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Ampcontrol IPM V2 User Manual

Integrated protection relay
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IPM V2 – INTEGRATED PROTECTION RELAY
User Manual
Part Number: 121549
Revision: 12 – August 2014
Designed and manufactured in Australia by Ampcontrol Electronics Pty Ltd

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Summary of Contents for Ampcontrol IPM V2

  • Page 1 IPM V2 – INTEGRATED PROTECTION RELAY User Manual Part Number: 121549 Revision: 12 – August 2014 Designed and manufactured in Australia by Ampcontrol Electronics Pty Ltd...
  • Page 2 Ampcontrol Electronics Pty Ltd – ABN 35 000 770 141 IPM2B003 IPM V2 User Manual Rev 12 – 08/14 WARNING! This safety alert symbol identifies important safety messages in this manual and indicates a potential risk of injury or even death to personnel.
  • Page 3 Rev 12 – 08/14 Copyright Notice The Ampcontrol IPM V2 described in this document is the property of AMPCONTROL PTY LTD. It is furnished under a license agreement and is to be used only in accordance with the terms of the agreement.

  • Page 4: Table Of Contents

    Ampcontrol Electronics Pty Ltd – ABN 35 000 770 141 IPM2B003 IPM V2 User Manual Rev 12 – 08/14 TABLE OF CONTENTS 1 SAFETY AND OTHER WARNINGS ..............6 1.1 Safe Use of Equipment ................6 2 RECEIVING AND STORAGE ................7 2.1 Receiving ....................
  • Page 5 Ampcontrol Electronics Pty Ltd – ABN 35 000 770 141 IPM2B003 IPM V2 User Manual Rev 12 – 08/14 9.4 Disposal ....................35 10 SPECIFICATIONS ..................36 11 EQUIPMENT LIST ..................37 APPENDIX 1 IPM Earth Leakage Tripping Curves ..............2 1.1 Tripping Curves for Instantaneous Trip Time Setting .........

  • Page 6: Safety And Other Warnings

    1.1.5 Operation As safety depends on the IPM V2 functioning correctly it is highly recommended that all safety functions of the IPM V2 be periodically tested to ensure correct operation.

  • Page 7: Receiving And Storage

    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.

  • Page 8: Installation

    These instructions have been designed to assist users of the IPM V2 relay with installation. Before the IPM V2 can be installed, there are a number of things that need to be considered and understood to prevent incorrect or unsafe operation of the relay or the system into which it is installed.
  • Page 9 IPM2B003 IPM V2 User Manual Rev 12 – 08/14 Modifications must not be made to any part of the IPM V2. As supplied, the unit is built to, and complies with the relevant standards. Modifications to its construction will render the unit non- compliant.

  • Page 10: Ipm V2 Relay Overview

    Rev 12 – 08/14 4 IPM V2 RELAY OVERVIEW The Ampcontrol IPM Integrated Protection Relay (Version IPM V10.0) is an intelligent protection relay based on microprocessor technology. The IPM Integrated Relay provides the necessary functions required for protecting electrical outlets supplying underground mining machinery, powered by reeling or trailing cables, in the metalliferous industry.

  • Page 11: Basic Display Operation

    Ampcontrol Electronics Pty Ltd – ABN 35 000 770 141 IPM2B003 IPM V2 User Manual Rev 12 – 08/14 4.2 Basic Display Operation The fascia of the IPM Integrated Protection Relay has a four line 20 character backlit Liquid Crystal Display (LCD), Status LED and a tactile keypad.

  • Page 12: Trip/Status Messages

    Ampcontrol Electronics Pty Ltd – ABN 35 000 770 141 IPM2B003 IPM V2 User Manual Rev 12 – 08/14 Line 1: A one-line status message is displayed and if more than one message is active the display cycles through all active messages at 1 second intervals.

  • Page 13: Last Trip Status Messages

    Ampcontrol Electronics Pty Ltd – ABN 35 000 770 141 IPM2B003 IPM V2 User Manual Rev 12 – 08/14 Residual Cur. Trip Residual Current function tripped Main Contactor Fail Main Contactor Fail function tripped RTM-Offline Trip IPM cannot communicate with RTM IPM Memory Error (see Corrupted memory in relay’s stored settings...

  • Page 14: Machine Data Transfer

    Ampcontrol Electronics Pty Ltd – ABN 35 000 770 141 IPM2B003 IPM V2 User Manual Rev 12 – 08/14 4.5 Machine Data Transfer 4.5.1 Remote Termination Module The Remote Termination Module is a microprocessor based fully encapsulated module that replaces the diode at the end of the pilot conductor of the trailing cable.

  • Page 15: Earth Protection Functions

    Given this, it is important to consider the performance of the Earth Leakage protection provided by the IPM V2 and assess how the relay’s performance compares with the requirements of AS/NZS 2081. Testing was completed to assess the ability of the IPM V2 relay to trip within acceptable levels.

  • Page 16: Insulation Test

    Ampcontrol Electronics Pty Ltd – ABN 35 000 770 141 IPM2B003 IPM V2 User Manual Rev 12 – 08/14 25mA 50mA 100mA 200mA 500mA 1000 Fault Current (mA) Figure 3: Instantaneous trip times for a selection of device trip level settings 5.1.2 Earth Leakage Protection Function...
  • Page 17 Ampcontrol Electronics Pty Ltd – ABN 35 000 770 141 IPM2B003 IPM V2 User Manual Rev 12 – 08/14 The IPM Relay measures the voltage on the line and calculates the resistance to earth for all phases. At the end of the test the result is stored in the Event Log as ‘It:X.XMΩ’ If the resistance value is above the preset threshold the MCR Relay picks up allowing the outlet to be energised.

  • Page 18: Earth Continuity

    Ampcontrol Electronics Pty Ltd – ABN 35 000 770 141 IPM2B003 IPM V2 User Manual Rev 12 – 08/14 The three functions shown on the screen are ‘Not Active’, ‘Arming Man.Ins.Test’ and ‘Manual Insulat. Test’. The display will show the last measured value.

  • Page 19: Current Related Functions

    Ampcontrol Electronics Pty Ltd – ABN 35 000 770 141 IPM2B003 IPM V2 User Manual Rev 12 – 08/14 6 CURRENT RELATED FUNCTIONS 6.1 Overload Protection The motor overload function is based on a thermal model of the motor. The three phase currents are squared to provide the I R heating input to the motor model.

  • Page 20: Short Circuit Protection

    Ampcontrol Electronics Pty Ltd – ABN 35 000 770 141 IPM2B003 IPM V2 User Manual Rev 12 – 08/14 CAUTION! Repeated restart attempts in this condition may damage the motor. The ‘Stopped Cooling Ratio’ modifies the cooling output of the thermal model when the motor is stopped.

  • Page 21: Residual Current Signal

    Ampcontrol Electronics Pty Ltd – ABN 35 000 770 141 IPM2B003 IPM V2 User Manual Rev 12 – 08/14 Cur: Ave: 0 Amp Ir: Ibal: Iel: 6.4 Residual Current Signal The three phase current signals are summed electronically in the IPM to produce a residual current signal that can be used to detect earth fault currents.

  • Page 22: Voltage Related Functions

    Ampcontrol Electronics Pty Ltd – ABN 35 000 770 141 IPM2B003 IPM V2 User Manual Rev 12 – 08/14 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.

  • Page 23: Operation Summary

    Ampcontrol Electronics Pty Ltd – ABN 35 000 770 141 IPM2B003 IPM V2 User Manual Rev 12 – 08/14 8 OPERATION SUMMARY 8.1 Analogue Output The IPM Relay provides an isolated 4-20mA analogue output. The output continuously monitors Average Current, Overload, Earth Leakage and the Insulation Level of the relay. The Monitor Output settings can be selected at ‘4-20mA Output’...

  • Page 24: Ipm Alarm Functions

    Ampcontrol Electronics Pty Ltd – ABN 35 000 770 141 IPM2B003 IPM V2 User Manual Rev 12 – 08/14 Modbus Address [01] Read[ÿ] CRC[ ] NF[ ] Wrt.[ ] Par[ ] FE[ ] Exc.[ ] The Modbus Status can be viewed on Level 4, Screen 4.

  • Page 25: Snore Function

    Ampcontrol Electronics Pty Ltd – ABN 35 000 770 141 IPM2B003 IPM V2 User Manual Rev 12 – 08/14 8.5 Snore Function The purpose of the IPM Snore Function is to, optionally, add a timed re-start to the IPM Relay after an undercurrent trip has been detected.

  • Page 26: Remote Ipm Control

    Ampcontrol Electronics Pty Ltd – ABN 35 000 770 141 IPM2B003 IPM V2 User Manual Rev 12 – 08/14 Key Button Start - Regardless of the status of the Snore Function, but with the digital input switch on, operation of the ‘Start’ key will cause the relay to proceed through a power-on sequence.
  • Page 27 Ampcontrol Electronics Pty Ltd – ABN 35 000 770 141 IPM2B003 IPM V2 User Manual Rev 12 – 08/14 8.6.2.2 Remote start - ‘yes’ 1. Start mode - ‘K/Ext’ (Keypad or External) Keypad and External start inputs are ignored. Remote input controls the IPM. Local stop input will still stop the IPM.

  • Page 28: Adjustable Settings

    Ampcontrol Electronics Pty Ltd – ABN 35 000 770 141 IPM2B003 IPM V2 User Manual Rev 12 – 08/14 This is most likely to happen if the RTM’s digital input is closed to allow the IPM to run and then a local stop is used to stop the IPM.
  • Page 29 Ampcontrol Electronics Pty Ltd – ABN 35 000 770 141 IPM2B003 IPM V2 User Manual Rev 12 – 08/14 % of FLC Res. Trip time Sets the trip time for the residual current function RCD Trp. Level Sets the sensitivity trip level for the earth leakage protection RCD Trp.

  • Page 30: System Control

    Ampcontrol Electronics Pty Ltd – ABN 35 000 770 141 IPM2B003 IPM V2 User Manual Rev 12 – 08/14 8.8 System Control 8.8.1 Digital Inputs The IPM provides six (6) voltage free digital inputs for correct operation. To activate an input a connection needs to be made from '+DiPwr' terminal to the respective digital input’s terminal.

  • Page 31: Event Log

    Ampcontrol Electronics Pty Ltd – ABN 35 000 770 141 IPM2B003 IPM V2 User Manual Rev 12 – 08/14 8.8.3 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 6, Screen 16).
  • Page 32 Ampcontrol Electronics Pty Ltd – ABN 35 000 770 141 IPM2B003 IPM V2 User Manual Rev 12 – 08/14 Event Log Record#01: Power Up We 26/07 14:57:13.64 We 26/07 14:58:21 A typical display shows: L2: Displays the event L3: Indicates the time that the relay powered up on Wednesday, 26 July.

  • Page 33: Time And Date

    Ampcontrol Electronics Pty Ltd – ABN 35 000 770 141 IPM2B003 IPM V2 User Manual Rev 12 – 08/14 main contactor is closed (proceeded by MCR closed). This log only appears when in RTM mode. RTM Off L Indicates a loss of communications with the RTM.

  • Page 34: Service, Maintenance & Disposal

    This type of inspection may involve opening cabinets to gain access to the IPM V2 and other equipment. This level of inspection may also include cleaning display windows that have become obscured by dirt.

  • Page 35: Disposal

    IPM2B003 IPM V2 User Manual Rev 12 – 08/14 It is recommended that the electrical protection system incorporating the IPM V2 be subject to regular functional tests at intervals determined by risk assessment or FMEA. These intervals typically coincide with periodic maintenance checks and will cover (but not limited to) tests such as earth continuity tests.

  • Page 36: Specifications

    Ampcontrol Electronics Pty Ltd – ABN 35 000 770 141 IPM2B003 IPM V2 User Manual Rev 12 – 08/14 10 SPECIFICATIONS General 24 VDC ± 20%, <10W Auxiliary Supply Voltage MCR (1/NO, 1 C/O), CBR and ALM (1 C/O) 5A/190VAC 100VA max...

  • Page 37: Equipment List

    Ampcontrol Electronics Pty Ltd – ABN 35 000 770 141 IPM2B003 IPM V2 User Manual Rev 12 – 08/14 360%, 400%, 500%, 600% Current Balance OFF, 5%, 10%, 20%, 50% Trip Setting 2sec Trip Time Other Protection Functions Under Voltage Protection...

  • Page 38: Appendix

    APPENDIX...

  • Page 39: Ipm Earth Leakage Tripping Curves

    Ampcontrol Electronics Pty Ltd – ABN 35 000 770 141 IPM2B003 IPM V2 User Manual Rev 12 – 08/14 1 IPM Earth Leakage Tripping Curves 1.1 Tripping Curves for Instantaneous Trip Time Setting The graph below shows the time taken for the IPM relay to trip for a given fault current when the relay is set to a trip time of Instantaneous, and a selection of trip levels.

  • Page 40: Ipm Full Load Current Selection Table (100:1 Ct)

    Ampcontrol Electronics Pty Ltd – ABN 35 000 770 141 IPM2B003 IPM V2 User Manual Rev 12 – 08/14 2 IPM Full Load Current Selection Table (100:1 CT) IPM Full Load Current Selection Table – Amps (100:1 CT) 0.5125 1.025 2.05...

  • Page 41: Ipm Full Load Current Selection Table (1000:1 Ct)

    Ampcontrol Electronics Pty Ltd – ABN 35 000 770 141 IPM2B003 IPM V2 User Manual Rev 12 – 08/14 3 IPM Full Load Current Selection Table (1000:1 CT) IPM Full Load Current Selection Table – Amps (1000:1 CT) 5.125 10.25 20.5...

  • Page 42: Ipm Menu Structure

    Ampcontrol Electronics Pty Ltd – ABN 35 000 770 141 IPM2B003 IPM V2 User Manual Rev 12 – 08/14 4 IPM Menu Structure Level Menu Level - Menu Message / Sub Menu Display Default Screen Function Start / Status / See Trip / Status Messages;...
  • Page 43 Ampcontrol Electronics Pty Ltd – ABN 35 000 770 141 IPM2B003 IPM V2 User Manual Rev 12 – 08/14 Level Menu Level - Menu Message / Sub Menu Display Default Screen Function O/L trp t @ 6x 3, 4, 5, 6, 7, 8, 10, 12, 14, 16, 20, 24, 28, 32, 40 Sec...

  • Page 44: Ipm Modbus Address Table

    Ampcontrol Electronics Pty Ltd – ABN 35 000 770 141 IPM2B003 IPM V2 User Manual Rev 12 – 08/14 5 IPM Modbus Address Table Modbus Address Description Modbus Address Description Unused Address 12 cont. Bit3 = Right key Trip Status 1 and 2...
  • Page 45 Ampcontrol Electronics Pty Ltd – ABN 35 000 770 141 IPM2B003 IPM V2 User Manual Rev 12 – 08/14 Modbus Address Description Modbus Address Description 45 cont. 4 = Pump 51 cont. 5 = 3.0 5 = Hpmp - Hydraulic Pump 6 =4.0...
  • Page 46 Ampcontrol Electronics Pty Ltd – ABN 35 000 770 141 IPM2B003 IPM V2 User Manual Rev 12 – 08/14 Modbus Address Description Modbus Address Description 58 cont. 1 = Ins. (Instantaneous) 66 cont. 6 = 85% 2 = 50ms 7 = 90%...

  • Page 47: Drawings

    Ampcontrol Electronics Pty Ltd – ABN 35 000 770 141 IPM2B003 IPM V2 User Manual Rev 12 – 08/14 6 Drawings Page 10 of 18 IPM2B003 18/12/2014 10:247/08/2014 12:59...
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