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IPDB014 IPD User Manual

1. lt L 4 B enu 5 z gt 26 m Position 45 gt cT 4 lt le 0 2 3 L gt 5 Eej T 2 8 u Leve a LondSCor 6 4 IPD 1 vor 2006 cu O Running 132Amps gt S N NotO7 00103 Ca Eu EN a AP lt X m ly ud a 3 3 3 x uU EVENT LOG 1 Log 1 Outlet On Log 2 lose 4 1073 Reset 4 INFORMATION RTU Code 6 gt Mo2 0 084802 gt Mo21 07 08327 gt 5 fa Z Jv 3 RIUOnline V4 4 Start Sip PTC 061 INFORMATION Machine Scar 6 gt D 95 98 97 1 4 5 i EARTH FAULT 3 EL 9 EF 2 lt C 2 3 CAM gt 3 INFORMATION EC R 21 1 1 gt 25 25 25MOhms 25 Sr edu B OE ESTEE Fut Be 5 88 845 1 ZETRZRRI SENSE 4 6 SYSTEM VOLTAGE 4 103 B102 103 ez5z9 E SAS INFORMATION B enf Timer 0 ot E me EP 2z RITE Fx EEE za 3 ERLER Z5 95
2. ess 27 8 EAM P 28 8 1 ce errr AE 28 8 2 Interlocking Sequence 29 9 User Adjustable 30 9 1 Parameter ondes bud uu rr 30 9 1 1 Group 1 Settings Stored the 31 9 1 2 Group 2 Settings Stored in the 31 IPDB014 IPD User Manual 1 Page 3 IPD1V03 USER MANUAL POWER THROUGH INNOVATION 9 2 Changing 69 05 xls cet 32 10 System METERS 33 10 1 bine tear re 33 10 2 LED 33 10 3 33 10 4 33 10 4 1 33 10 4 2 Remote Operation in Diode 33 10 5 Operational SSQUG aa 34 35 12 TIMOR IRR 37 13 Remote Data Communications cata ia ka ia lu calda nain tgs 37 14 Installation amp
3. dl Q311031NOONR Page 62 14 IPD User Manual 1 AMPCONTAOL IPD1V03 USER MANUAL POWER THROUGH INNOVATION AMPCONTROL DWG No IPD REMOTE TERMINATION UNT GENARAL ARRANGEMENT Hi Dcom UNCONTROLLED IF PRINTED NOISIAS 14 IPD User Manual 1 Page 63 IPD1V03 USER MANUAL AMPCONTROL lt gt POWER THROUGH INNOVATION xoc 0 80 2 03 9 016 0440034105210 382 ii W130 ONILNNOW TUN Q Was 14510 310438 TN i DLL 000 SE NEV ddl EEE TORINO 1527 LV NIVINIVW 01 380507383 JO 100 10 Q31Nn0H 38 01 0 763105 110 102 340501283 OLNI ONILNNOW ONIMOHS 7H INOJdAY sod suj nou pay4 Syuajuoa 4200 up peonpoudes sq you say 04 Pafgns 4 TOYLNDIdHY 30 ALW3dOMd JHL SNIVWI8 5 OLLLOLON LYVd 135590 13NVd 5 26 wuz XEN emi 011 340501283 13159 380507083 N TANI 20 JINVYIIOL WUN O es cs O 9 64 IPDB014 IPD User Manual 1 IPD1V03 USER MANUAL AMPCONTROL Ww POWER THROUGH INNOVATION 355 193339 317
4. indicates the status of the test Mtx Manual Test is blocked by any one or more of the conditions 1 to 8 above Mte Only the ENT key is required to initiate the manual test The manual test is timing through the enabling period 3 seconds The manual test is Active The display will show measured values IPDB014 IPD User Manual 1 Page 19 erm IPD1V03 USER MANUAL POWER THROUGH INNOVATION 5 3 Earth Continuity The earth continuity function tests for the continuity of the earthing between the outlet and the machine via the pilot core in the trailing cable This is in accordance with AS NZS 2081 2 2002 The pilot core is also used to transfer data when a Remote Termination Unit is used to achieve machine communication The IPD relay can be configured to operate in either diode or RTU mode The mode is selected in Pilot Type Level 8 Position 1 and determines what terminating device the relay is looking for on the pilot A The Remote Termination Unit will only be recognised by an IPD Relay and will not be seen as a diode by other earth continuity devices CAUTION Cable parameters are important to the correct operation of the Pilot E C function Resistance amp capacitance values can determine the length of cable that the relay can drive See Specifications Section 14 IPD Specifications The relay measures the resistance of the pilot earth loop and the leakage bet
5. AMPCONTROL IPD1V03 USER MANUAL POWER THROUGH INNOVATION IPD1V03 Integrated Protection Relay User Manual Issue 10 August 2014 User Manual Part No 110773 Designed and Manufactured in Australia by Ampcontrol CSM Pty Limited AMPCONTROL IPD1V03 USER MANUAL POWER THROUGH INNOVATION 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 Safety and other Warnings WARNING This safety alert symbol identifies important safety messages in this manual and indicates a potential risk of injury or even death to the personnel When you see STOP this symbol be alert your safety is involved carefully read the message that 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 A Supplementary information not directly affecting safety or damage to equipment Carefully read the message that follows and inform other relevant personnel Information concerning possible impact on the environment and actions required for prevention and proper response ENVIRONMENTAL ALERT
6. 12 4 Machine 9 13 4 1 Remote Termination Unit sse tette tnnt 13 4 2 Machine Type Codes M 14 43 Machine 14 5 Earth Protection Functions tenete 15 5 1 Earth co 15 52 Earth Fault Lockout sees 16 5 2 1 Intrinsically Safe EFLO 189 16 5 2 2 Automatic Insulation 5 tette nennen 17 5 2 3 Manual Insulation Test seen tnter tnnt 19 5 3 Earth 20 6 Curent Related 90 21 6 1 Basic Over current Protection Functions 21 6 2 Dependent time protection sese nnne 22 6 2 1 Characteristics seen erret tnnt nnne nnne 22 6 2 2 Motor Overload Characteristic 23 6 3 Short RT TN CP DE 24 6 4 Phase Current Balance aaa es 25 6 5 Overreach Compensation 4 ssssssssssssssssssssssssssssssssssssssssssssssssss 25 7 Voltage Related Functions oriente teatro 27 7 1 Main Contactor Fail Protection sss tnnt 27 7 2 Mri Nj Mem aE 27 7 3 Voltage
7. 6 3 Short Circuit The short circuit function has a definite time characteristic If the current exceeds the selected level for the pre set time then a trip occurs The SC LED on the Remote Display Module is illuminated and the open collector output on the relay is switched on to provide monitoring if required To reset the relay following a short circuit trip it is necessary to operate and hold the lock button closed and then close the reset button The relay can be programmed so that a short circuit condition can trip either the CBR relay or the MCR relay This can be achieved by selecting either relay at the SC Relay selection in the non volatile memory Level 8 Position 5 on the Remote Display Module Normally the selection would be used If MCR is selected then the user must ensure that the interrupting device that is operated by the short circuit trip output of the relay has sufficient current interrupting capacity at the system voltage for the situation in which it is installed The short circuit trip level is adjustable from 3 to 10 times full load current in 0 5 increments The trip time is selectable from 20 to 160mS CAUTION When CBR is selected for the Short Circuit trip it is important to consider the S C trip time in relation to the trip times for faults that trip the MCR and could occur at the same time as the S C e g Earth Leakage and Earth Continuity
8. 2 li SY Oy i iy 26 A SOLE NTS MOTOR OVERLOAD HOT amp COLD CURVES W ERROR SRE A3 Lu gt 79 m 2 lt 2270 LY Wt gt C gt E Dr XL KA Yop A CLM gt CLD E gt CG 7 gt Bx lt 2 be I I Ps 2 ectronics anpcontrolgroup com 02 4903 4888 02 4903 4800 lt gt 1 2 7 74 27 2 225 4 ZU 2 AMPCONTROL ELECTRONICS AMPCONTROL CSM PTY LTD ABN 35 00 770 141 CAMERON PARK N S W 2285 7 BILLBROOKE CLOSE lt p 2 OS GN 2 3 lt lt Lip pd 7 LII T lt 2 2 QP 2775 2 a TIME MULTIPLIER THIS DRAWING REMAINS THE PROPERTY OF AMPCONTROL IF Is subject fe thelr recall or whole or the contents divulged to Hird porty without the prior written approval from AMPCONTROL must not be reproduced in port 2 A 2 2 Uy UY 5 gt 0 a
9. IPD1V03 USER MANUAL POWER THROUGH INNOVATION 6 Current Related Functions 6 1 Basic Over current Protection Functions Two current transformers are used to measure the three line currents The measured currents are used to implement the following protection functions a Dependent time protection Over Current or Motor Overload section 6 2 b Short Circuit section 6 3 c Phase Current Balance section 6 4 Full load settings cover a range from 7 5 Amps to 464 Amps A current range and current multiplier are utilised to select and store the full load current value in the non volatile memory This forms the basic reference level for the over current protection functions The current range is selectable in 4 Amp increments between 60 and 116 Amps The current multiplier is selectable at 1 8 1 4 1 2 1 2 4 times See Section 9 1 User Adjustable Settings Example Full load current setting To obtain a full load current of 152 Amps select a current range of 76 Amps and a multiplier of 2 Two dependent time protection types can be selected and a time multiplier modifies the basic trip time characteristic There are eighteen 18 time multiplier settings that can be selected ranging from 0 005 times to 1 0 times See Section 9 1 User Adjustable Settings It should be noted that settings 0 005 0 01 0 015 0 02 0 03 and 0 04 are positioned after setting 1 0 in the stored setting s list Level 9 Position 4 The inst
10. IPDB014 IPD User Manual 1 Page 24 Comme IPD1V03 USER MANUAL POWER THROUGH INNOVATION 6 4 Phase Current Balance Phase current balance protection is selected via the Cur Bal Trp selection See Section 9 1 User Adjustable Settings The current balance measurement is displayed on the Remote Display Module and is calculated as Ibal MAXAIx 100 lave lave Average of the 3 phase currents maximum deviation of a phase current from the average The trip level is selectable at 5 10 20 50 and off The phase current balance protection is inhibited until the average current exceeds both 20 of the selected full load current and the selected balance trip level If the trip level is exceeded a timer is triggered If the imbalance remains above the set level for more than two seconds the relay trips The event log records Ibal to differentiate it from a true over current trip The status of the timer is displayed adjacent to the Ibal value Level 5 Position 2 trip condition occurs when the timer reaches 100 6 5 Overreach Compensation Transient overreach is a phenomenon experienced by overcurrent relays where a measured AC signal is offset by a decaying DC component see figure below taken from IEC 60255 151 The effect is typically caused by a step change in the measured signal such as at contact closure for a direct online motor IEC 1715 09 IPDB014 IPD Use
11. IPDB014 IPD User Manual 1 Page 1 em IPD1V03 USER MANUAL POWER THROUGH INNOVATION Copyright Notice No part of this publication may be reproduced transmitted or transcribed into any language by any means without the express written permission of Ampcontrol CSM Pty Ltd 7 Billbrooke Close Cameron Park NSW 2285 Australia Disclaimer Ampcontrol CSM Pty Ltd will make no warranties as to the contents of this documentation and specifically disclaims any implied warranties or fitness for any particular purpose Ampcontrol further reserves the right to alter the specification of the system and or manual without obligation to notify any person or organisation of these changes Before You Begin We would like to take a moment to thank you for purchasing the IPD Integrated Protection Relay WARNING To minimise the possibility of unsafe operation of this equipment the user must be competent via appropriate training in regards to international standards and safety requirements relating to its installation operation and maintenance Safety related Information contained within this manual is supplementary to such standards but must be equally understood and applied to both maximise safe use of this equipment and minimise risk to persons or other equipment WARNING To become completely familiar with this advanced protection and control relay system and to ensure correct operation we rec
12. Wiring Instructions sse 38 14 1 General SIUS 38 14 2 held EE 39 14 2 1 Integrated Protection ROI ca catches asa latae d atl e ei 39 14 2 2 Remote Display Module RDM 39 14 2 3 Cable Connection 39 14 24 Overload amp Earth Leakage 8 40 14 2 5 Toroid Installation Guide Limes 40 14 3 WIRING cs i 40 e RN 41 14 3 2 Initrimsically Safe CIRCUS ai oo rtr Has asas B di Es bebat qe Ted ut 41 14 3 3 Low Voltage Signals 42 14 3 4 High Voltage Circuits Em 43 15 IPD Equipment List 44 16 NG Si 45 T errr Terre LEM IE 46 17 1 x NIU PER 46 17 2 NER 46 17 3 Earth fault lockout P 46 17 4 Ean conin 46 17 5 Insulation N 46 17 6 Over Current Motor Overload current injection 46 17 7 Short 6 97 aha esasa 47 17 8 Current detection in 47 17 9 Main contactor fail 47 17 10 Voltage
13. 13 5 per curve B C 0 per curve 1 per curve Resultant values of TMS based on the range of m values is 0 066 lt s 13 33 0 005 m lt 1 0 The overall error in tripping accuracy for the Over Current and Short Circuit is 5 per IEC60355 151 part 6 3 The transient overreach performance is 35 per IEC60255 151 part 6 5 2 The response to time varying energising quantities is lt 5 per IEC60255 151 part 6 5 4 Motor Overload IEC60255 8 IPDB014 IPD User Manual 1 Page 84 p IPD1V03 USER MANUAL See m OL Curves Drawing IPDB019 and Motor Overload Functional Block Diagram Drawing 5 in Appendix A Drawings The Ampcontrol IPD implements the motor thermal model in line with IEC 60255 Part 8 represented by two curves 1 Cold Motor Curves 2 Hot Motor Curves Motor overload is implemented in conjunction with the time independent short circuit functions of the IPD The three measured phase currents are squared and added together to provide the heating input into the thermal model The overcurrent time dependent curve is based on a Motor Thermal Model Using this model the relay will trip according to the following formula 12 1 k I Where t is the operate trip time t is the thermal time constant Ig is the basic current A value of 1 0 is used k is a constant A value of 1 0601 is used in the IPD I is the relay current I is the specific load curre
14. 47 17 11 ROM eek P 47 17 12 PLC MENACE cius UID TIR RIMIS SOSTA 47 17 13 47 17 14 Start MCI and Stop 8 47 18 HODIE SDN Pee tere evr 48 19 Service Maintenance amp Disposal 50 19 1 Eq ipment SRG PUGS cR Saas 50 19 1 1 Visual Only INSpEC ONS uci aient odii 50 19 2 Hand On Detailed 50 19 3 Equipment Maintenance 51 194 Disposal of System 02 8 51 20 List of Drawings Refer Appendix A for Drawings 52 IPDB014 IPD User Manual 1 Page 4 P ea AMPCONTROL lt gt POWER THROUGH INNOVATION Earth Leakage Toroid type AMPCONTROL EL 500 E L Test Resistor Rleft 200 Ohms needs to produce_test current of 100 160 of Trip Level Cable Connection Module IPB Mode 415V System Ampcontrol CC 1000V System Ampcontrol CC IPD Mode 415V System MA 415 MA 1000 Ampcontrol CCMD 415 1000V System Ampcontrol 1 3 3kV System Ampcontrol CCMD 3 3k Earth Fault Test Resist
15. A PIG GENERAL ANGULAR TOLERANCE t 1 400 700 800 300 1000 CURRENT Full Load COLD curves in blue with error limits HOT curves in red showing 1 0 0 05 0 005 IPDB014 IPD User Manual 1 Page 59 AMPCONTROL lt o POWER THROUGH INNOVATION Motor Short Overload amp Circuit Curs IPD1V03 USER MANUAL CIRCUIT SHEET NUMBER VERLOAD amp SHORT n 0 MOTOR TIME MULTIPIER 0 050 0 040 0 030 m M 0 020 0 015 0 010 0 005 160mSec 120mSec LTD PARK N S W 2285 ampcontrolgroup t 50 BROOKE CLOSE ONTROL SM PTY ABN 35 000 770 141 100mSec 80mSec 60mSec AMPCONTROL ELECTRONICS AMP electronic THE 40mSec AMPCONTROL 20mSec r written approva from AMPCONTROL THIS DRAWING REMAINS PROPERTY SHORT 400 500 600 CURRENT Shows ull Load Selected Full Load Current S 0 05 amp 0 0 Cur Range 1 2 Cur 2 Trip Time 1800 32A ime Mul 34A 336A 352A 368A 364A 0 gt I gt n 400A un un un 2 un lt N gt gt gt gt gt 100 120 8 IPDB014 IPD User Manual 1 REFERENCE Hot Id CIRCUIT 100 000 EA Curve for 1 0 5 Multipliers GENERAL LI
16. IPD by checking the measured voltages on the RDM when the main contactor is closed 17 11 RDM Ensure that the RDM is functioning correctly by operating the menu system and checking that the corresponding trip indication LED is illuminated with each trip test conducted 17 12 PLC interface The correct operation of the PLC interface is determined by polling the IPD relay from either a PLC or a MODBUS capable PC via the IPSI 17 13 RTU Validate the correct operation of the RTU by making changes to Group 2 settings moving the machine to a different outlet and ensuring that the correct settings are available on the new outlet 17 14 Start MCI and Stop inputs Ensure that the digital inputs to the IPD are operating correctly by initiating an outlet start via the START input Wait 10 seconds to ensure that the MCI input has been correctly operated and then initiate a contact open via the STOP input Ensure that the outlet correctly de energises IPDB014 IPD User Manual 1 Page 47 5 AMPCONTHROL POWER THROUGH INNOVATION 18 Troubleshooting IPD1V03 USER MANUAL If a problem is experienced with the relay use the following tables to fault find the problem Should the fault persist remove the relay and return the relay plus a description of the fault to Ampcontrol for repairs amp Checking the Status page level 0 position 0 should be the first step in troubleshooting This displays what the relay requ
17. MCI input did not close within 5 Sec of MCR relay closing External MC Open IPD detected via MCI input that MC was opened not initiated by the IPD relay Insulation Alarm E Test result at alarm level 1 5 x selected trip level IPD waits 5 Sec between running or testing and re testing UM Enor 3 PO 8 181 3 RTUPTCpu Teu sopped ATU 3 RUST Bane Tap 2 Prese Curent Gare md Tied soppeaiPo _ Earth Leak CTF 3 Eart sage CT has Faia Trp Ocas ___ Earth leak Tip 5 Earn Leag Functor Toes Eann comt 3 60710 5 2 Over Curent Table 3 2 1 wo wl IPDB014 IPD User Manual 1 Page 11 a AMPCONTROL lt o POWER THROUGH INNOVATION IPD1V03 USER MANUAL 3 2 2 Last Trip Status Messages The IPD Relay has several functions which can stop trip the outlet and then self clear The IPD Relay therefore saves the non latched trip codes in a register and displays the Last Trip messages in the Status Message Page Note that the stop trip function also appears in the Event Log Messages that are displayed at Last T Message Comment EC Leak T E C Leakage Trip that provides additional information for E C Trip EC Q Trip E C Ohms Trip that provides additional information for E C Trip Fan Stop Fan interlock S
18. circuit trip level will increase to 3712A 116A x 4 x 8 until 150ms after the MCI input closes START input EFLO HV test output MCI input T ___ __ A __ Startup Transient Mode L1 bo IPDB014 IPD User Manual 1 Selected Time Page 26 IPD1V03 USER MANUAL POWER THROUGH INNOVATION 7 Voltage Related Functions 7 1 Main Contactor Fail Protection The Main Contactor Fail MCF protection operates if the Main Contactor MC fails to function by either 1 Failing to open when required This is achieved by comparing the state of the main contactor via the Main Contactor Input MCI against the state of the MCR relay output This test provides Frozen Contactor Protection 2 Failing to maintain insulation across the contacts when the contactor is open The Cable Connecting Module is used to measure the voltage on the load side of the contactor If this exceeds 10 of the rated line voltage a trip will occur This test provides Loss of Vacuum Protection This function is inhibited immediately after the main contactor opens to allow for back EMF voltages generated by some motors to dissipate The inbuilt time is adjustable from 2 to 20 seconds See Section 9 1 User Adjustable Settings A main contactor fail trip causes the CBR relay to de energise which trips the circuit breaker An internal battery backed flag in the IPD Rel
19. damage must not be used ancillary equipment used with the IPD integrated protection relay should be as specified in the IPD Equipment List to ensure safe operation of the relay e Cleaning the controller may create an electrostatic hazard Anti static cleaning media must be used WARNING To comply with the Conditions of Certification ensure full serviceable life of the 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 Appendix Approvals may STOP 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 Safe Use outlined in the certificate are met or the certificate and the IS rating will not be valid IPDB014 IPD User Manual 1 Page 8 IPD1V03 USER MANUAL POWER THROUGH INNOVATION 3 Overview 34 Introduction The Ampcontrol IPD Integrated Protection Relay IPD1 is an intelligent protection relay based on microprocessor technology The integrated relay provides the necessary functions required for protecting electrical outlets supplying underground mining machinery All of the protection functions are combined into a compact plug in unit which can be easily changed out to minimise down time in the event of a
20. gt OCT Mul 10 gt oc Types v nv f oct Mul 100 gt Cool Mul SO gt Cur Bal Trp Off gt 5 f f f f f 4 4 4 4 4 4 lt Stored Value e Stored Value 4 Stored Value 4 Stored Value lt Stored Value 4 Stored Value Stored Value 6 Stored Vale 4 SCI Trip 10 0 SC Trip lms gt Piot Latch OFF gt Time 20sec gt Fon Level 48 gt Remote Start No gt TstT 5 0MOhm gt Start Trns Dis gt lt m n 14 IPD User Manual 1 Page 54 AMPCONTROL lt o POWER THROUGH INNOVATION IPD1V03 USER MANUAL 9 5 4 7 7 2509041 1201 19945 SIN EW 348 00H Sv Cie enn as 325 I 069 20 g pay pabjnnp 3125 LON og 2 07 sv 0626 o 42018 S822 MSN sant P SNOISNANIG SV 92 99 Ta 956 TWNOILINAS 1N388028340 Us 2507 DOETE posas pos sar yon NOS ak ma ote 2 wem AW TRY NOLLIALOd 03 03 ee Se 3 96 oye asa 5 04 0 10443 1959 214s jeJeY 19588 1059 50 SWLX 8 9 241514943 4 45 juapuadag 1055 lt 0 lt 225
21. in determining the cable fault leakage levels IPDB014 IPD User Manual 1 Page 27 IPD1V03 USER MANUAL POWER THROUGH INNOVATION 8 Fan Control 8 1 Fan Interlocking A fan interlocking facility can be selected to prevent outlets from being energised until a mine section ventilation fan is operational This facility eliminates the need for dedicated outlets The configuration of the fan interlocking system is shown on Drawing IPD B 003 in Appendix A Drawings Each relay is linked together via the FIO Fan Interlock Input Output Terminal For single fan operation 100 resistor is connected between this link and earth This causes all relays in the system to default to a Slave mode waiting to receive an interlocking signal before they can run For dual fan operation it is necessary to connect two 1000 resistors in parallel to the FIO Terminal otherwise all FIR Inputs will read as off and the slave outlets will not run When an IPD Relay detects a Remote Termination Unit that has been programmed with the special machine type identifier iFan that particular relay switches to a Master configuration This relay controls the slave outlets allowing them to run when the fan current is above the selected threshold setting Each relay has the ability to read and drive the FIO link via the Fan Input Read FIR processor input and the Fan Interlock Drive FID processor output The status of the input output can
22. is important to ensure protection of equipment and validity of warranty All equipment should be stored indoors protected from the elements in a cool dry area If storing on the ground ensure that the storage area is not an area where water will collect 1 3 Unpacking of Equipment The method of packing used will depend on the size and quantity of the equipment Take care when unpacking the IPD to avoid damage The disposal of packaging materials replaced parts or components must comply with 4 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 p environmentally responsible manner Where possible dispose of all waste products i e oils metals plastic and rubber products ENVIRONMENTAL ALERT by using an approved recycling service centre IPDB014 IPD User Manual 1 Page 6 IPD1V03 USER MANUAL POWER THROUGH INNOVATION 2 General Safety STOP 2 1 Personnel Safety Warnings Relevant Personnel Ensure all personnel directly responsible or involved with the installation operation and maintenance of the equipment reference this manual in conjunction with information contained within any risk assessments conducted to identify risks and hazards Safety Communication All safety instructions and design requirements within this manual must be communicated to all users These requirem
23. minimum earth conductor size of 1 5 The intrinsic safety circuits have been tested to 60079 11 and require at least three independent connecting elements for ia circuits to maintain the intrinsic safety properties These three earth connections shall be connected in parallel back to the main earth point and are not to be connected in series The IKD interface must be infallibly connected to the main system earth via at least one of the earthed mounting bolts on the chassis The earth on pin 29 connects to the earth shield of the IPD Relay s internal transformer This earth is a protection earth and is not an intrinsic safety earth 14 3 2 Intrinsically Safe Circuits Reo 3 Cable Three core screened Connection Module Screen Earth Pilot Con 6 Pilot Single core screened 22 7 Screen Earth 8 Serial Comms Four core screened Port Screen Earth Remote Three core screened Display Screen Earth It is recommended that these circuits be loomed separately from all non IS circuits Wherever a screened cable is to be connected to Earth ensure that the screen is earthed at ONE END ONLY as near to the IPD as is practicable amp IPDB014 IPD User Manual 1 Page 41 IPD1V03 USER MANUAL POWER THROUGH INNOVATION 14 3 3 Low Voltage Signals Although these signals are not IS signals themselves care must
24. o POWER THROUGH INNOVATION 16 IPD Specifications Auxiliary Supply Volts Earth Leakage Protection Earth Continuity Protection Pilot Cable Parameters Earth Fault Lockout Protection Lockout Resistance IS Test Lockout Resistance Insulation Test Alarm Settings Over current Overload Protection Current Range Current Multiplier Time Multiplier Cooling Multiplier Current Balance Trip Settings Short Circuit Protection Trip Setting Trip Time Transient Delay Settings Back EMF Timer Trip Delay Settings Machine Numbers Fan Current Threshold Level Undervoltage Protection Serial Communications Relay Contacts IPDB014 IPD User Manual 1 IPD1V03 USER MANUAL 110vac 10 10VA 50Hz 2 Hz Trip Setting 100 500 mA in 50 mA increments Time Delay Instantaneous lt 50mS 100mS then 150 to 470mS in 40mS increments Reset if resistance 45 Ohms Trip if resistance gt 45 Ohms Shunt Leakage Trip if lt 1500 Ohms Operating Time 80 120 160 200 300 400 500mS C lt 0 3uF L lt 10mH lt 600 0 415V 4 15k Ohms 3 3kV lt 33k Ohms 1000V 10k Ohms Test Time 1 second Selectable at 0 1 0 2 0 5 1 2 5 10 and 15 MQ and off Test Time 2 seconds Insulation Test Trip setting x 1 5 7 5 to 464 Amps 60 to 116 Amps in 4 Amp increments times current multiplier 1 8 1 4 1 2 1 2 4 times 0 005 0 01 0 015 0 02 0 03 0 04 0 05 0 075 0 1 0 1
25. or other cables Try to maintain several CT diameters clearance 4 Many small cables tend to be worse than say three large ones Try to position the CT in the circuit with this in mind 14 3 Wiring Installation The connections to the IPD Relay consist of a mix of intrinsically safe circuits through to high voltage supplies and relay contact circuits To ensure the integrity of the intrinsic safety is maintained and to reduce induction from high voltages care needs to be taken in the layout of the wiring and the installation For installations on high voltage systems gt 3 3kV it is advisable to install a power supply filter eg Schaffner FN612 1106 1A 250VAC chassis mounted filter adjacent to the IPD Relay The earth should be connected to Pin 7 on the relay as directly as possible The IPD Relay s approval requires that the relay is installed in accordance with the Australian Standard for Intrinsic Safety Installation AS NZS 2381 7 This makes it necessary for anyone installing IPD Relays to be familiar with and have a good understanding of AS NZS 2381 7 IPDB014 IPD User Manual 1 Page 40 Cent IPD1V03 USER MANUAL POWER THROUGH INNOVATION 14 3 1 Earthing The IPD must be infallibly connected to the main system earth via the three earth terminal provided on pins 2 7 and 12 To maintain the intrinsically safe properties of the relay it is vital that the earth pins 2 7 and 12 are all individually connected with a
26. plugged into an outlet that has its Remote Termination Unit programmed iFan then that relay will be allowed to run when requested Provided there are no protection trips stops etc preventing its operation 3 When that outlet is running and the current is above the preselected current threshold a 5 second time delay is initiated At the completion of this delay that IPD Relay turns on its FID output The fan current threshold is adjustable from 32 to 96 of full load current in 8 increments See Section 9 1 User Adjustable Settings 4 Detecting the interlocking signal via their FIR inputs then enables all other IPD Relays on the FIO link 5 If at any stage the fan current drops below the threshold or the fan is stopped the master IPD Relay turns off the FID output This causes all slave IPD Relays to stop If fan interlocking is not required the system can be disabled by connecting a 10KO 1W resistor from the FIO Terminal Terminal 9 to OV Terminal 12 on each relay In this case the FIO Terminals are not interlinked This causes the FIR inputs to read high at all times An auxiliary fan being used in this situation would have its Remote Termination Unit programmed with machine type Fan IPDB014 IPD User Manual 1 Page 29 IPD1V03 USER MANUAL POWER THROUGH INNOVATION 9 User Adjustable Settings 9 1 Parameter Groups There are two groups of adjustable settings contained in the IPD Relay s non volatile memory Bo
27. problem with the relay The IPD Relay can provide machine communication through the use of a Remote Termination Unit RTU D connected between the pilot and earth at the machine end of the trailing cable Through the use of the RTU D Remote Termination Unit the relay parameters are automatically up loaded from a remote machine when a cable is inserted into a power outlet The earth fault lockout function tests the resistance of the 3 phase lines to earth by applying an intrinsically safe signal prior to the closure of the main contactor in accordance with AS NZS 2081 4 2002 The test is initiated once all starting conditions are met If the resistance is above the preset level then an automatic high voltage DC Insulation Test to earth of the cable can be carried out If the result of the Insulation Test is above the preset resistance level the IPD s MCR relay energises which in turn closes the main contactor A manual Insulation Test is provided as a maintenance fault finding tool When this test is performed the MCR relay does not close at completion of a healthy test The Insulation Test allows cable insulation levels to be trended as an aid to preventative maintenance The IPD Relay has 5 Digital inputs which feed into a microprocessor unit The microprocessor has been programmed to control four output relays Relay MCR for the main contactor and Relay CBR for the circuit breaker Relay RL3 can be turned off or configured to follow th
28. results in a thermal accumulation of 89 and e The cold curve corresponds to the trip time when the motor starts with zero accumulated thermal energy The actual tripping times will normally be between these bounds depending on the time the motor has been running and the load and hence the accumulated thermal energy in the motor The motor manufacturer s data should be consulted to select the time multiplier appropriate for the motor being protected Typically the capacity of a cold motor is given at six times its rated current The IPD trip curves can be used to select the time multiplier which best suits the motors overload capacity While the main contactor is closed the cooling output from the thermal model is calculated to achieve the necessary time constants When the main contactor is open a Cooling Multiplier is used to modify the basic time constant This can be used to account for the reduced cooling capacity while the motor is not running when applicable e g fan cooled motors This multiplier is selectable at 0 2 0 3 0 4 0 5 0 8 1 0 2 5 10 20 and 50 times When 0 2 times is selected the motor off cooling rate is reduced to 20 of the motor running cooling rate A selection of 1 0 times sets the motor off cooling rate equal to motor running cooling rate This selection is appropriate where cooling is maintained even when the motor is stopped eg water cooled motors A selection of 50 times effectively disables the
29. the Certificate IECEx ITA 07 0018X Issue 0 and IECEx ITA 07 0018X Issue 1 1 Associated Intrinsically Safe Apparatus The Integrated Protection Relay Type IPD comprises 5 printed wiring boards PWBs upon which electronic components are mounted including a lithium manganese dioxide battery The pwbs are enclosed within a metallic enclosure fitted with plugs and sockets for connections of external circuits The apparatus is designed to restrict the transfer of energy from the non hazardous area to the hazardous area by limitation of the voltage and current to intrinsically safe levels with the application of 2 faults applied External connections are made via terminal blocks mounted on the rear of the apparatus The CCMA modules comprise of a single printed wiring board upon which are mounted resistors and zener diodes The modules are designed to restrict the transfer of energy from the non hazardous area to the hazardous area by limitation of the voltage and current to intrinsically safe levels with the application of 2 faults applied The modules come in three different versions namely the 110V the 415V and the 1000V External connections are made via screw connections located on the top of the apparatus The CCMD Interface modules comprise up to 4 printed wiring boards upon which are mounted resistors zener diodes and other electronic components The modules are designed to restrict the transfer of energy from the non hazardous area to the h
30. 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 in the schedule of this certificate and the identified documents was found to comply with the following standards IEC 60079 0 2000 Electrical apparatus for explosive gas atmospheres Part 0 General requirements Edition 3 1 IEC 60079 11 1999 Electrical apparatus for explosive gas atmospheres Part 11 Intrinsic safety i Edition 4 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 ITA ExTRO08 0015 00 AU ITA ExTRO8 0015 01 Quality Assessment Report AU TSA QAR06 0007 02 IPDB014 IPD User Manual 1 Page 72 IPD1V03 USER MANUAL POWER THROUGH INNOVATION IECEx Certificate of Conformity Certificate No IECEx ITA 07 0018X Date of Issue 2009 04 20 Issue No 1 Page 3 of 4 Schedule EQUIPMENT Equipment and systems covered by this certificate are as follows The IPD System comprises of the following items of equipment which ar
31. the separation is maintained even if a wire termination comes loose etc IPDB014 IPD User Manual 1 Page 42 IPD1V03 USER MANUAL POWER THROUGH INNOVATION 14 3 4 High Voltage Circuits The high voltage circuits of the IPD Relay are the 110VAC supply pins 30 31 and the relay contacts Apart from keeping these separate from the other wiring to the relay there are no special requirements WARNING In accordance with Australian Standards the relay contacts of the IPD Relay must not be used to switch more than 190VAC 5A or 100VA the intrinsic safety will be compromised if any of these values are exceeded IPDB014 IPD User Manual 1 Page 43 A AMPCONTROL lt o POWER THROUGH INNOVATION IPD1V03 USER MANUAL 15 IPD Equipment List 162831 121115 110141 110145 101487 101489 101486 110146 110147 110148 101826 121170 110773 101296 117139 IPDB014 IPD User Manual 1 Integrated Protection Relay IPD1V03 IPD Base Plate IPD Remote Display Module RDM D IPD Remote Termination Unit RTU D CCMA 110V Cable Connection Module CCMA 415V Cable Connection Module CCMA 1000V Cable Connection Module CCMD 415V Cable Connection Module CCMD 1000V Cable Connection Module CCMD 3 3kV Cable Connection Module EFTM 415 1kV IPC Earth Fault Test EFTM 3 3kV IPC Earth Fault Test IPD1V03 User Manual Fuse Holder C W 3A 660V Fuse Fuse 3A 660V Spare Item Page 44 a AMPCONTROL lt
32. thermal memory With this selection as soon as the main contactor opens the thermal model resets quickly so that a cold restart is achieved CAUTION A Repeated restart attempts in this condition may damage the motor Typical fan cooled motor protection is based on a cooling multiplier setting of 0 4 however for the best protection consult your motor manufacturer The thermal model continues to simulate the motor s thermal behaviour even if the power is removed from the relay When power is restored the thermal memory would be at the same level had there been no loss of power IPDB014 IPD User Manual 1 Page 23 ENTO IPD1V03 USER MANUAL POWER THROUGH INNOVATION The OC Trip Accumulator shows the state of the thermal model 0 Cold 100 Trip When a trip occurs the IPD Relay cannot be reset by operation of the reset button until the accumulator is less than 80 In order that an emergency restart on a hot motor can be achieved a reset of the thermal memory is possible by selecting Level 5 Position 3 on the Remote Display Module The display shows ZERO THERM MEM RESET LOCK 100 The 100 indicates the current value of the trip accumulator Operating the lock and reset buttons simultaneously while the above display is being shown will zero the OC Trip Accumulator after 1 5 seconds Indication of the trip condition for motor overload is the same that occurs for an over current trip
33. 0 aw u pu d pu 335 SWO9L 0ZL 001 08 09 07 0Z 4106 10 aul 35 S00 0 L0 0 SL0 0 20 0 0 0 70 0 S0 0 S 0 0 L 0 SL 0 2 0 0 7 0 S 0 9 0 4 0 8 0 01 3 Jejdijjnu auj SI aJeuM WX EEL 6 jeseu 0 3 9 1050 jo e se paunBijuos uas 104 2280 uas 159 i BuisibJau3 9 9 asa jualin JaAQ N 1 105 9 cti X SWL 94 pe G 10203 juawainseay gt fi 7N Wy lt 4 2950 a i A VL N 7 J 2 E 5H JaAQ 5 911455 9 4 205 9 lt 48 Y 2 4305 9 5104100 SQ 10HS 38H 9 155320 4 TVNBIS 9 5 7 2 55 IPDB014 IPD User Manual 1 AMPCONTROL o POWER THROUGH INNOVATION Inverse Over Short Circuit IPD1V03 USER MANUAL Current Curves ed Full Load Current S Cur Mul 41 0 x gt 60 5 ELA 68A P 12 16 rod eed ew ELA lt gt gt n fates gt gt e ee I un tien IPDB014 IPD User Man
34. 1 RDM D to monitor and control more than one IPD Relay In these circumstances the following wiring arrangement is recommended 1 RE The 3 pole change over switch must have sufficient clearance and creepage allowance between IPD Relay channels in accordance with IEC installation requirements 14 2 3 CCMD Cable Connection Module The Cable Connection Module CCMD is a resistor diode barrier which interfaces between the power circuit and the IPD Relay It also provides an automatic High Voltage DC Insulation Test following a successful Intrinsically Safe Earth Fault Lockout Test The CCMD is housed in an encapsulated module Ensure that the earth connections are reliably installed as this is the basis of protection for all barriers including the CCMD IPDB014 IPD User Manual 1 Page 39 NTO IPD1V03 USER MANUAL POWER THROUGH INNOVATION 14 2 4 Overload amp Earth Leakage Toroids Current transformers are not ideal devices and if correct procedures are not followed during installation nuisance tripping can result If for example we consider a single phase earth leakage system where active and neutral pass through a toroid then at all times currents in the two wires are equal and opposite so that the net current through the toroid is zero An ideal current transformer would have all the flux from each wire contained in the core and so would accurately add the Opposing fluxes to get a n
35. 143579 3SWd3H 0 SSJINC 321 NI SN ie Jl Q31108 1NO2Nn Page 65 IPDB014 IPD User Manual 1 AMPCONTAOL IPD1V03 USER MANUAL POWER THROUGH INNOVATION AMPCONTROL No IPD INTEGRATED PROTECTION RELAY 415V CCMD DIMENSION AND MARKING DETAILS CCMD 415 Exia I 07 0018X 0 lt Ta lt 60 C WARNING The high voltage connections are not IS while insulation test is applied Strict adherance to the conditions in the certificate is required fo ensure the explosion protection is not invalidated his drawing remains the property of UNCONTROLLED IF PRINTED 14 IPD User Manual 1 Page 66 IPD1V03 USER MANUAL POWER THROUGH INNOVATION AMPCONTROL DWG INTEGRATED PROTECTION RELAY DIMENSION AND MARKING DETAILS CCMD 1 kV ia IECEx ITA 07 0018X 0 C lt Ta lt 60 WARNING The high voltage connections are 15 while an nsulation test is applied Strict adherance to the conditions in the certificate is requred to ensure the explosion protection is not mvalidated RL4 el Earth 110Vcom UNCONTROLLED IF PRINTED IPDB014 IPD User Manual 1 Page 67 IPD1V03 USER M
36. 15V 2004 05 18 ARTWORK CCMA Z 005 CABLE CONNECTION MODULE TYPE A 415V 2004 05 18 CONTRUCTION DETAILS CCMA Z 006 CABLE CONNECTION MODULE TYPE A 415V 2007 12 12 DIMENSIONS AND MARKING EE a uS ARTWORK per mm CONTRUCTION DETAILS CABLE CONNECTION MODULE TYPE A 110V DIMENSIONS AND MARKING IECEx ITA 07 0018X Issue 1 Table 2 Drawing list associated with ExTR AU ITA ExTRO8 0015 01 Table 2 w e 77717972 NN Integrated Protection Relay Typical IS System Diagram IPD Z 009 2009 03 09 PD 11kV EFLO Module Mechanical Certification Detail IPD Z 035 2009 03 09 Sheets 1 2 PD 11kV EFLO Module Schematic IPD Z 036 2009 03 09 Sheets 1 to 4 Sheets 1 to 3 PD 11 Relay Marking Details 2 040 2009 03 09 IPDB014 IPD User Manual 1 Page 83 eee IPD1V03 USER MANUAL POWER THROUGH INNOVATION Appendix Additional Information on Current Protection This section of the document will outline the equivalence of the Over Current and Motor Overload protection schemes employed in the IPD with IEC60255 parts 151 and 8 respectively See Section 6 of this manual for basic operational information for the time dependent protection schemes Very Inverse Overcurrent IEC60255 151 See vInv Curves Drawing IPDB018 and Overcurrent Functional Block Diagram Drawing 2 in Appendix Drawings Over Current protection is implemented in conjunction with the time indep
37. 5 0 2 0 3 0 4 0 5 0 6 0 7 0 8 1 0 times 0 2 0 3 0 4 0 5 0 8 1 0 2 0 5 0 10 20 50 times 5 10 20 50 and off 3 0 to 10 0 times in 0 5 increments times full load current 20 40 60 80 100 120 160mSec DISABLED 40 60 80 100 120 2 5 10 20 seconds Can be allocated from 1 to 40 32 to 96 in 8 increments 96 of full load current Selectable from 20 to 80 in 10 increments Trip delay 800mSec For information on Protocol and hardware requirements see DNET IP2 Serial Communication System User Manual MCR CBR RL3 RL4 1 0 5A 190VAC 100VA maximum 1 C 0 5A 190VAC 100VA maximum Page 45 ewe IPD1V03 USER MANUAL POWER THROUGH INNOVATION 17 Commissioning Prior to being used in 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 points can provide guidance on checking the correct operation of the IPD during commissioning This is not intended to provide an exhaustive commissioning checklist but should be considered to be a minimum set of tests 17 1 Fan interlock Ensure that systems employing fan interlock circuits do not allow outlets to energise until the interlocked fan outlet is running correctly 17 2 Earth leakage Test the correct ope
38. 5 20 None None Table 3 2 2 1 If the value is less than the preset trip level 0 1 MQ to 15 MQ a trip occurs and is latched and saved in a non volatile memory The EF LED on the Remote Display Module is illuminated and the open collector output on the relay is switched on to provide remote monitoring if required An Insulation Trip shares the EF LED on the Remote Display Module with an EFLO trip but has dedicated trip messages on the Status Page To reset the relay following an insulation test fail trip operate the reset button At the completion of a test the leakage level for each phase is retained in memory until the next test is carried out This can be viewed on the Remote Display Module RDM Level 3 Position 3 If the Insulation Test is not selected by either not selecting CCMD or setting Ins TstT value to None then the MCR Relay closes at the completion of a healthy EFLO Test The accuracy of the insulation test and expected trip ranges are outlined in table 3 2 2 1 The results from insulation test should only be used as a guide to confirm that insulation remains above the preset threshold Insulation tests apart from the generated insulation test via the IPD and CCMD should be still carried out on a regular basis for maintenance purposes IPDB014 IPD User Manual 1 Page 17 a AMPCONTROL Ww gt POWER THROUGH INNOVATION IPD1V03 USER MANUAL Actual Fault Resis
39. 5 V A 415 CCMA 1000 V CCMD 415 CCMD 1kV Va Vb Ve 1000 V CCMD 3 3kV Va Vb Ve 3300 V li Terminal ID mA 6 U C Li i V F H RDM D 700 8 Negligible IKD Keypad 100 700 10 Negligible 20 5 0 RTUD 304 141 737 3 Negiigibie IPDB014 User Manual 1 Page 77 IPD1V03 USER MANUAL POWER THROUGH INNOVATION ATTACHMENT To IECEx CERTIFICATE IECEx ITA 07 0018X Issue 1 Page 4 of 9 This Attachment forms an Integral Part of the IECEx Certificate and all pages MUST be presented and read whenever the IECEx ITA 07 0018X Issue 1 Certificate is presented Output Parameters IECEx ITA 07 0018X Issue 0 _ e un V uF mH pH Q EP E Vsc RDI TXD amp OV IPD 1749 To Boa 4 oc v FIO amp OV 4 5 oe mo Pilot amp Earth me v 8 sw we we ld we c cue yum wer um Tm cem Va Vb Vc Va Vb Vc 7 7 39 726 Vb Vc IKD Interface 1 000 1 000 6 000 A B C EFT Vkp Data Earth Vkp Data Earth Pilot Earth IPSI D module 5 RIU D module o o oj NA NA IPDB014 User Manual 1 Page 78 p m IPD1V03 USER MANUAL 6 POWER THROUGH INNOVATION ATTACHMENT To IECEx CERTIFICATE IECEx ITA 07 0018X Issue 1 Page 5 of 9 5 This Attachment forms an Integral Part of
40. 7sE E gt tacts OVER CURRENT 5 ANO BIB 4 Trip 98 4 Tero Therm Mem 58425 7 INFORMATION Average 132Amps gt Ibal 0 t 0 gt Reset Lock 98 as 28 ER X 2 3 3 3 DE eT A E g PEAY 8 DIGTAL6 MCR CBR RLA lt START STOP 4 Lock RESET lt FD FR FRS 2 9 INPUT STATUS no n Out Out gt Rs gt 0 0 ce se ES e az 57 i Se ee So mm 22 1 1 28 GS o 2 38 lt 8 ex ee o 1 DATE TET un 5 E 130107 08483 0 Tu 210798 0848 Se X 8 E OEE mS 8 IPD SETTINGS 8 Stored Value lt Stored Value 4 Stored Value 4 Stored Value 4 Stored Value 4 Stored Value 4 Stored Vale 4 Stored Value lt VIEW amp MODIFY Pilot Type RTU gt EL Tine ins Sec gt EL Sens lt 500nA gt EFLO CCM None gt U V Trip 20 gt SC Relay MR gt EC Time 120mSec gt Relay 3 FID gt EE 2 Bs i i Y Y 1 Eu NUN 3 3 3 f qr 1 1 4 4 sli 9 RTU SETTINGS 9 Stored Value e Stored Value Stored Value 4 Stored Value 4 Stored Value Stored Value 4 Stored Value Stored Value 4 SEI VIEW amp MODIFY RTU MC Type Scar gt RTU No 6 gt Range 60
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42. ANUAL POWER THROUGH INNOVATION 19134 3 NOISN3IWIC GW 13 NOILISLONd 031V3931NI 031 dl 04110 1 02 0 09 gt BL gt 00 0 VIIXHOHI I er xa Mee 9 59 Page 68 IPDB014 IPD User Manual 1 IPD1V03 USER MANUAL a lt 0 6 8 2 9 031108 1N02Nf ONDE 8 NOISNSAIQ 37000 ANT AOL Vd SEP FTUSVIMN 3080 WH CLL 000 NOV sozen QL VALd NSO IOHLNOOdAV pois O Dnonpoidoi aq you pur 000 WW 006 96 9 42 595 NHOO Or 8 69 IPDB014 IPD User Manual 1 IPD1V03 USER MANUAL a 1 3 804 AMEP LINA 108100 AVT34 0 Vdl 011 Ald WSO TONLNOOdWY i04ucodue 242524464 Ad mo xuy woy air OL Samed OL 10 10 aq you put eas nau a palons sia Dr ha 10 0085 76 5 05 CEL
43. Connecting Module Dimensions amp Marking Details 3 3kV Cable Connecting Module Dimensions amp Marking Details 110V Cable Connecting Module Dimensions amp Marking Details Relay Output Module PCB amp Card Holder General Arrangement The drawings appear in the following pages in the same order in which they are listed in the table above If this document is being read via a computer the hyper links may be used Press control and click on the drawing number to go to that drawing IPDB014 IPD User Manual 1 Page 52 AMPCONTROL POWER THROUGH INNOVATION Appendix Drawings Earth Leakage Toroid type AMPCONTROL EL 500 E L Test Resistor Rleft 200 Ohms needs to produce test current 100 160 of Trip Level eren Module IPB M LBV 1000V System IPD Mode 415V System Ampcontrol CCMA 415 Ampcontrol CCMA 1000 Ampcontrol CCMD 415 1000V System Ampcontrol CCMD 1k 3 3kV System Ampcontrol CCMD 3 3k Earth Fault Test Resistors CCMA 415 91K Ohms CCMD 415 CCMA 1000 220K Ohms CCMD 1K CCMD 3k3 Over Load CT cr 1000 1 Class 2 STC Rating 30k 3 Sec Note Phasing on Overload C T s Must be as Shown 5 terminals 2 7 amp 12 are to be individually connected to system earth with minimum 1 5mm connectors Optional Led Relay Module Is Refer Dwg 5005 2 06 01 92 FAN INTE
44. D IPSI D Enclosure and Marking Details 2008 05 12 IPD Z 022 IPD CCMD 3 3kV Dimension amp Marking Details 4 2008 06 18 Sheets 1 to 3 IPD Z 026 CCMD 3 3 kV PCB Artwork 2005 10 14 IPD Z 029 IKD Z 001 IKD IKD Interface Schematic Diagram 6 IKD Z 002 IKD Interface Artwork 3 IKD Z 003 IKD IKD Keypad Marking Details Sheet 1 Sheet 2 IPD Z 015 RTU D Artwork 1 2005 10 12 Sheets 1 to 5 2 016 IPD RTU D Enclosure Details 2 2006 12 04 2 020 ____ CCMD 415 V Dimension amp Marking Details 4 2008 06 17 IPD Z 021 IPD CCMD 1 KV Dimension amp Marking Details IPD Z 023 IPD CCMD 1 KV amp 415 V Construction Details 3 2007 11 28 IPDB014 IPD User Manual 1 Page 82 p m IPD1V03 USER MANUAL 6 POWER THROUGH INNOVATION ATTACHMENT To IECEx CERTIFICATE IECEx ITA 07 0018X Issue 1 Page 9 of 9 This Attachment forms an Integral Part of the Certificate and all pages MUST be presented and read whenever the IECEx ITA 07 0018X Issue 1 Certificate is presented Table 1 Document No Document Title Date IPD Z 028 IPD CCMD 1 kV Schematic Diagram 2007 02 26 CCMA Z 001 CABLE CONNECTION MODULE TYPE A 1000V 2004 05 18 ARTWORK CCMA Z 002 CABLE CONNECTION MODULE TYPE A 1000V 2004 05 18 CONTRUCTION DETAILS CCMA Z 003 CABLE CONNECTION MODULE TYPE A 1 kV 2007 12 12 DIMENSIONS AND MARKING CCMA Z 004 CABLE CONNECTION MODULE TYPE A 4
45. Drawing 2 in Appendix A Drawings If the selected current protection type is vInv then a very inverse over current characteristic set of curves are available for selection The Very Inverse curve implemented in the IPD is equivalent to Curve B in Annex A of IEC 60255 151 180xm I 1 t sec Where t sec is the trip time m is the selected time multiplier and is the input current ratio relative to the full load current setpoint The three phase currents are compared and the highest current is used to calculate the trip time If the current exceeds the selected full load current an over current trip accumulator increases at a rate determined by the above function The accumulated value can be displayed on the RDM Level 5 Position 2 If the over current condition persists so that the trip accumulator reaches 100 then a trip occurs If viewed during start up the trip accumulator can help determine if over current settings are correct When a trip occurs the OC LED on the Remote Display Module is illuminated and the open collector output on the relay is switched on to provide remote monitoring if required If the current falls below the selected full load current the trip accumulator reduces towards zero The reset time is determined by the following function 1440x m t D Where is the time to completely empty the accumulator from 100 and all other metrics are as abov
46. E 90 031 dl 03110 1 02 26 19 2 9005 TvAOBddv VON OL E Od AJEL SLOVLNOO AV BH E ON Nid S31VOIONI SE NOLLONDH S31 vOIQNI 000086 0000 OL ONIHIM 3O TIMXI Yd NO S38v8 OL 359 Zr OL SON WNNHAL 2 9661 NO UNN LALO AW Tad LNAOW OH 9 89d JO 5 00 06 0074 20 0 9 89d 30 dOL perm 000 6 8 Page 70 IPDB014 IPD User Manual 1 eS IPD1V03 USER MANUAL POWER THROUGH INNOVATION Appendix Approvals Certificate EN of Conformity INTERNATIONAL ELECTROTECHNICAL COMMISSION IEC Certification Scheme for Explosive Atmospheres for rules and details of the IECEx Scheme visit www iecex com Certificate No ITA 07 0018X issue No 1 Certificate history Issue No 1 2009 4 20 Issue No 0 2008 7 7 Status Current Date of Issue 2009 04 20 Page 1 of 4 Applicant AMPCONTROL CSM Pty Ltd 7 Billbrooke Close Cameron Park NSW 2285 Australia Electrical Apparatus Integrated Protection Relay IS System Type IPD
47. I is closed the earth continuity trips at 145 ohms It is also necessary to bridge the local start button or start input on the relay on the outlet controlled by this method Both the remote and local stop buttons will turn off the outlet WARNING Stop Start functions are operational only Emergency stops must be wired directly into the pilot circuit IPDB014 IPD User Manual 1 Page 33 IPD1V03 USER MANUAL POWER THROUGH INNOVATION 10 5 Operational Sequence Before an outlet can be energised the following conditions must apply a No protection faults present b Fan interlocking enabled Stop input open d Local and remote start inputs closed stop and PTC inputs closed Once these conditions are obtained a cable fault lock out test is performed automatically This takes 1 second If the result of this test is satisfactory the IPD Relay goes into the run mode and the MCR relay picks up The RUN LED on the Remote Display Module is illuminated and the open collector output on the relay is switched on to provide remote monitoring if required A time delay of 5 seconds is allowed for the Main Contactor Interlock MCI to close If it does not close within this time then the run mode is exited If a stop input is closed while the relay is in run mode the run is cleared and the MCR relay de energises The event log reads Stopped If a stop input is cl
48. It is extremely important that the limitations and functionality of the IPD 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 applications engineer Ensure that the application into which the IPD is being installed has been properly defined approved and designed 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 IPD will properly perform the required functions within the system design It is important to understand how the IPD is intended to interact with other equipment within a system For safe and reliable use it is crucial that neither the IPD s logical operation nor its signalling be compromised by incompatibilities with connected equipment IPDB014 IPD User Manual 1 Page 38 IPD1V03 USER MANUAL POWER THROUGH INNOVATION 14 2 Installation 14 2 1 IPD Integrated Protection Relay The IPD Relay has a powder coated sheet steel enclosure designed to be mou
49. LED s Equipment Description 3 below applies only to Certificate IECEx ITA 07 0018X Issue 1 and constitutes a change to the original Issue 0 3 Change introduced by Issue 1 of the Certificate The addition of the EFLO Test Module 11kV allows the IPD to be used on 11kV systems Refer to Equipment Description on Certificate IECEx ITA 07 0018X Issue 1 for details Conditions of Certification The following conditions listed under A and B Groups apply to certificate ITA 07 0018X Issue 0 and IECEx ITA 07 0018X Issue 1 IPDB014 IPD User Manual 1 Page 76 IPD1V03 USER MANUAL Ww POWER THROUGH INNOVATION ATTACHMENT To IECEx CERTIFICATE IECEx ITA 07 0018X Issue 1 Page 3 of 9 H 5 This Attachment forms an Integral Part of the IECEx Certificate and all pages MUST be presented and read whenever the IECEx ITA 07 0018X Issue 1 Certificate is presented A Conditions of manufacture Ae The apparatus must be manufactured in accordance with the certified drawings B Conditions of safe use 1 0 Input and Out Parameters not to be exceeded according to 1 1 and 1 2 below 1 1 The following parameters are not exceeded for product covered by ITA 07 018X Issue 0 Input Parameters IECEx ITA 07 0018X Issue 0 Integrated Protection Relay Type IPD 1 2 8 15 to 56 132 IKD Interface J2 94 132 V IKD Interface _______ _____ IPSI D DNIP DNIP 250 CCMA 110 A CCMA 41
50. N x m x In 1 1238 iplier 1 for Hot time 100mS mn AS 1100 Page 60 P di AMPCONTROL lt gt POWER THROUGH INNOVATION IPD1V03 USER MANUAL 1 0 nig pun synding W31SAS DNIYDOTYILNI ddl dl 84110 1 02 0 a nis uoo sj Jc 20 pod u pearpoudej sq puo 608 ej 634 jonuesduy jedou supe 541 a niu Aun pun 10451528 001 1495522044045 D Kop 1081 4024 5 041 Ol 94 dn Q papaju 10814024 55 204 4 01 10558304 4 91 Q ady 0 uoyrayedg Td adi JONINOJdWV TOYLNOINY Page 61 IPDB014 IPD User Manual 1 IPD1V03 USER MANUAL POWER THROUGH INNOVATION 19139 NOISN3WIG 3598 AV I3H NOIL23108d 380501283 713 031v0 4 E amp 3 DRE N gt
51. N S768 Drawing created in AUTOCAD Approved Date 12 06 08 AS1100 00 NOT SCALE ecc OIMENSIONS IN MILLIMETERS Appendix B Approvals tir m Rr FRE esas ese Uu 71 IPDB014 IPD User Manual 1 em IPD1V03 USER MANUAL POWER THROUGH INNOVATION Very Inverse Overcurrent 60255 151 84 1 Receiving and Storage 1 1 Receiving All possible precautions are taken to protect the IPD against damage or losses during shipment however before accepting delivery check all items against the packing list or Bill of Lading If there are shortages or evidence of physical damage notify Ampcontrol immediately Notify Ampcontrol within 7 days maximum in case of shortages or discrepancies according to the packing list This action will help ensure a speedy resolution to any perceived problems Keep a record of all claims and correspondence Photographs are recommended Where practicable do not remove protective covers prior to installation unless there are indications of damage Boxes opened for inspection and inventory should be carefully repacked to ensure protection of the contents or else the parts should be packaged and stored in a safe place Examine all packing boxes wrappings and covers for items attached to them especially if the wrappings are to be discarded 1 2 Storage after Delivery Where equipment is not to be installed immediately proper storage
52. Optional accessory Type of Protection Ex ia Marking Ex ia IECEx ITA 07 0018X lt ta lt 60C Ex ial 20C lt ta lt 60C 1 ITA 07 0018X Approved for issue on behalf of the IECEx D Gray Certification Body Position Certification Authority Signature for printed version Date 2o 2 099 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 Certificate issued by International Testing and Certification Services Pty Ltd 4 6 Second Street Bowden SA 5007 Australia IPDB014 IPD User Manual 1 Page 71 b IPD1V03 USER MANUAL POWER THROUGH INNOVATION IEC Certificate d Mm of Conformity 7 Billbrooke Close Cameron Park NSW 2285 Australia Certificate No IECEx ITA 07 0018X Date of Issue 2009 04 20 Issue No 1 Page 2 of 4 Manufacturer AMPCONTROL CSM Pty Ltd 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
53. R THROUGH INNOVATION 9 2 Changing Settings The procedure for adjusting the settings is independent of where the values are stored The pilot mode should be checked prior to making any other adjustments to be certain the changes are made to the desired memory a gt Ensure the outlet is stopped For Group 2 Settings RTU Mode ensure RTU is on line Display the parameter that has to be changed on the Remote Display Module s liquid crystal display Momentarily operate the lock push button A warning message appears Press the enter button to acknowledge the warning message and to confirm that a change is desired Use the left and right arrows to step through the allowable values until the desired new setting is displayed If the right arrow key is pressed when viewing the last parameter the display wraps back around to show the first parameter Press the enter button to indicate that the value is the required setting Momentarily operate the lock push button The display will show a confirming message then return to the viewing level If the up or down keys are operated during the procedure the IPD Relay aborts the modifying sequence When changes have been made to the stored values the old value and the new value are stored in the event log A separate log immediately proceeds this recording the time and date that the change was made NOTE 1 While in the diode mode the IPD Relay
54. RLOCKING To Other Fan FES walk 100 Ohm TW 2 Only one for whole loop Li 15 NOT required use 10K 1W 2 on each FIO pin amp DO NOT interlink Relays 110 Control Supply 2 4M Ohms 2 4M Ohms 7 68M Ohms Transformer Maximum Short Time Rating of 16kA 3 Sec 20 120 msec Intrinsic Safety ma compromised if this is exteded Control Isolator E Control wet amp 110 Sec to AS 3108 1 or AS 3126 Isolation Chamber to other Outlets AMPCONTROL el ell Integrated Protection Relay Type D Safe Area Incoming Supply IPD1V03 USER MANUAL Drawing Number B C INTEGRATED PROTECTION RELAY TYPICAL CONNECTION DIAGRAM Drawing created in AUTOCAD Approved Date CD 12 06 08 DIMENSIONS IN MILLIMETERS AS1100 00 NOT SCALE GENERAL TOLERANCES U N O Orawn AUSTRALIA Tek 61 2 4903 4800 61 2 4903 4888 dectronicsQcmpeon trolgroup com 7 BILLBROOKE CLOSE CAMERON PARK N S W 2285 Hazardous Zone 5 DRAWING REMAINS THE PROPERTY OF AMPCONTROL Shielded 2 Core Cable Earth 100 Ohm Remote Control Pilot Con art Pilot ME Local Contro ORIGINAL ISSUE CRN S768 10575 IPDB014 IPD User Manual 1 AMPCONTROL gt POWER THROUGH INNOVATION IPD1V03 USER MANUAL
55. addition to basic visual observations more detailed integrity checks would involve e Verify that equipment housings wall boxes and other mechanical fixtures are secured tightly in place This includes the lids of terminal boxes 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 IPDB014 IPD User Manual 1 Page 50 eon IPD1V03 USER MANUAL POWER THROUGH INNOVATION 19 3 Equipment Maintenance WARNING E The IPD Integrated Protection Relay has no user serviceable parts All repairs must be carried out by Ampcontrol personnel only If a fault develops return the IPD to Ampcontrol for repair It is essential that no attempt be made to repair the IPD as any attempt to dismantle or repair the IPD can seriously compromise the safety of the unit and the consequence can be fatal The Ampcontrol IPD does not have any customer serviceable parts and is not provided with any user adjustments It is recommended that the electrical protection system incorporating the IPD Integrated Protection Relay 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 such tests as Earth Leakage injection te
56. an earth leakage fault caused a trip condition on Monday 15 May at 9 46am Log 10 indicates that itis the 10th log in the list Log 1 is always the most recent event Each time a new log is recorded the 120th log is removed from the list IPDB014 IPD User Manual 1 Page 35 AMPCONTROL lt o IPD1V03 USER MANUAL POWER THROUGH INNOVATION The following events are logged Power Up The instant that power is applied to the relay Pwr Down Removal of power from the relay MCR Close Closure of the Main Contactor Relay Stopped Stopping of the outlet by operation of the local stop button RTU Stop Stopping of the outlet by operation of the remote stop button MC Opened Main Contactor has opened but not initiated by the IPD Relay MC Fail Main Contactor Fail Function Trip CloseFail Indicates that the MCI Input did not close within 5 seconds of MCR closing EC Trip Pilot Earth continuity loop exceeds 45 Ohms EC Leak T Leakage resistance between the pilot and earth is less than 1500 Ohms EL Trip Earth leakage protection tripped EFLR Fail Earth fault lock out test has failed EL CT Fail Earth fault current transformer has failed SC Trip Trip condition of short circuit protection OC Trip Trip condition of over current or overload protection RESET Records resetting of a protection trip function Setup Mod Records that set up data has been modified Fan Stp Outlet stopped by fan interlock uVOLT Trp Records that voltage was not pr
57. antaneous current in each of the three phases can be displayed on the RDM Level 5 Position 1 The three phase currents are displayed as a of the overload set current The average current value is expressed in Amps and is displayed at Level 5 and the Status Page Level 0 Position 0 Following a trip condition the following conditions must be met to achieve a reset a The IPD reset input must be closed b The trip accumulator must be less than 80 Example full load current setting To obtain a full load current of 152 Amps select a current range of 76 Amps and a multiplier of 2 The IPD has a transient overreach performance figure of 35 determined per IEC 60255 151 section 6 5 2 To compensate for spurious tripping resulting from overreach a startup transient mode has been implemented See section 6 5 IPDB014 IPD User Manual 1 Page 21 IPD1V03 USER MANUAL POWER THROUGH INNOVATION 6 2 Dependent time protection There are two types of dependent time protection implemented in the IPD Over Current per IEC 60255 151 e Motor Overload per IEC 60255 8 One of these two techniques may be selected at Level 9 Position 5 vInv for over current or m OL for motor overload See Appendix C Additional Information on Current Protection for information regarding compliance to IEC 60255 6 2 1 Over Current Characteristics See Curves Drawing IPDB018 and Overcurrent Functional Block Diagram
58. atic Insulation Test If a CCMD Mode has been selected in the Group 1 Settings an automatic High Voltage DC Insulation Test is carried out following a successful Intrinsically Safe Earth Fault Lockout Test i e the resistance is above the preset level selected in the Group 2 Settings Level 9 Position 15 The HV DC Insulation Test is initiated when the IPD Relay closes its relay output RL4 for 2 seconds This applies 110VAC to the CCMD Cable Connecting Module A HV DC voltage is generated in the CCMD Module which applies a voltage approaching the peak system voltage between each phase and earth The IPD Relay measures the voltage on the line and calculates the meg ohm resistance to earth for each phase At the end of the test the result is stored in the Event Log as it MQ If the resistance value is above the preset threshold the MCR Relay picks up allowing the outlet to be energised Additionally if the result is equal to or below an Alarm Level typically 1 5 times the selected trip level see Table 3 2 2 i the status message Insulation Alarm is displayed on the Status Page level 0 position 0 The alarm message is displayed until a new EFLO Test is initiated or the lt ENT gt key is pressed while displaying the alarm message Insul Alm is also recorded in the Event Log Ins TstT Selection Alarm Level MO MO 0 1 0 2 0 2 0 3 0 5 0 8 1 0 1 5 2 0 3 5 0 7 5 10 15 1
59. ay is also tripped A LED on the front panel of the IPD Relay begins to flash The MCF LED on the Remote Display Module is illuminated and the open collector output on the relay is switched on to provide remote monitoring if required To reset the flag access to the relay is necessary In the case of flameproof equipment the power has to be removed in accordance with AS1039 The reset button is accessible through the front fascia of the relay and must be pressed for 1 second 7 2 Under voltage Trip Under voltage protection is enabled as soon as the main contactor is closed indicated by closing the MCI input If any of the phase voltages drop below the selected trip setting of the nominal line voltage for 800mSec then the outlet is stopped This is recorded in the event log as uVOLT Trp The trip level is selectable from 20 to 80 in 10 increments Level 8 Position 4 on the Remote Display Module 7 3 Voltage Metering The cable connecting interface module CCMD CCMA is also used to provide line voltage metering The outgoing line voltages for each of the 3 phases are displayed as a of the selected rated line voltage on the Remote Display Module Level 4 Position 1 The maximum reading is 120 Line voltages from 415V 1000V 3300V or 110V are configured when the appropriate CCMD CCMA Cable Connecting Module is selected in the Group 1 Settings Level 8 Position 4 on the Remote Display Module This parameter is also used
60. azardous area by limitation of the voltage and current to intrinsically safe levels with the application of 2 faults applied The modules come in three different versions namely the 415V the 1000V and the 3 3kV External connections are made via screw connections or integral cables The IKD Interface module comprises of a single printed wiring board upon which electronic components are mounted The pwb is partially enclosed within a steel or stainless steel enclosure fitted with four terminal blocks for connections of external circuits The apparatus is designed to restrict the transfer of energy from the non hazardous area to the hazardous area by limitation of the voltage and current to intrinsically safe levels with the application of 2 faults applied External connections are made via terminal blocks mounted on the apparatus The IPSI D module comprises of a single printed wiring board upon which electronic components are mounted The pwb is enclosed within a plastic enclosure fitted with terminal blocks for connections of external circuits The modules are designed to prevent the transfer of energy from the non hazardous area to the hazardous via galvanically isolating opto couplers with the application of 2 faults applied IPDB014 IPD User Manual 1 Page 75 IPD1V03 USER MANUAL POWER THROUGH INNOVATION ATTACHMENT CERTIFICATE ITA 07 0018X Issue 1 Page 2 of 9 This Attachment forms an Int
61. be preset with operating values in the Group 2 memory prior to switching to the RTU mode When in this mode the relay uses the Remote Termination Unit settings If the Remote Termination Unit is replaced with a diode and the Pilot Mode switched back to diode the settings will revert back to the values preset in the IPD Relay NOTE 2 When the relay has been selected for RTU Mode the RTU must be on line before the RTU set A up mode can be entered IPDB014 IPD User Manual 1 Page 32 IPD1V03 USER MANUAL POWER THROUGH INNOVATION 10 System Control 10 1 Digital Inputs The IPD Relay has five digital inputs which are all voltage free contact inputs Shorting the two input terminals together activates them The inputs are MCI start stop lock and reset The status of inputs can be displayed on the Remote Display Module Level 6 Positions 2 and 3 10 2 Output Relays The IPD Relay has output relays to control the main contactor MCR and the circuit breaker CBR Both relays are fail safe with respect to power supply loss and are controlled on the basis of protection functions Relay 3 has a selective function See section 8 1 Fan Interlocking RL4 applies 110V for the Insulation Test See section 5 2 2 Automatic Insulation Test The status of the relays can be displayed on the Remote Display Module Level 6 Position 1 10 3 Open Collector Outputs The IPD Relay has eight open collector o
62. be taken to ensure these circuits cannot come into contact with higher voltages e g via insulation breakdown or broken wires etc It is recommended that these circuits be run in a separate loom from both the IS circuits and the high voltage circuits To ensure that interference is kept to a minimum the following cabling is recommended Duty Pins Signal Recommended Cable Type pu 6 1 EL1 Two core screened 2 EL2 Screen Earth Earth EL Test Single core not screened Loop Leakage EL Test Resistance 10 Toroid Test Current Protection Transformers 2 SpDig Two core screened digital input SpDig Screen Earth 2xTwo core screened Screen Earth Lock Switch a Lock Two core screened Digital Input Lock Screen Earth Reset Switch Reset Two core screened Digital Input Reset Screen Earth Start Switch Start Two core screened Digital Input Screen Earth Motor Contactor Two core screened Aux Contact Screen Earth Digital Input The IPD s digital inputs could alternatively be run in a screened multi core cable Separate cable for each IPD Relay in multiple installations Where these low voltage circuits need to connect near the power circuits e g current transformers cable connection module main contactor auxiliaries etc care needs to be taken to ensure that the circuits are adequately separated and restrained so that
63. be viewed on the Remote Display Module Relay and Digital Input Status Section Level 6 Position 4 The outlet control in each IPD Relay has been designed so that an outlet will not run unless either a The FIR input is b The Remote Termination Unit connected to that has been programmed with machine type iFan The result of these conditions is reflected in an internal Fan Run Status FRS bit The status of this can be viewed on the Remote Display Module If the FRS is on then the fan interlocking system will allow the associated outlet to run Relay 3 can be selected to be either non functional off or can be configured to follow the Fan Interlock Drive FID or Fan Interlock Read FIR outputs of the Relay For single fan operation select FID or FIR Relay 3 will energises as soon as current is above the preselected threshold If FID is selected for dual fan operation then Relay 3 will energise as soon as current from either fan is above the preselected threshold If FIR is selected Relay 3 will only energise if the current from both fans are above the preselected threshold IPDB014 IPD User Manual 1 Page 28 IPD1V03 USER MANUAL POWER THROUGH INNOVATION 8 2 Interlocking Sequence The fan interlocking operates as follows 1 Each IPD powers up with the FID output turned off At this point the FIR input all IPD Relays will read as off therefore no outlet will run 2 When machine is
64. cycles c The loop resistance of the CT Detection Signal circuit connected to pins 32 and 33 must remain below 10 IPDB014 IPD User Manual 1 Page 15 IPD1V03 USER MANUAL POWER THROUGH INNOVATION 5 2 Earth Fault Lockout The IPD Relay can provide a two step insulation test as part of the Earth Fault Lockout protection function The initial test is the mandatory intrinsically safe test and can be followed by an automatic High Voltage Insulation Test A manual Insulation Test is also provided A cable connecting module which is a resistive isolation device is used to interface the power conductors to the IPD Relay Modules are selected in the Group 1 Settings Level 8 Position 3 for rated line voltages of 110V 415V 1000V or 3 3kV IPD Cable Connection Modules CCMD are the preferred modules and must be used when the Insulation Test function is required IPA Cable Connecting Modules CCMA are available with rated voltages of 110V 415V amp 1000V for use with the IPD Relay The use of these modules only allows the normal Intrinsically Safe EFLO Test to be carried out The High Voltage DC Insulation Test is not available with the CCMA Modules The 3 3 kV CCMA is not to be used in conjunction with the with the IPD relay An CCMA110V Cable Connecting Module is available for use when the relay is installed to control the high tension supply and or to provide voltage related function
65. e The reset ratio of the IPD is 96 nominal To reset the relay following an over current trip operate the reset button IPDB014 IPD User Manual 1 Page 22 IPD1V03 USER MANUAL POWER THROUGH INNOVATION 6 2 2 Motor Overload Characteristic See m OL Curves Drawing 19 and Motor Overload Functional Block Diagram Drawing IPDB035 in Appendix Drawings The current protection type m OL is used when a motor overload characteristic is required This protection scheme uses thermal model of the motor to determine the tripping characteristic Thermal modelling is based on a thermal time constant of 30 minutes time multiplier setting of 1 0 times The time multiplier can reduce this value to a minimum thermal time constant of 1 5 minutes time multiplier setting of 0 05 times The three measured phase currents are squared and added together to provide the heating input into the thermal model which is described by IP h O LTriptime 1800 x mx In 5 17 1 1238 Where m is the time multiplier h is 0 for cold motor and 1 for hot motor Note that unlike Very Inverse current protection Motor Overload protection does not have strictly defined tripping times The curves and function above describe the boundaries of the trip time where e The hot curve corresponds to the trip time after the motor has been running at the selected full load current indefinitely which
66. e Fan Interlock Drive output of the IPD Relay Relay RL4 when closed applies 110V to the CCMD Cable Connecting Module for the Insulation Test All of the tripping logic and outlet control is performed by the microprocessor so that virtually no external control is required See Typical Connection Diagram IPDE001 in Appendix A Drawings Extensive information display and monitoring features are included to facilitate fault finding and system trending This information can be read locally on the Remote Display Module RDM D or remotely via a communication link Opto Isolated Outputs are available for connection to optional LED or Relay Modules to provide additional run and trip indications The Ampcontrol Relay Output Module ROU enables these indications to be interfaced with a PLC Direct connections to the Opto Isolated Outputs can also be made for remote monitoring with no additional interfacing required The maximum voltage for these outputs is 30V with an internal impedance of 4 7kQ The protection functions provided by the IPD are Earth Leakage Section 5 1 Earth Fault Lockout Section 5 2 Earth Continuity Section 5 3 Over current Overload Section 6 0 Short Circuit Section 6 3 Contactor Fail Section 7 1 Protection trips are stored in a non volatile memory requiring a reset function before power can be restored to the load This remains the case even if a power down occurs following a trip condition IPDB014 IPD User Man
67. e addition of the EFLO Test Module 11kV allows the IPD to be used on 11kV systems The module provides the interface between the 11kV System amp the IPD relay It consists of three epoxy encapsulated high voltage resistors two specified pwbs and one unspecified pwb assembly enclosed a stainless steel and aluminum enclosure Connections to the 11kV system are via integral flying leads Plug terminals are used for connections to the IPD Relay An interface port is also provided to allow a measurement signal from a separate non certified insulation test module be selectively channeled through to the IPD relay Refer to the attachment to this IECEx Certificate of Conformity available for download at the end of this On Line IECEx Certificate of Conformity for full product details If viewing a copy this certificate in paper form refer to the the IECEx website http www iecex com for full product description details including list of Manufacturer s drawings IPDB014 IPD User Manual 1 Page 74 IPD1V03 USER MANUAL POWER THROUGH INNOVATION ATTACHMENT CERTIFICATE ITA 07 0018X Issue 1 Page 1 of 9 8 This Attachment forms an Integral Part of the IECEx Certificate and all pages MUST be presented and read whenever the IECEx ITA 07 0018X Issue 1 Certificate is presented Equipment Description Items 1 2 Below apply to both the original Issue of
68. e taken in to account when the apparatus is installed within a flameproof Ex d enclosure 8 The IPD Module contains significant amount of capacitance that may be considered as becoming charged to the supply voltage U 132 V under fault conditions When the IPD module is installed within a suitably certified flameproof enclosure the enclosure is to be durably marked with the text Warning Do not open when an explosive atmosphere may be present 9 The High voltage connections of the CCMD Modules are NOT Intrinsically Safe while terminals RL 4 and 110Vcom are energized 10 The High voltage connections of the EFLO Test Module 11kV are NOT Intrinsically Safe while terminals 1 to 4 are energized 11 The EFLO Test Module 11kV must be infallibly connected to the main system earth via the dedicated connection IPDB014 IPD User Manual 1 Page 80 p m IPD1V03 USER MANUAL 6 POWER THROUGH INNOVATION ATTACHMENT To IECEx CERTIFICATE IECEx ITA 07 0018X Issue 1 F Page 7 of 9 This Attachment forms an Integral Part of the IECEx Certificate and all pages MUST be presented and read whenever the IECEx ITA 07 0018X Issue 1 Certificate is presented DRAWINGS The following list of drawings apply to Both Issues 0 and 1 of this Certificate IECEx ITA 07 0018X Issue O Table 1 Drawing list associated with EXTR AU ITA ExTRO8 0015 00 Table 1 Document No Document Title Issue Date IPD Z 009 IPD Integrated Protec
69. e to be located in a non hazardous area Integrated Protection Relay Type IPD CCMA or CCMD interface module IKD Interface IPSI D module RTU D module EFLO Test Module 11KV PAWN Connected to the non hazardous area equipment listed above are the following equipment which may be located in a hazardous area 11 RDM D Module 2 IKD Keypad Refer to the attachment to this IECEx Certificate of Conformity available for download at the end of this On Line IECEx Certificate of Conformity for full product details If viewing a copy this certificate in paper form refer to the the IECEx website www iecex com for full product description details CONDITIONS OF CERTIFICATION YES as shown below Refer to the attachment to this IECEx Certificate of Conformity available for download at the end of this On Line IECEx Certificate of Conformity for full details of Conditions of Safe Use that MUST be met in order for this to remain valid If viewing a copy this certificate in paper form refer to the the IECEx website www iecex com to download the certificate attachment IPDB014 IPD User Manual 1 Page 73 IPD1V03 USER MANUAL POWER THROUGH INNOVATION Certificate of Conformity Certificate No IECEx ITA 07 0018X Date of Issue 2009 04 20 Issue No 1 Page 4 of 4 DETAILS OF CERTIFICATE CHANGES for issues 1 and above Issue 1 of this Certificate covers the folowing changes Th
70. ections must be carried out by suitably trained people with knowledge of the IPD and the systems into which it is fitted Routine inspections may take the form of either simple visual only checks or visual and hands on checks 19 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 IPD and other equipment This level of inspection may also include cleaning display windows that have become obscured by dirt Observations would typically be e Check that equipment enclosures cable trays conduits wall boxes 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 e Check that labels on equipment wall boxes and cables are present and in good clean condition especially certification labels e Check that no modifications have been carried out to installed equipment 19 2 Hand On Detailed Inspections 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 In
71. egral Part of the Certificate and all pages MUST be presented and read whenever the IECEx ITA 07 0018X Issue 1 Certificate is presented The RTU D module comprises of a single printed wiring board upon which electronic components are mounted The pwb is enclosed within a steel enclosure fitted with a terminal blocks mounted on the top of the enclosure for connections of external circuits The Integrated Protection Relay Type IPD CCMA CCMD IKD Interface IPSI D and RTU D modules must be located either in a non hazardous area or within a suitably certified Group flameproof enclosure 2 Hazardous Area Intrinsically Safe Apparatus The RDM D module comprises of a single printed wiring board upon which electronic components are mounted The pwb is partially enclosed within an enclosure made from a steel fascia and a plastic box fitted with a terminal block mounted on the rear wall of the enclosure for connections of external circuits The front of the enclosure is fitted with 5 membrane switches with 8 indicating Light Emitting Diodes LED s and a Liquid Crystal Display LCD The IKD Keypad comprises of a single printed wiring board upon which electronic components are mounted The pwb is enclosed within plastic enclosure fitted with a terminal block mounted on the rear wall of the enclosure for connections of external circuits The front of the enclosure is fitted with 8 membrane switches with indicating 8 Light Emitting Diodes
72. endent short circuit functions of the IPD The overcurrent value energising quantity used in the IPD is calculated from the highest current of the three phases measured When the measured current exceeds the Full Load Current value Gs an accumulator begins incrementing according to the Very Inverse function 13 22 1 Where t G is the operate trip time TMS is the time multiplier is the input current ratio relative to the full load current setpoint Also TMS 133 Where mis the time multiplier setting programmed in the IPD menu The value of Gr the lowest value at which the relay is guaranteed to operate for this function is 110 relative to Gs Gp the threshold of independent time operation is made redundant by the independent time characteristic of the IPD s short circuit protection which has a maximum setting of 10 times Gs NOTE the function which has been published elsewhere in this document for Over Current is 180 t sec xm 1 Where t sec is the operate trip time m is the selected time multiplier and is the input current ratio relative to the full load current setpoint These two algorithms are mathematically and operationally identical For purposes of demonstrating conformance to Curve B of IEC 60255 151 the algorithm has been rewritten for clarity Equivalence with the IEC 60255 151 requirements is established with TMS 13 33 x m k
73. ents 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 This equipment has been manufactured in accordance with quality standard OD005 to ensure compliance to its certificate of conformity If there are any signs of modification or damage to this equipment it must not be used until it has been repaired and deemed fit for purpose by the equipment s manufacturer or by an AS3800 accredited workshop The instructions within this manual must be implemented as an aid towards achieving safe operation Intended Use of the Equipment The IPD integrated protection relay is intended to be used as a part of the electrical protection system operating on outlets supplying underground mining machinery Multiple protection functions as listed in this document are combined into a compact plug in unit which can be easily changed out to minimise down time in the event of a problem with the relay The IPD is not intended to be the sole method of providing electrical protection for machinery and personnel Other measures such as e stops interlocks and earth fault current limiting resistors are to be employed to ensure the highest level of operational safety It is recommended that safety analysis techniques such a
74. esent on at least one outgoing phase when the main contactor was closed MCF F Trp Internal battery backed main contactor fail trip RTU ptc T Operation of the remote termination units PTC T mem Rst Thermal memory has been manually reset to zero Records that the relay s non volatile parameter memory has been corrupted u P reset Internal microprocessor reset Tmem Loss The thermal memory data has been corrupted RTU mem E Records that the remote termination unit s non volatile memory has been corrupted or remote termination unit has gone off line while the outlet is running Outlet On Records RTU machine code and number when main contactor is closed proceeded by MCR closed This log only appears when in RTU mode RTU OffL Indicates a loss of communications with the RTU Meg Q Trp Insulation Test failed IT MQ Records the result of the Insulation Test Insul Alm Result of Insulation Test is equal to or less than the alarm level IPDB014 IPD User Manual 1 Page 36 IPD1V03 USER MANUAL POWER THROUGH INNOVATION 12 Time amp Date If there is a need to adjust the real time clock carry out the following procedure 1 Using the Remote Display Module select the time and date information page Level 7 Position 1 to display the Day Month Year Hours and Minutes MO 150595 09 46 Press the enter key v will appear in the top line above the minute section This indicates the number t
75. et result to zero A real current transformer has leakage fluxes That is a very small proportion of the total flux from each cable is not contained in the core but in the space outside it and as result it may link some turns but not others depending on the positioning of the cables The effect of this is that a small output may be obtained from the CT where none would arise if the device were ideal The size of the error will vary from CT to CT of the same type because of slight differences in the core and the symmetry of the winding Problems caused in this way become worse as CT sizes increase as currents increase and a decrease occurs in the symmetry of the cables Nuisance tripping tends to occur when the total current rises such as when a large motor is started This is not normally a problem with the current levels found in flameproof enclosure applications To help avoid problems in other applications select the smallest internal diameter CT to suit the cable size 14 2 5 Toroid Installation Guide Lines 1 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 at symmetry 2 Do not bring the cables back past the toroid within one diameter of the CT trying to cram cables into a small space reduces symmetry and may lead to problems which are difficult to solve 3 Avoid placing the CT near any device which produces magnetic fields whether it is a transformer
76. gt r 2 Si KED 2 CURRENT Full Load IPDB014 IPD User Manual 1 700 800 300 1000 IPD1V03 USER MANUAL 1 wem 033 Ufa wis IPDB Sheet 1 of 1 ERROR CURVES SCALE NTS OVERCURRENT amp SHORT CIRCUIT SUE A3 AMPCONTROL ELECTRONICS AMPCONTROL CSM PTY LTD electronks anpcontro group con ABN 35 900 770 141 CAMERON PARK N S W 2285 02 4903 4800 7 BILLBROOKE CLOSE TIME MULTIPLIER THIS DRAWING REMAINS THE PROPERTY OF AMPCONTROL Ir Is Subject thelr recall amp or whole zr the contents dhutged to third porty witheut the prior written apprevo from AMPCONTROL mest not be reproduced in port DIMENSIONS IN mm DO NOT SCALE GENERAL ANGULAR TOLERANCE t 1 Page 57 AMPCONTROL lt o POWER THROUGH INNOVATION IPD1V03 USER MANUAL 9 5 2 p 1911 SN 000 SV ira wotsinga 0 ME 35 345 I 008 604 zo lt q HP o cj 31s son 00 ame 4 9 ma 06 0 32018 0977 WS N NOH3RYO NORD hn Ni SNOISNAWIC TWNOILINNS GVOTHIAG YOLOW _ 7
77. he lock button closed and then closing the reset button When a trip occurs the EL LED on the remote display module is illuminated and the open collector output on the relay is switched on to provide remote monitoring if required The leakage current EL is displayed on the RDM Earth Fault Information page as a of the trip level When the leakage reaches 100 for the selected time delay a trip occurs The trip level is adjustable in 50 mA increments Range 100 to 500 mA The time delay is adjustable Range instantaneous lt 50mS 100mS then 150 to 470mS in 40mS increments The IPD generates a CT Detection Signal continuously to test the integrity of earth leakage circuit The CT Detection signal continually tests the toroidal current transformer the wiring loop to the toroid and the input to the protection relay as required by AS NZS 2081 3 2002 The signal generated by pins 32 and 33 is a 20mA signal at 200Hz It must be fed from pin 32 one loop through the toroid then back to pin 33 The CT detection signal can be monitored by pushing the Enter switch when viewing the Earth Fault Information on Level 3 position 1 of the Remote Display Module When the trip occurs the remote display module EL LED will flash and the open collector output on the relay is switched on to provide remote monitoring if required The trip time is derived from the main EL trip time but is constrained to a minimum of 80 mS 4 x 20 mS
78. ires to make it operate Also check the first six event logs Symptom Remote Display shows a blank screen The RDM Healthy LED indicator located on the top of the RDM module is off Remote Display shows a blank screen The RDM Healthy LED flashes at 1 Hz Status Message IPD Memory Error When in diode pilot mode Status Message IPD Memory Error When in RTU pilot mode Status Message RTU Memory Error Relay will not close EC fault indicated Status Message Need RTU Start or Stopped RTU or Stopped RTU PTC Status Message Locked Out Fan 14 IPD User Manual 1 Loss of power to the Display Faulty Display Module Power to RDM is healthy but there is no data Corruption in the Group 1 or 2 Settings stored in the IPD Relay Corruption in the Group 1 Settings in the IPD Relay Either the RTU is not on line or the RTU s non volatile memory has been corrupted Faulty pilot circuit open or high resistance or shorted to earth Relay is waiting for the RTU digital inputs to be closed Relay is waiting for fan interlocking system Check there is power to the relay and it is correctly plugged in The Relay supplies 15v dc to RDM Check cable between RDM and the relay Replace module Check data cable between the relay and the RDM Examine the Group 1 and 2 Settings level 8 and 9 to check the stored parameters in the non volatile memory Machine type and nu
79. mber are irrelevant and should be ignored One or several settings will show Re program lost settings into the memory Examine the Group 1 Settings level 8 to check the stored parameters in the non volatile memory One or several other settings will show Re program lost settings into the memory Check that the RTU is on line level 3 position 1 ie a healthy pilot loop If the RTU is on line examine the Group 2 Settings stored in the RTU level 9 One or several other settings will show 222 Re program lost settings into the memory Check pilot circuit eg operate relay with a dummy plug if in diode mode If still faulty replace the relay Check pilot fuse Ensure all three RTU digital inputs are closed If interlocking is not required then a 10k ohm resistor must be connected between terminals 9 and 12 Page 48 E Nma IPD1V03 USER MANUAL POWER THROUGH INNOVATION If fan interlocking is used ensure that the fan is running and the current threshold setting in the fan outlets RTU is correct The Fan Outlet IPD should pick up its FID Fan Interlock Drive signal which causes all other relays to pick up their FIR Fan Interlock Read Check these conditions level 6 position 4 If fan interlocking is not correct check the wiring between the fan relay and other relays terminal 9 Check that main contactor is closing If not check circuit or replace main contactor Check auxilia
80. nt before the overload occurs 0 for cold 7 gt 1 for hot Also 1800 m Where m is the time multiplier setting programmed in the IPD menu After a trip occurs the thermal time constant is modified by the cooling modifier T T Cooling Fator NOTE the function which has been published elsewhere in this document for motor overload is I h 1800 mx In 5 I 1 1238 Where mis the time multiplier his 0 for cold and 1 for hot These two algorithms are mathematically and operationally identical For purposes of demonstrating conformance to 3 1 2 of IEC 60255 8 the algorithm has been rewritten for clarity Equivalence with the IEC 60255 8 is established with lg 1 0 k 1 0601 T 1800m Resultant values of 7 based on the range of m values is 9 lt 7 lt 1800 0 005 lt ms 1 0 The overall error in tripping accuracy for Motor Overload is 5 IPDB014 IPD User Manual 1 Page 85
81. nted into existing enclosures ie flameproof equipment or other enclosures of adequate IP rating The relay is designed to operate when mounted either laid down flat or in a vertical position Vent holes are provided at both the top and bottom of the relay to assist in the cooling of the electronics inside the relay These vents should not be blocked or restricted in any way When installing the IPD Relay care should be taken to ensure sufficient space is allowed around the relay for the ease of change out during routine maintenance Connections to the IPD Relay are made via a plug in base This base is to be securely fastened to the enclosure in which it is being installed The base is clearly labelled for ease of terminal location and identification The base sockets are factory adjusted so that they are able to move to assist in alignment when the relay is inserted Do not tighten socket mounting screws For installation mounting see drawing IPDA017 in Appendix A Drawings 14 2 2 Remote Display Module RDM The Remote Display Module is an intrinsically safe device Ex ia designed to be mounted into the cut out of an IP54 enclosure and can therefore be mounted external to the switchgear it is controlling To provide maximum benefit to the operator one RDM is normally used per relay This allows information from several relays to be simultaneously accessed and compared However if space restrictions preclude this a compromise is to use one
82. o be changed Use the left and right arrow keys to move the to the desired position Press the enter key The v now changes to The right arrow key is used to increment the allowable values once the desired value is obtained press the enter key again The gt returns to a v Repeat steps 3 and 4 until the correct time and date is displayed With the showing press the lock push button The v then changes to E This is a prompt to press the enter key Press the enter key At that instant the seconds are zeroed and the selected time date information is transferred to the internal clock If the battery voltage is low the time will zero and the date will reset to 1st January on power up If the battery is flat or faulty the relay is likely to trip on main contactor fail on power up a The date and time are used only to time stamp the events in the log which are recorded sequentially regardless of the date time Date and time data is not used for any control functions 13 Remote Data Communications The IPD Integrated Protection Relay has the facility for connecting remote monitoring equipment This can be in the form of either the Remote Display Module or other peripheral equipment such as PLC s For PLC applications each integrated protection relay is connected to a Serial Interface Module IPSI D which has its output drop connected to a DNET IP2 Protocol Converter The Prot
83. ocol Converter provides the communications link to a PLC See User Manual 118626 for further details The Ampcontrol DNET IP2 Serial Communication System transfers data and commands between the Host System and the modules using 5232 5422 and RS485 protocols IPDB014 IPD User Manual 1 Page 37 IPD1V03 USER MANUAL POWER THROUGH INNOVATION 14 Installation amp Wiring Instructions The IPD Integrated Protection Relay is a microprocessor based protection relay that has the facility for connecting intrinsically safe remote monitoring equipment This can be in the form of either the Remote Display Module or other peripheral equipment such as PLC s These instructions have been designed to assist users of the IPD Relay with installation and special wiring techniques required maintaining the integrity of the intrinsically safe circuits 14 1 General Warnings The IPD Integrated Protection Relay is typically installed into a system along with appropriate devices providing input signals sensors and output control per IPDE001 Before the IPD can be installed there are a number of things that need to be considered and understood to prevent incorrect or unsafe operation of the IPD or the system into which it is installed Along with relevant competence and an understanding of the target application the following points should be considered Ensure that the information provided in this user manual is fully understood
84. ommend that you take the time to read this user manual thoroughly If this document is being read via a computer the hyper links may be used Press control and click on the blue highlighted text to go to that topic IPDB014 IPD User Manual 1 Page 2 IPD1V03 USER MANUAL POWER THROUGH INNOVATION TABLE OF CONTENTS Ampcontrol CSM Contact 5 22 22 2 4 2 20 402020 1 0140 00000004040 01 09 0 0 0 0 4 1 Safety and other 05 3 1 ss 2 2 Before 2 1 Receiving and 6 1 1 E 6 1 2 Storage after Delivery eem 6 1 3 Unpacking of EquipmenNt sss sss 6 2 General MENU TTE 7 21 Personnel Safety 7 2 2 7 2 3 Operational Restrictions and damen ett 8 EEUU PRO 9 3 1 Introduction 9 3 2 Remote Eusebio a 10 3 2 1 Trip Status Messages eee TRECE TS TON 10 3 2 2
85. on Test function must not be tripped Outlet must not be running Outlet must not be in the process of closing Outlet must not be Paused The Lock digital input must be closed OY When the above conditions are met the ENT key must be pressed and held for the duration of the test After 3 seconds the EFLO test will commence If the test result is healthy the manual insulation test is initiated The test voltage is applied to the outgoing feeder while ever the above conditions are held including holding the ENT key The test results are continuously calculated and displayed The operator should maintain the test at least long enough for the readings to stabilize this being a function of the cable length Once the test is completed usually by releasing the ENT key the results are held in memory until another insulation test is commenced either manually or as part of the starting sequence or IPD control power is lost The manual test can be carried out even if the Ins TstT selection is set to none ie the automatic insulation test in the starting sequence is turned off If the CCM selection see section 5 2 Earth Fault Lockout is not a CCMD Cable Connecting Module then the manual test will only perform an EFLO test The status of the manual insulation test is shown on the Insulation Test Information Page level 3 position 3 A single letter following
86. ors CCMA 415 91K Ohms CCMD 415 2 4M Ohms CCMA 1000 220K Ohms CCMD 1K 2 4M Ohms CCMD 3k3 7 68M Ohms Over Load 3 1000 1 Class 2 STC Rating 3 Sec Note Ehesing on Overload C T s Must be as Shown 1 5 terminals 2 7 amp 12 are to be individually connected to system earth with minimum 1 5mm connectors Optional Led Relay Module Refer Dwg 5005 2 06 01 92 AMPCONTROL 5 1 0 gt FAN INTERLOCKING wo R 100 Ohm 1W 2 Only for whole loop If Interlocking is NOT required use a 10 on each FIO pin amp DO NOT interlink Relays Safe Area 110 Controt AMPCONTROL el ell Integrated Protection Relay Type D IPD1V03 USER MANUAL Maximum Short Time Rating of 3 Sec 20 120 msec Intrinsic Safety ma compromised if this d is exceded Incoming Supply ABC Control Isolator E Control Transformer 110 Sec Isolation Chamber to AS 3108 1 or to other Outlets les passin rough foroi amp C f s to be Insulated to System Voltage Level AUSTRALIA Tek 61 2 4903 4800 Foc 61 2 4903 4888 dectronicsQcmpontrolorcup com 7 BILLBROOKE CLOSE CAMERON PARK N S W 2285 Hazardous Zone Shielded 2 Core Cable IPD Diode Pilot E Earth Remote Control Local Contro INTEGRATED PROTECTION RELAY TYPICAL CONNECTION DIAGRAM ORIGINAL ISSUE CR
87. osed during a cable fault lockout test then the test is aborted While the main contactor is closed the MCI input is continuously monitored If it opens the run is cleared and the MCR relay de energises In this case the event log records MC Opened which indicates that the outlet was turned off by something other than the IPD Relay e g open circuited main contactor coil or control supply It should be noted that if the main contactor does not close when the MCR relay closes and the start stop conditions are maintained then the IPD will cycle through the following start sequence testing run stopped pause then repeat the sequence while ever the start input is closed IPDB014 IPD User Manual 1 Page 34 IPD1V03 USER MANUAL POWER THROUGH INNOVATION 11 Event Log A real time clock calendar is included in the IPD Relay This combines with the non volatile memory to provide a data logging feature This log sequentially records the time date and details of the most recent event A chronological list of the previous 120 events is stored The event log can be automatically scrolled so as to view the entire log To achieve this press Enter followed by the Right or Left arrow keys to commence the scroll The log will scroll one log per second in the direction of the arrow key pressed Press Enter to stop the scroll at the desired log A typical display shows LOG 10 EL TRIP MO 15 05 09 46 21 This records that
88. perate successfully in the time expected according to the settings employed and that latched trips may be reset in the appropriate manner Repeat on the second set of CT terminals If Motor Overload that all relevant tripping circuits operate successfully in the time expected according to the settings employed and that latched trips may be reset in the appropriate manner IPDB014 IPD User Manual 1 Page 46 eee IPD1V03 USER MANUAL POWER THROUGH INNOVATION 17 7 Short Circuit current injection Test the Short Circuit protection by carrying out secondary injection on the CT terminals of the IPD Inject a current value relevant for the settings employed into one of the CT terminals and ensure that all relevant tripping circuits operate successfully in the time expected and that latched trips may be reset in the appropriate manner Repeat on the second set of CT terminals 17 8 Current detection in CTs Ensure the integrity of the current detection CTs by injecting primary current into the CT aperture and validating the reading on the RDM 17 9 Main contactor fail Validate the correct operation of the CCMD and MCF protection by applying a voltage on the load side of the contactor The voltage must be gt 10 of the rated voltage of the CCMD Ensure that a CBR trip is initiated by the IPD which can only be reset by pressing the MCF reset on the IPD relay 17 10 Voltage measurement Validate the voltage measurement function of the
89. quipment that collectively form the means to minimise the risk of injury or death to personnel selection installation commissioning and use of this protective device should only be undertaken following the application of a detailed risk assessment that is consistent with the methodology outlined in AS NZS ISO 31000 risk management Additionally identified risk control measures identified within the risk assessment additional to safety controls and or directions contained within the products operating manual must be validated as effective before use of the product in any capacity IPD integrated protection relay is NOT designed to be used as the sole means of ensuring safety to personnel or equipment e IPD integrated protection relay does NOT have an associated Safe Failure Fraction SFF e IPD integrated protection relay is NOT certified for use in Group hazardous area applications e IPD integrated protection relay is NOT water resistant and must be mounted within a suitably rated enclosure for use where the overall system is to be rated water resistant e IPD integrated protection relay is NOT on site repairable and contains no user serviceable parts e IPD integrated protection relay must NOT be modified in any way A controller that differs in any way from its as certified condition must not be used IPD integrated protection relay showing any visible signs of
90. r 3 S Ld Stage Loader 4 Hpmp Hydraulic Pump 5 Wpmp Water Pump 6 cMnr Continuous Miner 7 SCar Shuttle Car 8 Bk F Breaker Feeder 9 Crsh Crusher 10 Fan Fan 11 DCB Distribution Control Box 12 BLANK Not Used 13 iFan Fan with interlocking 14 AFCm Armoured Face Conveyor Main Gate 15 AFCt Armoured Face Conveyor Tail Gate 16 M BE Mobile Boot End 17 Bolt Bolter 18 HRMr Hard Rock Miner 19 Winc Winch 20 J bo Face Boring Machine 21 bBIt Belly Belt 22 Stak Stacker 23 aCar Add Car 24 IGG Inert Gas Generator 25 Transfer belt 26 Dplg Dummy plug 4 3 Machine Type Number Machine numbers 1 to 40 can be assigned to machines These numbers are programmed using the Remote Display Module Level 9 Position 2 IPDB014 IPD User Manual 1 Page 14 IPD1V03 USER MANUAL POWER THROUGH INNOVATION 5 Earth Protection Functions 5 1 Earth Leakage The earth leakage protection function uses an Ampcontrol EL500 series toroid to measure the earth fault current This function is tested to AS NZS 2081 3 2002 A definite time operating characteristic is provided with adjustable trip sensitivity and an adjustable time delay When a fault occurs and the trip level and time delay are exceeded a trip occurs The trip acts in the Main Contactor Relay MCR logic and is latched An earth leakage trip is treated as a special fault and requires an authorised person to perform the reset function This is achieved by operating and holding t
91. r Manual 1 Page 25 AMPCONTROL lt o POWER THROUGH INNOVATION IPD1V03 USER MANUAL For the IPD transient overreach may cause spurious tripping on short circuit due to resulting measurement inaccuracies To compensate for this effect a START TRANSIENT mode has been implemented with the following selectable options on Level 9 Position 16 of the Remote Display Module OFF 40ms 60ms 80ms 100ms 120ms When the START TRANSIENT mode is enabled the IPD current setting is increased for the specified period of time after the main contactor has been closed The increased current is achieved by the following 1 Forcurrent multiplier 1 8x to 2x the current multiplier will be increased one step e g 1 2x increases to 1x for the selected time period 2 Forcurrent multiplier 4x the base current will be increased to the maximum setting of 116A Examples 1 set to 88A 1x current multiplier and 6x short circuit multiplier resulting in a short circuit setpoint of 528A With START TRANSIENT mode set to 90ms the current multiplier goes to 2x and the short circuit trip level will increase to 1136A until 90ms after the MCI input from the auxiliary contact on the main contactor closes 2 set to 72A current multiplier and 8x short circuit multiplier resulting in a short circuit setpoint of 2304A With START TRANSIENT mode set to 150ms the base current goes to 116A and the short
92. ration of earth leakage circuits by injecting a fault current through the toroid Ensure that all relevant tripping circuits operate successfully and that latched trips may be reset in the appropriate manner Disconnect the toroid from the IPD and ensure that a toroid fault trip is issued with similar effect 17 3 Earth fault lockout Test the correct operation of Earth Fault Lockout protection by connecting test resistors on the relay side of the CCMD per IPDE001 With these resistors in circuit the outlet should be prevented from energising 17 4 Earth continuity Test that the Earth Continuity protection is operational by creating an open circuit on the pilot wire Ensure that all relevant tripping circuits operate successfully and that latched trips may be reset in the appropriate manner Repeat with a short circuit between pilot and earth 17 5 Insulation test If the Earth Fault Lockout and Earth Continuity tests are successful ensure that the a manual insulation test can be successfully conducted via the IPD Also check that an automatic insulation test is initiated by the IPD when a START signal is generated 17 6 Over Current Motor Overload current injection Test the Over Current Motor Overload protection by carrying out secondary injection on the CT terminals of the IPD Where Over Current IEC 60255 151 protection is employed inject 2x FLC into one of the CT terminals and ensure that all relevant tripping circuits o
93. ry contacts and wiring The relay s MCI input is not Closing within 5 Sec of MCR relay pickup level 6 position 2 Relay displays Outlet Close Fail message after start is pressed Check system voltage display level 4 position 1 as contactor closes Compare this with the under voltage threshold Relay not receiving lost Check continuity from the relay through the voltage feedback CCMD to power conductors This be achieved RDM displays Tripped No all three outlet phases by testing each phase to earth at the outlet Volts message when contactor closed provided the circuit is isolated Typical readings CCMD 415 2340k ohm CCMD 1000 2340k ohm CCMD 3 3k 7520k ohm Main contactor fail Check main contactor for leakage across condition terminals on frozen contactor condition Relay Trips on MCF on power up Return to Ampcontrol for battery replacement and Flat or faulty battery full testing Time and date incorrect Resets to 1 01 9 on Low IS battery power up Return to Ampcontrol for battery replacement and full testing IPDB014 IPD User Manual 1 Page 49 ewe IPD1V03 USER MANUAL POWER THROUGH INNOVATION 19 Service Maintenance amp Disposal 19 1 Equipment Service The IPD requires no internal servicing during its normal operating lifetime A number of external system based checks should however be made on a regular basis These routine insp
94. s risk assessment or FMEA be conducted on installations employing the IPD to maximise the safe operation of the installation Changes to Equipment Changes in the design and modifications to the equipment are not permitted Unauthorised changes made to the IPD 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 Equipment Knowledge Experience with or understanding of this equipment is essential for the safe installation and removal of the equipment If in doubt contact Ampcontrol Mechanical and or Electrical installation and maintenance of plant and equipment must only be carried out by appropriately trained qualified technical personnel IPDB014 IPD User Manual 1 Page 7 NTO IPD1V03 USER MANUAL POWER THROUGH INNOVATION 2 3 Operational Restrictions and Limitations The operational restrictions listed below must be understood before considering using the IPD within systems designed to ensure the safety of personnel Using the IPD 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 The IPD integrated protection relay is designed to operate as part of a Safety Instrumented System alongside other e
95. s via 110V PT s In this application the EFLO and Insulation test functions are not provided When CCM None is selected the IPD Relay does not provide an EFLO or Insulation Test or voltage functions Also under voltage checking does not occur CAUTION The CCM None and CCMA110V Modes MUST NOT BE USED in applications where A EFLO is required by mining regulations 5 2 1 Intrinsically Safe EFLO Test The initial earth fault lockout function tests the resistance of the 3 phase lines to earth by applying an intrinsically safe signal prior to the closure of the main contactor in accordance with AS NZS 2081 4 2002 The test is initiated by closure of the start button once all starting conditions are met See Section 8 5 Operational Sequence This test takes 1 second If the value is less than the preset level See Specifications in Section 14 IPD Specifications a trip occurs The EF LED on the Remote Display Module is illuminated and the open collector output on the relay is switched on to provide remote monitoring if required To reset the relay following an earth fault lockout trip operate the reset button The earth fault leakage level EF of the three phases is displayed on the RDM Earth Fault Information page as a of the trip level and relates to the last earth fault lockout test performed IPDB014 IPD User Manual 1 Page 16 IPD1V03 USER MANUAL POWER THROUGH INNOVATION 5 2 2 Autom
96. sts Earth Continuity tests Earth Fault Lockout tests Overcurrent injection tests 19 4 Disposal of System Parts ENVIRONMENTAL ALERT 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 environment and human health which could otherwise be caused by incorrect waste handling of this product IPDB014 IPD User Manual 1 Page 51 S AMPCONTROL lt POWER THROUGH INNOVATION 20 List of Drawings Refer Appendix for Drawings IPD1V03 USER MANUAL Drawing No IPDE001 IPDB002 IPDB018 IPDB019 IPDB003 IPDB032 IPDB033 IPDB034 IPDB035 IPDA021 IPDA015 IPDA016 IPDA017 IPDA018 IPDA019 IPDA020 IPAA033 031 Description Typical Connection Diagram Display Map Over current Curve amp Short Circuit Curves Very Intense Curve Motor Overload amp Short Circuit Curves Fan Interlocking System Overcurrent Functional Block Diagram Overcurrent amp Short Circuit Curves Motor Overload Hot amp Cold Curves Motor overload Block Diagram IPD Relay amp Base Dimension Details Remote Termination Unit General Arrangement Remote Display Module RDM D G A amp Mounting Details IPD Baseplate Connection Details and General Arrangement 415V Cable Connecting Module Dimensions amp Marking Details 1000V Cable
97. t these functions are operational only and that any emergency stops should be wired direct into the pilot circuit PTC terminals are provided for a semiconductor thermistor connection These terminals are protected in a similar manner to the stop and start circuits If the remote stop start and PTC functions are not required each set of terminals must be bridged or the IPD Relay will not energise Four RTD inputs are provided for PT 100 temperature measuring devices These terminals could also be used with resistor networks to provide digital information back at the IPD Relay RX TX and OV terminals are no longer required On Off Line Status machine type machine number software version and input status of the Remote Termination Unit can be examined by selecting Machine Module Information Level 2 Positions 1 2 RTD temperature is available Level 2 Position 4 IPDB014 IPD User Manual 1 Page 13 AMPCONTROL lt _ POWER THROUGH INNOVATION 4 2 Machine Type Codes IPD1V03 USER MANUAL There are 26 selectable machine type codes available for use in the Remote Termination Unit The descriptive code is transmitted to the IPD Relay to identify the type of machine connected to the outlet The codes are selected using the Remote Display Module Level 9 Position 1 Item Code Type of Machinery 1 Belt Conveyor 2 SHRr Sheare
98. tance MO Trip Setting Minimum Maximum 0 5 0 4 0 6 1 0 8 1 2 2 1 6 2 4 5 4 0 6 4 Table 3 2 2 ii The values in the expected fault resistance range represent 20 of the nominal value with the exception of the higher end of the 5 range Trip setting values of 10 0 and 15 aren t specified above but are available for configuration within the software These trip settings of and 15 are not recommended for use by Ampcontrol values to be utilised for the insulation test trip settings are to be less than 5 To obtain A The start input must be held closed for the duration of the test The recommended trip setting optimum results the 2 trip setting is recommended IPDB014 IPD User Manual 1 Page 18 IPD1V03 USER MANUAL POWER THROUGH INNOVATION 5 2 3 Manual Insulation Test A manual Insulation Test is provided as a maintenance fault finding tool The manual test can only be carried out when the load is not energized When this test is performed the MCR relay is prevented from closing at the completion of a healthy test Before a manual Insulation Test can be performed the following conditions must apply 1 The Remote Display Module must be online with the Insulation Test page being displayed This is located on the EARTH FAULT INFORMATION Page level 3 position 2 Pilot must be healthy and any previous trips reset EFLO function must not be tripped Insulati
99. th groups can be viewed and modified via the Remote Display Module The first group of settings is always stored in the relay and relates to parameters which are linked to the system rather than the particular load connected to the outlet The second group of settings consists of parameters that are related to the load connected to the protected outlet These settings are stored and retrieved to from the memory in the IPD Relay or the memory in the Remote Termination Unit depending on the Pilot Mode setting Figure 9 1 shows how the memory is switched If diode pilot mode is selected the IPD Relay reads and writes to and from the relay s internal memory for the Group 2 settings If RTU Mode is selected the Group 2 settings are sent to and retrieved from the memory in the Remote Termination Unit Figure 9 1 IPDB014 IPD User Manual 1 Page 30 NTO IPD1V03 USER MANUAL POWER THROUGH INNOVATION 9 1 1 Group 1 Settings Stored the IPD Pilot Mode Determines if the pilot is to be terminated with a diode or remote termination unit EL Time Sets the trip time for the earth leakage protection EL Sens Sets the sensitivity trip level for the earth leakage protection EFLO Selects the Cable Connection module to be used with the IPD Relay UN Trip Selects the under voltage trip threshold as a of line volts SC Relay Selects which output relay MCR or CBR is tripped in event of a short circ
100. the Certificate and all pages MUST be presented and read whenever the IECEx ITA 07 0018X Issue 1 Certificate is presented 1 2 The following parameters are not exceeded for product covered by IECEx ITA 07 018X Issue 1 Input Parameters IECEx ITA 07 0018X Issue 1 EFLO Test Module 11kV Integral cables Vb 13200 V max M to phase 7 622 V max phase to earth EFLO Test Module 11kV Terminals 1 to 4 2500 EFLO Test Module 11kV Terminals 5 to 8 The connections to these terminals must directly connected to the IPD Relay module terminals 3 4 5 Output Parameters IECEx ITA 07 0018X Issue 1 Uo Po Co Lo LIR V mW mH uH Q EFLO Test Module 11kV 19 62 0 01 0 01 7 8 3 000 1 000 Va Vb Vc The following apply to the above Tables for both 1 1 and 1 2 above Maximum output voltage determined by IPD Relay module Note The above load parameters apply where a The external circuit contains no combined lumped inductance Li and capacitance Ci greater than 196 of the above values or b The inductance and capacitance are distributed as in a cable or c The external circuit contains only lumped inductance or only lumped capacitance in combination with a cable In all other situations e g the external circuit contains combined lumped inductance and capacitance up to 5096 of each of the inductance and capacitance values is allowed 2 The IKD Interface must infallibl
101. tion Relay Typical IS System 2007 12 06 Diagram IPD Z 037 IPD Parallel Feeder Configuration General 2007 02 20 Arrangement IPD Z 001 IPD Analogue Board PCB Artwork Sheets 1 to 6 pc Rl Sheet 1 Sheet 2 M nma Mcd Sheet 3 ea pne Sheet 4 Sheets 1 to 5 Sheet 1 Sheet 2 2 IPD Z 005 IPD Processor Board Schematic Diagram CPU 2007 11 23 Sheet 3 IPD Z 005 IPD Processor Board Schematic Diagram ADC 2007 11 23 Sheet 4 IPD Z 005 IPD Processor Board Schematic Diagram Battery 2 2007 11 23 Sheet 5 RTC RAM IPD Z 007 IPD Integrated Protection Relay Fascia Plate 2007 12 12 Marking Details IPD Z 030 IPD Integrated Protection Relay Enclosure Details 2007 04 11 PCB Mounted Detail and Clearance IPD Z 032 ____ Relay Board Schematic Diagram 0 2006 10 13 IPDB014 IPD User Manual 1 Page 81 IPD1V03 USER MANUAL lt gt POWER THROUGH INNOVATION ATTACHMENT To IECEx CERTIFICATE IECEx ITA 07 0018X Issue 1 Page 8 of 9 El This Attachment forms an Integral Part of the IECEx Certificate and all pages MUST be presented and read whenever the IECEx ITA 07 0018X Issue 1 Certificate is presented 2007 02 26 2008 06 17 2005 08 08 Table 1 imm dd BARRIERS __ IPD Z 011 IPD RDM D Enclosure amp Marking Details IPD Z 012 IPD Z 017 IPD IPSI D Schematic Diagram 6 2008 06 30 IPD Z 018 IPSI D PCB Artwork m 2008 07 03 Sheets 1 to 3 IPD Z 019 IP
102. top bal Trp Current Balance Trip Differentiates balance trip from basic over current trip MC Opened Main contactor opened opening not initiated by the IPD Relay RTU mem E RTU Memory error Errors in set up data from RTU RTU Off L RTU Off Line IPD can t communicate with RTU RTU ptc T RTU PTC input tripped Stopped IPD Stop Input Tripped UVOLT Trp Under Voltage trip voltage on load side too low IPDB014 IPD User Manual 1 Page 12 IPD1V03 USER MANUAL POWER THROUGH INNOVATION 4 Machine Communication 4 1 Remote Termination Unit The Remote Termination unit is a microprocessor based fully encapsulated module that replaces the diode at the end of the pilot conductor of the trailing cable It is powered by and communicates via the pilot line Its non volatile memory stores the parameters to configure the outlet as appropriate for that machine All terminals are fully shrouded with the pilot and earth terminals being kept segregated from the other terminals See RTU D General Case Dimensions Drawing 015 in Appendix A Drawings The Remote Termination Unit RTU D provides remote stop start facilities of the IPD Relay s controlled outlet The circuitry involved for these functions are self diagnostic and will cause the outlet to tum off if the circuits are earthed or interconnected This reduces the chance of the outlet operating when not required to do so due to wiring faults It should be noted tha
103. ual 1 TIME MULTIPIER 1 0 0 8 0 7 0 6 0 075 3 050 0 040 0 039 0 022 0 015 6 010 0 005 160mSec 120mSec 100inSec 80 800 900 1000 Current Trip time 180xm 1 1 m time Multiplier Foult Current Selected Full Load Current t sec Short Circuit Selectable at 30 3 8 4D 4 5 5 0 55 55 2 0 7 5 8 0 8 5 9 0 9 5 10 0 Times Selected Full Load Current imes Selectable at 20 40 60 80 100 120 amp 160 mSec REFERENCE 0255 151 OVERCURRENT amp SHORT CIRCUIT CSM PTY LTD AMPCONTROL ELECTRONICS 1 THIS DRAW PROPERT ANGULAR Page 56 REVISION DRAWING NUMBER IPD B 018 3 RVE must not be reprodured in part VERY INVERSE 03 4800 02 4903 4888 221 electrenics amocentrelgroup com whole the contents AMPCONTROL Wo POWER THROUGH INNOVATION a T 2 IPD Very Inverse Curve Short Circuit w Error Margins 52 gt lt 2 7 Gp Wns gt 7 22 Ly 1 A gt 2 KA gt KZ 2 2 E Gr 7227 CLLR 22 GRIP i d 7 25 Dp Ci 2 Rr NB DS 2
104. ual 1 Page 9 IPD1V03 USER MANUAL POWER THROUGH INNOVATION 3 2 Remote Display Module This module Ampcontrol RDM D consists of a two line 16 character LCD display LED status indicators and a tactile keypad The display level is changed with the Up Down arrow keys and the Left Right arrow keys control the display position The display map Drawing IPDB002 in Appendix Drawings shows the layout of the various display screens The module is approved to Ex ia Intrinsic Safety Standards so that it can be installed outside of a flameproof enclosure The healthy LED located top centre of the module flashes at 3Hz to indicate healthy communications with the relay A flash rate of 1Hz indicates that the module is powered but is not receiving data The module displays the following information 1 IPD Status 2 Software version and serial number 3 Operational information from the protection functions eg earth leakage current earth continuity resistance etc 4 System information including the line voltage and current Status of digital inputs and relay outputs 6 Protection trip settings which can be viewed at any time Authorised personnel can modify these settings via the RDM thus eliminating the need to open the flameproof enclosure 7 Data logging information The 120 most recent events are logged with time and date a non volatile memory for example power up trip reset close etc A A re
105. uit trip EC Time Sets the trip time for the earth continuity protection Relay 3 Selects off FID or FIR operation of the relay 9 1 2 Group 2 Settings Stored in the RTU RTU MC Type Selects the RTU descriptive code transmitted to identify the machine connected to the outlet Selects the assigned machine number to be transmitted by the Remote termination Unit OC range Sets the basic current range OC mul Combines with OC range to define the full load current OC Type Selects either very inverse over current or motor overload protection OC t mul Modifies the basic over current time curves to achieve the desired trip times Cool mul Allows the cooling rate of the thermal model to be modified Cur Bal Trp Adjusts current phase balance trip SC trip Sets the short circuit trip level SC Trip t Sets the trip time for the short circuit function Pilot Latch Determines whether earth continuity trips are self resetting or not B emf TIME Adjustable time delay to inhibit main contactor fail following opening of main contactor Fan i Level Sets the fan current threshold at which other outlets are allowed to run Remote Start When Yes is selected the IPD Relay ignores the local start input When is selected the local start stop inputs control the relay Ins TstT Sets the trip threshold or disables the function IPDB014 IPD User Manual 1 Page 31 IPD1V03 USER MANUAL POWE
106. utputs which are driven through opto couplers to provide additional indication if required These can be used to drive LED s or additional relays with appropriate drive circuitry The eight outputs correspond to the LED s on the display module turning on whenever the corresponding LED is flashing The signals are available on the IPD Relay s base pins 35 42 and the common is on pin 34 Contact Ampcontrol if further information is required about these outputs 10 4 Outlet Control The outlet can be energised by local or remote operation depending on the Remote Start option The selection is Yes or No Level 9 Position 14 10 4 1 RTU Mode If Yes is selected the relay ignores the local start input thus allowing operation of the outlet from the remote machine Both the remote and local stop buttons will turn off the outlet If No is selected the local start stop buttons control the outlet The Remote Termination Unit s start stop and PTC terminals must be bridged to energise the outlet 10 4 2 Remote Operation in Diode Mode In this mode the stop start station is connected in the pilot See Typical Connection Diagram IPD E 001 in Appendix A Drawings The pilot has a hysteresis of 100 ohms This is to allow 100 ohm resistor to be connected across the start button The hysteresis is linked to the main contactor input MCI If MCI is open then the earth continuity will trip at 45 ohms If the MC
107. view of the first few log events is a useful tool for fault finding The IPD status display is one of the most useful features of the relay s display system and should be viewed as the first step in fault finding The Status display is the default screen on power up and indicates what the IPD Relay requires in order to allow the outlet to close These messages are useful to unskilled personnel If more than one message is active the display cycles around all active messages showing them for 1 second each Through the use of the serial communications port PLC s and SCADA Systems can be configured to display the same messages that appear on the Remote Display Module This helps to provide consistent information to operators 3 2 1 Trip Status Messages The following table shows a list of the twenty eight 28 status messages and the category type of the messages Messages are cleared according to their message category Type 1 Messages are cleared by either pressing the lt ENT gt key while on the Status Display Page or by starting a new starting sequence i e EFLO test started Type 2 Messages are enabled and cleared automatically Type 3 Messages are triggered by the respective trip functions and are cleared by resetting the trip function IPDB014 IPD User Manual 1 Page 10 e IPD1V03 USER MANUAL POWER THROUGH INNOVATION Tripped No Volts Voltage on load side of contactor is too low MC Close Fail E
108. ween the pilot and earth conductors The leakage measurement ensures that pilot to earth faults are detected If the pilot earth loop is not healthy a trip occurs See Specifications Section 14 IPD Specifications which in turn opens the main contactor control circuit The fault can be configured as latching or non latching This allows the user to determine if the fault is manually or automatically reset once the pilot earth loop is healthy The selection is either Pilot Latch On or Pilot Latch Off Level 9 Position 11 To manually reset the relay operate the reset button The EC LED on the Remote Display Module is illuminated and the open collector output on the relay is switched on to provide remote monitoring if required The earth continuity resistance ECR of the pilot earth loop and the leakage L between the pilot and earth conductors is displayed on the RDM Earth Fault Information page as a of the trip levels When either value reaches 100 a trip occurs Pilot Trip Time is adjustable to allow for operation in noisy electrical environments The following trip times are available 80 120 160 200 300 400 and 500mS A setting of 120mS should be suitable for most installations Long time delays gt 200 ms should only be used where necessary Consequence of long trip times should be thoroughly assessed from a safety point of view before using the higher values IPDB014 IPD User Manual 1 Page 20
109. y connected to the main system earth via at least one of the earthed mounting bolts on the chassis S The Integrated Protection Relay Type IPD must be infallibly connected to the main system earth via the earth terminals provided J2 J7 and J12 4 The pilot circuit connections of the IPD Integrated Protection Relay and the IKD Interface module must not be connected to a power source where the nominal pilot to earth fault current may exceed 5A r m s unless protected by a fuse The fuse must be suitable for the system voltage having a breaking capacity not less than 1 500 A and have a maximum rating of 3A IPDB014 IPD User Manual 1 Page 79 m IPD1V03 USER MANUAL Ww POWER THROUGH INNOVATION ATTACHMENT To IECEx CERTIFICATE IECEx ITA 07 0018X Issue 1 Page 6 of 9 n This Attachment forms an Integral Part of the IECEx Certificate and all pages MUST be presented and read whenever the IECEx ITA 07 0018X Issue 1 Certificate is presented 5 The following modules are to be mounted such that the connection facilities have a minimum ingress protection level of not less than IP20 Integrated Protection Relay Type IPD CCMA and CCMD RDM D IKD Keypad RTU D module IPSI D IKD Interface EFLO Test Module 11KV 6 The RDM D module shall be installed such that the exposed area of the front membrane is less than 100cm 7 The IPD module contains a single non rechargeable non user replaceable cell This must b

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