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Ampcontrol Pty Ltd

– ABN 28 000 915 542

IPD USER MANUAL

IPDB014 Version 14

– SEP/2020

Uncontrolled Copy - Refer to Ampcontrol Website for Latest Version

Page 64 of 96

FOR

ION

–

LTD

–

Table 10: Event Log Identifiers and Descriptions

Log Identifier

Description

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



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 I Stp

Outlet stopped by fan interlock

uVOLT Trp

Records that voltage was not present 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

Mem.ERROR

Records that the relay’s non-volatile parameter memory has been

corrupted



- 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 Off L

Indicates a loss of communications with the RTU.

Meg



Trp

Insulation Test failed

IT: -- . -M



Records the result of the Insulation Test

Insul . Alm

Result of Insulation Test is equal to or less than the alarm level

Содержание IPD

Страница 1: ...Version 14 September 2020 Designed and manufactured in Australia by Ampcontrol Pty Ltd IPD INTEGRATED PROTECTION RELAY User Manual ...

Страница 2: ...NING 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 whi...

Страница 3: ... to make changes to any products described herein to improve reliability function or design and reserves the right to revise this document and make changes from time to time in content hereof with no obligation to notify any persons of revisions or changes AMPCONTROL PTY LTD does not assume any liability arising out of the application or any use of any product or circuit described herein neither d...

Страница 4: ...1 3 3 Storage after Delivery 11 3 4 Unpacking of Equipment 11 4 PRODUCT OVERVIEW 12 4 1 IPD Integrated Protection Relay 12 4 2 Accessories 15 5 INSTALLATION 19 5 1 General Warnings 19 5 2 Mandatory Installation Practices 20 5 3 Mechanical Installation Information 20 5 4 Electrical Installation Information 27 6 COMMISSIONING AND CALIBRATION 31 6 1 Fan Interlock 31 6 2 Earth Leakage 31 6 3 Earth Fau...

Страница 5: ...T RELATED FUNCTIONS 45 10 1 General Information 45 10 2 Time Dependent Current Protection 47 10 3 Short Circuit Protection 49 10 4 Phase Current Balance 50 10 5 Transient Overreach Compensation 50 11 VOLTAGE RELATED FUNCTIONS 52 11 1 Main Contactor Fail Protection 53 11 2 Under Voltage Trip 53 11 3 Voltage Metering 53 12 FAN CONTROL 54 12 1 Fan Interlocking 54 12 2 Interlocking Sequence 55 13 USER...

Страница 6: ...al Details 26 Figure 5 9 Current Transformer 88mm I D Part 101703 Dimensional Details 26 Figure 9 1 Earth Leakage Protection Circuit Terminations 38 Figure 9 2 Earth Fault Lockout Protection Circuit Terminations 39 Figure 10 1 Current Transformer Circuit Terminations 45 Figure 10 2 Transient Overreach During Contactor Closure Source IEC 60255 151 50 Figure 10 3 Transient Overreach Protection Timin...

Страница 7: ...ction for short circuit V04 15 DEC 2014 Isolated release only not generally released Extended the maximum delay for the transient inrush function to 320ms V05 10 MAR 2015 Removed the extended delay for the transient inrush function that was implemented in Version V04 Extended the trip time for CT detect trips to 4 seconds Changed the AC detection method to make the CT detect less prone to false tr...

Страница 8: ...l 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 as risk assessment or FMEA be conducted on installations employing the IPD to maximise the safe operation of the installation 2 1 2 Changes to Equipme...

Страница 9: ...pacity CAUTION The IPD integrated protection relay is NOT designed to be used as the sole means of ensuring safety to personnel or equipment CAUTION The IPD integrated protection relay is NOT water resistant and must be mounted within a suitably IP rated enclosure for use where the overall system is to be rated water resistant 2 2 2 Certification WARNING To comply with the Conditions of Certificat...

Страница 10: ...CAUTION The IPD integrated protection relay is NOT on site repairable and contains no user serviceable parts CAUTION An IPD integrated protection relay showing any visible signs of damage must not be used CAUTION All 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 CAUTION Cleaning the controlle...

Страница 11: ...umentation for your safety file as applicable prior to wrapping being discarded 3 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 3 3 Storage after Delivery When the equipment is...

Страница 12: ...round 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 problem with the relay IPD features include Earth leakage protection Earth fault lockout protection Earth continuity protection Over current overload protection Short circuit protection Frozen failed contactor protection Machine rec...

Страница 13: ...e operation of the machine communication function refer to Section 8 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 r...

Страница 14: ...lso 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 For detailed information on the operation of the Earth Fault Lockout protection function refer to Section 9 2 4 1 3 Earth Continuity Protection The earth conti...

Страница 15: ...umber of accessories to perform its protection functions These accessories will be introduced in the following subsections Some accessories are marked as optional and are not required for the IPD to perform its basic protection functions Purchasing these optional items will however expand the capabilities of the installation 4 2 1 IPD Base Plate The IPD Base Plate provides a mounting point for the...

Страница 16: ...rent transformers are panel mounted units 4 2 4 Earth Leakage Toroid The IPD requires a summation toroid to be installed around the outlet s three phase conductors This toroid allows the IPD to measure the magnitude of outlet s earth leakage current Only one 1 earth leakage toroid is required per IPD Earth leakage toroids are available in two standard sizes 60mm inner diameter and 112mm inner diam...

Страница 17: ... temperature inputs 4 2 7 IKD Keypad Pushbutton System IKD Optional The IKD Keypad Pushbutton system consists of an IKD Interface and an IKD Keypad The IKD Interface is mounted inside the enclosure with the IPD whilst the IKD Keypad is mounted external to the enclosure The IKD Interface receives the intrinsically safe control signals from the IKD Keypad and communicates these signals to the IPD th...

Страница 18: ...l 4 2 9 Earth Fault Test Module EFTM Optional The Ampcontrol EFTM can be used to test the operation of the IPD s earth fault lockout EFLO protection This connection is made between the CCMD and the IPD via a three 3 pole relay The EFTM is connected between this relay and earth To test the operation of the EFLO protection the relay is held closed during an attempted start of the outlet The IPD will...

Страница 19: ...al representative 5 1 2 Ensure that the application into which the IPD is being installed has been properly defined designed and approved Any system intended to mitigate the risk of injury needs to be properly designed and implemented Such a system must be the result of structured risk analysis with the outcomes used to define the system requirements These requirements in turn will guide the choic...

Страница 20: ...Codes of Practice Modifications must not be made to any part of the IPD As supplied the unit is built to and complies with the relevant standards Modifications to its construction will render the unit non compliant Complete and accurate records of the installation must be kept as part of the site installation The equipment is to be installed and maintained as per the conditions in the certificatio...

Страница 21: ...ficient 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 ali...

Страница 22: ...ar 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 1 RDM D to monitor and control more than one IPD Relay In these circumstances the following wiring arrangement is recommended Figure 5 3 Option...

Страница 23: ...ion 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 f...

Страница 24: ...d in the core and so would accurately add the opposing fluxes to get a net 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 ...

Страница 25: ... 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 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 Ther...

Страница 26: ... Refer to Ampcontrol Website for Latest Version Page 26 of 96 APPROVED FOR EXTERNAL DISTRIBUTION PROPERTY OF AMPCONTROL PTY LTD NOT TO BE REPRODUCED IN PART Figure 5 8 Current Transformer 45mm I D Part 101272 Dimensional Details Figure 5 9 Current Transformer 88mm I D Part 101703 Dimensional Details ...

Страница 27: ...he 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 60079 14 This makes it necessary for anyone installing IPD Relays to be familiar with and have a good understanding of AS NZS 60079 14 The IPD Integrated Protection Relay is typically installed into a system along with ap...

Страница 28: ...Signal Cable Type Cable Connection Module 3 4 5 7 VcmA VcmB VcmC Earth Three core screened Screen Earth Pilot Core 6 7 Pilot Earth Single core screened Screen Earth Serial Comms Port 8 9 10 11 12 Vsc FIO TXD RDI Earth Four core screened Screen Earth Remote Display 13 14 12 Data Vdm Earth Three core screened Screen Earth NOTE It is recommended that these circuits be loomed separately from all non I...

Страница 29: ...kage Toroid Test 32 33 EL Test EL Test Single core not screened Loop Resistance 1 Current Protection Transformers 15 16 17 18 Ia1 Ia2 Ic1 Ic2 2xTwo 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 E...

Страница 30: ... PART 5 4 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 wil...

Страница 31: ...ilar effect 6 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 6 4 Earth Continuity Test that the Earth Continuity protection is operational by creating an open circuit on the pilot wire Ensure that all relevant trip...

Страница 32: ...he voltage must be 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 6 10 Voltage Measurement Validate the voltage measurement function of the IPD by checking the measured voltages on the RDM when the main contactor is closed 6 11 RDM Ensure that the RDM is functioning correctly by operating the men...

Страница 33: ...mber 3 Operational information from the protection functions e g earth leakage current earth continuity resistance etc 4 System information including the line voltage and current 5 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...

Страница 34: ...t Trip record Need IPD Start 2 Awaiting IPD start digital input Need RTU Start 2 Awaiting RTU start digital input Outlet Paused 2 IPD waits 5 Sec between running or testing and re testing Closing MainCont 2 MCR closed waiting for MCI feedback 5 Sec max EFLO Testing 2 In process of EFLO Test 1 second Insulat Testing 2 In process of Insulation Test 2 seconds Manual Ins Test 2 In process of manual In...

Страница 35: ...the stop trip function also appears in the Event Log Messages that are displayed at Last T Table 4 RDM D Last Trip Status Messages Message Comment EC Leak T E C Leakage Trip that provides additional information for E C Trip EC Ω Trip E C Ohms Trip that provides additional information for E C Trip Fan I Stop Fan interlock Stop I bal Trp Current Balance Trip Differentiates balance trip from basic ov...

Страница 36: ...to turn 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 that these functions are operational only and that any emergency stops should be wired direct into the pilot circuit CAUTION Emergency Stops should not be wired into the Stop input of the RTU D They should be directly wired int...

Страница 37: ...Machine Type Codes Item Code Type of Machinery 1 Belt Conveyor 2 SHRr Shearer 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 M...

Страница 38: ... an earth leakage trip is initiated The trip opens the Main Contactor Relay MCR and is latched 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 ...

Страница 39: ...ote 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 for a CT detection fault has been fixed at 4 seconds in Version 5 of the IPD relay This differs from earlier versions of the IPD firmware that derived the trip time from the Earth Leakage Time Delay setting NOTE The loop resistance of the CT Detectio...

Страница 40: ...on supply and or to provide voltage related functions 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 EFLO is required by mining re...

Страница 41: ... The alarm message is displayed until a new EFLO Test is initiated or the ENT key is pressed while displaying the alarm message Insul Alm is also recorded in the Event Log Table 6 Insulation Test Trip Threshold and Alarm Level Comparison Ins TstT Selection MΩ Alarm Level MΩ 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 15 20 None None If the value is less than the preset trip level 0 1 MΩ to...

Страница 42: ...he higher end of the 5MΩ range CAUTION Trip setting values of 10MΩ and 15MΩ aren t specified above but are available for configuration within the software These trip settings of 10MΩ and 15MΩ are not recommended for use by Ampcontrol NOTE The start input must be held closed for the duration of the test NOTE The recommended trip setting values to be utilised for the insulation test trip settings ar...

Страница 43: ...econds 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 ...

Страница 44: ...trol 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 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 loo...

Страница 45: ...s tripping from overreach at start up The IPD has a transient overreach performance figure of 35 determined per IEC 60255 151 section 6 5 2 See Section 10 5 for more information Figure 10 1 Current Transformer Circuit Terminations 10 1 1 Full Load Current Parameter 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...

Страница 46: ...see Section 13 User Adjustable Settings NOTE 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 10 1 3 Viewing the Instantaneous Current The instantaneous 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 cur...

Страница 47: ...nex A of IEC 60255 151 Where t sec is the trip time m is the selected time multiplier and I is the input current ratio relative to the full load current set point 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 ...

Страница 48: ...rip time after the motor has been running at the selected full load current indefinitely which results in a thermal accumulation of 89 and 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 therma...

Страница 49: ... 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 10 3 Short Circuit Protection 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...

Страница 50: ...rotection 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 t...

Страница 51: ...ltiplier will be increased one step e g 1 2x increases to 1x for the selected time period 2 For current multiplier 4x the base current will be increased to the maximum setting of 116A NOTE Example 1 Start Transient Setting IPD set to 88A 1x current multiplier and 6x short circuit multiplier resulting in a short circuit set point of 528A With START TRANSIENT mode set to 90ms the current multiplier ...

Страница 52: ...CMD CCMA to monitor the magnitude of the voltage on the load side of the outlet s main contactor The voltage measurement is used to implement the following functions Main Contactor Fail Protection Under Voltage Trip Voltage Metering Figure 11 1 Voltage Monitoring Circuit Terminations IPD Relay VCmA 03 VCmB 04 05 VCmC A B C Phase Conductors From Contactor CCMD VcmA VcmB VcmC Earth Minimum 4mm2 Va V...

Страница 53: ...tors to dissipate The inbuilt time is adjustable from 2 to 20 seconds See Section 13 User Adjustable Settings 11 1 3 Resetting a Trip 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 11 2 Under Voltage Trip...

Страница 54: ...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 be viewed on the Remote Display Module Relay and Digital Input Status Se...

Страница 55: ... 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 13 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 ...

Страница 56: ...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 13 1 sho...

Страница 57: ...he RTU descriptive code transmitted to identify the machine connected to the outlet RTU MC No Selects the assigned machine number to be transmitted by the Remote termination Unit OC I range Sets the basic current range OC I mul This multiplier 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 b...

Страница 58: ...sired 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 7 Press the enter button to indicate that the value is the required setting 8 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 pro...

Страница 59: ...he desired position 4 Press the enter key The v now changes to a The right arrow key is used to increment the allowable values once the desired value is obtained press the enter key again The returns to a v 5 Repeat steps 3 and 4 until the correct time and date are displayed 6 With the v showing press the lock push button The v then changes to E This is a prompt to press the enter key 7 Press the ...

Страница 60: ...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 12 1 Fan Interlocking RL4 applies 110V for the Insulation Test see Section 9 2 3 Automatic Insulation Test The status of the relays can be displayed on the Rem...

Страница 61: ...p and PTC terminals must be bridged to energise the outlet WARNING Stop Start functions are operational only Emergency stops must be wired directly into the pilot circuit 14 2 2 Remote Operation in Diode Mode In this mode the stop start station is connected in the pilot see Typical Connection Diagram IPDE001 in Appendix A Drawings The pilot has a hysteresis of 100 ohms This is to allow a 100 ohm r...

Страница 62: ...this time then the run mode is exited NOTE The Start input must be held closed whilst the IPD is performing the initial EFLO test If the Start input is released prior to the completion of this test the start sequence will be aborted 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...

Страница 63: ...e 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 an earth leakage fault caused a trip condition o...

Страница 64: ...t 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 I Stp Outlet stopped by fan interlock uVOLT Trp Records that voltage was not present on at least one outgoing phase when the main contactor was closed ...

Страница 65: ...eral 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 Protocol Converter provides the communications link to a PLC see DNET IP2 Serial Communication System User Manual for further details The Ampcontrol DNET IP2 Serial Communication System transfers...

Страница 66: ...in good order and correctly fitted Check 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 17 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 connect...

Страница 67: ...3 Repair and Overhaul This is required every 4 years The following components shall be returned to Ampcontrol for AS3800 inspection repair and overhaul Integrated Protection Relay IPD Part 162131 Remote Display Module RDM D Part 110141 CCMD Cable Connection Module s Part 110146 110147 110148 Remote Termination Unit RTU D3 Part 161575 where used available Keypad Interface Module IKD Part 110142 IS ...

Страница 68: ... 120ms 160ms 200ms 300ms 400ms 500ms Pilot Cable Parameters C 0 3 F L 10mH L R 600uH Ω Earth Fault Lockout Protection Lockout Resistance IS Test 415V 4 15kΩ 1000V 10kΩ 3 3kV 33kΩ IS Test Time 1 second Lockout Resistance Insulation Test Selectable at 0 1 0 2 0 5 1 2 5 10 and 15 MΩ and off Insulation Test Time 2 second Alarm Settings Insulation Test Trip Setting x1 5 Over Current Overload Protection...

Страница 69: ... AMPCONTROL PTY LTD NOT TO BE REPRODUCED IN PART Machine Numbers Machine Numbers Can be allocated from 1 to 40 Fan Current Threshold Level 32 to 96 in 8 increments of full load current Undervoltage Protection Trip Setting Selectable from 20 to 80 in 10 increments Trip Delay 800ms Serial Communications For information on Protocol and hardware requirements see DNET IP2 Serial Communication System Us...

Страница 70: ...49 Toroid EL500 60 100T 500mA 60mm Inner Diameter 101654 Toroid EL500 112 100T 500mA 112mm Inner Diameter PHASE CURRENT TRANSFORMERS Two Phase Current Transformers are required for each installation Select size to suit the cable diameter Part Number Description 101272 CT 1000 1 45mm Inner Diameter OL1 1000 1 101703 CT 1000 1 88mm Inner Diameter OL2 1000 1 REMOTE TERMINATION UNITS The IPD requires ...

Страница 71: ...ebsite for Latest Version Page 71 of 96 APPROVED FOR EXTERNAL DISTRIBUTION PROPERTY OF AMPCONTROL PTY LTD NOT TO BE REPRODUCED IN PART OTHER ACCESSORIES Part Number Description 101826 EFTM 415 1kV IPC Earth Fault Test 121170 EFTM 3 3kV IPC Earth Fault Test 101296 Fuse Holder C W 3A 660V Fuse 117139 Fuse 3A 660V Spare Item ...

Страница 72: ...age IPD Memory Error When in diode pilot mode Corruption in the Group 1 or 2 Settings stored in the IPD Relay Examine the Group 1 and 2 Settings level 8 and 9 to check the stored parameters in the non volatile memory Machine type and number are irrelevant and should be ignored One or several settings will show Re program lost settings into the memory Status Message IPD Memory Error When in RTU pil...

Страница 73: ...lays Outlet Close Fail message after start is pressed The relay s MCI input is not closing within 5 Sec of MCR relay pickup level 6 position 2 Check that main contactor is closing If not check circuit or replace main contactor RDM displays Tripped No Volts message Relay not receiving lost voltage feedback on one or all three outlet phases when contactor closed Check system voltage display level 4 ...

Страница 74: ...load Short Circuit Curves IPDB003 Fan Interlocking System IPDB032 Overcurrent Functional Block Diagram IPDB033 Overcurrent Short Circuit Curves IPDB034 Motor Overload Hot Cold Curves IPDB035 Motor overload Block Diagram IPDA021 IPD Relay Base Dimension Details IPDA015 Remote Termination Unit General Arrangement IPDA016 Remote Display Module RDM D G A Mounting Details IPDA017 IPD Baseplate Connecti...

Страница 75: ...00 915 542 IPD USER MANUAL IPDB014 Version 14 SEP 2020 Uncontrolled Copy Refer to Ampcontrol Website for Latest Version Page 75 of 96 APPROVED FOR EXTERNAL DISTRIBUTION PROPERTY OF AMPCONTROL PTY LTD NOT TO BE REPRODUCED IN PART ...

Страница 76: ...00 915 542 IPD USER MANUAL IPDB014 Version 14 SEP 2020 Uncontrolled Copy Refer to Ampcontrol Website for Latest Version Page 76 of 96 APPROVED FOR EXTERNAL DISTRIBUTION PROPERTY OF AMPCONTROL PTY LTD NOT TO BE REPRODUCED IN PART ...

Страница 77: ...00 915 542 IPD USER MANUAL IPDB014 Version 14 SEP 2020 Uncontrolled Copy Refer to Ampcontrol Website for Latest Version Page 77 of 96 APPROVED FOR EXTERNAL DISTRIBUTION PROPERTY OF AMPCONTROL PTY LTD NOT TO BE REPRODUCED IN PART ...

Страница 78: ...00 915 542 IPD USER MANUAL IPDB014 Version 14 SEP 2020 Uncontrolled Copy Refer to Ampcontrol Website for Latest Version Page 78 of 96 APPROVED FOR EXTERNAL DISTRIBUTION PROPERTY OF AMPCONTROL PTY LTD NOT TO BE REPRODUCED IN PART ...

Страница 79: ...00 915 542 IPD USER MANUAL IPDB014 Version 14 SEP 2020 Uncontrolled Copy Refer to Ampcontrol Website for Latest Version Page 79 of 96 APPROVED FOR EXTERNAL DISTRIBUTION PROPERTY OF AMPCONTROL PTY LTD NOT TO BE REPRODUCED IN PART ...

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Страница 94: ... 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 1 5 13 S G G TMS G t Where t G is the operate trip time TMS is the time multiplier G Gs is the input current ratio relative to the ful...

Страница 95: ... The response to time varying energising quantities is 5 per IEC60255 151 part 6 5 4 Motor Overload IEC60255 8 See m OL Curves Drawing IPDB019 and Motor Overload Functional Block Diagram Drawing IPDB035 in Appendix A Drawings The Ampcontrol IPD implements the motor thermal model in line with IEC 60255 Part 8 represented by two curves Cold Motor Curves Hot Motor Curves Motor overload is implemented...

Страница 96: ...difier tor CoolingFac cold NOTE the function which has been published elsewhere in this document for motor overload is 1238 1 ln 1800 2 2 I h I m LTriptime MO Where m is the time multiplier h is 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 E...

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