ECDB005 ECD User Manual
Contents
1. 5 5 jeuondo dnoiBjonuoodure S822 XH Vd NOH3AVO 7417 59140819373 TOHINOOdAV i 3oud Sjuejuoo Jo 10 wed peonpoidei eq jou snus 35010 2 171 042 000 SE NEV Aeg ot 9 888 506 20 3 008p 506 20 7IOH1NOOdMWV 30 ALH3dOHd JHL SNIVIW3H SIHL HHH euog 2 99 Qo VAZE S IVNIAS31 SI NON x o eq sn 10 2009093 2003003 995 SI juo siejeure Jed 9 qe S Jo Jojoej euin e 07 ANZ 09 od vu o 82 on S sieune S AB aiva SI sii SI NON 34 dv VN 61190 9 dv VN L yun jo uo jeues pue uoneotnuepi 991 uoneuuojul JO2. 1 APPENDIX B APPROVALS 1 Page 4 of 20 Ampcontrol CSM Pty Ltd 35 000 770 141 AMPCONTROL ECD User Manual gt Rev 1 August 2014 1 SAFETY AND OTHER WARNINGS For safety reasons the ECD must be installed operated and serviced only by competent personnel Read and understand this instruction manual completely before installing operating or servicing this equipment Failure to install or operate this instrument in accordance with the instructions contained in this manual may result in non conformance to the conditions of certification and create hazardous operating conditions To comply with the Conditions of Certification ensure full serviceable life of the WARNING product and avoid nullifying the warranty it is essential to exercise great care with the installation use and storage of the system components Failure to comply with the Conditions of Certification may seriously compromise the integrity of the system and or its components and the consequence could be fatal The user must ensure that the Conditions of Certification outlined in the certificate are met or the certificate and the IS rating will not be valid 1 1 Safe Use of Equipment The equipment supplied has been manufactured according to the state of the art and designed to ensure a safe operation The equipment may only be used within the d
3. 1X6 eu urejuoo siege SUWWAZEL 50 1 1 1 1 1 1 1 1 S UON 1 1 1 1 1 1 1 6 12 6 pue Weiss 103 00Q93 014 Page 2 of 2 3 APPENDIX APPRO AMPCONTROL Ampcontrol CSM Pty Ltd ABN 35 000 770 141 ECD User Manual Rev 1 August 2014 IECEx Certificate Conformity INTERNATIONAL ELECTROTECHNICAL COMMISSION IEC Certification Scheme for Explosive Atmospheres for rules and details of the IECEx Scheme visit www iecex com Certificate No TSA 13 0004X issue 0 Certificate history Status Current Date of Issue 2013 06 21 Page 1 of 3 Applicant Ampcontrol CSM Pty Ltd 7 Billbrooke Close Cameron Park NSW 2285 Australia Electrical Apparatus Optional accessory ECD Earth Continuity Relay Type of Protection Ex ia when 1 Im not connected Marking Ampcontrol ECD Ex ia Ta 20C to 65 IECEx TSA 13 0004X S No Approved for issue on behalf of the IECEx Debbie Wouters Certification Body Position Acting Qualit
4. Earth Continuity Protection Relay User Manual Exia l 20 C lt lt 65 IECEx 5 13 0004 166351 Revision 1 August 2014 Designed and manufactured in Australia by Ampcontrol CSM Pty Ltd Ampcontrol CSM Pty Ltd ABN 35 000 770 141 AMPCONTROL ECD User Manual gt Rev 1 August 2014 This safety alert symbol identifies important safety messages this manual and indicates a potential risk of injury or even death to the personnel When you see this symbol be alert your safety is involved carefully read the message that STOP follows and inform other operators CAUTION This safety alert symbol identifies important information to be read in order to ensure the correct sequence of work and to avoid damage or even destruction of the equipment and reduce any potential risk of injury or death to the personnel Carefully read the message that follows and inform other relevant personnel c Supplementary information not directly affecting safety or damage to equipment y Information concerning possible impact on the environment and actions required for prevention and proper response ENVIRONMENTAL ALERT Page 2 of 20 Ampcontrol CSM Pty Ltd ABN 35 000 770 141 AMPCONTROL ECD User Manual lt gt Rev 1 August 2014 Copyright Notice The Ampcontrol ECD descri
5. 7 1 2 Latching Switch Position Function Off left Latching mode disabled Trips will be automatically reset after the fault has been cleared On right Latching mode enabled Trips must be manually reset after the fault has been cleared 7 2 Rotary Switches Configuration 7 2 1 Trip Level selection The user can select the trip level via one of the rotary switches at the front of the unit The trip level represents the threshold for the series resistance If the resistance is measured to be greater than this threshold 30 a trip will occur The allowed values for the trip level setting are 100 150 200 250 350 and 450 The shunt resistance trip level is fixed at 1 25kQ A trip will occur if the pilot to earth resistance is detected to be below this level 7 2 2 Trip Time Selection The user can select the trip time via one of the rotary switches at the front of the unit The trip time represents the delay after which a trip condition has occurred when the ECD relay will de energise The allowed settings for the trip time are 50ms 100ms 200ms 300ms 400ms and 500ms 7 3 Indication LEDs 7 3 1 Status Green LED state Indication Off Power Off Flashing Power is ON and ECD is running relay contacts switched to the non default state On Power is ON but ECD is not running relay contacts in the default state 7 3 2 Healthy Green LED state Indicati
6. 13 Pilot IS Pilot connection protected by internal IS barrier 14 IS Earth IS Earth 15 IS Earth IS Earth 16 IS Earth IS Earth Page 11 of 20 A Ampcontrol CSM Pty Ltd 35 000 770 141 AMPCONTROL ECD User Manual lt gt Rev 1 August 2014 4 2 1 Supply The appropriate power supply is dependent on the ECD model The ECD relay is available as either a 24Vdc 20 or as a 48Vdc 20 model 4 2 2 Pilot Terminal The pilot terminal is an IS terminal protected by an internal IS barrier through which the ECD performs resistance measurements Typically the pilot terminal will be connected to the pilot conductor of a trailing or reeling cable The load end of the pilot conductor will then be terminated with a diode to earth creating a return path through the earth conductors of the cable to the main earth point of the outlet and then to the ECD s IS earth terminals The primary function of the ECD relay is to verify the resistance of this pilot earth loop is below a selectable level 4 2 3 IS Earth Terminals The IS earth terminals provide the earth connection for the ECD s internal IS barrier as well as the earth reference for the pilot resistance measurement These terminals must be connected directly to the outlet s main earth point by 3 x 1 5mm2 cables No other connections are permitted 4 2 4 Reset Optional This is an active high input that allows ECD trips to be reset in latching mode after the fault ha
7. PFDave with proof test interval 1 year See below for PFD V s proof test interval Probability of Dangerous 2 6x10 Failure Per Hour Systematic Safety Integrity Route 15 not assessed Systematic Capability Compliance Approach Systematic Capability No assessed Overall SIL Capability SIL2 excluding systematic integrity Test Interval months ECD 48V Module ECD 24 Module Probability of Failure on Demand PFD 1001 Marcus Punch _ TUV FSExpert Machinery 10 154 10 FSEng SIS ID 735 07 CPEng NPER RPEQ Director Per AS61508 2 2011 Clauses 7 4 2 and 7 4 4 21 FIT 1 failure per billion hours or a failure rate of 1x10 hour Per AS61508 2 2011 Clauses 7 4 2 and 7 4 4 Per AS61508 2 2011 Clause 7 4 3 Overall SIL capability is determined by the minimum SIL indicated by the above parameters
8. and the measurements can no longer be trusted A power cycle is needed to reset this state If this happens repetitively please contact Ampcontrol as the unit may be damaged The ECD continuously checks the health of its internal circuitry If these checks fail the ECD will show an internal fault by flashing all LEDs and returning the relay contacts to the default position 7 5 Starting the ECD When first powered the ECD will begin checking its internal circuitry as well as the pilot circuit If no faults are detected within 1 7s the ECD will be ready to start e f remote start mode is not selected the ECD will automatically start energising its output relay e If remote start mode is selected the ECD will wait for the start button to be pressed After a trip has occurred and the fault cleared the ECD can be reset and re started depending on the configured modes Latching Mode Remote Start Starting the ECD Mode No No Automatic re start 1s after the fault has been cleared No Yes Press the start button a minimum of 1s after the fault has been cleared Yes No Automatic re start immediately after manual reset Yes Yes Press the start button after manual reset Page 17 of 20 Ampcontrol CSM Pty Ltd 35 000 770 141 AMPCONTROL ECD User Manual gt Rev 1 August 2014 8 SERVICE MAINTENANCE amp DISPOSAL 8 1 Equipment Service The ECD requires no internal servicing during
9. 2 1 Receiving All possible precautions are taken to protect the equipment against damage or losses during shipment however before accepting delivery check all items against the packing list or bill of loading If there are shortages or evidence of physical damage notify Ampcontrol immediately Notify Ampcontrol within 7 days maximum in case of shortages or discrepancies according to the packing list This action will help ensure a speedy resolution to any perceived problems Keep a record of all claims and correspondence Photographs are recommended Where practicable do not remove protective covers prior to installation unless there are indications of damage Boxes opened for inspection and inventory should be carefully repacked to ensure protection of the contents or else the parts should be packaged and stored in a safe place Examine all packing boxes wrappings and covers for items attached to them especially if the wrappings are to be discarded 2 2 Inspection Equipment that is found to be damaged or has been 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 2 3 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 preferabl
10. Start Button timed out trip will occur The start timed out fault is automatically reset once the start resistor is detected A manual reset is not required 6 4 Latching mode Latching mode can be selected via the DIP switches at the front panel When a fault occurs in latching mode the trip will be latched preventing the ECD from starting even if the fault is cleared until a manual reset occurs will be latched If another fault occurs while the previous trip is still latched the LED In latching mode if a fault occurs the corresponding LED will be turned on and the trip corresponding to that fault will flash 6 5 Manual reset procedure To use the reset function the user must connect a switch typically a NO momentary pushbutton between the RST input and the positive of the supply see Electrical Connections section 4 3 for more information In latching mode the user must manually reset the unit after a fault has occurred The procedure is as follows 1 Clear the fault 2 Pressthe reset button for a minimum of 500ms Page 15 of 20 lt o AMPCONTROL 7 OPERATION SUMMARY 7 1 DIP Switches Configuration 7 1 1 Remote Start Switch Position Function Off left Remote Start disabled A remote start button with a 100Q resistor must not be installed On right Remote Start Enabled A remote start button with a 100Q resistor must be installed
11. agram 1 7 2886 Layouts Certificate issued Test Fe A Y A 1 Page 1 of 1 Sv Ampcontrol CSM Pty Ltd ABN 35 000 770 141 AMPCONTROL ECD User Manual gt Rev 1 August 2014 Marcus Punch Pty Ltd Risk and Reliability Declaration of Conformity ECD 120613 Marcus Punch Pty Ltd was engaged by Ampcontrol Group to perform a safety integrity verification on their ECD 24V and ECD 48V Earth Continuity Relays against the requirements of AS61508 2 2011 The verification was conducted according to the traditional probabilistic deterministic route The details of the analyses and reviews that lead to these findings are provided in our report AMP 13 06 A 0 ECD Earth Continuity Relay Failure Modes and Effects and Diagnostics Analysis FMEDA and Safe Failure Fraction SFF Report dated 12 June 2013 ECD 24V and ECD 48V Earth Continuity Relays Drawing No s ECDE001 Rev 1 002 2 and ECDE003 1 Earth Continuity Protection Description Finding Conclusion Hardware Safety Integrity Route 14 Compliance Approach Architectural Constraints SFF 98 6 HWFT 0 Type B SIL2 Random Hardware Failures 1 9 10 hour or 19 000 FITS per AS61508 2 Appendix C MTTF 54 046 hours or 6 1 years FMEDA Agu 2 6x10 hour or 260 FITS MTTF y 3 797 670 hours 433 years Probability of Failure on 1 2x10 Demand
12. alling a resistor which is 1KO or less or creating a short circuit between the pilot conductor and earth and verifying that the ECD relay trips within the selected trip time and indicates a short circuit fault 5 3 Remote Start Function The remote start function can be verified by repeating the two previous tests in the remote start mode with the remote start resistor installed Page 13 of 20 Ampcontrol CSM Pty Ltd 35 000 770 141 AMPCONTROL ECD User Manual gt Rev 1 August 2014 6 ASINZS 2081 PROTECTION FUNCTION EARTH CONTINUITY The primary function of the ECD relay is to provide Earth Continuity protection in accordance with AS NZS 2081 2011 This protection ensures the integrity of the earth connection between an outlet and a load via the pilot conductor in the cable In a typical installation the ECD s pilot terminal will be connected to the pilot conductor of a trailing or reeling cable The load end of the pilot conductor will then be terminated with a diode to earth creating a return path through the earth conductors of the cable to the main earth point of the outlet and then to the ECD s IS earth terminals The ECD measures the resistance of this pilot earth loop series resistance and the pilot resistance to earth shunt resistance If the pilot earth loop is not healthy series resistance greater than the selected trip value or shunt resistance lower than 1 25kO a trip occurs which de energises the out
13. bed 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 hardware 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 We would like to take a moment to thank you for purchasing the ECD Earth Continuity Relay WARNING To become completel
14. certification e Complete and accurate records of the installation must be kept as part of the site installation Page 8 of 20 Ampcontrol CSM Pty Ltd 35 000 770 141 AMPCONTROL ECD User Manual gt Rev 1 August 2014 4 ECD RELAY OVERVIEW The ECD is an intrinsically safe electrical protection relay designed for operation in underground coal mining applications It provides earth continuity protection in accordance with AS NZS 2081 2011 ensuring the integrity of the earth connection through a trailing or reeling cable is maintained Earth Continuity protection is another layer of protection that along with earth leakage protection can help keep step and touch voltage potentials at a safe level by ensuring the earth resistance is below a determined safe level The ECD relay is based on microprocessor digital logic and features a user friendly LED and switch interface It is installed within a compact DIN rail mounted unit with pluggable connectors that can easily be changed out in the event of a problem with the relay The relay contains an internal IS barrier Key Features e Compact size e DIN rail mounted e Simple wiring and installation e 6 settings for trip time e settings for trip level AS NZS 2081 2011 Compliant e IEC 60079 Certification e 5112 Capable See appendix B Typically the ECD relay will be connected to the pilot conductor of a trailing or reeling cable With the pilot conductor terminated to
15. d manufactured to comply with the requirements of certification standards If modifications of any form are made to the ECD the conditions of certification will no longer be valid and the equipment will no longer be fit for use in a hazardous area If any modifications or damage to the ECD is evident do not use the equipment and contact Ampcontrol for advice 3 2 Mandatory Installation Practices The following information must be adhered to when installing the ECD Failure to adhere to this information may give rise to unsafe operation and could render the product invalid against its certificate Using the ECD 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 ECD must be powered within the specified voltage range e installation of the ECD must be carried out by suitably trained and qualified personnel e Certification and identification labels fixed to the ECD must not be damaged removed or covered before during or after installation e installation is to be in accordance with the relevant installation Standards Codes of Practice e Modifications must not be made to any part of the ECD As supplied the unit is built to and complies with standards against which it has been certified Modification to its construction will render the unit incompatible with its
16. e considered 3 1 1 Ensure that the information provided in this user manual is fully understood It is extremely important that the limitations and functionality of the ECD are understood to prevent incorrect installation and use from creating a potentially dangerous risk If in doubt as to the nature of the limitations or their implication consult a competent authority such as a supervisor or Ampcontrol technical representative 3 1 2 Ensure that the application into which the ECD relay 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 3 1 3 Ensure that the ECD relay will properly perform the required functions within the system design It is important to understand how the ECD is intended to interact with other equipment within a system For safe and reliable use it is crucial that neither the ECD s logical operation nor its signalling be compromised by incompatibilities with connected equipment 3 1 4 Modifications of any form to the ECD relay are prohibited The ECD as supplied has been designed an
17. earth through a diode the relay measures the resistance of the pilot earth loop series resistance to ensure the integrity of the earth conductors and the pilot to earth resistance shunt resistance to ensure the integrity of the pilot earth loop If these tests fail the ECD will trip de energising its output relay which can be used to switch a contactor circuit breaker or for signalling The ECD can be configured for latching or non latching operation and has a remote start option The ECD relay can also be used as an IS interlock with the pilot terminal connected to a circuit that passes through interlocks and switches CAUTION A safe resistance level for the pilot earth loop should be determined by risk assessment A and analysis of the system Page 9 of 20 Ampcontrol CSM Pty Ltd ABN 35 000 770 141 AMPCONTROL ECD User Manual gt Rev 1 August 2014 4 1 Mechanical Arrangement 4 1 1 Enclosure The ECD is housed in a plastic enclosure and is rated IP20 The dimensions are shown in Figure 1 below 117x45x114mm Figure 1 ECD enclosure dimensions 4 1 2 Mounting arrangement The ECD enclosure is designed be mounted on a standard 35mm DIN rail The IS connections are located at the top of the enclosure and the non IS connections power and user inputs and outputs are located at the bottom of the enclosure The fascia of the relay includes two 2 adjustable DIP switches and two 2 r
18. esign parameters The instructions within this manual must be observed as an aid towards achieving maximum safety during operation The owner user is responsible for observing the following instructions 1 1 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 certification the integrity of the system into which it is installed and other connected equipment 1 1 2 Equipment Knowledge Experience with or understanding of this equipment is essential for the safe installation and removal of the equipment Therefore in case of a question on how to safely proceed contact Ampcontrol immediately 1 1 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 1 1 4 Installation Correct operation and safety depend on the ECD and associated equipment being installed correctly Mechanical and or electrical installation and maintenance of plant and equipment must only be carried out by appropriately qualified personnel and must be tested thoroughly prior to operation 1 1 5 Operation As safety depends on the ECD functioning correctly it is highly recommended that all safety functions of the ECD be periodically tested
19. ical Connections ipren 11 5 COMMISSIONING AND CALIBRATION 13 5 1 Earth Continuity Test Series 13 5 2 Earth Continuity Test Shunt Resistance eeeeeseeseeeeeneeeene 13 5 3 Remote Start Function 13 6 AS NZS 2081 PROTECTION FUNCTION EARTH CONTINUITY 14 6 1 Series enne nA EE nnne nnn nnne nennen 14 6 2 Shunt Resistance 14 6 3 Remote Start ert n e ed 15 6 4 Latching mode 15 6 5 Manual reset procedure es 15 OPERATION SUMMARY 16 7 1 DIP Switches MONDE scs copas 16 7 2 Rotary Switches Configuration m 16 LEDS EE 16 7 4 Fault Indication HH Hee 17 7 9 Starting the ete Seba 17 8 SERVICE MAINTENANCE amp DISPOSAL 555 antt rit tn nai rtr nk Kp 18 8 1 Equipment 18 8 2 Equipment en 18 9 3 T 18 9 SPECIFICATIONS c 19 1O ec c ET 20 APPENDIX A DRAWIN SS
20. in the schedule of this certificate and the identified documents was found to comply with the following standards 60079 0 2011 Explosive atmospheres Part 0 General requirements Edition 6 0 IEC 60079 11 2011 Explosive atmospheres Part 11 Equipment protection by intrinsic safety i Edition 6 0 This Certificate does not indicate compliance with electrical safety and performance requirements other than those expressly included in the Standards listed above TEST amp ASSESSMENT REPORTS A sample s of the equipment listed has successfully met the examination and test requirements as recorded in Test Report AU TSA ExTR13 0003 00 Quality Assessment Report AU TSA QAR06 0007 05 Ampcontrol CSM Ltd 35 000 770 141 AMPCONTROL ECD User Manual lt gt Rev 1 August 2014 IECEx Certificate of Conformity Certificate No IECEx TSA 13 0004X Date of Issue 2013 06 21 Issue No 0 Page 3 of 3 Schedule EQUIPMENT Equipment and systems covered by this certificate are as follows The ECD Earth Continuity Relay is used to measure the continuity of the loop connected at its pilot earth terminals This is typically used to measure the continuity of the pilot earth of a trailing cable The ECD may also be used as an intrinsically safe interlock relay The pilot earth circuit can be considered intrinsically safe only when the non intrinsically safe circuits are isolated from the pilot ear
21. ings 30 Shunt Resistance 1 25kO Trip Time Settings 50ms 100ms 200ms 300ms 400ms 500ms Pilot Measurement Voltage 24Vdc Optional Start Button 1000 196 Mechanical Dimensions 117x45x114mm Weight 503g IP Rating IP20 Page 19 of 20 gt lt a gt Ampcontrol CSM Ltd 35 000 770 141 AMPCONTROL ECD User Manual lt gt Rev 1 August 2014 10 EQUIPMENT LIST Part Number Description 163554 ECD 24VDC IS 163555 ECD 48VDC IS Accessories 141479 P SUPPLY 24V 1A DIN MOUNT 115119 MODULE PTB PILOT TERMINATION FOR ECB D M 169732 RES 100R 5W 1 NA Normally Open Reset Button Contact Ampcontrol Page 20 of 20 mu User Manual Rev 1 August 2014 Ampcontrol CSM Pty Ltd ABN 35 000 770 141 Ni AMPCONTROL EEE LIUS SIN L 500953 avos azs H38I QN DNIMVHO VIN waysks pue siuejuoo l r goa eius JO 0 nias 0 N3dO LON OG Sjusuodwoo 5 004 sued aiqeysn pe Jasn 10 ejqeaoejdo ou aay paoueuejai S 003 5 y o eq 1snu 101234010 SI eu O jeonuo 91 uonoeuuoo 003 941 ayes
22. its normal operating life A number of external system based checks should however be completed on a regular basis These routine inspections must be carried out by suitably trained people with knowledge of the ECD and the systems into which it is fitted Routine inspections may take the form of either visual only checks or visual and hands on checks 8 1 1 Visual Only Inspections A basic visual inspection focuses on looking at the installation for signs of physical damage water or dust ingress and the condition of cables and labels This type of inspection may involve opening cabinets to gain access to the ECD and other equipment This level of inspection may also include cleaning display windows that have become obscured by dirt Observations would typically be Check that equipment enclosures cable trays conduits etc are in good order with no physical damage e Check that sealed wall boxes are free from water and dust ingress internally Door seals are in good condition e Check that connected cables are free from cuts abrasions and obvious signs of damage Cable restraints are in good order and correctly fitted Check that labels on equipment wall boxes and cables are present and in good condition especially certification labels e Check that no modifications have been carried out to installed equipment 8 1 2 Hands On Detailed Inspections A more detailed inspection would include all of the elements of a visual inspec
23. n series with the pilot conductor The start button is then installed in parallel to this resistor The start button should be a normally open switch Page 12 of 20 Ampcontrol CSM Pty Ltd 35 000 770 141 AMPCONTROL ECD User Manual gt Rev 1 August 2014 5 COMMISSIONING AND CALIBRATION Prior to being put into service the electrical protection system must be correctly commissioned This manual does not cover system commissioning the full scope of commissioning tests should be determined during the risk assessment or FMEA covering the design of the electrical protection system The following test can provide guidance on checking the correct operation of the ECD during commissioning This is not intended to provide an exhaustive commissioning checklist but should be considered to be a minimum set of tests The Earth Continuity function performs two measurements to ensure the integrity of the pilot earth loop Series resistance measurement and shunt resistance measurement 5 1 Earth Continuity Test Series Resistance The series resistance measurement can be verified by installing a resistor which is a minimum of above the selected trip level or creating an open circuit in series with the pilot conductor and verifying that the ECD relay trips within the selected trip time and indicates an open circuit fault 5 2 Earth Continuity Test Shunt Resistance The shunt resistance measurement can be verified by inst
24. on Pilot is not healthy series resistance above the selected setting or shunt resistance below Off 1 25kQ Flashing N A Pilot is healthy series resistance below the selected and shunt resistance above 1 25 16 20 Ampcontrol CSM Pty ABN 35 000 770 141 ECD User Manual Rev 1 August 2014 AMPCONTROL lt o 7 3 3 Short Circuit Red Ampcontrol CSM Pty Ltd ABN 35 000 770 141 ECD User Manual Rev 1 August 2014 LED state Indication Off Shunt resistance above 1 25kQ Non latch mode Shunt resistance is below 1 25 but for less than trip time setting Flashing Latch mode ECD has tripped on series resistance and shunt resistance is now below 1 25kQ On Shunt resistance below 1 25kQ 7 3 4 Open Circuit Red LED state Indication Off Series resistance is below trip setting Non latch mode Series resistance is above trip setting but for less than trip time setting Flashing Latch mode ECD has tripped on shunt resistance and series resistance is now above trip setting On Series resistance is above trip setting 7 3 5 Start Timed Out Red LED state Indication Off Start button not pressed Flashing Start button is pressed On Start button has timed out held down for more than 15s 7 4 Fault Indication CAUTION A When an internal fault occurs all the LEDs will be flashing together
25. onment and human health E ALERT which could otherwise be caused by incorrect waste handling of this product Page 18 of 20 gt Ampcontrol CSM Ltd 35 000 770 141 AMPCONTROL ECD User Manual Ww o Rev 1 August 2014 9 SPECIFICATIONS Certificates Approvals Type Ex ia for use in non hazardous area only Certificate Number IECEx TSA 13 0004X IS Parameters Non IS Terminals Um 132V rms phase to earth IS Parameters On the blue coloured terminals providing the output for the Pilot Earth Line When Pilot Earth Line is considered intrinsically safe Uo 28V lo 184mA Po 1 28W Co 2 00 10 0 The load can have the above Co as a lumped value provided the Lo is lt 1 or it can have above Lo as a lumped value provided the Co is 196 Optionally the load can have the full value of Co and Lo if distributed as in a cable When Pilot Earth Line is not considered intrinsically safe Im 5 25A for 1s Environmental Conditions Temperature Range 20 C lt lt 65 C Supply Voltage 24V Model 24Vdc 20 5W 48V Model 48Vdc 20 5W Relay Contacts Contacts 2xNO 1xNC 2xCOM Ratings 1A 110Vac 1A 30Vdc Resistive Earth Continuity Protection AS NZS 2081 2011 Series Resistance Trip 100 150 200 250 350 450 Sett
26. otary switches for configuration of relay settings and five 5 indication LEDs to assist in fault finding Page 10 of 20 Ampcontrol CSM Pty Ltd 35 000 770 141 AMPCONTROL ECD User Manual gt Rev 1 August 2014 4 2 Electrical Connections Once the ECD relay has been mounted at a suitable location it is necessary to wire it correctly Figure 2 shows a typical wiring diagram for the application of the relay Also refer to drawing for installation information 1 F Ni USER SAFE AREA HAZARDOUS SAFE AREA PUSHBUTTON AREA Ale 1 2 RST OPTIONAL e d c SUPPLY pees dio e STOP d d DIODE PILOT amp H gt USER RESISTOR 1000 DEFINED 1000 R IS EARTH B IS EARTH B b Figure 2 ECD Typical Electrical Application The table below lists the terminal connections into the ECD relay Terminal Label Description 1 RST Reset 2 Power Supply Positive 3 Power Supply Negative 4 NC1 Relay Output Normally Closed Contact 1 5 NO1 Relay Output Normally Open Contact 1 6 COM1 Relay Output Common Contact 1 7 NO2 Relay Output Normally Open Contact 2 8 COM2 Relay Output Common Contact 2 9 NC Not connected 10 NC Not connected 11 NC Not connected 12 NC Not connected
27. put relay within the selected trip time The trip can be configured as latching or non latching This allows the user to choose if the trip is manually or automatically reset once the pilot earth loop is healthy CAUTION Cable parameters are important to the correct operation of the Pilot E C function A Resistance amp capacitance values limit the length of cable that the relay can drive 6 1 Series Resistance The ECD relay measure the series resistance of the pilot earth loop by applying a positive voltage to the pilot conductor and measuring the pilot current If the series resistance is detected to be above the user selected level the ECD de energises its output relay and the LEDs on the front panel will indicate an open circuit fault The pilot earth loop resistance will still continuously be monitored even in the event of a trip The ECD cannot be re started until the fault has been cleared A power cycle will not reset the trip In non latching mode the ECD will automatically reset after the fault has been cleared In latching mode a manual reset is needed after the fault has been cleared The trip level and time can be selected using the rotary switch on the front panel 6 2 Shunt Resistance The ECD measures the shunt resistance pilot to earth by applying a negative voltage to the pilot conductor and measuring the pilot current If the shunt resistance is detected to be below 1 25kO the ECD s outpu
28. s been cleared The reset input has no affect in non latching mode The Reset input should be connected to the ECD s terminal a normally open switch with a minimum rating of the supply voltage 4 2 5 Relay Contacts The default position of the relay contacts Normally Open or Normally Closed is described on the ECD front label and Figure 2 The relay contacts will change state when the ECD is started Status LED flashing and will return to the default state when the ECD trips The relay contacts are rated for 1A 110Vac and 1A 30Vdc Resistive 4 2 6 External Fuse The ECD s IS Pilot Terminal is protected by an internal IS barrier In the event of a phase to pilot fault this barrier will clamp the voltage at the pilot terminal to a safe level and protect the relay from damage However this barrier can only withstand 5 25A for 1s The ECD relay must therefore be installed in a system with earth fault current limitation of 5A or less and an earth fault clearance time of less than 1s Alternatively a 3A external fuse rated to system voltage can be installed between the ECD s pilot terminal and the pilot conductor 4 2 7 Stop Button Optional The stop button should be a normally closed switch installed in the pilot conductor When opened the ECD will detect an open circuit pilot and trip on open circuit 4 2 8 Start Button and Resistor Optional When remote start mode is selected a 100O 196 5W resistor must be installed i
29. t relay will be de energised and the LEDs on the front panel will indicate a short circuit fault The shunt resistance will still continuously be monitored even in the event of a trip The ECD cannot be re started until the fault has been cleared A power cycle will not reset the relay In non latching mode the ECD will automatically reset after the fault has been cleared In latching mode a manual reset is needed after the fault has been cleared The trip time can be selected using the rotary switch on the front panel Page 14 of 20 N Ampcontrol CSM Pty Ltd 35 000 770 141 AMPCONTROL ECD User Manual gt Rev 1 August 2014 6 3 Remote Start Remote start mode can be selected via the DIP switches at the front of the panel Switching to or from remote start mode while the power is applied will cause a trip the relay will de energise and the Start Timed Out LED will come ON In remote start mode a 1000 resistor 1 5W must be connected in series with the pilot circuit and a normally open button connected in parallel to this resistor The loop resistance of the circuit will then be 1000 plus the resistance of the cable To start the ECD in remote start mode the following sequence must be followed 1 Alltrips must be clear 2 The start resistor must be detected in the pilot circuit 3 The start button must be pressed for a minimum of 500ms 4 The start button must be released within 15s or
30. th output CONDITIONS OF CERTIFICATION YES as shown below See Annexe for details Annexe Annex for IECEx TSA 13_0004X pdf 4 Mx Ampcontrol CSM Pty Ltd ABN 35 000 770 141 ANIPCONTHROL ECD User Manual 4 gt Rev 1 August 2014 Conditions of Certification pertaining to Issue 0 of this Certificate 1 The following parameters shall be taken into account when connecting the ECD Earth Continuity Relay On all the non i s connections of the Relay Um 132V rms max On the blue coloured terminals providing the output for the Pilot Earth Line When Pilot Earth Line is considered intrinsically safe LINE ees The load can have the above Co as lumped value provided the Lo is 196 or it can have the above Lo as a lumped value provided the 196 Optionally the load can have the full value of Co and Lo if distributed as in a cable When Pilot Earth Line is not considered intrinsically safe 5 25A for 1s 2 Thel S output is galvanically connected to the system earth This shall be taken into consideration during installation 3 copy of the drawing ECDM003 must be provided to the user Drawing list pertaining to Issue 0 of this Certificate Drawing Document Pagel s Revision Date Number Level yyyy mm dd 001 Relay Earth Continuity G A Certification ECDB002 ECD Bill of Material 1 IS Board Schematics 1 2013 06 11 pical system di
31. tion plus some checks that cover the integrity of connections fixtures and fittings In addition to basic visual observations more detailed integrity checks would involve e Verify that equipment housings wall boxes and other mechanical fixtures are secured in place This includes terminal box lids tightness of cable glands integrity of wall box mountings security of equipment fixing to walls DIN rails etc e Verify all electrical connections are secure with no loose screw terminals or DIN rail terminals not fitted to rails etc 8 2 Equipment Maintenance WARNING The ECD Relay has no user serviceable parts All repairs must be carried out by Ampcontrol only If a fault develops return the ECD to Ampcontrol for repair It is STOP essential that no attempt be made to repair the ECD as any attempt to dismantle or repair the ECD can seriously compromise the safety of the unit It is recommended that the electrical protection system incorporating the ECD be subject to regular functional tests at intervals determined by risk assessment or FMEA These intervals typically coincide with periodic maintenance checks and will cover but not limited to tests such as earth continuity tests 8 3 Disposal 4 The electronic equipment discussed in this manual must not be treated as general waste By ensuring that this product is disposed of correctly you will be helping to prevent potentially negative consequences for the envir
32. to ensure correct operation Page 5 of 20 Ampcontrol CSM Ltd 35 000 770 141 AMPCONTROL ECD User Manual lt gt Rev 1 August 2014 1 2 Intrinsic Safety Considerations The ECD relay s IS Pilot Terminal is protected by an internal IS barrier In the event of a phase to pilot fault this barrier will clamp the voltage at the pilot terminal to a safe level and protect the relay from damage However this barrier can only withstand 5 25A for 1s The ECD relay must therefore be installed in a system with earth fault current limitation of 5A or less and an earth fault clearance time of less than 1s Alternatively a 3A external fuse rated to system voltage can be installed between the relay s pilot terminal and the pilot conductor The ECD relay must be located in a non hazardous safe area The ECD IS earth connection is critical to the IS protection and must be infallibly connected to the system earth This must be done with a minimum of 3 conductors each of 1 5mm as per the IS installation standards The installation is to be in accordance with the relevant installation Standards Codes of Practice There are no user replaceable or user adjustable parts in the ECD system s components DO NOT OPEN the ECD enclosure Return to Ampcontrol for service amp repair Page 6 of 20 Ampcontrol CSM Pty Ltd ABN 35 000 770 141 AMPCONTROL ECD User Manual gt Rev 1 August 2014 2 RECEIVING AND STORAGE
33. y amp Certification Manager Signature for printed version Date 2 Dowd 2013 1 This certificate and schedule may only be reproduced in full 2 This certificate is not transferable and remains the property of the issuing body 3 The Status and authenticity of this certificate may be verified by visiting the Official IECEx Website Test ete T A 5 1 Certificate issued TestSafe Australia 919 Londonderry Road Londonderry NSW 2753 Australia Page 2 of 6 Ampcontrol CSM Ltd 35 000 770 141 AMPCONTROL ECD User Manual lt o Rev 1 August 2014 IECEx Certificate of Conformity Certificate No IECEx TSA 13 0004X Date of Issue 2013 06 21 Issue No 0 2 of 3 Manufacturer Ampcontrol CSM Pty Ltd 7 Billbrooke Close Cameron Park NSW 2285 Australia Additional Manufacturing location s This certificate is issued as verification that a sample s representative of production was assessed and tested and found to comply with the IEC Standard list below and that the manufacturer s quality system relating to the Ex products covered by this certificate was assessed and found to comply with the IECEx Quality system requirements This certificate is granted subject to the conditions as set out in IECEx Scheme Rules IECEx 02 and Operational Documents as amended STANDARDS The electrical apparatus and any acceptable variations to it specified
34. y familiar with this equipment and to ensure correct operation we strongly recommend that you take the time to read and thoroughly understand this user manual Ampcontrol CSM Contact Details 7 Billbrooke Close Cameron Park NSW 2285 P 61 2 4903 4800 F 61 2 4903 4888 EMAIL electronicsorders ampcontrolgroup com WEB www ampcontrolgroup com Page 3 of 20 ao Ampcontrol CSM Pty Ltd ABN 35 000 770 141 AMPCONTROL ECD User Manual gt Rev 1 August 2014 TABLE OF CONTENTS 1 SAFETY AND OTHER es P nep iur cipit etat 5 1 1 Safe Use of Equipment nennen nnne nnne 5 1 2 Intrinsic Safety CorIsiderelloffS cs cocta cul ERA ESTE eM mU EN MEE 6 2 RECEIVING AND STORAGE cm ms 7 7 2 2 9 _______ 7 2 3 Storage after Delivery 7 2 4 Unpacking of Equipment 7 MON eet 8 3 1 General 8 3 2 Mandatory Installation 8 OVERVIEW 9 4 1 Mechanical 10 4 2 Electr
35. y on shelves and protected from the elements 2 4 Unpacking of Equipment The method of packing used will depend on the size and quantity of the equipment The following cautions should be interpreted as appropriate CAUTION Take when unpacking crates as the contents may have shifted during transport The disposal of packaging materials replaced parts or components must comply with environmental restrictions without polluting the soil air or water Ensure that any timber and cardboard used as packaging is disposed of a safe and environmentally responsible manner nib 5 Where possible dispose of all waste products i e oils metals plastic and rubber products by using an approved recycling service centre Page 7 of 20 Ampcontrol CSM Pty Ltd 35 000 770 141 AMPCONTROL ECD User Manual gt Rev 1 August 2014 3 INSTALLATION These instructions have been designed to assist users of the ECD Relay with installation and special wiring techniques required to maintain the integrity of the intrinsically safe circuits 3 1 General Warnings Before the ECD can be installed there are a number of things that need to be considered and understood to prevent incorrect or unsafe operation of the ECD or the system into which it is installed Along with relevant competence and an understanding of the target application the following points should b
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