HPB Protection Relay
Contents
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3. 4 Aiddng l 3 03TI0 1NOJNN a i 4 amp 4 soian S 5 P x Br 4 t 1 END VEW Tn UNCONTROLLED IF PRINTED R B 5 06 6 1 92 VEW OF PCB amp HOLDER SIDE VIEW OF amp HOLDER IPCONTHROL HPB INTEGRATED RELAY USER MANUAL Issue R3 Date 09 2010 CRN 8060 Appendix B Approvals SYSTEMS APPROVALS PTY LTD Postal Address Business Address P O Box 45 14 Raymond St Boolaroo NSW 2284 Speers Pt NSW 2284 Phone 049 586811 Fax 049 586827 A C N 054191347 Mobile 049 018 685252 The Manager Ampcontrol CSM Pty Ltd P O Box 304 WARNERS N S W 2282 OUR REF N SA654 FILE REF C92 0362 DATE 16 02 1995 SUPPLEMENTARY APPROVAL Dear Sir ITEM INTEGRATED PROTECTION RELAY IDENTIFICATION HPB ORIGINAL APPROVAL 11388 ORIGINAL APPROVAL HOLDER AMPCONTROL SWG PREVIOUS APPROVAL N Ex 11388 SUPPLEMENTARY APPROVAL 11388 Modified for use high voltage systems for open cut coal mines as follows a Change input resistor on E L toroid to give adjustable trips 200ma 1000ma b Trip time adjustable 80 470ms Status and event log information added and provision for adjusting the trip s
4. lun eu 11 4 2 2 High Voltage 12 4 2 3 12 5 Communication 13 HPB Termination Ya M 13 5 2 Machine a 13 5 3 Machine aee aa 13 5 4 Receiver Sensitivity ET 13 6 Earth Protection Functions seen tenente nnne trt tette 15 o 15 6 2 Earth Fault sse tnnt tenete nennen N E tenir tenni 15 6 2 1 15 6 2 2 EB ZZ eNOS 15 MEDII 16 7 Current Related Functions 18 7 1 Basic Over current Protection sese ennt tnnt tnter 18 eatis 18 EE I 19 7 4 Phase Current Balance NR 19 8 Voltage 211519 9 20 8 1 Main Contactor Protection tnnt tentent 20 8 2 MV Voltage 2 20 8 3 VONAGE dte E ehe i nct kn en te diu Gi asian quar cud 20 HPBB012R5 docx Page 3 S am AMP
5. 001 6 6 kV Cable Connection Module Overall amp Mounting Dimensions 018 CCMB 22 kV Cable Connection Module Overall amp Mounting Dimensions IPAS005 IPA IPB Relay LED Output Module IPAA031 Relay Output Module General Arrangement The drawings appear in the following pages in the same order in which they are listed in the table above HPBB012R5 docx Page 35 8 miii gt 5 ve 1000 1 2M STC Rating Phasing on Overload C T Must be as Shown R 299 Ohms need to produce test current of 109 10096 of Trip Level Notus amp leads should be Twisted 8 Shellded with the Shelide connected to pin 7 possible to the HPB MO Incoming Supply type AMPCONTROL EL 500 2 E L Test Resistor Rielt Calculate to give between 10055 160 of tre Level 11259 Nomnall eg At use 50 Ohms of 2 turns of 013 injection wire toroid with 90 Ohms 3 Cable Connection Module Ampcontrol CCMB 22kV b Over Load CT s 2900 1 Class 1 0 STE Rating 45 3 Notes Phosing on Overload C T s Must Shown toroid leads should be Twisted with the shields connected n 7 05 clase 05 possible to C T 22kV TYPICAL CONNECTION DIAGRAM
6. I Selected Full Current SFLC Cur Range H P B Extremely Inverse Over Current amp Short Circuit Curves enets uns CUIT mna 100 Se eem 7 EXTREMELY INVERSE CURVES OVER CURRENT amp SHORT CIR x Ht T MULTIPIER 25 clectrareesPompronte AMPCUNTROL ELECTRUNK 5 AMPCONTROL CSM PTY LTO ABN 35 209 770 1 7 BILLBRODKE CLOSE CAMERON PARK NSW P 12 4407 4800 02 4903 6838 gt gt tuber to reall mof be amp part whele or the contents miget 10 4 Ihr party without the prior wr ten approval APP CONTRI THS DRAMNG REMAINS THE PROPERTY OF 0 0 5 es 1 60mSec GOmSec SHORT i CIRCUIT 200 300 400 500 600 700 800 900 1000 of Selected Full Load CURRENT HPB 22kV Range STD HPB Range b Selected Full Load Current SFLC Over Current Trip time Cur Mul 198 m sec 151 m Multiplier 1 Fa
7. MPCONTROL INTEGRATED PROTECTION RELAY USER MANUAL Issue R5 Date 6 2011 WARNING The CCMB generates 5kVd c This high voltage d c is produced and applied to the 3 j phase lines even when the high voltage 3 phase supply is not available Care should therefore always be taken when working close to high voltage 3 phase cables bus etc STOP audible tone is generated whenever the CCMB is active warning of the presence of high voltage d c CAUTION Like all insulation tests a faulty open circuit connection to the power circuit will create the appearance of a high insulation 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 50 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 HPB 22 kV which is adjustable between 10 and 25 seconds to allow for the charging of cable capacitance The start input must be held closed for the duration of the test including the 3 s delay on Setting the EFLR Test value to off disables the Earth Fault test If this is done and the system is ready to start the MCR Relay closes as soon as the start input is closed 6 3 Earth Continuity The earth continuity function tests for
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9. HPB INTEGRATED PROTECTION RELAY 6 6 kV and 22 kV USER MANUAL Issue R5 May 2011 CRN 8575 Ampcontrol User Manual Part No 117829 Designed and Manufactured in Australia by Ampcontrol CSM Pty Limited AMPCONTHROL INTEGRATED PROTECTION RELAY USER MANUAL Issue R5 Date 6 2011 Safety and other Warnings WARNING This safety alert symbol identifies important safety messages in this manual and indicates a potential risk of injury or even death to the personnel When you see this symbol be alert your safety is involved carefully read the message that follows and inform other operators CAUTION NEP This safety alert symbol identifies important information to be read in order to ensure the correct sequence of work and to avoid damage or even destruction of the equipment and reduce any potential risk of injury or death to the personnel Carefully read the message that follows and inform other relevant personnel Supplementary information not directly affecting safety or damage to equipment Information concerning possible impact the environment and actions required for prevention and proper response ALERT HPBB012R5 docx Page 1 AMPCONTHROL INTEGRATED PROTECTION RELAY USER MANUAL Issue R5 Date 6 2011 Copyright Noti
10. LED on the HDM Remote Display Module is illuminated and the open collector output on the HPB Relay is switched on to provide remote monitoring if required A time delay of 5 seconds is allowed for the Main Contactor Interlock MCI to close If it does not close within this time then the run mode is exited If a stop button is operated while the relay is in run mode the run is cleared and the MCR Relay de energises The event log reads Stopped or HTU Stop depending on which stop button caused the stop condition If a stop button is operated during a cable fault lockout test then the test is aborted While the main contactor is closed the MCI input is continuously monitored If it opens the run is cleared and the MCR relay de energises In this case the event log records MC Opened which indicates that the outlet was turned off by something other than the HPB Relay e g open circuited main contactor coil or control supply HPBB012R5 docx Page 23 X AMPCONTROL p HPB INTEGRATED PROTECTION RELAY USER MANUAL Issue R5 Date 6 2011 11 Event Log A real time clock calendar is included in the HPB Relay This combines with the non volatile memory to provide data logging This log sequentially records the time date and details of the HPB Relay s operations A chronological list of the previous 120 events is stored The event log can be scrolled so as to view the entire log To achieve this press Enter followed by the ri
11. Unit EL Sens Sets the sensitivity for the Earth Leakage protection trip EL Time Sets the trip time for the Earth Leakage protection EFLR Test Sets the Earth Fault lockout level Eft time Selects the test time for the Earth Fault lockout test to allow for line capacitance U V Trip Selects the under voltage trip threshold as a 96 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 Termination Unit depending on the Pilot Mode setting If the Resistor Pilot Mode is selected the HPB Relay reads and writes to and from the relay s internal memory for the group 2 settings If the HTU Pilot Mode is selected the settings are sent to and retrieved from the memory in the Remote Termination Unit 9 1 2 Group 2 Settings HTU MC Type Allows the HTU 1 to transmit a descriptive code to identify the machine connected to the outlet HTU MC No Allows the HTU 1 to transmit an assigned machine number OC I range Sets the basic current range OC I mul Combines with OC range to define the full load current OC Type Selects either very inverse or extremely inverse over current curves OC t mul Modifies the
12. and or assessment to assist the Approval Holder and User to comply with the obligations of the Occupational Health and Safety Act 1983 The onus is on the Supplier and or User to ensure the Approved Item and any deviation from the list of recommendations in reference to that item is not inferior in any way to the item tested and or assessed this includes the supply installation continuing use of the approved item The Approval Number shall appear in a conspicuous place and in a legible manner on each approved item unless specifically excluded copy of this Approval Document together with a copy of the recommendations from the Authority issuing the Approval shall be supplied to each user of the approved item Any Maintenance Repair or Overhaul of Approved Items shall carried out in accordance with the requirements of the Coal Mines Regulation Act 1982 A J Weeks Assessing Authority No MDA A2507 FOR THE CHIEF INSPECTOR OF COAL MINES 3 3 Minerals amp Energy House Box 536 St Leonards NSW 2065 Australia Telephone 02 901 888 Facsimile 02 901 8777 HPBB012R5 docx Page 51
13. and the installation When using a 110V HPB a power supply filter e g Schaffner FN612 1106 1A 250Va c chassis mounted filter or similar should be installed adjacent to the HPB Relay The earth should be connected to Pin 7 on the relay as directly as possible HPBB012R5 docx Page 10 ao amp AMPCONTHROL HPB INTEGRATED PROTECTION RELAY USER MANUAL Issue R5 Date 6 2011 421 Low Voltage Signals Care must be taken to ensure these circuits cannot come into contact with higher voltages e g via insulation breakdown or broken wires etc It is recommended that these circuits be run in a separate loom from the high voltage circuits To ensure that interference is kept to a minimum the following cabling is recommended Duty Pin Signal Recommended Type 6 Pilot Single core screened Pilot Core 7 Earth Screen 8 Serial Comms Port Four core screened 11 Screen 12 Two core screened Remote Display Screen 0 Earth Leakage Toroid Two core screened Screen Earth Three core screened Cable Connection Module Screen Earth 15 la1 Current Protection 16 la2 Two core screened Transformers Ic1 Screen Earth 2 Local Stop Button digital SpDig Two core screened input SpDig Screen Earth m Lock Two core screened Lock Switch digital input Reset Switch Reset Two core screened digital input Reset Screen Earth Start Switch Start Two core screene
14. for the HPB Stat lays elatus page display Modules Stop HTU Stop to be closed Outlet was turned off but not by the relay Check there is power to the relay and it is correctly plugged in Relay supplies 15Vd c to the HDM Check cable between HDM and the relay Replace module Check data cable between the relay and the HDM Examine the Group 1 Settings level 8 to check the stored parameters in the non volatile memory or several settings will show 227 Re program lost settings into the memory Check that the HTU 1 Module is on line level 3 position 1 ie a healthy pilot loop If the HTU 1 Module is on line examine the Group 2 Settings stored in the HTU Settings level 9 One or several other settings will show Re program lost settings into the HTU 1 memory 1 As outlined above for Errors 1 and 2 Check pilot circuit See detailed fault finding information page 15 If still faulty replace the relay Ensure HTU 1 Module s stop input is closed through a diode to earth Check main contactor coil or control circuit HPBB012R5 docx Page 31 AMPCONTROL INTEGRATED PROTECTION RELAY USER MANUAL Issue R5 Date 6 2011 Symptom Cause Remedy Check that main contactor is closing If not check circuit Check auxiliary contacts and wiring The relay s MCI input is not closing level 6 position 2 Check system voltage d
15. the continuity of the earthing between the outlet and the machine via the pilot core in the trailing cable The pilot core is also used to transfer machine data when a remote HTU HPB Termination Unit is used to achieve machine communication The pilot resistance is measured with a d c signal and communication is achieved by a high frequency a c signal The HPB Relay can be configured to operate in either Resistor or HTU Mode The mode is selected in Pilot Type Level 8 Position 1 and defines the type of termination unit to be connected between the pilot and earth at the machine end of the trailing cable being protected by the HPB Relay The advantage of using the resistor mode is that it uses a simple signal and a robust termination device making the system easy to fault find The disadvantages are incorrect healthy Earth Continuity indication could be produced by a pilot that has faulted to earth with a resistance within the pickup range of the HPB Relay For example if the selected trip level 15 500 then the fault to earth in the range of 2000 to 2850 would be seen as a healthy circuit b Machine Communication functions of the HPB Relay are not available The advantages of using HTU mode are a Machine communication b Machine stops can be differentiated from Earth Continuity Trips in the HPB Event Log c Increased security in pilot system as the HPB Relay must receive an intelligent signal from the HT
16. to open when required This is achieved by comparing the state of the main contactor via the Main Contactor Input MCI against the state of the MCR Relay output This provides a Pilot Fail Timer function b Failing to maintain insulation across the contacts when the contactor is open The Cable Connection Module is used to measure the voltage on the load side of the contactor If this exceeds 10 of the rated line voltage a trip will occur This function is inhibited immediately after the main contactor opens or a cable test is performed to allow for the cable capacitance to discharge The back EMF inhibit time is adjustable from 2 to 40 seconds See Section 9 User Adjustable Settings A main contactor fail trip causes the CBR Relay to de energise which trips the circuit breaker An internal battery backed indication flag in the HPB Relay is also tripped A 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 fascia of the relay and must be pressed for 1 second 8 2 Under Voltage Trip Under voltage protection is enabled as soon as the main contactor is closed indicated by closing the MCI input If any of the phase voltages drop below the selected trip setting of the nominal line vo
17. 5 Chie to other to Outlets INOT USED AMPCONTROL H P B 22kV High Voltage Integrated Protection Relay 22kV ou OXF Optional os 48Vd c OX Led Relay 7 Module ji tiectronks angcontroigrouncon CAMERON PARK MS W 2245 F amp MPCONTRDL AMPCONTROL LP S I gt lt 24 5 it ie to ther recall 4 wus tet be o part b 2 E 5 tables passing through 4 Iv be Systan 1011248 Level QLNERAL LINEAR TOLERANCE 0 5 1100 359v Surge Protectien gt Cable AME CONTROL HOM 1 Ampcontrol HTU 1 HPB Termination Uni ax Pist 3 Step HPB Toop gt Resistor Mode oU Connection terminate the stop Pilot 235 ohms Egeth VE Ay NOISH3A B MSN E MNA NOUSIN 85 0056 3008718 tu NYO 802 20 eet 5067 19 saud 7 038 dH utro VOIES IHI TOXSIMOOdWN L4 0 SV sin f d E561 2b kc ARMOR 5002 Xvid WIWO
18. CONTROL HPB INTEGRATED PROTECTION RELAY USER MANUAL Issue R5 Date 6 2011 21 Parameter nias ie dus dh 21 9 1 1 1 Settings 21 9 1 2 21 9 2 Changing 22 Scc 23 pec C 23 10 2 SDUIDUE Relay 23 10 3 Open Collector Outputs c P 23 EST decus OOE 23 UE rase NND m MTM 23 M LL 24 12 Tim e amp dece 26 13 Remote Data Communications essent tette 27 14 HPB Equipment Parts List sse tnter tnnt 28 15 APB peace d CERRO TA 29 31 16 1 Pilot Fault Finding Information 33 Appendix 1 35 Appendix Approvals seen tner entre tete tete terne 49 HPBB012R5 docx Page 4 AMPCONTROL p HPB INTEGRATED PROTECTION RELAY USER MANUAL Issue R5 Date 6 2011 1 Receiving and Storage 1 1 Receiving All possible precautions are taken to protect the equipment against damage or losses during shipment however before accepting del
19. CTION RELAY USER MANUAL Issue R5 Date 6 2011 16 1 Pilot Fault Finding Information To carry out tests on a faulty earth continuity circuit adopt the following procedures Open circuit pilot Check the voltage between the pilot and earth at the HPB Relay Pins 6 and 7 The reading should be 30Vd c To determine the location of the fault continue the above test along the pilot until no reading is obtained Current check Connect a d c ammeter between the pilot and earth at the HPB Relay Pins 6 and 7 The reading should be 45 mA at the HPB Relay or at any point along a continuous pilot Repeat this test at the machine end of the pilot If the voltage is normal 30V d c but the current is less than 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 2350 resistor The voltage measured across the resistor should be 10 6V d c The voltage measured at the HPB Relay will vary depending on the amount of resistance in the pilot earth loop For example if the loop resistance is 1000 then the voltage at the HPB Relay will increase by 4 5 volts 100 x 0 045 resulting in a reading of 15 1 V d c Tests in HTU Mode When HTU Mode has been selected the pilot is terminated with an HTU 1 Termination Module The voltage measured across the Pilot and Earth terminals of the module should be approximately 20V d c The voltage measured at the HPB Relay will vary dependi
20. EV um Dum 5 3S83ANI AYIA 11380 LHOWS 7 Ls Dao 49 ma Zt 3 994049 aod ast 105 4 poi 0 4120 TOW sea 3D 1 Of 000 St wavy 7 M 00 SV 37 25 LON 00 50152340 33474301 MIND SWJH 01 dey 30 ALBA Dant 50 TUND 8dH TIME MULTIPIER ecmr ou m 2 e EHE A COT ELITR T OE LLL DLE E RR ER EE EA EH 120 amp 160 mSec 700 800 900 Fault Current Selected Full Load Current t Selectable at 3 0 3 5 4 0 4 5 5 0 5 5 6 0 6 5 90 7 5 8 0 8 5 9 0 9 5 10 0 Times Selected Full Load Current Times Selectable at 40 60 80 100 time Multiplier 9 f urrent amp 00 500 Load CURRENT HPB 22kV Range Over Current Trip time f Short 4 gt 3 w 4 a S gt e qi gt gt gt
21. In mode the relay settings that pertain to the actual load connected are stored in the HTU 1 Termination Module which is installed in the machine If a machine cable is moved to a different outlet or substation then the protection settings for the machine are automatically uploaded to the HPB Relay The earth continuity resistance ECR of the pilot earth loop is displayed in ohms on the HDM Earth Fault Information page level 3 position 1 The leakage SC between the pilot and earth conductors is displayed as OK or Trp The Event Log will display EC Short if a short occurs between pilot and earth when the outlet is energised The Earth Continuity EC Trip resistance for both modes is selectable to 50 75 and 100 ohms Pilot Trip Time is adjustable to allow for operation in noisy electrical environments The following trip times are available 300 ms 400 ms 500 ms 600 ms 800 ms 1 0 s 1 2 s 1 5 s and 2 s A maximum setting of 600 ms should be suitable for most installations AUTION Long time delays should only be used where necessary Consequences of long trip times should be thoroughly assessed from a safety point of view before using the higher values When an Earth Continuity trip occurs the HPB Relay 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 re
22. MB 22 kV then disconnects the primary windings of its 3 x voltage transformers from earth they are connected to earth at all other times and generates 5 kV d c which is applied to the primary star point resulting in 5 kV d c between all three phases and earth The HPB Relay then measures the current to earth and calculates the resistance of the line insulation to earth of all three phases in parallel Three seconds 3 s after the end of the test if the calculated resistance is above the preset threshold the MCR relay closes allowing the outlet to be energised If the calculated resistance is below the preset threshold an Earth Fault Trip occurs At the completion of a test the result is retained in memory until the next test is carried out This can be viewed on the HDM Remote Display Module Level 3 Position 2 An insulation test will yield one of the following results a Hardware Fault The HPB cannot detect the presence of the CCMB Check power supply to the CCMB and all wiring Note An open circuit connection between the CCMB and power circuit cannot be detected and will not display as Hardware Fault b lt 10 The resistance between the power circuit and earth is less than 10 MO c A value between 10 MO and 120 The resistance between the power circuit and earth 10 d gt 120 The resistance between the power circuit and earth is greater than 120 MO HPBB012R5 docx Page 15
23. The current time trip characteristics can be selected as either Very Inverse or Extremely Inverse corresponding to the OC Type values of vinv xInv The drawings Very Inverse Over current Curves 003 in Appendix A Drawings and Extremely Inverse Over current Curves HPBB001 in Appendix A Drawings show the trip characteristics HPBB012R5 docx Page 18 AMPCONTROL p HPB INTEGRATED PROTECTION RELAY USER MANUAL Issue R5 Date 6 2011 7 3 Short Circuit The short circuit function has a definite time characteristic If the current exceeds the selected level for the pre set time then a trip occurs When a trip occurs the SC LED on the display module flashes and the open collector output on the HPB Relay is switched on to provide monitoring if required To reset the relay following a short circuit trip it is necessary to hold the lock input closed and then close the reset button The HPB Relay be programmed so that a short circuit trip will operate either the relay or the MCR Relay This can be achieved by selecting the required relay at the SC Relay selection in the non volatile memory See Section 9 User Adjustable Settings Normally the CBR selection would 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 instal
24. U 1 Termination Module in order to deem the pilot circuit healthy The net disadvantage is that the increased complexity in the system may make trouble shooting difficult Resistor Mode When the pilot is set to Res Mode the trailing cable pilot is terminated with a 235 resistor to earth 2 x 470 5 Watt resistors connected in parallel The HPB Relay measures the resistance of the pilot earth loop and HPBB012R5 docx Page 16 AMPCONTROL p s HPB INTEGRATED PROTECTION RELAY USER MANUAL Issue R5 Date 6 2011 assumes that the pilot circuit is healthy if the resistance measured is between 235 and 235 the selected trip resistance If the resistance measured is below 200 a short circuit fault between the pilot and earth conductors is assumed and a trip occurs which in turn de energises the MCR Relay Res mode all of the relay settings are stored in the HPB Relay load is moved to a different outlet substation then the HPB Relay s settings need to be checked and updated if necessary HTU Mode When the pilot is set to Mode the trailing cable pilot is terminated with a HTU 1 Termination Module The HPB Relay measures the resistance of the pilot earth loop and assumes that the pilot circuit is healthy if the resistance measured is below the selected trip resistance level If the resistance exceeds the preset level a trip will occur The Event Log will display EC Trip
25. akage protection function uses a toroid to measure the earth leakage current A definite time operating characteristic is provided with an adjustable trip sensitivity and time delay When a fault occurs and the trip level and time delay are exceeded a trip occurs The trip acts in the Main Contactor Relay MCR logic and is latched An earth leakage trip is treated as a special fault and requires an authorised person to perform the reset function This is achieved by holding the lock input closed and then closing the reset button When an earth leakage trip occurs the EL LED on the display module flashes and the open collector output on the HPB Relay is switched on to provide additional monitoring if required The measured instantaneous leakage current EL is displayed on the HDM Earth Fault Information page as a percentage of the trip level When the leakage reaches 100 for the selected time delay a trip occurs For the HPB 6 6kV the trip level is adjustable in 100mA increments over the range 200mA 1000mA and for the HPB 22 kV the trip level is selectable in 250mA increments over the range 500mA 2500mA The time delay is selectable as instantaneous lt 80mS or adjustable in 40mS increments over the range of 150mS 470mS 6 2 Earth Fault Lockout 6 2 1 6 6kV On 6 6 kV systems the earth fault lockout function tests the resistance of the 3 phase lines to earth by applying a megger test prior to closing the main contactor The tes
26. al Communication Port Relay Contacts 22 kV Transformers 11 kV Transformers HPB INTEGRATED PROTECTION RELAY USER MANUAL Issue R5 Date 6 2011 Can be allocated from 1 to 40 Selectable from 3096 to 80 in 1096 increments or disabled Trip delay 800ms For information on data format and hardware see DNET IP2 Serial Communication System User Manual 118626 MCR CBR 1 0 5A 190 Va c 100 VA maximum 1 C 0 5 190 Va c 100 VA maximum RL3 1 N 0 5A 190Va c 100 VA maximum Rated Voltage 22 kV 50Hz Insulation 24150 125 kV Voltage Factor 1 9 30 sec Ratio 22 kV 1 to 110 Class 0 2 VA Rating 10 VA Standard AS60044 2 N terminal capable of withstanding 5kV d c test voltage Rated Voltage 11 kV 50Hz Insulation 12128175 Voltage Factor 1 9 30 sec Ratio 11 kV N3 to 110 N3 Class 0 2 VA Rating 10 VA Standard AS60044 2 N terminal capable of withstanding 5kV d c test voltage Transformers must be able to withstand 5 kV d c on the primary side HPBB012R5 docx Page 30 X MPCONTHROL a 16 Trouble Shooting HPB INTEGRATED PROTECTION RELAY USER MANUAL Issue R5 Date 6 2011 If a problem is experienced with the relay use the following table to fault find the problem Should the fault persist remove the relay and return the relay plus a description of the fault to Ampcontrol for repairs WARNING consequence c
27. an be fatal The HBP has no user serviceable parts Ampcontrol personnel only If a fault develops return the HBP to Ampcontrol for repair It is essential that no attempt be made to repair the HBP as any attempt to dismantle or repair the HBP can seriously compromise the safety of the unit and the All repairs must be carried out by e The Status page level 0 position 1 should be the first step in troubleshooting This displays what the relay requires to make it operate Also check the first six event logs Symptom Cause Remedy Remote Display shows a blank screen The HDM LED indicator located on the top of the HDM module is off Loss of power to the Display Faulty Display Module Remote Display shows a blank screen The HDM Led flashes at 1 Hz but there is no data Error Indication 1 level 0 Position 1 Error Indication 2 level 0 Position 1 when in HTU pilot mode Module s non volatile memory has been corrupted Error Indication 3 level 0 Combination of faults position 1 Relay will not close EC fault indicated Outlet is off and the log records MC Opened Power to HDM is healthy Corruption in the Group 1 Settings stored in the relay Either the HTU 1 Module is not on line or the HTU causing errors 1 and 2 Faulty pilot circuit open or high resistance or shorted to earth Relay is waiting
28. as been manufactured according to the state of the art and designed to ensure a safe operation The equipment may only be used within the design parameters The instructions within this manual must be observed as an aid towards achieving maximum safety during operation The is responsible for observing the following instructions 2 2 1 Changes to Equipment Changes in the design and modifications to the equipment are not permitted 2 2 Equipment Knowledge Experience with or understanding of this equipment is essential for the safe installation and removal of the equipment Therefore in case of a question on how to safely proceed contact Ampcontrol immediately 2 2 3 Manual Handling The transformers supplied with the CCMB 22kV are heavy Care should be taken when transporting and handling these transformers Precautions have been taken to ensure all equipment is safe to handle and free from sharp edges However care should always be taken when handling metal enclosures and gloves should be worn 2 24 Installation Correct operation and safety depend on the HPB and associated equipment being installed correctly Mechanical and or electrical installation and maintenance of plant and equipment must only be carried out by appropriately qualified personnel and must be tested thoroughly prior to operation 2 2 5 Operation As safety depends on the HPB functioning correctly it is highly recommended that all safety function
29. basic over current time curves to achieve the desired trip times Cur Bal Trp Adjusts the current phase balance trip level SC I trip Sets the short circuit trip level SC Trip t Sets the trip time for the short circuit function Pilot Latch Determines whether earth continuity trips are self resetting or not B emf TIME Adjustable time delay to inhibit main contactor fail routine following opening of main contactor Remote Start No function this version HPBB012R5 docx Page 21 M AMPCONTROL HPB INTEGRATED PROTECTION RELAY USER MANUAL Issue R5 Date 6 2011 9 2 Changing Settings The procedure for adjusting the settings is independent of where the values are stored a b c d f 9 Ensure the outlet is stopped For Group 2 Settings in HTU Mode ensure the HTU 1 Termination Unit is on line Display the parameter that has to be changed on the HDM Remote Display Module s liquid crystal display Level 8 or 9 Momentarily operate the lock input warning message appears Press the enter button to acknowledge the warning message and to confirm that a change is desired Use the left and right arrows to step through the allowable values until the desired new setting is displayed Press the enter button to indicate that the value shown is the required new setting Momentarily operate the lock input The display will show a confirming message then return to the viewing
30. ce No part of this publication may be reproduced transmitted or transcribed into any language by any means without the express written permission of Ampcontrol CSM Pty Ltd 7 Billbrooke Close Cameron Park NSW 2285 Australia Disclaimer Ampcontrol CSM Pty Ltd will make no warranties as to the contents of this documentation and specifically disclaims any implied warranties or fitness for any particular purpose Ampcontrol further reserves the right to alter the specification of the system and or manual without obligation to notify any person or organisation of these changes Before You Begin We would like to take a moment to thank you for purchasing the HPB Protection Relay WARNING RS To become completely familiar with this equipment and to ensure correct f operation we strongly recommend that you take the time to read and thoroughly understand this user manual Ampcontrol CSM Contact details 7 Billbrooke Close Cameron Park NSW 2285 P 61 2 4903 4800 F 61 2 4903 4888 EMAIL electronicsorders ampcontrolgroup com WEB www ampcontrolgroup com HPBB012R5 docx Page 2 X AMPCONTROL HPB INTEGRATED PROTECTION RELAY USER MANUAL Issue R5 Date 6 2011 Table of Contents Safety andelher sca acne ec ce cata 1 Copyright Pert ear 2 2 Before gt
31. connections The earth pin 7 is for the communication and pilot circuits The earth on Pin 29 connects to the earth shield of the HPB Relay s internal transformer 110V version only and chassis The CCMB 6 6 kV also has an earth connection and the CCMB 22 kV has two earth connections The CCMB 22 kV signal earth should be connected to the HPB pin 7 All other earth connections should be run back separately to the main earth point HPBB012R5 docx Page 12 AMPCONTROL p HPB INTEGRATED PROTECTION RELAY USER MANUAL Issue R5 Date 6 2011 5 Machine Communication 5 1 HPB Termination Unit HTU 1 The HTU 1 Remote Termination Unit is a microprocessor based module that is connected between the pilot and earth at the remote end of the trailing cable to provide machine communication It is powered by and communicates via the pilot line Its non volatile memory stores the parameters to configure the outlet as appropriate for that machine See Drawing 013 in Appendix A Drawings The HPB Termination Unit HTU 1 provides remote stop of the HPB Relay s controlled outlet by tripping the Earth Continuity function The EC LED on the HDM Remote Display Module is illuminated and the Earth Continuity will need to be reset if Pilot Latch On has been selected Stop switches are connected in series with a diode between the stop and earth terminals Alternately the internal HTU 1 Termination Module s diode can be used to terminate the st
32. control DNET IP2 Serial Communication System transfers data and commands between the Host System and the modules using RS232 5422 and RS485 protocols Each integrated protection relay is connected to a Serial Interface IPSI which has its output drop connected to a DNET IP2 Protocol Converter The Protocol Converter provides the communications link to a PLC See User Manual 118626 for further details HPBB012R5 docx Page 27 X MPCONTROL INTEGRATED PROTECTION RELAY USER MANUAL Issue R5 Date 6 2011 14 Equipment Parts List 144069 142842 118732 142848 142845 118542 117648 143369 144371 101503 117829 143911 HPBB012R5 docx HPB 6 6 kV Integrated Protection Relay HPB 22 kV Integrated Protection Relay HTU 1 Termination Unit HPB Base HPB Base 48 HDM Remote Display Module Flush Mount 6 6 kV Cable Connection Module 22 kV Cable Connection Kit 11 kV Cable Connection Kit Relay LED Output Module HPB User Manual 48Vd c 120W Power Supply Page 28 AMPCONTHROL P d 15 Specifications HPB INTEGRATED PROTECTION RELAY USER MANUAL Issue R5 Date 6 2011 Note An 11kV system includes the HPB 22 relay Auxiliary Supply Volts Earth Leakage Protection Earth Continuity Protection Earth Fault Lockout Protection Lockout Resistance Test Time Over current Protection Current Range Current Multi
33. d digital input Start Screen Earth Motor Contactor Aux 27 MCI Two core screened Contact digital input 28 Screen Earth Low Voltage Signals For explanations and refer to notes following on the next page HPBB012R5 docx Page 11 ao MPCONTROL p HPB INTEGRATED PROTECTION RELAY USER MANUAL Issue R5 Date 6 2011 NOTES The OV is internally connected to the HPB Relay s earth Pin 7 The screen therefore must NOT be earthed at any other point A The HPB Relay s digital inputs could alternatively be run in a screened multicore cable Separate cable for each HPB in multiple installations Where these low voltage circuits need to connect near the power circuits e g current transformers cable connection module main contactor auxiliaries etc care needs to be taken to ensure that the circuits are adequately separated and restrained This ensures that the separation is maintained even if a wire termination becomes loose etc 4 2 2 High Voltage Circuits The high voltage circuits of the HPB are the 110Va c 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 relay contacts of the Relay must not be used to switch more than 190Va c 5A or 100VA 4 2 3 Earthing The HPB has two earth
34. elay 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 tripping logic and outlet control is performed by the microprocessor so that only minimal external control is required See Typical Connection Diagrams HPBE006 and 013 in Appendix A Drawings Extensive information display and monitoring features are included to facilitate fault finding and system trending This information can be read locally on the HPB Display Module HDM 1 or remotely a communication link Opto isolated outputs are available for connection to optional LED or Relay Modules to provide additional run and trip indications See Drawing 5005 in Appendix A Drawings The Ampcontrol Relay Output Module ROU enables these indications to be interfaced with a PLC See Drawing 031 in Appendix A Drawings There are currently two HPB models available the HPB 6 6kV which is suitable for 6 6kV systems and the HPB 22kV which is suitable for 11 and 22kV systems Protection Functions Earth Leakage Section 6 1 Earth Fault Lockout Section 6 2 Earth Continuity Section 6 3 Over current Overload Section 7 1 Short Circuit Section 7 3 Contactor Fail Sect
35. esistance etc System information including the line voltage and current Status of digital inputs and relay outputs Protection trip settings which can be viewed at any time Authorised personnel can modify these settings via the HDM Remote Display Module Data logging information The 120 most recent events and parameter changes are logged with time and date in a non volatile memory e g power up trip reset close etc c A review of the first few log events is a useful tool for fault finding The HPB Relay status display is one of the most useful features of the relay s display system and should be viewed as the first step in fault finding This display shows a list of 9 prompts in order of priority indicating what the HPB Relay requires to allow the outlet to close The prompts are listed as follows RUNNING Outlet energised TESTING Performing EFLO Test TRIPPED Trip Condition see HDM LEDs HPB Mem Err HPB Relays non volatile memory is corrupted HTU Mem Err HTU 1 non volatile memory is corrupted HTU STOP Waiting for HTU 1 stop input to be closed HPB STOP Waiting for HPB stop input to open START Waiting for the HPB Relay s start input to close WAITING Pause between successive Megger Tests An error status indicator is also shown on the status page which is normally zero exceptions are as follows Error 1 Indicates corr
36. ettings at the remote display module d Provision to use the machine recognition module for auto configuring of machine protection settings e Change name labels to suit Modifications do not effect the actual operating software 1 3 HPBB012R5 docx Page 49 SUR INTEGRATED RELAY USER MANUAL Issue R3 Date 09 2010 CRN 8060 SUPPLEMENTARY APP EX 11388 FILE REF N C92 0362 DATE 16 02 1995 DITIO RAWIN 2 001 Rev Dated 14 02 1995 HPB 2 002 Rev O Dated 14 02 1995 ADDITIONAL RECOMMENDATIONS FOR SUPPLY amp USE 1 The manufacturer shall on his own responsibility carry out such tests and examinations are necessary to ensure that the HPB module provides satisfactory operation in service 2 No changes shall be made to the software which effect the operational performance of the relay as required by standards Other software parameters may be changed as required by the manufacturer MARKING ON APPARATUS The manufacturers name or mark and the approval number MDA No EX 11388 shall be inscribed in a durable manner in prominent position on the apparatus Please find enclosed herewith the relevant approval documentation Yours Faithfully u A J Weeks Assessing Authority No MDA A2507 2 3 HPBB012R5 docx Page 50 HPB INTEGRATED RELAY USER MANUAL Issue R3 Date 09 2010 CRN 8060 Department of Mineral Resources Accredited Asse
37. formation page Level 7 Position 1 to display the Day Month Year Hours and Minutes MO 150595 09 46 Press the enter key A v will appear in the top line above the minute section This indicates the number to be changed Use the left and right arrow keys to move the v to the desired position Press the enter key The v now changes to a The right arrow key is used to increment the allowable d m values once the desired value is obtained press the enter key again The gt returns to a v Repeat steps c and d until the correct time and date is displayed With the v showing press the lock push button The v then changes to E This is a prompt to press the enter key Press the enter key At that instant the seconds are zeroed and the selected time date information is transferred to the internal clock If the battery voltage is low the time will zero and the date will reset to 1st January on power up If the battery is flat or faulty the relay is likely to trip on main contactor fail on power up HPBB012R5 docx Page 26 AMPCONTROL INTEGRATED PROTECTION RELAY USER MANUAL Issue R5 Date 6 2011 13 Remote Data Communications The HPB Integrated Protection Relay protection relay has the facility for connecting remote monitoring equipment This can be in the form of either the Remote Display Module or other peripheral equipment such as PLC s For PLC applications the Amp
38. ght 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 record shows that an earth leakage caused a trip condition on Monday 15 May at 9 46am Log 10 indicates that it is the 10th log in the list Log 1 is always the most recent event Each time a new log is recorded the 120th log is removed from the list and all others move along one The following events are logged 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 the HPB Relay EC Trip Pilot Earth continuity loop exceeds the trip level EC Short Low resistance between pilot and earth EL Trip Earth leakage protection tripped EF trip Earth Fault test has failed A phase HPB 6 6kV EF trip Earth Fault test has failed B phase HPB 6 6kV EF trip Earth Fault test has failed C phase HPB 6 6kV trip Earth Fault test has failed HPB 22 kV SC Trip Trip condition of short circuit pr
39. ion 8 1 Protection trips are stored in a non volatile memory requiring a reset function before power can be restored This remains the case even if a power down occurs following a trip condition 3 2 Remote Display Module The Ampcontrol HDM Remote Display Module communicates with the HPB Relay via a three wire connection The Module consists of a two line 16 character alpha numeric liquid crystal display LCD LED status indicators and a tactile keypad The various display pages are arranged on levels with each level having a number of positions The display level is changed with the Up Down arrow keys and the Left Right arrow keys control the display position An Enter key is used when programming the relay The display map shows how the movement is controlled between levels and positions See Drawing 004 in Appendix A Drawings HPBB012R5 docx Page 7 AMPCONTHROL m HPB INTEGRATED PROTECTION RELAY USER MANUAL Issue R5 Date 6 2011 The healthy LED located top centre of the module flashes at 3Hz three times per second to indicate healthy communications with the relay A flash rate of 1Hz once every second indicates that the module is powered 15Vd c but not receiving data The module displays the following information 5 9 Software version and serial number HPB Status Operational information from the protection functions e g earth leakage current earth continuity r
40. isplay level 4 position 1 as contactor closes Compare this with the under voltage threshold Relay will not remain closed and cycles while the start input is held closed Check continuity from the relay through the Relay not receiving voltage CCMB 6 6 kV to power conductors feedback on all three outlet phases within 800mS of contactor closing WARNING Be sure to follow the STOP appropriate high voltage isolation procedures HPB 6 6kV Typical reading CCMB 6 6K 27 Meg Ohm Main contactor fail Check main contactor for leakage across condition terminals on frozen contactor condition AA cell installed under the top cover requires replacement The owner in a workshop environment can replace a direct replacement Flat or faulty battery battery It is recommended that the relay be returned to Ampcontrol for battery replacement and full testing Relay Trips on MCF on power up AA cell installed under the top cover requires replacement The owner in a workshop Time and date incorrect environment can replace a direct replacement Resets to 1 01 9 on power Low battery battery It is recommended that the relay be returned to Ampcontrol for battery replacement and full testing Displays Hardware CCMB has not been fault detected Check all wiring to the CCMB and earthing HPBB012R5 docx Page 32 AMPCONTROL p s HPB INTEGRATED PROTE
41. ivery check all items against the packing list or Bill of Loading If there are shortages or evidence of physical damage notify Ampcontrol immediately Notify Ampcontrol within 7 days maximum in case of shortages or discrepancies according to the packing list This action will help ensure a speedy resolution to any perceived problems Keep a record of all claims and correspondence Photographs are recommended Where practicable do not remove protective covers prior to installation unless there are indications of damage Boxes opened for inspection and inventory should be carefully repacked to ensure protection of the contents or else the parts should be packaged and stored in a safe place Examine all packing boxes wrappings and covers for items attached to them especially if the wrappings are to be discarded 1 2 Storage after Delivery When the equipment is not to be installed immediately proper storage is important to ensure protection of equipment and validity of warranty All equipment should be stored indoors preferably on shelves where practicable and protected from the elements If storing on the ground use wooden blocks to elevate the equipment above the ground and ensure that the storage area is not an area where water will collect When applicable correct handling and fork lift procedures must be in place to ensure that any crates and pallets are moved safely 1 3 Unpacking of Equipment The method of packing used will de
42. led 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 160 5 7 4 Phase Current Balance Phase current balance protection is selected via the Cur Bal Trp selection See Section 9 User Adjustable Settings The current balance measurement is displayed on the Remote Display Module and is calculated as la MAX A I x 10096 Where lave Average of the 3 phase currents The maximum deviation of a phase current from the average The trip level is selectable at 5 10 20 50 and off The phase current balance protection is inhibited until the average current exceeds both 20 of the selected full load current and the selected balance trip level If the trip level is exceeded a timer is triggered If the imbalance remains above the set level for more than two seconds the relay trips The event log records to differentiate it from a true over current trip The status of the timer is displayed adjacent to the Iba value Level 5 Position 2 on Remote Display Module A trip condition occurs when the timer reaches 100 HPBB012R5 docx Page 19 AMPCONTROL p HPB INTEGRATED PROTECTION RELAY USER MANUAL Issue R5 Date 6 2011 8 Voltage Related Functions 8 1 Main Contactor Fail Protection The Main Contactor Fail MCF protection operates if the Main Contactor fails to function by a Failing
43. level If the up or down keys are operated during the procedure the HPB Relay aborts the modifying sequence When changes have been made to the stored values the old value and the new value are stored in the event A separate log immediately proceeds this recording the time and date that the change was made When the relay has been selected for HTU Mode the HTU Remote Termination Unit must be on line shown at level 2 position 1 on the HDM before Group 2 settings can be adjusted HPBB012R5 docx Page 22 AMPCONTROL p s HPB INTEGRATED PROTECTION RELAY USER MANUAL Issue R5 Date 6 2011 10 System Control 10 1 Digital Inputs The HPB Relay has five digital inputs which are all voltage free contact inputs Shorting the two input terminals together activates them The inputs are MCI start stop lock and reset The status of inputs can be displayed on the HDM Remote Display Module Level 6 Positions 2 3 The Lnk input shown in the display is used in tests by Ampcontrol Engineers 10 2 Output Relays The HPB Relay has output relays to control the main contactor and the circuit breaker under voltage control All relays are fail safe with respect to power supply loss and are controlled on the basis of protection functions Relay RL3 operates to initiate the cable fault lockout test There is one spare relay reserved for future development The status of the relays can be displayed on the HDM Rem
44. ltage for 800ms then the outlet is stopped This is recorded in the event log as uVOLT Trp The trip level is selectable from 30 to 80 in 10 increments or can be set to Level 8 Position 6 on the HDM Remote Display Module The Off selection disables the under voltage trip function and is usually used for non 6 6 kV installations 8 3 Voltage Metering The Cable Connection Module CCMB in addition to enabling the Earth Fault test is used to provide line voltage metering The outgoing line voltages for each of the 3 phases are displayed as a of the nominal line voltage on the Remote Display module Level 4 Position 1 The maximum reading is 140 for the 6 6 kV systems and 120 for the 11 kV and 22 kV systems HPBB012R5 docx Page 20 X AMPCONTROL p HPB INTEGRATED PROTECTION RELAY USER MANUAL Issue R5 Date 6 2011 9 User Adjustable Settings 9 1 Parameter Groups The HPB Relay has many user adjustable settings which are stored in non volatile memory These can be viewed and modified via the HDM Remote Display Module The settings are split into two groups as outlined below The first group of parameters relates to settings which are linked to the power system rather than the particular load connected to the outlet These are always stored in the HPB Relay 9 1 1 Group 1 Settings Pilot Mode Determines if the pilot is to be terminated with a Resistor or a HTU 1 Termination
45. ng on the amount of resistance in the pilot earth loop For example if the loop resistance is 100Q then the voltage at the HPB Relay will increase by 4 5 volts 100 x 0 045 resulting in a reading of 24 5 d c HPBB012R5 docx Page 33 Issue R5 Date 6 2011 HPB INTEGRATED PROTECTION RELAY USER MANUAL ao X AMPCONTROL 3004 1014 54015 TWNDIS NOLLYIINNWWOD JINVLSISIY 318V 10714 us TWNDIS NOLLV2INDAAO2 AJN30032u3 HDIH HDIH 300 40151534 1014 ADE suyo O 4015 534 DNILYNIWHIL lollid 151534 318V 10714 JNIHO VA 34 HPBB012R5 docx AMPCONTHROL INTEGRATED PROTECTION RELAY USER MANUAL Issue R5 Date 6 2011 Appendix A Drawings Drawing Number Description 006 Typical Connection Diagram HPB 6 6 kV 013 Typical Connection Diagram 22 kV HPBE012 Typical Connection Diagram CCMB 22 kV 004 HPB Display HPBB003 Very Inverse Over current amp Short Circuit Curves 001 Extremely Inverse Over current amp Short Circuit Curves IPBB003 Adjustable Setting Storage 05 HPB Enclosure Dimensions 13 HPB HTU 1 Termination Unit 015 Enclosure Details Remote Display Module HPB Base Connections 29 48 V Base Connections
46. of 76 Amps and a multiplier of 2 Two curve types can be selected 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 current exceeds the full load current level a trip accumulator is incremented at a rate dependant on the current When this accumulator reaches 10096 an over current trip occurs The trip accumulator can be viewed on the HDM Remote Display Module Level 5 Position 2 This may be useful to determine how close an outlet gets to trip condition during start up If the accumulator reaches almost 100 as the load gets away then this may indicate that the over current settings are too low Conversely if the trip accumulator only builds up slightly on a heavy start then the over current settings may be set too high If an over current trip occurs the LED flashes and the open collector output switches on to provide remote monitoring if required Following an over current trip the following conditions must be met to affect a reset a The trip accumulator must be less than 80 b The HPB Relay s reset input must be closed 7 2 Over current Characteristic
47. op loop Machine stops can be differentiated from other pilot trips in the HPB Relay s Event Log by connecting machine stops into the HTU I Module s Stop input instead 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 an HPB Relay If the remote stop function is not required the stop terminal must be bridged to the diode terminal or the HPB Relay will not energise The status of the Remote Stop input is displayed Online Run Online Stp and can be viewed on the HDM Module s Pilot and HTU Information page Level 2 Position 1 Also displayed on this page is Off Line Status and pilot information The HTU 1 software version and machine type is displayed on Position 2 The Remote termination settings are programmed via the HDM Remote Display Module Section 9 User Adjustable Settings 5 2 Machine Type Codes There are 5 selectable machine type codes available for use in the HTU 1 Termination Unit The descriptive code is transmitted to the HPB Relay to identify the type of machine connected to the outlet The codes are selected using the HDM Remote Displa
48. ote Display Module Level 6 Position 1 10 3 Open Collector Outputs The HPB Relay has eight open collector outputs which are driven through opto couplers to provide additional indication if required These can be used to drive LED s or additional relays with appropriate drive circuitry The Ampcontrol Relay Output Module ROU enables these indications to be interfaced with a PLC See Drawing 031 in Appendix A Drawings The eight outputs correspond to the LED s on the display module turning on whenever the corresponding LED is flashing The signals are available on the 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 following conditions must apply a No protection faults present b Local stop input open remote stop loop closed c Local start input closed Once these conditions are obtained a cable fault lock out test is performed automatically The start button must remain closed during the test which may take up to 25 seconds to complete due to the charging of the cable capacitance If the result of this test is satisfactory the HPB Relay goes into the run mode and the MCR Relay picks up The RUN
49. otection Trip Trip condition of over current overload protection bal Trp Current balance trip condition RESET Records resetting of a protection trip Setup Mod Records that setup data has been modified The log preceding this shows the old and new values uVOLT Trp Records that voltage was not present on at least one outgoing phase when the main contactor was closed MCF Trp Internal battery backed main contactor fail flag tripped MCF V trp Main Contactor Fail trip due to sensing voltage on the load side of the main contactor when the contactor should be open MCI Fail Main Contactor Input MCI shows the main contactor to be closed HPBB012R5 docx Page 24 S A AMPCONTROL u P reset Mem ERROR HTU mem E HPBB012R5 docx HPB INTEGRATED PROTECTION RELAY USER MANUAL Issue R5 Date 6 2011 when it should be open Internal microprocessor reset Records that the relay s non volatile parameter memory has been corrupted 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 Page 25 AMPCONTROL gt HPB INTEGRATED PROTECTION RELAY USER MANUAL Issue R5 Date 6 2011 12 Time amp Date If there is a need to adjust the real time clock carry out the following procedure a Using the Remote Display Module select the time and date in
50. output may be obtained from the CT where none would arise if the device was ideal The size of the error will vary from CT to CT of the same type because of slight differences in the core and the symmetry of the winding Problems caused in this way become worse as CT sizes increase as currents increase and a decrease 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 the smallest internal diameter CT which will allow the cables to fit through 4 1 5 Toroid Installation Guide Lines a Keep cables as close to the centre of the toroid as possible Do not tie them to one side of the toroid Remember aim at symmetry b Do not bring the cables back past the toroid within one diameter of the CT trying to cram cables into a small space reduces symmetry and may lead to problems which are difficult to solve c 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 d Many small cables tend to be worse than for example three large ones Try to position the CT in the circuit with this in mind 4 2 Wiring Installation The connections to the HPB Relay consist of a mix of low and high voltage supplies and relay contact circuits To reduce induction from high voltages care needs to be taken in the layout of the wiring
51. pend on the size and quantity of the equipment The following cautions should be interpreted as appropriate CAUTION Take care when unpacking crates as the contents may have shifted during transport Make sure that cable drums are securely attached to their shipping pallets before attempting to move them The disposal of packaging materials replaced parts or components must comply with environmental restrictions without polluting the soil air or water Ensure that any timber and cardboard used as packaging is disposed of in a safe and environmentally responsible manner omm Where possible dispose of all waste products i e oils metals plastic and rubber products ALERT by using an approved recycling service centre HPBB012R5 docx Page 5 AMPCONTROL p HPB INTEGRATED PROTECTION RELAY USER MANUAL Issue R5 Date 6 2011 2 General safety 21 Personnel Safety Warnings All personnel involved in the installation and operation of this equipment should ensure they are familiar with this manual prior to installing or operating this equipment WARNING This equipment generates dangerously high voltage levels Because of the a potential risks associated with this equipment it is essential that only STOP appropriately qualified and experienced personnel be permitted to work on or around this equipment 2 2 Safe Use of Equipment The equipment supplied h
52. play 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 1 3 Cable Connection Module CCMB 6 6 kV 6 6kV systems The CCMB 6 6 kV Cable Connection Module type B 6 6 kV is a resistive isolation device which interfaces between the power circuit and the HPB Relay allowing the HPB to measure both the line voltage and the insulation resistance to Earth A 5 kV d c voltage is generated within the CCMB which under normal operation applies up to 2 5 kV d c between each phase and earth The CCMB 6 6 kV is housed in a polycarbonate enclosure CCMB 22 kV 11kV and 22kV systems The CCMB 22 kV Cable Connection Module type B 22 kV is an isolation device that allows the HPB Relay to interface with the power circuit to measure both the line voltage and the insulation resistance to Earth The CCMB 22 kV connects to the 11 22 kV power circuit via 3 x voltage transformers connected in a phase to earth configuration with the primary star point connected to Earth through the CCMB 22 kV The line voltage is measured on the secondary side of the voltage transformers and an insulation test is performed by lifting the primary star point from earth and applying 5 kV d c to the star point which passes through the primary windings and is applied to all three phases in parallel CAUTION The and
53. plier Time Multiplier Current Balance Trip Settings Short Circuit Protection Trip Setting Trip Time ms Back EMF Timer Trip Delay Settings HPBB012R5 docx HPB 6 6kV 110Vac 20 gt 20VA 50Hz 2 Hz HPB 22 kV 48Vd c 20 gt 40 W Recommended Power Supply Meanwell DR 120 Ampcontrol Part No 143911 6 6kV Trip Setting 200 mA to 1000mA in 100 mA increments HPB 22 kV Trip Setting 500 mA to 2500 in 250 mA increments Time Delay Instantaneous 80ms and 150ms to 470ms in 40 ms increments Trip Setting 50 750 and 100 Shunt Leakage Trip if lt 200 Resistor Mode Operating Time 300 ms 400 ms 500 ms 1 0 1 25 1 5 s and 2 s HPB 6 6kV Selectable at 2 5 10 20 and 50 Meg Ohm and off HPB 22 kV Selectable at 15 20 30 50 and 100 Meg Ohm and off Selectable at 10 15 20 and 25 seconds HPB 6 6kV 7 5 to 464 Amps 60 to 116 Amps in 4 Amp increments times current multiplier HPB 22kV 15 to 928 Amps 60 to 116 Amps in 4 Amp increments times current multiplier HPB 6 6kV 1 8 1 4 1 2 1 2 4 times HPB 22kV 1 4 1 2 1 2 4 8 times 0 05 0 075 0 1 0 15 0 2 0 3 0 4 0 5 0 6 0 7 0 8 1 0 times 5 10 20 50 and OFF 3 0 to 10 0 times in 0 5 increments times full load current 40 60 80 100 120 160 2 5 10 15 20 25 30 35 40 seconds Page 29 AMPCONTROL Machine Numbers Under Voltage Protection Seri
54. quired 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 selection is either Pilot Latch On or Pilot Latch Off For Pilot Fault Finding information see Section 16 1 HPBB012R5 docx Page 17 AMPCONTROL HPB INTEGRATED PROTECTION RELAY USER MANUAL Issue R5 Date 6 2011 7 Current Related Functions 7 1 Basic Over current Protection Two current transformers are used to measure the three line currents The measured currents are used to implement the following protection functions a b 5 Circuit c Phase Current Balance Full load settings cover a range from 7 5 Amps to 464 Amps for the HPB 6 6kV and 15 Amps to 928 Amps for the HPB 22 A current range and current multiplier are utilised to select and store the full load current value in the non volatile memory This forms the basic reference level for the over current protection functions The current range is selectable in 4 Amp increments between 60 and 116 Amps The current multiplier is selectable at 1 8 1 4 1 2 1 2 4 times for the HPB 6 6kV and at 1 4 1 2 1 2 4 8 times for the HPB 22kV The selected Range and Multiplier combine to give the basic level Example To obtain a full load current of 152 Amps select a current range
55. s of the HPB be periodically tested to ensure correct operation HPBB012R5 docx Page 6 rk AMPCONTROL p HPB INTEGRATED PROTECTION RELAY USER MANUAL Issue R5 Date 6 2011 3 Overview of Equipment 3 1 Introduction The Ampcontrol HPB Integrated Protection Relay is an intelligent protection relay based on microprocessor technology The Relay has been specifically designed to operate with very high interference to the pilot conductor that occurs on cables in open cut mining operations This is more prevalent on a non symmetric position of the pilot and earth conductors The integrated relay provides the necessary functions required for protecting electrical outlets supplying draglines shovels drills etc 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 The HPB Relay can provide machine communication through the use of a HPB Termination Unit HTU 1 connected between the pilot and earth at the machine end of the trailing cable Through the use of the HTU 1 Termination Unit the relay parameters are automatically up loaded from a remote machine when a cable is inserted into a power outlet The relay can perform an automatic H V Insulation test on the cable prior to the closure of the main contactor The results of the test are displayed on the HPB Display Module HDM 1 and can be remotely monitored The HPB R
56. ssing Authority MDA A2507 COAL MINES REGULATION ACT 1982 NOTICE OF SUPPLEMENTARY APPROVAL SUPPLEMENTARY APPROVAL MDA Ex 11388 FILE 92 0362 16 02 1995 It is hereby notified that the Approved Item listed herein has been assessed for compliance with the Coal Mines Regulation Act and appropriate standards or requirements and is hereby APPROVED in accordance with the requirements of the COAL MINES REGULATION 1982 This approval is issued pursuant to the provisions of Clause 6 amp 7A of the Coal Mines Regulation Approval of Items Regulation 1984 This APPROVAL is issued to AMPCONTROL CSM PTY LTD Address of Approval Holder P O BOX 304 WARNERS BAY N S W 2282 Description of Item s INTEGRATED PROTECTION RELAY Item Identification HPB C M R A Approval Clause 27 b EXPLOSION PROTECTED Specific Approval Category PROTECTION Ex This Approval issued subject to compliance with the requ rements of the Occupational Health and Safety Act 1983 with part cular reference to Sections 15 to 17 of the said Act as it applies to USERS of Approved Items and to Section 18 of the said Act as it applies to the MANUFACTURERS and or SUPPLIERS of Approved Items The Authority issuing this Approval may for the purposes of the Occupational Health and Safety Act 1983 append a list of recommendations including drawings documents etc that are applicable to this approved item as identified during test
57. t is initiated by closing the start input provided all other starting conditions are met see Section 10 5 Operational Sequence The HPB Relay closes its relay output RL3 which applies 110Va c to the CCMB 6 6 kV Cable Connecting Module type B 6 6 kV This is a resistive isolation device used to interface the HPB Relay to the power conductors A 5 kV d c voltage is generated within the CCMB 6 6 kV which under normal operation applies up to 2 5 kV d c between each phase and earth The HPB Relay measures the voltage on the line and calculates the meg ohm resistance to earth of each phase At the end of the test provided the value is above the preset threshold the MCR relay closes allowing the outlet to be energised If the value is below the preset threshold an Earth Fault Trip occurs At the completion of a test the resistance to earth of each phase is retained in memory until the next test is carried out This can be viewed on the HDM Remote Display Module Level 3 Position 2 6 2 2 HPB22kV On 11 kV and 22 kV systems the earth fault lockout function tests the resistance of the 3 phase lines to earth by applying megger test prior to closing the main contactor The test is initiated by closing the start input provided all other starting conditions are met see Section 10 5 Operational Sequence The HPB Relay closes its relay output RL3 which applies 48Vd c to the CCMB 22 kV Cable Connecting Module type B 22 kV The CC
58. the HPB Relay must be earthed to the same earth connection as the trailing cable on systems with separate earth grids Ensure that the earth connections are reliably installed as this is the basis of protection for the isolation device HPBB012R5 docx Page 9 MPCONTROL p s HPB INTEGRATED PROTECTION RELAY USER MANUAL Issue R5 Date 6 2011 CAUTION When installing the CCMB 22 kV measure the resistance between the transformer primary star point and earth before applying power Ensure that it is less than 100 4 14 Overload amp Earth Leakage Toroids Current transformers CT are not ideal devices and if correct procedures are not followed during installation nuisance tripping can result If using for example a single phase earth leakage system where active and neutral pass through a toroid then at all times currents in the two wires are equal and opposite so that the net current through the toroid is zero An ideal current transformer would have all the flux from each wire contained in the core and so would accurately add the opposing fluxes to get a 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
59. ult Current Selected Full Load Current RA Short Circuit Selectable at 1 736A 3 0 3 5 4 0 4 5 50 5 5 6 0 6 5 JALA 768 7 0 7 5 8 0 8 5 9 0 9 5 10 0 Times Selected Full Load Current 1955 532A ESLA Times Selectable at 40 60 80 100 120 amp 160 mSec 3 E GENERAL LINEAR TOLERANCE RAL ANGULAR RANCE COMENSIONS N mm DO NOT SCALE a sBugjes drow ack sues sus UON S 010 Agidsiq arpon 007 CHERE T 3TIOHINOONn IF PRINTED 984 2024 001 11015 908 8 10 OL 20 ELJON vod Apes JO SIL sf 2 UOISJOA iuf 181 GENERAL DETAILS ETT 3l 4 ETT PROT RELA Y 7057 12 030 INTERGRATED lo
60. uption in the Group 1 Settings HPB Mem Error Error 2 Indicates corruption in the Group 2 Settings HTU Mem Error Error 3 Is a combination of faults in both groups For details of Groups see Section 9 1 Parameter Groups HPBB012R5 docx Page 8 AMPCONTHROL INTEGRATED PROTECTION RELAY USER MANUAL Issue R5 Date 6 2011 4 Installation and Wiring Instructions This manual has been designed to assist users of the HPB Relay with installation and special wiring techniques required to reduce induction from high voltage circuits 4 1 Installation 411 Integrated Protection Relay The HPB Relay has a powder coated sheet steel enclosure designed to be mounted into existing enclosures of adequate IP rating The relay is designed to operate when mounted either laid down flat or in a vertical position CAUTION Vent holes are provided at both the top and bottom of the relay to assist in the cooling A of the electronics inside the relay These vents should not be blocked or restricted in any way When installing the HPB Relay care should be taken to ensure sufficient space is allowed around the relay for the ease of change out during routine maintenance Connections to the HPB 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 4 1 2 Remote Dis
61. y Module Level 9 Position 1 DrgL Drag Line Shvl Shovel Dril Drill PSTx Portable Transformer Water Pump 5 3 Machine Number Machine numbers 1 to 40 can be assigned to machines 1 to 40 for each machine type These numbers are programmed using the HDM Remote Display Module Level 9 Position 2 54 Receiver Sensitivity The HPB allows the sensitivity of the receiver to be adjusted to suit different installations installations HPBBO012R5 docx Page 13 S A AMPCONTROL p HPB INTEGRATED PROTECTION RELAY USER MANUAL Issue R5 Date 6 2011 where multiple HPBs are located close to each other the sensitivity can be reduced 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 corresponding to decreased sensitivity For most installations starting with the sensitivity set to 8 should yield good results If the HTU is connected through a long trailing cable and the HTU is not coming online try increasing the sensitivity Alternatively if there are multiple relays installed near each other and they do not behave as expected try decreasing the sensitivity to prevent crosstalk HPBB012R5 docx Page 14 AMPCONTROL p HPB INTEGRATED PROTECTION RELAY USER MANUAL Issue R5 Date 6 2011 6 Earth Protection Functions 6 1 Earth Leakage The earth le
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