Ef lr fo do third portion wifout prior written from arol Pty 16 thair recall md m t not be nepreckined In Fett ce in hota ur ita 1 8 Sd 5 5 ddI E08 H 94 10 Jaquny 5 dnous Piuouiey SIHELOA YON SLY einpoy fiaydsiq YU TWHESOY TUSYOME uum erae pass SNA TNO BRANDON ew di oR vb JUSYOMGH DELO Ort PCN TUR FERE GIS pig peu Kay ar ALI i vemm i 5 Z dnoug o 9035 UON Saal 91 HM
45. utput switches on to provide remote monitoring if required Following an overcurrent 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 4 2 Overcurrent Characteristic The current time trip characteristics can be selected as either Very Inverse or Extremely Inverse corresponding to the Type values vInv or xInv The drawings Very Inverse Overcurrent Curves HPB B 003 Page 18 and Extremely Inverse Overcurrent Curves HPB B 001 Page 19 show the trip characteristics 4 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 relay 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 6 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 Rel
46. vantages 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 500 then the fault to earth in the range of 2000 to 2850 would be seen as a healthy circuit b The Machine Communication functions of the HPB Relay are not available HPB6 V04 USER MANUAL ISSUE 1 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 disadvantage is that the increased complexity in the system may make trouble shooting difficult Resistor Mode When the pilot is set to Res Mode the trailing cable pilot is terminated with a 2350 resistor to earth 2 x 4700 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 2350 and 2350 the selected trip resistance If the resistance measured is below 2000 a 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 relay setti
47. y and return the relay plus a description of the fault to Ampcontrol for repairs Note 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 m Remote Display shows a Loss of power to the Check there is power to the relay and it is blank screen The HDM Display correctly plugged in Relay supplies LED indicator located on 15VDC to the HDM Check cable between the top of the HDM HDM and the relay module is off Faulty Display Module Replace module Remote Display shows a Power to HDM is healthy Check data cable between the relay and the blank screen The HDM but there is no data HDM Led flashes at 1 Hz Error Indication 1 level 0 Corruption in the Group 1 Examine the Group 1 Settings level 8 to Position 1 Settings stored the check the stored parameters in the non relay volatile memory One or several settings will show 7222 Re program lost settings into the memory Error Indication 2 level Either the HTU 1 Module Check that the HTU 1 Module is on line 0 Position 1 when in is not on line or the HTU 1 level 3 position 1 ie a healthy pilot HTU pilot mode Module s non volatile loop If the HTU 1 Module is on line memory has been examine the Group 2 Settings stored in the corrupted HTU Settings level 9 One or several other settings will show Re program lo
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