Ampcontrol ELV-PRO User Manual Download

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Version: 5, November 2020

Designed and manufactured in Australia by Ampcontrol Pty Ltd

ELV-PRO

EARTH LEAKAGE RELAY

User Manual

Summary of Contents for ELV-PRO

Page 1: ...Version 5 November 2020 Designed and manufactured in Australia by Ampcontrol Pty Ltd ELV PRO EARTH LEAKAGE RELAY User Manual ...

Page 2: ... WARNING The warning symbol highlights a potential risk of injury or death Please share these warnings with other operators CAUTION The caution symbol highlights a potential risk of damage to equipment Please share these cautions with other operators NOTE The note symbol highlights key information Please share these notes with other operators ENVIRO The enviro environmental symbol highlights areas...

Page 3: ...issions in this document or from misuse of the information obtained herein The information in this document has been carefully checked and is believed to be entirely reliable with all of the necessary information included AMPCONTROL PTY LTD reserves the right to make changes to any products described herein to improve reliability function or design and reserves the right to revise this document an...

Page 4: ... 11 Application 11 4 INSTALLATION 12 General Warnings 12 Mandatory Installation Practices 12 Mechanical Installation Information 13 Electrical Installation Information 15 5 PRODUCT OPERATION 22 Earth Leakage Protection 22 Earth Leakage Analysis Tool 22 Data Logging 23 Real Time Clock RTC 23 IP Configuration 24 Protection Settings 26 ELV PRO CIP over EtherNet IP Interface 28 ELV PRO Modbus TCP Inte...

Page 5: ...ection 47 APPENDIX B ELV PRO CURRENT TRANSFORMERS 48 B1 Earth Leakage Toroids 48 B2 Toroid selection 48 B3 Toroid installation guidelines 48 APPENDIX C ELV PRO CIP OVER ETHERNET IP 49 C1 ELEMENTARY DATA TYPES 49 C2 LIVE DATA SEGMENT DEFINITION 50 C3 CONTROLS 51 C4 EXPLICIT MESSAGES 52 C5 EVENT LOGS 54 APPENDIX D ELV PRO Modbus TCP 56 D1 Modbus Commands 56 D2 Modbus Status 56 D3 Read Modbus Address...

Page 6: ...le Connections 19 Figure 4 11 ELV PRO Toroid Installation Examples 20 Figure 5 1 Taskbar Icon Wired Connection Available 24 Figure 5 2 Network and Sharing Center 25 Figure 5 3 Local Area Connection Status left and Properties right 25 Figure 5 4 Internet Protocol Versions 4 TCP IPv4 Properties 26 Figure 6 1 ELV PRO Relay Fascia Interface 29 Figure 6 2 ELV PRO Web Interface Overview 30 Figure 6 3 EL...

Page 7: ... TO BE REPRODUCED IN PART TABLE OF TABLES Table 1 Definitions 8 Table 2 ELV PRO Terminal Designators 14 Table 3 Earth Leakage Trip level 27 Table 4 Earth Leakage Trip Time 27 Table 5 Digital Input Settings 28 Table 6 ELV PRO Relay Fascia LED Operation 29 Table 7 Web Interface Status Indicators 31 Table 8 Event ID Descriptions 37 Table 9 Login Details 39 Table 10 Modbus Commands 56 Table 11 Modbus ...

Page 8: ...th loop resistance DHCP Dynamic Host Configuration Protocol EFLO Earth Fault Lock Out FFT Fast Fourier Transform FLC Full Load Current GUI Graphical User Interface HMI Human Machine Interface HTTP Hypertext Transfer Protocol IP Internet Protocol MC Main Contactor the main power circuit opening device The main contactor is opened and closed in order to turn the outlet on and off MCR Main Contactor ...

Page 9: ...to Equipment Changes in the design and modifications to the equipment are not permitted Unauthorised changes made to the hardware or operating firmware will void the manufacturer s warranty and may compromise the integrity of the system into which it is installed and other connected equipment 1 1 2 Equipment Knowledge Experience with or understanding of this equipment is essential for the safe ins...

Page 10: ...proval documentation for your safety file as applicable prior to wrapping being discarded Inspection Equipment that is found to be damaged or has been modified away from its published specifications must not be used Please contact Ampcontrol if the equipment is suspected to be different than that ordered or if it does not match the published specifications Storage after Delivery When the equipment...

Page 11: ...easurement 20 Hz to 8 kHz Wideband Narrowband and Weighted Frequency Response Modes Adjustable trip level and trip times On board memory logs last 1000 data logs and 50 events CIP over EtherNet IP for control and Monitoring Modbus TCP Continuous Toroid Connection Monitoring DIN rail mounted International patent application number PCT AU2011 000705 Application The ELV PRO is intended for use at tra...

Page 12: ...c solvers and actuators needed to implement the system Understanding the needs of the system will ensure proper selection of equipment 4 1 3 Ensure that the relay will properly perform the required functions within the system design It is important to understand how the relay is intended to interact with other equipment within a system For safe and reliable use it is crucial that neither the logic...

Page 13: ...TION PROPERTY OF AMPCONTROL PTY LTD NOT TO BE REPRODUCED IN PART Mechanical Installation Information 135 135 107 Figure 4 1 ELV PRO Dimensions The ELV PRO metal enclosure is rated at IP20 It is DIN Rail mounted and measures 135mm x 135mm and 107mm deep as per Figure 4 1 The terminal layout and description is shown in Figure 4 2 and Table 2 respectively 1 2 4 5 6 3 Figure 4 2 ELV PRO Terminal Layou...

Page 14: ...Normally Closed P4_3 Digital Input 3 P1_1 Contact 1 Common P4_2 Digital Input 2 P4_1 Digital Input 1 2 P2_6 Digital Input 6 24V Supply P2_5 Digital Input 5 24V Supply 5 P5_3 Phase CT Cable Shield P2_4 Digital Input 4 24V Supply P5_2 Phase CT Input Signal P2_3 Digital Input 3 24V Supply P5_1 Phase CT Input Common P2_2 Digital Input 2 24V Supply P2_1 Digital Input 1 24V Supply 6 P6_8 Zero Crossing I...

Page 15: ...ircuit Breaker Main Contactor M NER A B C N O 2 COM 2 N O 1 N C 1 COM 1 PHASE CT PHASE CT CT SCRN DO NOT CONNECT SIGNAL EL CT EL CT EL CT SCRN CT TEST INPUT 110VAC ZERO CROSSING Relay Output 2 Relay Output 1 Zero Crossing Detector Optional Front Panel RESET Button Front Panel IP RESET Button 24VDC 0V 24V RESET INPUT P3_2 P3_3 P3_4 P2_6 P2_5 P2_4 P2_3 P2_2 P2_1 P4_6 P4_5 P4_1 P4_2 P4_3 P4_4 P1_5 P1...

Page 16: ...rnally connected input supply terminations for each input The additional connection is to allow for daisy chaining to other devices 4 4 2 Trip Reset and Digital Inputs Plug 2 Plug 4 The trip reset and digital inputs are split across two plugs Plug 2 and Plug 4 see Figure 4 5 Plug 2 right is a dedicated digital input and Trip Reset 24V supply All terminals of plug 2 are internally connected Plug 4 ...

Page 17: ...s connected and the signal the relay monitors is correct a CT test output is provided on terminals P6_5 P6_6 A missing CT Test signal through the CT will cause the ELV PRO relay to trip The test signal is applied every two seconds and may be seen on the live screens and data logs Terminal P6_4 of Plug 6 should not be connected The Zero Crossing input terminals P6_7 P6_8 is provided for logging pur...

Page 18: ... to terminals P5_1 P5_2 Terminal P5_3 is the screen termination point for the cable connecting the phase CT to the relay Typical connection is shown in Figure 4 7 NOTE No settings are required within the unit for the connection of this additional toroid but the ratio of the toroid should be recorded so that when data is analysed the actual phase current can be calculated ELV PRO Phase Conductors P...

Page 19: ...trol Contact Outputs Connections Plug 1 4 4 6 ELV PRO Dongle Input Dedicated Dongle Slot The ELV PRO has a dedicated dongle input item 2 of Figure 4 10 The dongle is keyed and therefore has a specific orientation Refer to Figure 4 9 Figure 4 9 ELF PRO Parameter Dongle 4 4 7 Ethernet Input Dedicated Ethernet Socket The ELV PRO has an Ethernet socket to allow the ELV PRO to be connected to a network...

Page 20: ...time is typically set at instantaneous The three power phases are passed symmetrically through the centre of the toroid If there is no earth fault present the vector sum of the currents in a three phase supply is zero If current from any phase flows to earth the toroid flux becomes unbalanced allowing the toroid to produce an output which in turn trips the relay A test current is injected through ...

Page 21: ...ng the wideband EL relays on an outlet with VSD or VVVF drive it is recommended that the relays toroid be installed on the cables before the drive This will allow the relay to provide EL protection that includes the drive itself 4 4 10 ELV PRO Phase Monitoring Toroid The ELV PRO has provision for the connection of a suitable toroid with a secondary rating of 5A to monitor a phase current in the sy...

Page 22: ...covered by AS NZS 2081 The collective systems are designed to limit touch and step potentials The relay is also suitable for industry where equipment or system earth leakage protection is required The relay is not suitable for personal protection which requires trip levels of 20 30mA with instantaneous operation refer to AS NZS 3190 The ELV PRO has three operating modes Wideband mode The relay wil...

Page 23: ... selected to prevent the unit from continuously logging Real Time Clock RTC Recorded data is stored on the ELV PRO with a time stamp indicating the system time when the log was made For the purposes of aligning recorded data with other records it is important that the user regularly checks that the time on the RTC reflects a level of accuracy acceptable to the user Without regular synchronisation ...

Page 24: ... settings will need to be configured correctly to successfully connect to the ELV PRO web server If there are multiple ELV PRO relays used on a single network switch initial configuration through a dedicated connection may be required before you can access through a network switch NOTE Minimum recommended browser versions for full functionality Microsoft Internet Explorer 9 Google Chrome 20 Apple ...

Page 25: ...N PROPERTY OF AMPCONTROL PTY LTD NOT TO BE REPRODUCED IN PART You will need to configure the network adapter settings by right clicking on this icon and selecting Open Network and Sharing Center The following should appear Figure 5 2 Network and Sharing Center Click on Local Area Connection for the status page to appear as in Figure 5 3 Figure 5 3 Local Area Connection Status left and Properties r...

Page 26: ...IPv4 Properties Assign the following IP address and Subnet mask IPv4 Address 10 1 1 xxx where xxx is a value between 1 and 250 excluding address 10 The ELV PRO default setting is 10 so will cause a clash IPv4 Subnet Mask 255 255 255 0 Once you have configured the network adapter settings open up a web browser and type the following IP address into the browsers address bar 10 1 1 10 The ELV PRO Web...

Page 27: ...mA 1400mA 3400mA 250mA 1500mA 3500mA 300mA 1600mA 3600mA 350mA 1700mA 3700mA 400mA 1800mA 3800mA 450mA 1900mA 3900mA 500mA 2000mA 4000mA 550mA 2100mA 4100mA 600mA 2200mA 4200mA 650mA 2300mA 4300mA 700mA 2400mA 4400mA 750mA 2500mA 4500mA 800mA 2600mA 4600mA 850mA 2700mA 4700mA 900mA 2800mA 4800mA 950mA 2900mA 4900mA 1000mA 3000mA 5000mA 5 6 2 Earth Leakage Trip Time This defines how quickly the Ear...

Page 28: ...The value can be set to any value between 5 seconds and 300 seconds inclusive The web server however has used values in set intervals of 5 seconds to make adjustment easier and quicker 5 6 6 Digital Input Settings The five 5 digital inputs are individually configured to suit the user s application requirements The following settings can be selected Table 5 Digital Input Settings Digital Input Pola...

Page 29: ...er when connected to a network The ELV PRO interface is shown in Figure 6 1 The front of the relay has two buttons and two indicators The Reset button Item 3 in Figure 6 1 functions as a local reset button allowing a trip to be reset provided the fault has cleared The IP Reset button Item 4 in Figure 6 1 is used to reset the IP address to the factory default setting 10 1 1 10 An IP Reset requires ...

Page 30: ... PRO Web Interface In order to connect to the ELV PRO Web Interface the user must type the IP address of the Analyser that they wish to connect to into their web browsers address bar To view the Web Interface the computer that is accessing the Analyser must be connected to the same network as the Analyser For more information on IP configuration refer to Section 5 5 The Live Graphs tab is the defa...

Page 31: ...nt The relay description in the top of the screen is defined in the ELV PRO dongle settings see Section 6 2 6Error Reference source not found This description is also used to correctly identify the connected ELV PRO relay Item 3 ELV PRO Analyser Status Indicators The ELV PRO Status Indicators display the status of the Web Interface network connection to the Analyser and the status of the Relay The...

Page 32: ...n the three possible options These are OSC Oscilloscope graph Plots the instantaneous values of earth leakage current measured by the ELV PRO At every update it displays the last 80ms of data Figure 6 4 RMS graph In this view Root Mean Square RMS values of the measured current are shown The user is able to select the time interval on the graph by selecting from the buttons below the graph Figure 6...

Page 33: ...0 Uncontrolled Copy Refer to Ampcontrol Website for Latest Version Page 33 of 59 APPROVED FOR EXTERNAL DISTRIBUTION PROPERTY OF AMPCONTROL PTY LTD NOT TO BE REPRODUCED IN PART 1 2 3 4 Figure 6 4 ELV PRO Web Interface Live Graphs OSC 1 2 3 4 Figure 6 5 ELV PRO Web Interface Live Graphs FFT ...

Page 34: ... two seconds after the log initiation making the command instant at the centre of the graph Once a particular log is selected from the list Item 1 of Figure 6 6 in the drop down menu OSC RMS and FFT views are available as they are in the Live Graph tab The RMS view Figure 6 8 is calculated using a running window of 300 data points The FFT graph Figure 6 9 corresponds to the selected 80ms of signal...

Page 35: ...MBER 2020 Uncontrolled Copy Refer to Ampcontrol Website for Latest Version Page 35 of 59 APPROVED FOR EXTERNAL DISTRIBUTION PROPERTY OF AMPCONTROL PTY LTD NOT TO BE REPRODUCED IN PART 1 Figure 6 7 ELV PRO Web Interface Data Logs OSC 1 Figure 6 8 ELV PRO Web Interface Data Logs RMS ...

Page 36: ...PTY LTD NOT TO BE REPRODUCED IN PART 2 1 Figure 6 9 ELV PRO Web Interface Data Logs FFT 6 2 4 Event Logs Tab This tab shows the 50 most recent user changes made at the unit see Figure 6 10 To export this list use the link above the log item 1 to show the log entries in a separate popup window for printing or copy pasting The Event log descriptions can be found in Table 8 below 1 2 Figure 6 10 ELV ...

Page 37: ...as failed The internal EEPROM chip has failed 13 OS Scheduler fault The internal Threading Scheduler has failed 14 Open Toroid Trip Unit tripped because it could not sense the earth leakage current detection toroid 15 Relay failed to close Relay contacts failed to close when expected 16 Relay failed to open Relay contacts failed to open when expected 17 System Restarted The unit has restarted un e...

Page 38: ...NOT TO BE REPRODUCED IN PART 6 2 5 Device Information Tab The Device Information Tab Figure 6 11 shows settings states and measurements relating to the hardware and software of the Analyser The information is updated once a second and includes Trip Settings Network Settings NTP Settings ADC Settings Software Information General Settings Systems Trips Digital Input Settings Hardware Status Figure 6...

Page 39: ...6 12 allows for configuration of the following Trip Settings Network Settings NTP Settings Date and Time Digital Input Settings Unit Configuration ADC Settings Passwords To access the Settings page the user will be prompted to enter a Username and Password The default login details are shown in Table 9 below Once the desired settings have been changed select Save Settings to save and return to the...

Page 40: ...otecting should not be energised This will allow the relay to factor in the cable wiring toroid differences and any influences due to the installation and location of the equipment for the application installation 6 2 7 About Tab The About Tab Figure 6 13 provides contact details and licensing information about the device and website Figure 6 13 ELV PRO Web Interface About 6 2 8 Interactive graph ...

Page 41: ...ted range from the box in the top left of the plot To remove the marked range click the box To refine the selection use single clicks near either end of the marked range to move the markers Figure 6 14 ELV PRO Web Interface Interactive Graph Navigation 6 2 9 Protection Function Trip Should a trip occur the trip indicator illuminates red Item 3 of Figure 6 15 and the header block Item 1 of Figure 6...

Page 42: ...heck that labels on equipment wall boxes and cables are present and in good condition especially certification labels Check that no modifications have been carried out to installed equipment 7 1 2 Hands 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 additio...

Page 43: ...ed out by Ampcontrol only If a fault develops return the unit to Ampcontrol for repair It is essential that no attempt be made to repair the unit as any attempt to dismantle or repair the unit can seriously compromise the safety of the unit and voids product warranty It is recommended that the electrical protection system incorporating the ELV PRO be subject to regular functional tests at interval...

Page 44: ...ø 1 ELV PRO Inputs Inputs 1 5 Programmable Trip Log functions Input 6 Trip Reset Manual trip reset by external pushbutton Earth Leakage Toroid CT Toroid 100 1A Ampcontrol EL500S series recommended Phase Monitoring Toroid CT Optional 5A secondary toroid for monitoring a selected phase current Zero Crossing 110VAC Optional Phase current zero crossing detection Communication Interface Ethernet Socket...

Page 45: ...enting a touch potential hazard As described in AS NZS 4871 1 2012 the system assessment must determine the earth fault limitation current that will protect people based on the achievable earth leakage clearance times and knowledge of the system in which it is installed A1 Variable Speed Drives Variable speed drives VSDs are now finding wide use in mining applications Most of these drives use vari...

Page 46: ...tion relays approved for use in mining applications are designed to detect 50 Hz currents not dc or high frequency currents so the relays may not trip or if they do trip they may take longer than expected The overall result is that with standard earth leakage protection relays and electrical system assessments based only on consideration of faults driven by the supply system 50 Hz protection perfo...

Page 47: ...ncy Where equipment is installed and operated within systems at other than a constant 50 Hz cyclic frequency the characteristics in paragraph B2 are not immediately applicable In such instances individual calculation to determine requirements at the frequency or frequencies in question will be required Standards AS NZS 60479 1 and AS NZS 60479 2 should be referenced in relation to the effects upon...

Page 48: ...in this way increase as the toroid size increases as currents increase and symmetry decreases Nuisance tripping tends to occur when the total current rises such as when a large motor is started The following guidelines would help to avoid such problems B2 Toroid selection 1 Select the smallest internal diameter toroid which will allow the cables to fit through Avoid very large toroids 200mm apertu...

Page 49: ...rom table C 2 1 from the CIP Specification and are as follows Character String Data Types The declaration of a variable of type STRING is equivalent to declaring a structured data type for the variable which allocates a UDINT variable containing the current size of the string in characters and an array of declared character size elements Keyword Description Range Minimum Maximum BOOL Boolean 0 1 S...

Page 50: ... 6 Digital IO Digital Input status 7 Reserved Reserved C2 1 Trip Mask 1 Bitmask Trip Name Details 0x0001 System Tripped General Bitmask denoting the system is currently Tripped 0x0002 Earth Leakage CT Detect The Earth Leakage CT is not being detected This trip will automatically clear once the CT is detected 0x0004 Unused Unused 0x0008 Relay Fault The Relay didn t respond quickly enough or has fai...

Page 51: ...r Defined digital Input 1 CLOSED INPUT 0x0020 Digital Input 6 External Reset Input 1 CLOSED INPUT C3 CONTROLS This is a Write Only Class 1 service Value Assemble Instance 150 Size 4 Data Type UINT Offset Value Name Details 0 Reset Control Resets various trip types if safe to do so 1 Unused 2 Unused 3 Unused C3 1 Reset Control This reset bit should only be set by an authorised person An EL Trip req...

Page 52: ...t Earth Leakage Trip Level UINT Value returned in mA 3 Get Earth Leakage Trip Time UINT Value returned in ms 4 Get EL Alarm Trip Level UINT Value returned in mA 5 Get EL Alarm Trip Time UINT Value returned in ms 6 Get Alarm Cool Down UINT Values returned in seconds 7 Get EL Mode USINT 0 Narrow Band 1 Wide Band 2 Weighted Band 8 Get Digital Input Settings 1 USINT See table below 9 Get Digital Input...

Page 53: ...yte Name Data Structure 0 19 Unit Name Byte array String 20 21 Earth Leakage Trip Level UINT 22 23 Earth Leakage Trip Time UINT 24 25 EL Alarm Trip Level UINT 26 27 EL Alarm Trip Time UINT 28 29 Alarm Cool Down UINT 30 EL Mode USINT 31 Digital Input Settings 1 USINT 32 Digital Input Settings 2 USINT 33 Digital Input Settings 3 USINT 34 Digital Input Settings 4 USINT 35 Digital Input Settings 5 USI...

Page 54: ...tored within an instance can be read using the Get_Attributes_All service as described below Class Code 72 hex Class Attributes Name Access Type Value 1 Revision Get UINT Object revision current value 0001h 2 Max Instance Get UINT 3 Number of Instances Get UINT Implemented Instances 5 Instance Attributes Attribute ID Access Rule Name Data Type Description of Attribute 1 Get Event Log N EVENT STRUC...

Page 55: ... attributes See the Get_Attributes_All_Response definition below Get_Attributes_All Response Data Instance Level Byte Name Data Structure 0 5 Event Log Instance N Attribute 0 EVENT STRUCT 6 11 Event Log Instance N Attribute 1 EVENT STRUCT 12 17 Event Log Instance N Attribute 2 EVENT STRUCT 18 23 Event Log Instance N Attribute 3 EVENT STRUCT 24 29 Event Log Instance N Attribute 4 EVENT STRUCT 30 35...

Page 56: ...n attempt to read a register outside this range will result in an exception scan Supported Modbus exception responses are Table 11 Modbus Exception Modbus Exception Comment 01 Illegal Function 02 Illegal Data Address 03 Illegal Data Value D2 Modbus Status Table 12 Modbus Status Status Comment Address The Modbus slave address the ELV PRO is set to Read A solid block when a READ command is received ...

Page 57: ...EEPROM Fault 2 RTC Fault 3 Digital Input Fault 4 15 Reserved 9 Internal Temperature Temperature measured inside the ELV PRO Value is given to 1 decimal point by multiplying actual temp by 10 Range of values is 20 C to 100 C 10 Digital IO Bit Description 0 open 1 closed 0 Digital Input 1 1 Digital Input 2 2 Digital Input 3 3 Digital Input 4 4 Digital Input 5 5 Digital Input 6 6 15 Reserved 11 17 Re...

Page 58: ...3 85 Log Details 86 88 Log Details 89 91 Log Details 92 94 Log Details 95 97 Log Details 98 100 Log Details 101 103 Log Details 104 106 Log Details 107 109 Oldest Log Details D4 Uint16 Encoded String To help with efficient data transfer all strings transmitted via Modbus have been compressed to contain two characters per 16bit word with the upper byte containing the first character and the lower b...

Page 59: ...dated once a setting is modified If a dongle has been configured or has been initialised from another ELV PRO then the settings may not match those in the table below If a dongle is removed when in operation the settings will not be altered WARNING Ampcontrol recommends the user review the configured settings before operating equipment Parameter Setting Trip Level 150mA Trip Time 50mS Alarm Level ...

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