background image

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Version:  9, March/2020 

PN: 117829 

Designed and manufactured in Australia by Ampcontrol Pty Ltd 

 

 

 

 

 

 

 

HPB 

Integrated Protection Relay 

User Manual 

Summary of Contents for HPB

Page 1: ...Version 9 March 2020 PN 117829 Designed and manufactured in Australia by Ampcontrol Pty Ltd HPB Integrated Protection Relay User Manual ...

Page 2: ...RNING 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 wh...

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

Page 4: ...ALLATION 12 4 1 General Warnings 12 4 2 Mandatory Installation Practices 12 4 3 Installation and Wiring Instructions 13 5 MACHINE COMMUNICATION 17 5 1 HPB Termination Unit HTU 17 5 2 Machine Type Codes 17 5 3 Machine Number 18 5 4 Receiver Sensitivity 18 6 EARTH PROTECTION FUNCTIONS 19 6 1 Earth Leakage 19 6 2 Earth Fault Lockout 19 6 3 Earth Continuity 20 7 CURRENT RELATED FUNCTIONS 23 7 1 Basic ...

Page 5: ...PERTY OF AMPCONTROL PTY LTD NOT TO BE REPRODUCED IN PART 10 1 Digital Inputs 28 10 2 Output Relays 28 10 3 Open Collector Outputs 28 10 4 Outlet Control 28 10 5 Operational Sequence 28 11 EVENT LOG 29 12 TIME DATE 31 13 REMOTE DATA COMMUNICATIONS 32 14 SPECIFICATIONS 33 15 EQUIPMENT LIST 35 16 TROUBLESHOOTING 36 16 1 Pilot Fault Finding Information 38 APPENDIX A DRAWINGS 40 APPENDIX B APPROVALS 59...

Page 6: ... FOR EXTERNAL DISTRIBUTION PROPERTY OF AMPCONTROL PTY LTD NOT TO BE REPRODUCED IN PART TABLE OF FIGURES Figure 16 1 HPB Pilot Resistor HTU Mode 39 TABLE OF TABLES Table 1 HPB Display Messages 10 Table 2 HPB Error Status Indicator 11 Table 3 Low Voltage Signals 15 Table 4 Machine Type Codes 18 Table 5 Group 1 Settings 26 Table 6 Group 2 Settings 26 Table 7 Event Logs 29 ...

Page 7: ...e the following instructions 1 1 1 Changes to Equipment Changes in the design and modifications to the equipment are not permitted Unauthorised changes made to the hardware or operating firmware will void the manufacturer s warranty and may compromise the integrity of the system into which it is installed and other connected equipment 1 1 2 Equipment Knowledge Experience with or understanding of t...

Page 8: ...ocumentation for your safety file as applicable prior to wrapping being discarded 2 2 Inspection Equipment that is found to be damaged or has been modified away from its published specification must not be used Please contact Ampcontrol if the equipment is suspected to be different than that ordered or if it does not match the published specifications 2 3 Storage after Delivery When the equipment ...

Page 9: ... Display Module HDM 1 and can be remotely monitored The HPB Relay has 5 digital inputs which feed into a microprocessor unit The microprocessor has been programmed to control three output relays Relay MCR for the main contactor and Relay CBR for the circuit breaker RL3 is used to control the supply to the Cable Connection Module enabling it to perform the Earth Fault Lockout test All of the trippi...

Page 10: ...rsion and serial number b HPB Status c Operational information from the protection functions e g earth leakage current earth continuity resistance etc d System information including the line voltage and current e Status of digital inputs and relay outputs f Protection trip settings which can be viewed at any time Authorised personnel can modify these settings via that HDM Remote Display Module g D...

Page 11: ...TO BE REPRODUCED IN PART An error status indicator is also shown on the status page which is normally zero exceptions are as follows Table 2 HPB Error Status Indicator Display Message Description Error 1 Indicates corruption in the Group 1 Settings HPB Mem Error Error 2 Indicated corruption in the Group 2 Settings HTU Mem Error Error 3 Is a combination of faults in both groups For details of Group...

Page 12: ...equirements 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 4 1 3 Ensure that the HPB will properly perform the required functions within the system design It is important to understand how the HPB is intended to interact with other equipmen...

Page 13: ...nal location and identification 4 3 2 Remote Display Module HDM The Remote Display Module is housed in an IP55 polycarbonate enclosure The Module has been designed to be flush mounted external to the switchgear it is controlling 4 3 3 Cable Connection Module CCMB 6 6kV 6 6kV systems The CCMB 6 6kV Cable Connection Module type B 6 6kV is a resistive isolation device which interfaces between the pow...

Page 14: ...zes increase as currents increase and a decrease in the symmetry of the cables Nuisance tripping tends to occur when the total current rises such as when a large motor is started To help avoid such problems select to smallest internal diameter CT which will allow the cables to fit through 4 3 5 Toroid Installation Guide Lines a Keep cables as close to the centre of the toroid as possible Do not ti...

Page 15: ...7 VcmA VcmB VcmC Earth Three core screened Screen Earth Current Protection Transformers 15 16 17 18 Ia1 Ia2 Ic1 Ic2 Two core screened Screen Earth Local Stop Button digital input 19 20 SpDig SpDig Two core screened Screen Earth Lock Switch digital input 21 22 Lock Lock Two core screened Screen Earth Reset Switch digital input 23 24 Reset Reset Two core screened Screen Earth Start Switch digital in...

Page 16: ...4 3 8 High Voltage Circuits The high voltage circuits of the HPB are the 110 VAC supply 110V version Pins 30 31 only and the relay contacts Apart from keeping these separate from other wiring to the relay there are no special requirements CAUTION The relay contacts of the HPB Relay must not be used to switch more than 190 VAC 5A or 100VA 4 3 9 Earthing The HPB has two earth connections The earth p...

Page 17: ...tead of being connected in the pilot loop WARNING Emergency stops must be wired directly into the pilot circuit A transient protected internal diode is connected between the diode terminal and earth When the pilot is connected to the diode terminal the machine can be used with a conventional pilot protection relay such as an Ampcontrol PCA Relay but will not operate when connected to a HPB Relay I...

Page 18: ...ity The HPB allows the sensitivity of the HTU receiver to be adjusted to suit different installations For installations where multiple HPB s are located close to each other the sensitivity can be reduces to prevent crosstalk between the pilot signals In installations with long trailing cables the sensitivity can be increased The sensitivity can be adjusted from 1 32 with larger values correspondin...

Page 19: ... see Section 10 5 Operational Sequence The HPB Relay closes its relay output RL3 which applies 100VAC to the CCMB 6 6kV Cable Connection Module type B 6 6kV This is a resistive isolation device used to interface the HPB Relay to the power conductors A 5kVDC voltage is generated within the CCMB 6 6kV which under normal operation applies up to 2 5kVDC between each phase and earth The HPB Relay measu...

Page 20: ...nsulation resistance to earth To verify the connection to the power circuit it is recommended that periodic insulation tests be performed using the HPB with a known resistance e g 50MΩ or a short circuit to earth on the line This should be done on an isolated system high voltage supply disconnected using control power only NOTE The start input must be held closed for the duration of the test inclu...

Page 21: ...h in turn de energises the MCR Relay In Res mode all of the relay settings are stored in the HPB Relay If a load is moved to a different outlet or substation then the HPB Relay s settings need to be checked and updated if necessary HTU Mode When the pilot is set to HTU Mode the trailing cable pilot is terminated with a HTU 1 Termination Module The HPB Relay measures the resistance of the pilot ear...

Page 22: ...y de energises the MCR Relay The EC LED on the display module is illuminated and the open collector output on the relay is switched on to provide remote monitoring if required The Earth Continuity can be set to be latching or non latching See Section 9 User Adjustable Settings This allows the user to determine if the fault is manually or automatically reset once the pilot earth loop is healthy The...

Page 23: ...ed A selected time multiplier modifies the basic trip time characteristic This multiplier is selected from 0 05 times to 1 0 times The instantaneous current in each of the three phases can be displayed on the display module level 5 position 1 The display is expressed as a percentage of the selected full load current and reads between 0 and 999 i e up to 9 99 times full load current When the load c...

Page 24: ...ld be used If MCR is selected then the user must ensure that the interrupting device that is operated by the MCR 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 40 to 160ms 7 4 Phase Current Balance Ph...

Page 25: ...e circuit breaker An internal battery backed indication flag in the HPB Relay is also tripped An LED on the front panel of the HPB Relay begins to flash The MCF LED on the Remote Display Module flashes and the open collector output on the HPB is switched on to provide remote monitoring if required To reset the flag access to the relay is necessary The reset button is accessible through the front f...

Page 26: ...e trip threshold as a of line volts SC Relay Selects which HPB output relay is tripped in event of a short circuit trip HTU rx Lev Adjusts the sensitivity of HTU data receiver The second group of settings consists of parameters that are related to the load connected to the protected outlet These settings are stored retrieved to from the memory in the HPB Relay or the memory in the HTU 1 Terminatio...

Page 27: ...iquid crystal display level 8 or 9 d Momentarily operate the lock input A warning message appears e Press the enter button to acknowledge the warning message and to confirm that a change is desired f Use the left and right arrows to step through the allowable values until the desired new setting is displayed g Press the enter button to indicate that the value shown is the required new setting h Mo...

Page 28: ...e signals are available on the HPB Relay s base pins 35 42 and the common is on pin 34 10 4 Outlet Control Closing the Start input energises the outlet Both the remote and local stop buttons will turn off the outlet If a remote stop is not required the Stop input must be bridged to earth via a diode at the HTU 1 Termination Module 10 5 Operational Sequence Before an outlet can be energised the fol...

Page 29: ...gged Table 7 Event Logs Event Description Power Up Records the time when the HPB Relay is powered up Pwr Down Records the time when the HPB Relay loses power MCR Close Closure of the Main Contactor Relay Stopped Stopping of the outlet by operation of the local stop button HTU Stop Stopping of the outlet by operation of the remote stop button MC Opened Main Contactor has opened but not initiated by...

Page 30: ...TY LTD NOT TO BE REPRODUCED IN PART MCI Fail Main Contactor Input MCI shows the main contactor to be closed when it should be open µ P reset Internal microprocessor reset Mem ERROR Records that the relay s non volatile parameter memory has been corrupted HTU mem E Records that the remote termination unit s non volatile memory has been corrupted or the remote termination unit has gone offline while...

Page 31: ...on This indicates the number to be changed c Use the left and right arrow keys to move the v to the desired position d Press the enter key The v now changes to a The right arrow key is used to increment the allowable value once the desired value is obtained press the enter key again The returns to a v e Repeat steps c and d until the correct time and date is displayed f With the v showing press th...

Page 32: ...mote monitoring equipment This can be in the form of either the Remote Display Module or other peripheral equipment such as PLC s For PLC applications the Ampcontrol DNET IP2 Serial Communications System transfers data and commands between the Host System and the modules using RS232 RS422 and RS485 protocols Each integrated protection relay is connected to a Serial Interface IPSI which has its out...

Page 33: ...50Ω 75Ω and 100Ω Shunt Leakage Trip if 200Ω Resistor Mode Operating Time 300ms 400ms 500ms 1 0s 1 2s 1 5s and 2s Earth Fault Lockout Protection Lockout Resistance Test Time HPB 6 6kV Selectable at 2 5 10 20 and 50 Meg Ohm and off HPB 22kV Selectable at 15 20 30 50 and 100 Meg Ohm and off Selectable at 10 15 20 and 25 seconds Over current Protection Current Range Current Multiplier Time Multiplier ...

Page 34: ...unication System User Manual 118626 Relay Contacts MCR CBR 1 N O 5A 190 VAC 100VA maximum 1 C 0 5A 190 VAC 100VA maximum RL3 1 N O 5A 190 VAC 100VA maximum 22 kV Transformers Rated Voltage 22 KV 50Hz Insulation 24 50 125kV Voltage Factor 1 9 30 sec Ratio 22kV 3 to 110 3 Class 0 2 VA Rating 10VA Standard AS60044 2 N Terminal capable of withstanding 5kVDC test voltage 11kV Transformers Rated Voltage...

Page 35: ...T Part Number Description 144069 HPB 6 6kV Integrated Protection Relay 162922 HPB 22kV 200mA EL Integrated Protection Relay 142842 HPB 22kV Integrated Protection Relay 118732 HTU 1 Termination Unit 142848 HPB Base 142845 HPB Base 48V 118542 HDM Remote Display Module Flush Mount 117648 6 6kV Cable Connection Module 143369 22kV Cable Connection Kit 144371 11kV Cable Connection Kit 101503 IPA IPB Rel...

Page 36: ...to the Display Check there is power to the relay and it is correctly plugged in Relay supplied 15VDC to the HDM Check cable between HDM and the relay Faulty Display Module Replace module Remote Display shows a blank screen The HDM LED flashes at 1Hz Power to the HDM is healthy but there is no data Check data cable between the relay and the HDM Error indication 1 level 0 position 1 Corruption in th...

Page 37: ...k on all three outlet phases within 800ms of contactor closing Check system voltage display level 4 position 1 as contactor closes Compare this with the under voltage threshold Check continuity from the relay through the CCMB 6 6kV to power conductors WARNING Be sure to follow the appropriate high voltage isolation procedures HPB 6 6kV Typical reading CCMB 6 6kV 27 Meg Ohm Relay Trips on MCF on po...

Page 38: ...hine end of the pilot If the voltage is normal 30VDC but the current is less that 45mA then the loop resistance may be too high Tests in Resistor Mode When Resistor Mode has been selected the pilot is terminated with a 235Ω resistor The voltage measured across the resistor should be 10 6VDC The voltage measured at the HPB Relay will vary depending on the amount of resistance in the pilot earth loo...

Page 39: ...MANUAL HPBB012 Version 9 March 2020 Uncontrolled Copy Refer to Ampcontrol Website for Latest Version Page 39 of 61 APPROVED FOR EXTERNAL DISTRIBUTION PROPERTY OF AMPCONTROL PTY LTD NOT TO BE REPRODUCED IN PART Figure 16 1 HPB Pilot Resistor HTU Mode ...

Page 40: ...cal Connection Diagram CCMB 22kV HPB Display Map HPBB003 Very Inverse Over current Short Circuit Curves HPBB001 Extremely Inverse Over current Short Circuit Curves IPBB003 Adjustable Setting Storage HPBM005 HPB Enclosure Dimensions HPBM013 HPB HTU 1 Termination Unit HPBM015 Enclosure Details Remote Display Module HDM HPBM030 HPB Base Connections HPBM029 HPB 48V Base Connections HPBM001 CCMB 6 6kV ...

Page 41: ...B012 Version 9 March 2020 Uncontrolled Copy Refer to Ampcontrol Website for Latest Version Page 41 of 61 APPROVED FOR EXTERNAL DISTRIBUTION PROPERTY OF AMPCONTROL PTY LTD NOT TO BE REPRODUCED IN PART TYPICAL CONNECTION DIAGRAM HPB 6 6kV Drawing HPBE006 Rev 0 ...

Page 42: ...BB012 Version 9 March 2020 Uncontrolled Copy Refer to Ampcontrol Website for Latest Version Page 42 of 61 APPROVED FOR EXTERNAL DISTRIBUTION PROPERTY OF AMPCONTROL PTY LTD NOT TO BE REPRODUCED IN PART TYPICAL CONNECTION DIAGRAM HPB 22kV Drawing HPBE013 Rev 1 ...

Page 43: ...B012 Version 9 March 2020 Uncontrolled Copy Refer to Ampcontrol Website for Latest Version Page 43 of 61 APPROVED FOR EXTERNAL DISTRIBUTION PROPERTY OF AMPCONTROL PTY LTD NOT TO BE REPRODUCED IN PART TYPICAL CONNECTION DIAGRAM CCMB 22kV Drawing HPBE012 Rev 2 ...

Page 44: ...42 HPB USER MANUAL HPBB012 Version 9 March 2020 Uncontrolled Copy Refer to Ampcontrol Website for Latest Version Page 44 of 61 APPROVED FOR EXTERNAL DISTRIBUTION PROPERTY OF AMPCONTROL PTY LTD NOT TO BE REPRODUCED IN PART HPB DISPLAY MAP ...

Page 45: ...rsion 9 March 2020 Uncontrolled Copy Refer to Ampcontrol Website for Latest Version Page 45 of 61 APPROVED FOR EXTERNAL DISTRIBUTION PROPERTY OF AMPCONTROL PTY LTD NOT TO BE REPRODUCED IN PART HPB OVER CURRENT SHORT CIRCUIT VERY INVERSE CURVES Drawing HPBB003 Rev 1 ...

Page 46: ...ion 9 March 2020 Uncontrolled Copy Refer to Ampcontrol Website for Latest Version Page 46 of 61 APPROVED FOR EXTERNAL DISTRIBUTION PROPERTY OF AMPCONTROL PTY LTD NOT TO BE REPRODUCED IN PART HPB OVER CURRENT SHORT CIRCUIT EXTREMELY INVERSE CURVES Drawing HPBB001 Rev 1 ...

Page 47: ...HPBB012 Version 9 March 2020 Uncontrolled Copy Refer to Ampcontrol Website for Latest Version Page 47 of 61 APPROVED FOR EXTERNAL DISTRIBUTION PROPERTY OF AMPCONTROL PTY LTD NOT TO BE REPRODUCED IN PART IPB ADJUSTABLE SETTINGS STORAGE Drawing IPBB003 Rev 0 ...

Page 48: ...AL HPBB012 Version 9 March 2020 Uncontrolled Copy Refer to Ampcontrol Website for Latest Version Page 48 of 61 APPROVED FOR EXTERNAL DISTRIBUTION PROPERTY OF AMPCONTROL PTY LTD NOT TO BE REPRODUCED IN PART HPB ENCLOSURE DIMENSIONS Drawing HPBM005 Rev 0 ...

Page 49: ...AL HPBB012 Version 9 March 2020 Uncontrolled Copy Refer to Ampcontrol Website for Latest Version Page 49 of 61 APPROVED FOR EXTERNAL DISTRIBUTION PROPERTY OF AMPCONTROL PTY LTD NOT TO BE REPRODUCED IN PART HPB HTU 1 GENERAL DETAILS Drawing HPBM013 Rev 0 ...

Page 50: ...UAL HPBB012 Version 9 March 2020 Uncontrolled Copy Refer to Ampcontrol Website for Latest Version Page 50 of 61 APPROVED FOR EXTERNAL DISTRIBUTION PROPERTY OF AMPCONTROL PTY LTD NOT TO BE REPRODUCED IN PART HDM 1 ENCLOSURE DETAILS Drawing HPBM015 Rev 0 ...

Page 51: ...HPBB012 Version 9 March 2020 Uncontrolled Copy Refer to Ampcontrol Website for Latest Version Page 51 of 61 APPROVED FOR EXTERNAL DISTRIBUTION PROPERTY OF AMPCONTROL PTY LTD NOT TO BE REPRODUCED IN PART BASE HPB INTEGRATED PROT RELAY Drawing HPBM030 Rev 0 ...

Page 52: ...AL HPBB012 Version 9 March 2020 Uncontrolled Copy Refer to Ampcontrol Website for Latest Version Page 52 of 61 APPROVED FOR EXTERNAL DISTRIBUTION PROPERTY OF AMPCONTROL PTY LTD NOT TO BE REPRODUCED IN PART HPB 48V BASE CONNECTIONS Drawing HPBM029 Rev 0 ...

Page 53: ...BB012 Version 9 March 2020 Uncontrolled Copy Refer to Ampcontrol Website for Latest Version Page 53 of 61 APPROVED FOR EXTERNAL DISTRIBUTION PROPERTY OF AMPCONTROL PTY LTD NOT TO BE REPRODUCED IN PART CCMB 6 6KV CABLE CONNECTION MODULE Drawing HPBM001 Rev 0 ...

Page 54: ...NUAL HPBB012 Version 9 March 2020 Uncontrolled Copy Refer to Ampcontrol Website for Latest Version Page 54 of 61 APPROVED FOR EXTERNAL DISTRIBUTION PROPERTY OF AMPCONTROL PTY LTD NOT TO BE REPRODUCED IN PART CCMB 22KV DIMENSIONS Drawing HPBA018 Rev 0 ...

Page 55: ...BB012 Version 9 March 2020 Uncontrolled Copy Refer to Ampcontrol Website for Latest Version Page 55 of 61 APPROVED FOR EXTERNAL DISTRIBUTION PROPERTY OF AMPCONTROL PTY LTD NOT TO BE REPRODUCED IN PART IPA RELAY LED OUTPUT MODULE DETAILS Drawing IPAS005 Rev 0 ...

Page 56: ...ion 9 March 2020 Uncontrolled Copy Refer to Ampcontrol Website for Latest Version Page 56 of 61 APPROVED FOR EXTERNAL DISTRIBUTION PROPERTY OF AMPCONTROL PTY LTD NOT TO BE REPRODUCED IN PART RELAY OUTPUT MODULE PCB CARD HOLDER GENERAL ARRANGEMENT Drawing IPAA031 Rev 0 ...

Page 57: ... HPBB012 Version 9 March 2020 Uncontrolled Copy Refer to Ampcontrol Website for Latest Version Page 57 of 61 APPROVED FOR EXTERNAL DISTRIBUTION PROPERTY OF AMPCONTROL PTY LTD NOT TO BE REPRODUCED IN PART 11KV VT MECHANICAL DRAWING AND MOUNTING DIMENSIONS ...

Page 58: ... HPBB012 Version 9 March 2020 Uncontrolled Copy Refer to Ampcontrol Website for Latest Version Page 58 of 61 APPROVED FOR EXTERNAL DISTRIBUTION PROPERTY OF AMPCONTROL PTY LTD NOT TO BE REPRODUCED IN PART 22KV VT MECHANICAL DRAWING AND MOUNTING DIMENSIONS ...

Page 59: ...HPB USER MANUAL HPBB012 Version 9 March 2020 Uncontrolled Copy Refer to Ampcontrol Website for Latest Version Page 59 of 61 APPROVED FOR EXTERNAL DISTRIBUTION PROPERTY OF AMPCONTROL PTY LTD NOT TO BE REPRODUCED IN PART APPENDIX B APPROVALS ...

Page 60: ...00 915 542 HPB USER MANUAL HPBB012 Version 9 March 2020 Uncontrolled Copy Refer to Ampcontrol Website for Latest Version Page 60 of 61 APPROVED FOR EXTERNAL DISTRIBUTION PROPERTY OF AMPCONTROL PTY LTD NOT TO BE REPRODUCED IN PART ...

Page 61: ...00 915 542 HPB USER MANUAL HPBB012 Version 9 March 2020 Uncontrolled Copy Refer to Ampcontrol Website for Latest Version Page 61 of 61 APPROVED FOR EXTERNAL DISTRIBUTION PROPERTY OF AMPCONTROL PTY LTD NOT TO BE REPRODUCED IN PART ...

Reviews: