VSDB009R1 VSDguard User Manual
Contents
1. 15 oo FOFOIGMOMMONMG SIGN ii dali 15 6 TESTING AND COMMISSIONING uu uz ii do 16 E Le EE 17 AMA CINES oh 17 E2 SCINS gebraddelt 17 IND HOT an o on 17 Pies MEM 18 Page 4 of 29 Ampcontrol Pty Ltd VSDguard User Manual VSDB009 Rev 1 April 2014 B SAVE NANO u uuu au A O bo oh oa on ooo as 18 7 2 5 Personal Identification Number DIN 18 1 2 0 Operating MAASI austin da 19 Cer Role Z ETS Ume Sel dO 19 2 O A N DN ol e dodo 19 729 Wala lOG MN e en e en e o al ed 20 MAI A dacia toho bos 20 UZ Real Unie ClOCK RAG EEN 21 2 12 Screen E UNC SS 21 LRE EIBemel ee id a oa 21 ko Remo access Via ENEE uuu u an ia pasapusaq o q 21 ZA PLNE 22 L AE EE 23 sa EVENT LOGS ii o o e i 23 LIA Device IOMA 23 WA Da ala 23 90 Interactive graph NAVIGATION ssl 23 8 SERVICE MAINTENANCE AND DISPOSAL NNN 24 O T EQUIPMENES e EE 24 8 121 VISHALONIV INSDECHONS ai lo ss suska 24 O 2 Detaled A A 24 O Z EGUPNen nn ale 24 0 9 BCEE 24 A MONA au kon A A Aaaa Ee 25 OA EG UIDIMIOMU BEE 25 ARENA RA V N ii WA o o yu x 26 Page 5 of 29 Ampcontrol Pty Ltd VSDguard User Manual VSDB009 Rev 1 April 2014 1 RECEIVING AND STORAGE 1 1 Receiving All possible precautions have been taken to protect the equipment against damage 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 immedi2. Ampcontrol proprietary format 7 3 3 Event Logs This tab shows the 50 most recent user changes made at the unit To export this list use the link above the log to show the log entries in a separate popup window for printing or copy pasting 7 3 4 Device Information This tab shows settings states and measurements relating to both the hardware and software of the unit This list is updated once a second 7 3 5 About Provides contact details and licensing information about the device and website 7 3 6 Interactive graph navigation The graphs shown on the website are interactive The user can zoom pan and display values e To zoom in click and drag either horizontally or vertically on the graph area on mouse driven devices or pinch in touchscreen devices e To zoom out double click the graph area or pinch out on touchscreen devices e To pan around shift click and drag mouse driven devices or swipe touchscreen devices e To display signal values simply mouse over the plot to show the extended legend in the top right of the graph area not available on touchscreen devices In the Oscilloscope and RMS graphs of an historic data log time intervals can be determined by marking the start and end time with single clicks and then reading off the selected range from the box in the top left of the plot To remove the marked range click the box To refine the selection use single clicks near either end of the marked range to move the
3. Local Trip Reset is On to allow this method of reset before the unit tripped Pushbutton Reset A normally open push button when installed between the VSDguard 24V output and digital input 6 can be used to reset the trip This option cannot be turned off but the user may choose to not connect to the digital input Home trip reset If the unit is tripped and the Home trip reset is On the user may reset the tripped unit by holding the up and down keys simultaneously for two seconds when on the home screen Page 19 of 29 Ampcontrol Pty Ltd VSDguard User Manual VSDB009 Rev 1 April 2014 7 2 9 Data log triggering Data logs are triggered by a trip or alarm event a trigger from a digital input or can be set to happen periodically On each event trigger VSDguard stores system data for 2 seconds before and 2 seconds after the event including system time earth leakage current phase current with connection of a toroid 5A secondary connection within 5 of full scale zero crossing of the phase current with connection of a 110Vac supply and Temperature The last 1000 events are stored in the unit The internal storage cannot be overwritten by the user When the unit s memory reaches capacity the oldest entries are overwritten Besides being triggered by a trip logging can be initiated in three other ways Digital Inputs By a signal at digital inputs 1 5 must be set in the CONFIGURATION Digital Input Se
4. gt to cancel D CONFIGURATION Digital input Settings INPUT 1 Pokarity CONFIGURATION Digital Input Settings Change trip state of INPUT 1 gt NOT TRIPPED B TRIPPED ENTER to confirm BACK D to cancel o CONFIGURATION Digtal input Settings Change polarity of INPUT 1 gt NORMALLY CLOSED CONFIGURATION Date and Time Change DATE AND TIME EN 5 2013 21 36 DAY MONTH YEAR ENTER to confirm BACK gt to cancel INFORMATION SYSTEM TRIPS HISTORIC DATA lt INFORMATION System Trips gt lt HISTORIC DATA Event Log gt 0 LOCAL RESET CONFIGURATION General Settings gt Aros Input 1 State Input 2 State Input 3 State Input 4 State Input 5 State Open Open Open Open Open Open FIRMWARE ADC D OFFSET INFORMATION ADC 1 OFFSET 23 02 2013 11 09 41 Settings 23 02 2013 10 45 00 Settings Change 23 02 2013 10 43 22 Trippod 23 02 2013 10 43 20 Settings Change 23 02 2013 10 41 09 Power Up 23 02 2013 10 43 20 Settings Change 21 02 2013 09 01 31 Settings Change 21 02 2013 06 43 20 Power Up DIGITAL INPUT STATE lt INFORMATION Digital input State gt any lt HISTORIC DATA EL Graph Logs gt 23 02 2013 12 11 06 EL Trip Los 23 02 2013 11 09 41 EL Trip Log 23 02 2013 10 45 00 EL Trip Log 23 02 2013 10 43 22 EL Trip Log 23 02 2013 10 43 20 DI Log 23 02 2013 10 41 09 DI Log 23 02 2013 10 43 20 DI Log v D 21 02 2013 09 01 31 Df Log 21 02 2013 06 43 2
5. Take care when unpacking crates as the contents may have shifted during transport The disposal of packaging materials replaced parts or components must comply with ENVIRONMENT _ 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 e oils metals plastic and rubber products by using an approved recycling service centre Page 6 of 29 Ampcontrol Pty Ltd VSDguard User Manual VSDB009 Rev 1 April 2014 2 GENERAL SAFETY 2 1 Personnel safety warnings 2 1 1 Relevant personnel Ensure all personnel directly responsible or involved with the installation operation and maintenance of the equipment reference this manual in conjunction with any relevant risk assessments to identify all hazards 2 1 2 Safety communication All safety instructions and design requirements within this manual must be communicated to all users These requirements are necessary to identify and control any foreseeable risk associated with this piece of equipment In the event of any damage or malfunction that results in the potential to harm the health or safety of any person the owner operator should notify the manufacturer immediately 2 2 Safe use of equipment The equipment supplied has been manufactured according to the state of the art and designed to ensure safe opera
6. User Manual VSDB009 Rev 1 April 2014 5 INSTALLATION 5 1 General warnings Before VSDguard can be installed there are a number of things that need to be considered and understood to prevent incorrect or unsafe operation of the equipment or the system into which it is installed Along with relevant competence and an understanding of the intended application the following points should be considered Ensure that the information provided in this user manual is fully understood It is extremely important that the functionality of the equipment is fully understood to prevent incorrect installation and use which could potentially create a dangerous situation If in doubt as to the nature of the limitations or their implications consult a competent authority such as a supervisor or Ampcontrol technical representative Ensure that the application into which VSDguard is being installed has been properly defined designed and approved Any system intended to mitigate the risk of injury needs to be properly designed and implemented Such a system must be the result of structured risk analysis with the outcomes used to define the system requirements These requirements in turn will guide the choice of instrumentation logic solvers and actuators needed to implement the system Understanding the needs of the system will ensure proper selection of equipment Ensure that the VSDguard relay will properly perform the required functions within the s
7. as expected and that when it trips it also operates the intended circuit breaking device Section 7 2 8 provides more information on how to reset the relay after a trip CAUTION Insulation Resistance or megger testing MUST NOT be done when VSDguard is wired in to the circuit Disconnect wiring to the unit before performing insulation resistance tests Page 16 of 29 Ampcontrol Pty Ltd VSDguard User Manual VSDB009 Rev 1 April 2014 7 OPERATION The VSDguard relay can be configured via the user interface and keypad The user interface and home screen are shown in Figure 4 User Interface Showing Home Screen Power On LED Processor Healthy LED Trip LED Directional Keypad ENTER 4 Button Contextual HELP Button BACK 9 Button Figure 4 User interface home screen 7 1 Indication LEDs There are three 3 LEDs at the front of the unit that indicate the status of the VSDguard relay and the nature of any faults if relevant e Power On LED green e Trip LED latched red e Processor Healthy LED 1 Hz green 7 2 Settings 7 2 1 Navigation Under normal operation VSDguard has four live status screens as shown in Figure 5 lt UVEGRAPH OSC gt ui CZO lt LIVE GRAPH FFT Figure 5 Live Status Screens These screens show 1 Bar graph of real time RMS current with trip state home screen 2 RMS current history 3 Plot of the real time current seen by the earth leakage toroi
8. cable The earth fault current will flow through the fault to the machine frame and return to the supply transformer star point via the trailing cable earth conductors The voltage drop caused will result in a potential rise above earth on the frame presenting a touch potential hazard As described in AS NZS 4871 1 2012 the system assessment must determine the earth fault limitation current that will protect people based on the achievable earth leakage clearance times and knowledge of the system in which it is installed 3 1 Variable speed drives Variable speed drives VSDs are now finding wide use in mining applications Most of these drives use variable frequency outputs that are produced by rectifying the supply to dc and then inverting this voltage back into ac using a high frequency carrier and pulse width modulation PWM to produce variable frequency currents in the motor They complicate the situation in several ways 1 VSDs introduce a new and complex voltage source into the power system This may mean that earth faults can now be direct current dc in nature or may be driven by the inverter of the drive and so have a frequency that is primarily that of the drive PWM carrier frequency 1000 Hz for example 2 To minimise interference with protection and control systems many drives employ electromagnetic compatibility EMC or EMI filters that consist primarily of a capacitive circuit between the input of the drive and earth This provide
9. impedance of the filter at the frequency of interest should be examined in order to determine the earth fault current that will flow when a fault occurs in the machine The earth leakage trip time must then be used to ensure that the touch voltage and exposure time guarantee a safe system Care must be taken when multiple filters are connected to a single supply as this presents many modes of possible earth fault that need to be considered and actual earth fault currents may exceed the current seen by any single filter An earth leakage relay must be able to accurately sense earth fault currents of any frequency from dc to the maximum frequency of interest It can be seen that this is not a trivial matter and it is likely that the industry will need to adapt to this new and complex environment Page 10 of 29 Ampcontrol Pty Ltd VSDguard User Manual VSDB009 Rev 1 April 2014 4 AMPCONTROL VSDguard EARTH LEAKAGE RELAY Ampcontrol VSDguard is a high performance microprocessor based wide bandwidth earth leakage relay that is capable of measuring and analysing power and switching frequency currents flowing in IT power systems The VSDguard relay is designed for use with variable speed drives in mining environments Some of the features of the relay are e Complies with AS NZS 2081 2011 Section 6 e Patented earth leakage analysis method International patent application number PCT AU2011 000705 e Fail safe operation e Detects earth leak
10. user to view Pressing ENTER takes the user to a similar set of screens as the real time data graphs The user can zoom in and out and view the FFT of a selected range of data Page 20 of 29 Ampcontrol Pty Ltd VSDguard User Manual VSDB009 Rev 1 April 2014 7 2 11 Real time clock RTC Recorded data is stored on VSDguard with a time stamp from the on board RTC indicating the system time when the log was made For the purposes of aligning recorded data with other records it is important that the user regularly checks that the time on the RTC reflects a level of accuracy acceptable to the user Without regular synchronisation the RTC may become different from actual time For example it may be set incorrectly by the user or the clock may drift over time 7 2 12 Screen timeouts When the VSDguard relay receives no input it re directs to the home screen and locks itself if PIN is set There are two timeout settings available under CONFIGURATION General Settings Graph Timeout The number of minutes after which the screen returns to the home screen when viewing any of the real time graphs General Timeout The number of minutes after which the screen returns to the home screen when navigating the unit s menus includes viewing historic data 7 2 13 Ethernet Access The Ethernet connection of the unit can be viewed at CONFIGURATION Network Settings shown in Figure 12 If there is a DHCP server running on your local network the DH
11. 0 DI Log ADC 2 OFFSET lt INFORMATION Firmware Information a ek ADC 3 OFFSET CPU 1 MAJOR CPU 1 MINOR CPU 1 BUILD CPU 2 MAJOR CPU 2 MINOR 0 6 840 0 6 DISPLAY BUILD 840 lt CONFIGURATION Network Settings gt USE DHCP No Y IP ADDRESS 192 168 0 6 IP MASK 255 255 255 0 GATEWAY IP 192 168 0 1 DNS IP 192 168 0 1 Unit T s Storage Fault EEPROM Fault RIC Fault Ethernet Fauit Rotay Faut ADC Rail Fault USE DHCP No IP ADDRESS 192 168 0 6 IP MASK 255 255 255 0 GATEWAY IP 192 168 0 1 DNS IP 192 168 0 1 D CONFIGURATION Network Settings Use DHCP NO o CONFIGURATION Network Settings Change IP ADDRESS Saved IP Address 192 168 0 23 119 2 1168 000 023 ENTER to confirm BACK Dlo cancel INFORMATION Hardware Status gt 390 30 Falso False False False False False BACK to exit b VSDGUARD CONNECTION DETAIL qQ lluuuc L 9S9 LOL GI WUIO9 859101 GI WWGSZ LEtS LI A NO SLO S00S13 104LNODdWY HLIM ASN HOT SLAdNI Il 1N344N9 ASVHd 319NOG 13NY3HLIA ys swe SAV 138 LNdLNO VA001 OG OVAOL L YG Z ON VAOO0E OGA0S OVAOSe VY OJ INVITdWODS 9 NOILOAS L LOZ 802 SZN SV S AN BATTERY z s T L CONTAIN ILS NON USER SERVICABLE SLAdNI IVLIDIO HEJ SLAdLNO AlddNsS AER JIVMVA 1 HLYVS G6 OAAVE NI 4H4MOd SWOOS 0S A T3LNI43GNI VS XVIN 13
12. 955 Settings menu can be selected by pressing the ENTER key KAA P Kg Then SET PIN can be selected using the ENTER key If a PIN is already set in the unit the user will be required to enter the current PIN before selecting a new PIN using the arrow CURRENT 265mA TRIP 500mA 500ms Narrowband keys and the prompts to save the change Figure 9 Saving Changes Page 18 of 29 Ampcontrol Pty Ltd VSDguard User Manual VSDB009 Rev 1 April 2014 Once a PIN is set the PIN must be entered to change any setting on the unit The default PIN is 1000 Once the password is entered the VSDguard is unlocked This is denoted by the lock symbol in the bottom right hand corner being open Once the PIN is entered the unit remains unlocked until the user CONFIGURATION General Settings gt navigates to the home screen or the unit times out and Change PIN automatically returns to the home screen Setting the PIN to 0000 turns off the password function Bong O 7 2 6 Operating mode selection o 8 VSDguard has three operating modes ENTER d to confirm Wideband mode The relay will see all currents between BACK to cancel CURRENT 265mA TRIP 500mA 500ms Narrowband 20 Hz and 8 kHz and trips if the true RMS level of leakage current is above the trip level adjustable from 50mA to 5A This mode is Figure 10 Change PIN Screen compliant with AS NZS 2081 2011 and would be used in most cases Narrowband power frequenc
13. Ampcontrol Pty Ltd VSDguard User Manual VSDB009 Rev 1 April 2014 E VSDguard arth Leakage Relay Revision Table O Z I o 26 08 2013 Draft with comments from JEJ TB SC em O e a communications for Version 1 Page 1 of 29 Ampcontrol Pty Ltd VSDguard User Manual VSDB009 Rev 1 April 2014 Safety and other warnings WSA This safety alert symbol identifies important safety messages in this manual and indicates a potential risk of injury or even death to personnel Be alert as your safety is involved Carefully read the message that follows and inform others CAUTION This safety alert symbol identifies important information to be read in order to ensure the reduce any potential risk of injury or death to personnel A correct sequence of work and to avoid damage or even destruction of the equipment and Supplementary information not directly affecting safety or damage to equipment Carefully read the message that follows and inform other relevant personnel ENVIRONMENT Information concerning possible impact on the environment and actions required for prevention and proper response Page 2 of 29 Ampcontrol Pty Ltd VSDguard User Manual VSDB009 Rev 1 April 2014 Copyright notice The Ampcontrol VSDguard described in this document is the property of Ampcontrol Pty Ltd It is furnished under a license agreement and is to be used only in accordance with the terms of the agreement No part of the hard
14. CP y CONFIGURATION Network Settings gt setting should be set to Yes Select No if you wish to manually GR configure a static IP address USE DHCP No IP ADDRESS 192 168 0 6 i IP MASK 255 255 255 0 DHCP Yes Requires no further user configuration Geen POSTE DNS IP 192 168 0 1 Static IP No Allows you to manually set up the required network parameters These include IP address subnet mask and gateway address These are typically specified by your network administrator CURRENT 265mA TRIP 500mA 500ms Narrowband Figure 12 Network Settings The Network Settings page also indicates if the unit can detect an ethernet cable connection and the MAC address of the unit 7 3 Remote access via Ethernet The VSDguard Ethernet connection enables access to real time earth leakage current measurements device parameters and past data and event logs simply by using a web browser VSDguard needs to be connected to a network that the user s browser can reach via HTTP port 80 For information on Ethernet settings see Section 1 2 13 Minimum recommended browser versions for full functionality Microsoft Internet Explorer 9 Google Chrome 20 Apple Safari 5 or Mobile Safari from OS 6 Mozilla Firefox 13 Opera 12 The VSDguard website has five main tabs accessible from the left hand side of the page The first tab is loaded automatically when the page is visited The information shown in the header of the
15. age currents from 20 Hz to 8 kHz e Wideband narrowband and weighted frequency modes e Adjustable trip level and trip times e High resolution 3 2 colour LCD e Last 20 data and event logs can be displayed on the local display e Onboard memory logs last 1000 data logs and 50 events e Ethernet communications allow real time and post event viewing of the system from an internet browser e Continuous toroid connection monitoring VSDguard provides data logging to assist in fault finding On each event trigger the relay stores system data 2 seconds before and 2 seconds after the event including system time earth leakage current phase current and zero crossing of the phase current The VSDguard user interface has four live status screens Bar graph and numeric display of real time RMS current with colour coded trip state RMS current history Plot of the real time current seen by the earth leakage toroid oscilloscope view and 4 Frequency spectrum of the real time current IA The user interface can also view data on the most recent 20 data and event logs VSDguard includes LEDs which can be used to indicate a fault These include a Power On LED Trip LED and Processor Healthy LED Ethernet connection to the VSDguard relay provides the ability to monitor the device parameters and real time measured current from an internet browser All data logs stored on the unit can also be viewed Page 11 of 29 Ampcontrol Pty Ltd VSDguard
16. ately 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 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 Equipment that is found to be damaged or modified away from its published specification must not be used Please contact Ampcontrol if the equipment is suspected to be different than that ordered or if it does not match the published specifications 1 2 Storage after delivery When the equipment is not to be installed immediately proper storage 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 When applicable correct handling procedures must be in place to ensure that any items are moved safely 1 3 Unpacking of equipment The method of packing used will depend on the size and quantity of equipment The following cautions should be interpreted as appropriate CAUTION L
17. d oscilloscope view and 4 Frequency spectrum of the measured current The screens can be scrolled through using the left lt and right gt arrow keys on the keypad 7 2 2 Home screen display colours Figure 6 Earth Leakage Indication Page 17 of 29 Ampcontrol Pty Ltd VSDguard User Manual VSDB009 Rev 1 April 2014 The home screen s side bar and orb change colour depending on the earth leakage current detected to give a simple indication of the state of the unit as shown in Figure 6 The same colour code is used on the bottom left hand corner of every display page for quick reference Red Indicates that the VSDguard relay has tripped and is awaiting reset Orange Shows the unit has measured an earth leakage current of greater than 80 of the trip level but insufficient to trip Green The earth leakage current is significantly below the trip level 7 2 3 Main Menu From the home screen the main menu can be entered by MENU pressing the ENTER key and navigated using the up ft and e CONFIGURATION d Trip Setting e down P keys This page is shown in Figure 7 Any page is Digital Input Settings then selected using the ENTER key Date and Time General Settings Once on a page in a submenu the pages in that same sub ADC Settings menu can be moved between using the left and right gt Klee arrow keys System Trips Digital Input State When a user presses the HELP button on the device a
18. e duration Thresholds Design criteria for the protection devices have been chosen to enable compliance to the touch voltage operating times for systems operating at 50 Hz as described by Figure B1 Page 9 of 29 Ampcontrol Pty Ltd VSDguard User Manual VSDB009 Rev 1 April 2014 B3 Systems at other than 50 Hz Cyclic Frequency Where equipment is installed and operated within systems at other than a constant 50 Hz cyclic frequency the characteristics in paragraph B2 are not immediately applicable In such instances individual calculation to determine requirements at the frequency or frequencies in question will be required Standards AS NZS 60479 1 and AS NZS 60479 2 should be reference in relation to the effects upon the human body of other supply frequencies What this means is that when VSDs or other non 50 Hz sources are used in a mining electrical system then the standard approach needs to be interpreted to ensure that protection is adequate The key factors to consider are as follows 1 3 The sensitivity of the human body to electric shock varies with frequency In general for a given exposure time the allowable touch voltage magnitude increases with frequency For example at 10 kHz the let go voltage is about 5 times the level at 50 Hz When EMC filters are used this forms a path for earth currents alternative to the NER When considering touch potentials at a mobile machine for example strictly speaking the
19. e relay end If both ends are earthed the possibility exists for the shield to become an earth loop having finite resistance and injecting noise into the toroid leads 9 9 9 Toroid monitoring signal The VSDguard relay continually monitors for the presence of a toroid When the toroid sees no signal the VSDguard relay injects a test current through the toroid primary The test signal is every two seconds and may be seen on the live screens and data logs Page 15 of 29 Ampcontrol Pty Ltd VSDguard User Manual VSDB009 Rev 1 April 2014 6 TESTING AND COMMISSIONING Prior to being put into service the electrical protection system must be correctly commissioned This manual does not cover system commissioning the scope of commissioning tests should be determined during the risk assessment or FMEA covering the design of the electrical protection system The following points can provide guidance on checking the correct operation of VSDguard during commissioning This is not intended to provide an exhaustive commissioning checklist but should be considered to be a minimum Ensure that the system is connected in accordance with the manufactures instructions and conforms to the intended design In the case of monitoring the NER circuit ensure that no alternate earth paths exist that bypass the NER Perform an earth continuity test by injecting a current through the primary window of the VSDguard toroid and verify that the unit behaves
20. f data RMS graph In this view Root Mean Square RMS values of the measured current are shown The user is able to select the time interval on the graph by selecting from the buttons below the graph FFT graph This plot shows the frequency content of the past 80ms worth of instantaneous measurements For information on navigating the interactive graphs see Section 7 3 6 Page 22 of 29 Ampcontrol Pty Ltd VSDguard User Manual VSDB009 Rev 1 April 2014 7 3 2 Data Logs This tab is similar to the Live Graph tab in that it allows inspection of measured earth leakage currents However in this tab historic measurements from data logs stored on the VSDguard relay are shown refer also to Section 7 2 9 Each data log is centred on a trip or log event i e the log covers the 2 seconds before and after the log initiation making the command instant at the centre of the graph Once a particular log is selected from the list in the drop down menu Oscilloscope RMS and FFT views are available as they are in the Live Graph tab The RMS view is calculated using a running window of 300 data points The FFT graph corresponds to the selected 80ms of signal To select another window over the recording the slider below the plot a small oscilloscope plot of the signal is provided to indicate where in the recording the data is being analysed Data logs can also be downloaded by clicking on the Download Log button which exports the data in an
21. help CURRENT 265mA TRIP 500mA 500ms Narowband screen will be shown giving contextual information on the current view The up ft and down keys scroll the help screen information An example of this is shown in Figure 8 To exit the screen the user is instructed to press the BACK button i Figure 7 Main Menu Screen On home screen plots the up 1 and down arrow keys aldi zoom the horizontal scale The vertical scale automatically Use the arrow keys to set the date and time for the device When you have completed the changes scales to suit press ENTER on the keypad to SAVE AND COMMIT I these changes 7 2 4 Saving changes Before any changes are saved to the settings on VSDguard the user will be presented with a screen displaying the user BACK Oto exit changes in blue as shown in Figure 9 SAVE AND COMMIT CURRENT 265mA TRIP 500mA 500ms Narrowband 8 CHANGES should be selected to save the change or CANCEL for the unit to ignore the changes 7 2 5 Personal Identification Number PIN The VSDguard relay can be set with a PIN to prevent Figure 8 Contextual Help Screen unauthorised changes being made to the settings of the unit It lt CONFIGURATION Network Settings gt is found under CONFIGURATION General Settings SET Q SAC AND COMMIT CHANGES 0 PIN and is shown in Figure 10 USE DHCP No IP ADDRESS 192 168 0 6 From the main menu the CONFIGURATION General IP MASK 955 955
22. ication labels v Check that no modifications have been carried out on installed equipment 8 1 2 Detailed inspection A more detailed inspection would include all of the elements of a visual inspection plus some checks that cover the integrity of connections fixtures and fittings such as verifying that i Equipment housings wall boxes and other mechanical fixtures are secured tightly in place This includes the lids of terminal boxes tightness of cable glands the integrity of wall box mounting and security of equipment fixing ii All electrical connections are secure with no loose screw terminals 9 2 Equipment maintenance ARNO The VSDguard relay has no user serviceable parts All repairs must be carried out by Ampcontrol personnel only If a fault develops return the equipment to Ampcontrol for repair lt is essential that no attempt be made to repair the equipment as any attempt to dismantle or repair VSDguard can seriously compromise the safety of the unit It is recommended that the electrical protection system incorporating VSDguard be subject to regular functional tests at intervals determined by risk assessment or FMEA The intervals typically coincide with periodic maintenance checks and will cover but not be limited to tests such as earth continuity tests 9 3 Disposal VSDguard should be disposed of responsibly as per typical electronics waste ENVIRONMENT VSDguard and its associated equipment must not be trea
23. le 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 toroid would have all of the flux from each wire contained in the core and so would accurately add the opposing fluxes to get a net result of zero A real toroid 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 a 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 toroid where none would arise if the device were ideal The size of the error may vary from toroids of the same type because of slight differences in the core and the symmetry of the winding Problems caused in this way increase as the toroid size increases as currents increase and symmetry decreases Nuisance tripping tends to occur when the total current rises such as when a large motor is started The following guidelines would help to avoid such problems The VSDguard relay is designed for use with Ampcontrol 100 1A EL5005 series Toroids They are available with window sizes 25 60 amp 112mm A 112mm split toroid is also available 5 5 2 Phase monitoring toroid Optional VSDguard has provision for the connection of a toroid monitoring a phase current in the system by connectio
24. llation by protecting the outlet supplying power to a machine In this application the relay operation time is typically set at instantaneous The three power phases are passed symmetrically through the toroid If there is no earth fault present the vector sum of the currents in a three phase supply is zero If current from any phase flows to earth the toroid flux becomes unbalanced The toroid produces an output which trips the relay A test current is injected through the window of the toroid to test the operation of the relay Series neutral protection is the backup protection method and may have an operation time up to a maximum of 500ms In this method the neutral to earth connection is passed through the toroid An earth fault on any of the phase conductors causes an earth current which returns through the neutral to the star point of the transformer and is detected by the toroid A test circuit can connect a test resistor between a phase and earth or inject a current through the toroid as previously described The test resistor to earth method is recommended with this type of protection as this test also proves the neutral to earth connection Page 14 of 29 Ampcontrol Pty Ltd VSDguard User Manual VSDB009 Rev 1 April 2014 5 5 1 Earth leakage toroids Toroids current transformers are not ideal devices and if correct procedures are not followed during installation nuisance tripping can result Consider for example a sing
25. markers Page 23 of 29 Ampcontrol Pty Ltd VSDguard User Manual VSDB009 Rev 1 April 2014 9 SERVICE MAINTENANCE AND DISPOSAL 9 1 Equipment service VSDguard requires no internal servicing during its normal operating lifetime There are however a number of external system based checks that should be made on a regular basis These routine inspections must be carried out by suitably trained people with knowledge of VSDguard and the systems into which it is fitted Routine inspections may take the form of either simple visual only checks or more detailed checks 8 1 1 Visual only inspections A basic visual inspection will focus on looking at the installation for signs of physical damage water or dust ingress as well as the condition of cables and labels This type of inspection may involve opening cabinets to gain access to the equipment This level of inspection may also include cleaning displays that have become obscured by dirt Observations would typically be I Check that equipment enclosures cable trays conduits etc are in good order with no physical damage li Check that sealed wall boxes are free from water and dust ingress Door seals are in good condition lil Check that connected cables are free from cuts abrasions and obvious signs of damage Cable restraints are in good order and correctly fitted iv Check that labels on equipment wall boxes and cables are present and in good condition especially certif
26. n e Modifications must not be made to any part of VSDguard As supplied the unit is built to and complies with standards against which it has been certified e Complete and accurate records of the installation must be kept as part of the site installation Page 12 of 29 Ampcontrol Pty Ltd VSDguard User Manual VSDB009 Rev 1 April 2014 5 3 Mechanical arrangement 5 3 1 Enclosure VSDguard is housed in a metal enclosure rated at IP20 The dimensions of the VSDguard relay are shown in Figure 2 The front panel is 155mm wide by 155mm high The unit is 107mm deep from the front panel to the rear of the enclosure VSDguard is designed to be panel mounted through a 135mm x 135mm cut out When panel mounted VSDguard is rated at IP55 Figure 2 VSDguard dimensions Page 13 of 29 Ampcontrol Pty Ltd VSDguard User Manual VSDB009 Rev 1 April 2014 5 4 Electrical connections Figure 3 shows the typical connections to the VSDguard relay which are made at the rear of the unit Parameter Storage Trip Reset Test CCT Lien Phase es Cura Aasu erer ido gt VSDguard c Alternative Installation Figure 3 VSDguard connections Se 5 5 VSDguard current transformers The VSDguard relay has been designed for compliance to AS NZS 2081 2011 for use on earth fault limited systems There are generally two locations where VSDguard may be installed Core balance protection performs the primary protection in an insta
27. n of a Suitable toroid with a secondary rating of 5A No settings are required within the unit for the connection of this additional toroid but the ratio of the toroid should be recorded so that when data is analysed the actual phase current can be calculated 9 9 3 Toroid selection i Select the smallest internal diameter toroid which will allow the cables to fit through Avoid very large toroids gt 200mm aperture or toroids with square apertures li Only use approved toroids specified by Ampcontrol as these have been designed to minimise problems 5 5 4 Toroid installation guidelines i Keep cables as close to the centre of the toroid as possible Do not tie them to one side of the toroid Remember to aim for symmetry li Do not bring the cables back past the toroid within one diameter of the toroid Trying to cram cables into a small space reduces symmetry and may lead to problems iii Avoid placing the toroid near any device that produces magnetic fields This includes bus bars transformers or other cables Try to maintain several toroid diameters clearance iv Many small cables tend to be worse than say three large ones Try to position the toroid in the circuit with this in mind v Toroids used for core balance earth leakage protection cannot have bus bars passed through them vi To prevent possible nuisance tripping it is suggested that the conductor screen of the earth leakage toroid should be earthed one end only th
28. ng CANBUS address 155W x 155 H x 113 D mm 135 W x 135 H mm 0 60 C IP20 IP55 Description VSDguard Wideband earth leakage relay Toroid EL500S 25mm ID Toroid EL500S 60mm ID Toroid EL500S 112mmID 112mmID 101653 Toroid Split Page 25 of 29 oz r a 2 Sa d ES D C Da O NI A le APPENDIX A DRAWINGS u 6 9 _ SYAO MOITOS U pa 18942 B um 81H el 401 583 3 HITUH NI SN0ISN3 Hp EN ere 104LNOJ4HY W0J4 LOOVUSA AT TENUT mrs neo sir a PET INIK3ONYBHY TAINAD O ro Rama immens S PEN EA Jed ul paan posdas 39 you ysnw Ek EU buy Ta pay huye HLS gt 00 4Y3NI7 u U dy n D U SA w 505 Joog 0 443117 ap _ 2 lbl G22 000 GC HBY 104 LNOJd HN 40 A 1934094 VA duaa LIVROS S9INOHLOTIITOHLNOJdUY 201 are H34 eren SIM seat 2 8X887 UJLEJ PIERBOSA v RR ara fu Sb e e o e e o S 9 O Oh B O O a dr o PS ORC OM O ka Ze a OPA V 77 e o ee 0 Do 0 Co BRO BNN RS ORO One Wee AST AS PSCC pe O O ORO SLO O OVEJ SO II 8 CO OST Be O ORO Ya Oo MONONOKE O OI N OR Moke lo e dd VSDGUARD DISPLAY NAVIGATION MAP HOME SCREEN uli CZO lt LIVE GRAPH AMS CONFIGURATION TRIP LEVEL TRIP DELAY D CONFIGURATION Trip Settings Change TRIP DELAY Saved Trip Delay 150ms Min 50ms Max 1500ms Increment 50ms EEN ENTER to confirm BACK
29. page is continuously updated There are also two indicator lights on the right hand side of the page for further status information e _ If the unit trips the indicator labelled Tripped changes to red The header block and page background also change to red Page 21 of 29 Ampcontrol Pty Ltd VSDguard User Manual VSDB009 Rev 1 April 2014 e The Network indicator flashes green every time a network request is made to the unit If a network request fails this indicator will flash red 7 3 1 Live Graphs The live graphs in this tab are refreshed every second provided the Live Update button above the plots is activated default is ON Otherwise the last plot shown is held which can allow for better inspection of the data shown using the interactive features of the plots described in Section 7 3 6 Figure 13 shows the VSDguard live graph interface VSDguard Web Interface Live Graphs wl Graphs li pes AMPCONTROL Live Graphs i nt Logs 3 l Network Tripped ha ra E d Data Logs Event Logs D Device Info FFT window centred on 42 1 ms Widih 82 ms About Figure 13 VSDguard live graphs There is also a Help button below the plots which allows access to online help information In the live tab three types of graphs can be shown OSC Oscilloscope graph Plots the instantaneous values of earth leakage current measured by VSDguard At every update it displays the last 80ms o
30. peration Page 7 of 29 Ampcontrol Pty Ltd VSDguard User Manual VSDB009 Rev 1 April 2014 3 MINING EARTH LEAKAGE PROTECTION WITH VARIABLE SPEED DRIVES The mining working environment presents a range of unique challenges for electrical distribution systems due to the equipment used and associated hazards As such various protection schemes have evolved to prevent damage to equipment and injury to personnel In particular these include a Earth fault current limitation usually consisting of a resistor connected between the supply transformer star point and earth commonly referred to as a Neutral Earthing Resistor NER b Earth continuity monitoring devices c Earth leakage protection devices d Earth fault lockout protection As described in Appendix C of AS NZS 4871 1 2012 the protection scheme is intended to ensure that when persons are exposed to touch potentials the level of voltage and time exposed before protection systems trip is limited to an acceptable level The acceptable levels are given in Figure C1 of the standard for 50 Hz touch voltages CAUTION Relays designed to operate on earth fault limited systems are not suitable for direct personal protection These protection systems were originally devised to protect against touch potential hazards caused by earth fault currents driven by the power supply 50 Hz Consider for example that an earth fault occurs in a mobile machine powered by a trailing
31. pplications Power EMC Filter OW Motor aa al Cabled Earth NER Z Low impedance Se High impedance Interference Feed Transformer high frequenc return path e GE I current 3 2 Improving protection The design of earth leakage relays used in mining applications in Australia and New Zealand must comply with AS NZS 2081 The latest version of this standard AS NZS 2081 2011 better recognises that system protection needs to be assessed in accordance with AS NZ 4871 1 2010 and with the changes in the mining electrical environment The following extracts from AS NZS 2081 2011 provide some key statements of interest 1 1 Scope Whereas this standard is based upon 50 Hz supply systems it is envisaged that the equipment described may also be installed in systems with higher lower or variable frequencies or in dc supplied systems AS NZS 60479 Part 1 and 2 should be referenced for consideration of the effects of current at other supply frequencies upon the human body Appendix B The diversity of operating conditions and equipment addressed by this Standard precludes reliance solely on explicitly prescribed trip levels or fault current levels and their duration in order to ensure a safe working environment Rather the onus is placed on the system designer to ensure appropriate touch voltage operating times when integrating the protection devices addressed by this Standard B2 Voltag
32. s a path for the earth currents that represents an alternative path to the NER as shown in Figure 1 below In fact it is the intention of the filter to provide this alternative path for the high frequency currents that flow through the motor and cable stray capacitances to earth under normal conditions They will also provide an alternative path under fault conditions particularly if the fault is driven by the high switching frequency drive output Page 8 of 29 Ampcontrol Pty Ltd VSDguard User Manual VSDB009 Rev 1 April 2014 It has also been shown that when one or more drives and filters are in use and an earth fault occurs there can be circulating currents between the drives and filters and or the fault location The fault current magnitudes may then greatly exceed the nominal current limitation value typically 5A determined by the NER These large currents may cause touch potentials that greatly exceed the expected values 3 Most earth leakage protection relays approved for use in mining applications are designed to detect 50 Hz currents not dc or high frequency currents so that the relays may not trip or if they do trip they may take longer than expected The overall result is that with standard earth leakage protection relays and electrical system assessments based only on consideration of faults driven by the supply system 50 Hz protection performance is unlikely to be adequate when variable speed drives are used in mining a
33. ted as general waste By ensuring that this product is disposed of correctly you will be helping to prevent potentially negative consequences for the environment and human health Page 24 of 29 9 SPECIFICATIONS Relay supply Supply Voltage Power consumption Trip level and time settings Trip current level Trip operation time Relay contacts fail safe Inputs Inputs 1 5 Input 6 Earth Leakage Toroid CT Phase Monitoring Toroid CT 110VAC Communication Ethernet Cable Connection CANBUS Dimensions Overall Cut out Operating conditions Ambient operating temperature IP Rating IP Rating installed 9 1 Equipment List Ampcontrol part number 162129 115437 101658 101656 Ampcontrol Pty Ltd VSDguard User Manual VSDB009 Rev 1 April 2014 24VDC 25 approx 12W 50mA 5A 50mA 1A in 50mA increments 1A 5A in 100mA increments Instantaneous 500ms in 50ms increments 1xCO Mechanical 6A 250Vac 50Vdc 300VA cos 1 1xNO Solid State 2 9A 110Vac dc 100VA cose 1 Programmable Trip Log functions Manual trip reset by external pushbutton Toroid 100 1A Ampcontrol EL5005 series recommended Optional 5A secondary toroid for monitoring a selected phase current Optional Phase current zero crossing detection 10BASE TX or 100BASE TX accessible via http using a standard web browser CATS UTP For future expansion dip switches used for setti
34. the user should become completely familiar with the safety requirements and correct operating procedures detailed in this user manual Please check the Ampcontrol website for the latest revision of this User Manual Page 3 of 29 Ampcontrol Pty Ltd VSDguard User Manual VSDB009 Rev 1 April 2014 TABLE OF CONTENTS Salely and other WA MIN edu saabl zs O on 2 Sol A One O P O P ated al oe 3 Me Clan ett 3 Before you Benn a BUK VOL een eee 3 ly RECEMNGAND STORAGE o rod ono 6 SR RECEIVING uu O RE u u eee 6 Pao AAPP uo 6 E o AA AA AA AA 6 ll GENE RAES EE 7 SEET Ee 7 A zana na naa 7 ZZ Daley COMMUNICA OM irte 7 22 SAE USE OF QUIM su sia u tes k E di 7 221 Change tO a o do 7 22 2 EQUIDMENUKMOWICUGG ina 7 PAP AA AWA WA WA obora 7 JI Si gt u i 55 uu A 7 Z 25 le GE E 7 3 MINING EARTH LEAKAGE PROTECTION WITH VARIABLE SPEED DRIVES 8 co o 8 9 2 Improviia Bel tee Nr rzi dczna ms 9 4 AMPCONTROL VSDguard EARTH LEAKAGE RELAY 11 Ox INS TALLA MON apli 12 REENERT e used on rh so teta 12 5 2 Mandatory installation practice a caia 12 9 9 Mechanical arandelas 13 SE GE 13 O74 ElCCHiICal Beeler TEE 14 EISE HEH REES 14 90 EE a e asi 15 5 5 2 Phase monitoring toroid Optional 15 29 9 OO eN aaa 15 9 9 4 Toroid installation guidelines
35. tion The equipment may only be used within the design parameters The instructions within this manual must be observed as part of 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 Unauthorised changes made to the hardware or operating firmware will void the manufacturer s warranty and may compromise the conditions of compliance the integrity of the system into which it is installed and other connected equipment 2 2 2 Equipment knowledge Experience with or understanding of this equipment is essential for the safe installation operation and removal of the equipment If in doubt contact Ampcontrol immediately 2 2 3 Manual handling 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 enclosures and gloves should be worn 2 2 4 Installation Correct operation and safety depend on the 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 equipment functioning correctly it is highly recommended that all safety functions of VSDguard are routinely tested to ensure correct o
36. ttings page Periodically Logging initiated by the VSDguard software at a regular interval can be set in the CONFIGURATION General Settings Periodic Log Time Alarm level logging The user selects a trip level and delay below that of the unit s main trip settings typically those of the downstream protection This allows the user to see the operation of the downstream protection A cool down time can also be selected to prevent the unit from continuously logging 7 2 10 Viewing historic data VSDguard stores the last 1000 data logs and 50 events The last 20 of each of these logs can be viewed from the user interface in the HISTORIC DATA menu The Event Log shows the following statements for user changes next to a time stamp System Powered Up When the unit received power following a normal shut down System Powered Down When the unit had power removed in a normal shut down Loss of RTC Detected The Real Time Clock has been lost Trip Reset Local When the unit has been reset after a trip using the Local Trip Reset Earth Leakage Trip s due to detection of an earth leakage current at or exceeding the trip Ext Input Trip Unit tripped due to a signal from an external input Periodic Log Periodic log has been taken Settings Changed User has changed settings Relay failed to close Relay contacts failed to close when expected Relay failed to open Relay contacts failed to open when expected The Event Log shows a list of past logs for the
37. ware or documentation may be reproduced transmitted transcribed stored in a retrieval system or translated into any language or computer language in any form or by any means without prior written permission of Ampcontrol Pty Ltd Disclaimer While every effort has been made to assure the accuracy and clarity of this document Ampcontrol Pty Ltd assumes no liability resulting from any omissions in this document or from misuse of the information obtained herein The information in this document has been carefully checked and is believed to be entirely reliable with all of the necessary information included Ampcontrol Pty Ltd reserves the right to make changes to any products described herein to improve reliability function or design and reserves the right to revise this document and make changes from time to time in content hereof with no obligation to notify any persons of revisions or changes Ampcontrol Pty Ltd does not assume any liability arising out of the application or any use of any product or circuit described herein neither does it convey license under its patent rights or the rights of others Before you begin Ampcontrol would like to take a moment to thank you for using the VSDguard wideband earth leakage relay To become familiar with this product and to ensure correct operation it is recommended that you take the time to read this user manual thoroughly WARNING To ensure the correct and safe operation of this equipment
38. y mode The relay will see all currents between 20 Hz and 100 Hz and trips if the true RMS level of leakage current is above the trip level adjustable from 50mA to 5A This mode operates as a traditional earth leakage relay Weighted frequency mode This mode sets a modified form of wideband operation for demanding applications these settings allow increased trip levels at higher freguencies to take into account the reduced sensitivity of the human body to touch potentials at these frequencies G CONFIGURATION Trip Settings l Change TRIP DELAY The operating mode can be selected on the CONFIGURATION Saved Trip Delay 150ms Trip Settings Trip Mode page Min 50ms Max 1500ms Increment 50ms 7 2 7 Trip level and time selection VSDguard has selectable trip levels of 50mA 1A in 50mA increments and 1A 5A in 100mA increments ms TE l ENTER to confirm The trip time is selectable from instantaneous 500ms in 50ms BACK Sto cancel increments CURRENT 265mA TRIP 500mA 500ms Narrowband o The trip level and operating time of the VSDguard relay can be set Figure 11 Configuration Trip Settings page from the CONFIGURATION Trip Settings menu as shown in Figure 11 7 2 8 Resetting a Trip Trips can be reset in three ways Local Reset If the unit is password protected the password must be entered to reset the trip The local rest option is only available if WSDguard was set where CONFIGURATION
39. ystem design It is important to understand how VSDguard is intended to interact with other equipment within a system For safe and reliable use it is critical that VSDguard s operation is not compromised by incompatibility with connected equipment Modifications of any form to VSDguard are prohibited VSDguard has been designed and manufactured in compliance with the requirements of AS NZS 2081 2011 If modifications of any form are made to the relay the conditions of compliance will no longer be valid and the equipment will no longer be fit for use If any modifications or damage to the relay is evident do not use the equipment and contact Ampcontrol for advice 5 2 Mandatory installation practice The following information must be adhered to when installing the VSDguard relay Failure to adhere to this information may give rise to unsafe operation and could render the product invalid against its certificate Using VSDguard in a manner that exceeds its electrical functional or physical specifications or in a way that is contrary to its operating restrictions may create risks to personnel and or equipment resulting in injury or death e The VSDguard relay must be powered with the specified voltage e The installation of VSDguard must be carried out by suitably trained and qualified personnel e Certification and identification labels fixed to the VSDguard relay must not be damaged removed or covered before during or after installatio
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