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MAG-182 V2 OCS User Manual

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1. WV 6C TT vT0OC v 6 a o a lt 5 elm H 1000 2 5 2 700 8 600 3 500 a gt x lt 400 300 200 a A 100 E 8 Sec e 80 uut 70 5 825 50 40 8 3 a 8 30 5 TMS 30 c 20 eo e 10 Sec 8 5 3 2 Very Inverse 10 TMS 1 0 Sec 0 8 07 5 06 Ext Inverse 0 5 TMS 1 0 04 03 0 2 i 8 Sc 5 005 2 7 80 60 Short Circuit Trip Level ul E 50 Shown at 7 5x 1 D Adj 1 5x to 12 5x 8 5 5 30 2 Short Circuit Trip Time 8 3 20 Shown at 40 5 t Adj 40mS to 200ms 10m Sec 100 150 200 300 400 500 600 700 800 900 1000 1500 2000 96 of Selected Full Load Current m Very Inverse as per IEC 60255 151 B Curve Full Load Current Adjustable from 5 125A to 640A 5 m The trip time in seconds for current follows the characteristic TMS Selectable from 0 05 to 30 EMT defined by i aj 4135 II 10 TMS 3 H 8 Extremely Inverse as per 60255 151 C Curve alls The trip time in seconds for current follows the characteristic Note E defined by 1 The per unit current is clipped to a maximum of 125096 1 TMS 40 Therefore the trip time for input currents above this level will Where not decrease any further ie the trip characteristic flat lines 40 is the
2. 20 SIRTA E oe 20 21 6 1 eiTe rr J 21 6 2 Control of Resets 6 festa elas eed retia Esta cid ai inani 21 6 3 Internal S 21 6 4 Events 23 6 5 Protection Module 26 6 6 Time and T 28 6 7 Cassette Isolation 8 Earthing OCS 28 7 AS NZS 2081 2011 PROTECTION 29 TR TEE 29 7 2 Earth 30 7 3 Earth Fault E 32 Ampcontrol Pty Ltd ABN 28 000 915 542 AMPCC OCS USER MANUAL gt MAG 182 Version 2 AUG 15 7 4 Main Contactor Protection 34 8 CURRENT RELATED PROTECTION 37 8 1 Inverse Time Protection anna anna na ann napa ann 37 41 8 3 eU
3. 182 Version 2 AUG 15 8 1 2 Motor Overload Table 17 Protection Module Motor Overload Trip Characteristics Parameter Action Power Cycle Trip Status maintained Reset Requires a general reset and all three measured phase currents must be below the 100 Open Main Contactor Prevent Main Contactor from closing Trip Actions Block restart if the thermal accumulator is not below the selected start block level Active Period When Over Current curve is set to Motor Overload Logging Always Time Multiplier Parameters Full Load Current Cooling Multiplier Monitoring Phase currents displayed as a percentage of selected full load current TAC This protection scheme uses a simple first order thermal model of the motor to determine the tripping characteristic It is fundamentally different to the Over Current protection outlined above in that it all current levels contribute to the model heating and the effects of that heating persist in the model where as in the Over Currents functions the trip accumulator resets relatively quickly if the current falls below the selected full load current level The three measured phase currents are squared and added together to provide the heating input into the thermal model The cooling is assumed to be proportional to the model s temperature at any given time The Thermal Accumulator TAC is the model s temperature where 096 repres
4. 9 puejuleus An 5 jou suogeJeylv 2600721 WLI 10 uonejueuinoop JO SI DUIARAR SIH si vio saos Li 1 2 OCS USER MANUAL MAG 182 Version 2 AUG 15 Ampcontrol Pty Ltd ABN 28 000 915 542 AMPCONTROL TSE ele V L L 8320 22222 B 222220 81 21 21 02 Jex eAA uo qai sv 31715 LON 00 NI SNOISN3HIO t V 03 se Bue uoneaunua S9NINHYM 3ALLVOIONI 38V S T38V 1 914881 Jequunu jeas ei Aguauewsed AH S HuoN pue 51 343 aiquepul 9 Jaquunu 10314 LHOd 40 51 HOLO3NNOO 1079 1159325 8898 xouddy 169 HOIOV INOO pue 51 e uogeuedas 5 jeas k xojddy Ampcontrol Pty Ltd ABN 28 000 915 542 OCS USER MANUAL MAG 182 Version 2 AUG 15
5. MAG 182 Version 2 AUG 15 6 PRODUCT OPERATION 6 1 Outlet Control In a typical installation the outlet contactor is directly controlled by the Protection Module The supervising PLC will send commands to the Protection Module to start or stop the outlet The Protection Module will respond by controlling its MCR output accordingly In the event of any trip condition occurring the Protection Module will open the MCR output or CBR output as appropriate and prevent reclosing the output until the fault condition has cleared and the trip has been reset To close an outlet controlled by a Protection Module the supervising PLC will send a start command The following start sequence will be followed e there are any active trips the Protection Module will ignore any start command received e If all trips are cleared and the Protection Module will initiate start sequence e earth fault lockout test is conducted This test checks for a cable fault to earth The test voltage and current are limited to intrinsically safe levels If the test fails the start sequence will be cancelled and the Protection Module will report an earth fault lockout trip e If the earth fault lockout test passes the Protection Module may then conduct an optional high voltage DC insulation test on the cable If the insulation test fails the start sequence will be cancelled and the Protection Module will report an insulation test trip The insulatio
6. esses nennen nnne 8 1 1 Safe 2 nb pu E 8 2 RECEIVING AND STORAGE neri es 10 suco M 10 2 2 10 2 3 Storage after 10 2 4 Unpacking of 10 S PRODUCT 11 Em 14 4 1 General WANS eu E En bn bui prie Supe td a 14 4 2 Mandatory Installation Practices 15 4 3 Mechanical 16 4 4 Electrical Installation Information 17 4 5 External Accessories M 18 5 COMMISSIONING AND CALIBRATION mem 19 Dell Earth Leakage 19 5 2 Earth Ee ai T m 19 222 Earth PR Cp 19 5 4 Insulation Test High 19 5 5 Over Current Motor Overload Current 20 5 6 Short Circuit Current 441 20 5 7 Main Contactor 20 5 8 Voltage
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9. Gateway Address Byte 4 Pilot mode Selects the pilot termination method diode or RTX Loss Of Vacuum Level Trip level for loss of vacuum protection Voltage Level Defines the system voltage level SC Output Relay Selects which output relay the short circuit trips 6 5 2 Load Parameters Load Parameters relate to the properties of different loads that may be connected to the Outlet Cassette Examples include the motor current EC trip latch and remote control Load parameters can be stored in either the RTX if present or the Parameter Dongle NOTE Parameters cannot be changed while the Protection Module is running Ampcontrol Pty Ltd ABN 28 000 915 542 OCS USER MANUAL MAG 182 Version 2 AUG 15 AMPCONTROL o Table 4 Load Parameter Descriptions Load Parameter Name Description Load Machine Type Text describing the type of machine RTX only Load Machine ID Number identifying the machine RTX only Full Load Current Range Defines the full load current the Protection Module expects to see This determines the scaling of current readings the base current for motor overload or inverse time over current protection and the trip levels for short circuit protection Short Circuit Trip Level Defines the short circuit trip level as a multiple of the full load current setting Short Circuit Trip Time Determines how long the cur
10. 8 3 Current Balance Table 19 Protection Module Current Balance Trip Characteristics Parameter Action Power Cycle Trip Status maintained Reset General reset Trip Actions Open Main Prevent Main Contactor from closing Active Period Always Logging Always Parameters Trip Level Monitoring Phase currents displayed in Amps Ampcontrol Pty Ltd 28 000 915 542 OCS USER MANUAL 182 Version 2 AUG 15 The current balance measurement is available and is calculated MAX Ai x 10096 EET CONES av Where iav the average of the 3 phase currents i the maximum deviation of a phase current from the average The trip level is selectable at 5 10 20 and 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 8 4 Under Current Table 20 Protection Module Under Current Trip Characteristics Parameter Action Power Cycle 5 Reset Automatic Trip Actions Open Main Prevent Main Contactor from closing Active Period When outlet is running Logging When a fault occurs Parameters Trip Level Monitoring Phase c
11. EU 42 8 4 Under rv 43 S OTHER PROTECTION FUNCTIONS irren rain etn tratte rnt reet 44 44 10 SERVICE MAINTENANCE amp 15 45 10 1 Equipment Service mI oo 45 10 2 Equipment 46 111 313 0058 eee ee meee eevee aren ere seer at rere tee eee rer emer d E 46 TI SPEOIFICATIONS gor pu 47 11 1 Cassette 47 11 2 Protection Module Specifications 47 12 EQUIPMENT LIST 49 APPENDIX A PROTECTION MODULE LOAD CURRENT TABLES 50 A1 Protection Module Full Load Current 50 A2 Protection Module TMS 52 APPENDIX Be DRAWINGS iue pU dS DUMP EU RN T MU D MR 54 APPENDIX APPROVALS ibn ote ria par M pe Him beni prine bus 60 Y AMPCONTROL o TABLE OF FIGURES Ampcontrol Pty Ltd ABN 28 000 915 542 OCS USER MANUAL MAG 182 Version 2 AUG 15
12. Parameter Action Power Cycle Trip Status maintained Reset Specific short circuit reset Open selected output circuit breaker or main contactor Trip Actions Prevent Main Contactor from closing Active Period Always Logging When a fault occurs Short Circuit Output Relay Parameters Short Circuit Trip Level Short Circuit Trip Time Monitoring Phase currents displayed as a percentage of selected full load current 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 short circuit trip level is adjustable from 1 5 to 12 5 times full load current in 0 25 increments Note however that there is also an upper limit in the current measuring system of 6kA RMS This limit will effectively over ride selections where the combination of the selected full load current and the selected Ampcontrol Pty Ltd ABN 28 000 915 542 OCS USER MANUAL 182 Version 2 AUG 15 short circuit level exceeds 6kA For example if 640A is selected the short circuit will trip at 9 4PU 94096 even if the short circuit level is set to 9 5x or above The per unit current at which the limit takes effect is listed as SC max along with the full range current values in Appendix A The trip time is selectable from 40 to 200ms If the Over Current function is set to Motor Overload the short circuit functionality is
13. Shown at 7 5x 1 5x to 12 01 8 m TMS 0 05 z 4 9 80 T 5 i 40 5 88 E S2388 30 Short Circuit Trip Time Ss Shown at 40ms 8 5 20 Adj 40m to 3 10m Eg Sec 100 150 200 300 400 500 600 700 800 900 1000 1500 2000 i E 96 of Selected Full Load Current 3 m Full Load Current Adjustable from 5 125A to 640A 5 TMS Selectable from 0 05 to 30 Motor Overload Characteristic 5 3 The trip time in seconds for a simple theoretical alle scenario of a fixed overload current of is given T p n Note 10 TMS 729 h 2 1 05 1 The per unit current is clipped to a maximum of 125096 Where Therefore the trip time for input currents above this level will t I is the idealized trip time not decrease any further ie the trip characteristic flat lines 3 I 18 input current ratio relative to the full beyond 125096 of the selected full load current 1 5 load current set point per unit current 2 Inde 2 3 26 pendent of the selected TMS setting the minimum trip 3112 oi odi Over Current Time Multiplier times for the Overload function is nominally 100 mS i Ip is the load current that was flowing long 3 The trip times calculated from the above formulae are enough to reach thermal stability prior to the idealized The trip calculations are executed every 20 mS so overload occurrence there is an additional delay and un
14. 0 525 0875 63 6 5 5 25 9 75 4 0 070 0 057 0 105 34 0 70 0 566 1 050 64 7 0 5 66 10 50 5 0 075 0 061 0 113 35 0 75 0 606 1 125 65 7 5 6 06 11 25 6 0 080 0 065 0 120 36 0 80 0 646 1 200 66 8 0 6 46 12 00 7 0 085 0 069 0 128 37 0 85 0 687 1 275 67 8 5 6 87 12 75 8 0 090 0 073 0 135 38 0 90 0 727 1 350 68 9 0 7 27 13 50 9 0 10 0 081 0 150 39 1 0 0 808 1 50 69 10 0 8 08 15 0 10 0 11 0 089 0 165 40 1 1 0 889 1 65 70 11 0 8 89 16 5 11 0 12 0 097 0 180 41 1 2 0 970 1 80 71 12 0 9 70 18 0 12 0 13 0 105 0 195 42 1 3 1 05 1 95 72 13 0 10 51 19 5 13 0 14 0 113 0 210 43 1 4 1 13 2 10 73 14 0 11 31 21 0 14 0 15 0 121 0 225 44 1 5 1 21 2 25 74 15 0 12 12 22 5 15 0 16 0 129 0 240 45 1 6 1 29 2 40 75 16 0 12 93 24 0 16 0 17 0 137 0 255 46 1 7 1 37 2 55 76 17 0 13 74 25 5 17 0 18 0 145 0 270 47 1 8 1 45 2 70 77 18 0 14 55 27 0 18 0 19 0 154 0 285 48 1 9 1 54 2 85 78 19 0 15 35 28 5 19 0 20 0 162 0 300 49 2 0 1 62 3 00 79 20 0 16 16 30 0 20 0 22 0 178 0 330 50 2 2 1 78 3 30 80 22 0 17 78 33 0 21 0 24 0 194 0 360 51 2 4 1 94 3 60 81 24 0 19 39 36 0 22 0 26 0 210 0 390 52 2 6 2 10 3 90 82 26 0 21 01 39 0 23 0 28 0 226 0 420 53 2 8 2 26 4 20 83 28 0 22 63 42 0 24 0 30 0 242 0 450 54 3 0 2 42 4 50 84 30 0 24 24 45 0 Ampcontrol Pty Ltd ABN 28 000 915
15. OCS OUTLET CASSETTE SYSTEM User Manual Version 2 AUG 15 Designed and manufactured in Australia by Ampcontrol Pty Ltd Mx AMPCONTROL gt 2 Ampcontrol Pty Ltd ABN 28 000 915 542 AMPCONTROL OCS USER MANUAL MAG 182 Version 2 AUG 15 gt WARNING 2 The warning symbol highlights a potential risk of injury or death Please share these warnings with other operators N 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 p Please share these notes with other operators ENVIRO The enviro environmental symbol highlights areas which may have an Y impact on the surrounding fauna and or flora Ampcontrol Pty Ltd ABN 28 000 915 542 OCS USER MANUAL 182 Version 2 AUG 15 Copyright Notice The Ampcontrol OCS 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 No part of the hardware or documentation may be reproduced transmitted transcribed stored in a retrieval system or translated into any language or computer language in any form or by any means without prior written permission of AMPCONTROL PTY LTD Disclaimer While every effort has
16. i Edition 60 This Certficate does not indicate compliance w amp h electrical safety a nd performance requyements other than those expressly included in the Standards listed above TEST amp ASSE SSMEHT REPORTS A sampie s of the equipment listed has successfully met the examination and test requirements as recorded in Test Report AJAT AVExTR1 3 000100 AJAT AE xTR13 0002 00 Quality Assessment Report ALITSAJG AROB 00077 05 Ampcontrol Pty Ltd ABN 28 000 915 542 AMI OCS USER MANUAL MAG 182 Version 2 AUG 15 IECEx Certificate IEC e of Conformity Certificate No IECEx ITA 12 0032X Date of Issue 2013 01 11 Issue No 0 Page 3of 4 Schedule E QUIPMEHT Equipment and systems covered by this certificate are asfollows The Integrated Protection Relay IS System Type IPX is designed to provide the necessary functions required for protecting electrical outlets in underground coal mines These functions indude earth leakage earth continuity earth fault and insulation failure lockout over current under voltage and contactor fail protection The IP X System comprisesthe following apparatusthat are to be located in a non hazardous safe area An Ampcontrol Integrated Protection Relay IPX and 2 An Ampcontrol RT X module The IP X comprises three printed circuit boards upon which are mounted electronic components including a small battery for memory retention The three printed circuit boards
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18. Closed 9 Under Current Trip Phase currents were measured to be below the selected trip level 10 General Trip Reset A Trip was cleared via a General Reset request 11 Power Down The system has been powered down correctly 12 Protection Module There was an error with the Protection Module Dongle Parameter Error parameter dongle 13 Unexpected Restart The MEM Processor restarted without a clean power down most likely due to the watchdog resetting the system 14 Frozen Contactor The MCI Detects the contactor is closed while the Main Contactor is requested to be open This is a type of MCF Trip and will also have a Main Contactor Failure event log as the next log message Ampcontrol Pty Ltd ABN 28 000 915 542 OCS USER MANUAL gt MAG 182 Version 2 AUG 15 Event ID String Description 15 Loss of Vacuum Voltage was detected at the outlet while the Main Contactor was open This is a type of MCF Trip and will also have a Main Contactor Failure event log as the next log message 16 Current Balance Trip The difference between the measured phase currents is greater that the selected trip level 17 Thermal Memory Loss The system was unable to read the Thermal Memory value from Battery Backed up Ram while booting The Motor Overload value will be initialised to 10096 18 Main Contactor Opened The main contactor auxiliary contact opened
19. Protection Module High Voltage Insulation Test 33 Table 11 Protection Module Voltage Detection Loss of Vacuum Trip 34 Table 12 Protection Module Frozen Contactor Trip lS rE dud du 35 Table 13 Protection Module Contactor Close Fail Trip 8117 18 19 cio M 35 Table 14 Protection Module External Open Trip Characteristics 36 Table 15 Protection Module Coil Voltage Detection Trip Characteristics Pese 36 Table 16 Protection Module Over Current Trip Characteristics 37 Table 17 Protection Module Motor Overload Trip lial SGIBPISUES sida 441 39 Table 18 Protection Module Short Circuit Trip Characteristics 41 Table 19 Protection Module Current Balance Trip 42 Table 20 Protection Module Under Current Trip Characteristics 43 Table 21 Protection Module Under Voltage Trip Characteristics 44 Ampcontrol Pty Ltd ABN 28 000 915 542 A TEC OCS USER MANUAL MAG 182 Version 2 AUG 15 DEFINITIONS Table 1 Definitions Term Definition A Cassette is th
20. a physical reset after a trip The reset button is found on the front cover of the Protection Module Trip Actions Open Circuit Breaker Prevent Main Contactor from closing Active Period After closing MCR prior to receiving confirmation from the MCI Logging Always Parameters No parameters Monitoring None AS NZS 2081 2011 Clause 9 2 2 states that the MC s auxiliary interlocks must be in agreement with the control signals being sent to the MC else tripping of the upstream CB shall commence Close fail detects the event when the Protection Module attempts to close the output by closing its MCR output but receives no confirmation of the close output contactor via the MCI digital input Close fail protection activates in approximately 1sec Ampcontrol Pty Ltd ABN 28 000 915 542 OCS USER MANUAL 182 Version 2 AUG 15 7 4 4 External Open Table 14 Protection Module External Open Trip Characteristics Parameter Action Power Cycle Trip status maintained Reset Requires a physical reset after a trip The reset button is found on the front cover of the Protection Module Trip Actions Open arem Breaker Prevent Main Contactor from closing Active Period While running Logging Always Parameters No parameters Monitoring None An External Open trip occurs if the main contactor is detected as having been opened while the system is i
21. are designated IPX Top P CB Thetop board contains the majority ofthe intrinsically safe interface circuitry b IPX CCM PCB The CCM board is a totally encapsulated board that com prises of a high voltage resistor chain and shunt connected voltage shunts that provide intrinsically safe connectionsto the high voltage source c IPX Bottom PCB The bottom board contains unspecified non hazardous area circuitry The equipment is housed in a stainless steel enclosure and is fitted with terminal block mounted in the endosure walls The IP X plugs into the IPX Base which housesthe PCB The HYR comprises of three high voltage resistor strings which connect to the high voltage via integral flying leads CONDITIONS OF CERTIFICATION YES as shown below Conditions Applicable to this Certification exist and are availble for downloading as an ent to this Certificate on the IECEx Website and fom s an integral part ofthis Certificate which must be read in conjunction with this Certificate These Special Conditions MUST be met and applied during installation and use ofthe IP X Integrated Relay P rote dive System Ampcontrol Pty Ltd ABN 28 000 915 542 OCS USER MANUAL CONTROL 182 Version 2 AUG 15 IECEx Certificate of Conformity Certificate No IE CEx ITA 12 0032X Date of Issue 2013 01 11 Issue No 0 Page 4014 E T continued Drawing Asscoiated wi
22. been made to assure the accuracy and clarity of this document AMPCONTROL PTY LTD assumes no liability resulting from any omissions in this document or from misuse of the information obtained herein The information in this document has been carefully checked and is believed to be entirely reliable with all of the necessary information included AMPCONTROL PTY LTD reserves the right to make changes to any products described herein to improve reliability function or design and reserves the right to revise this document 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 does it convey license under its patent rights or the rights of others Before You Begin Thank you for purchasing the Ampcontrol Outlet Cassette System WARNING 4 In the interests of safety and correct equipment operation please take the time to read and understand the content in this manual N Ampcontrol Contact Details 7 Billbrooke Close Cameron Park NSW 2285 P 61 1300 267 373 F 61 2 4903 4888 EMAIL customerservice ampcontrolgroup com WEB ampcontrolgroup com Ampcontrol Pty Ltd ABN 28 000 915 542 AMPCC rS OCS USER MANUAL gt MAG 182 Version 2 AUG 15 TABLE OF CONTENTS 1 SAFETY AND OTHER WARNINGS
23. cannot be reset by the PLC These trips require an inspection of the switching equipment associated with the outlet controlling Protection Module and as such the reset is provided by way of a push button accessible from the front of the Protection Module 6 3 Internal Trips The Protection Module has a number of trip functions that are not directly associated with the protection of the outlet but signal that other dangerous faults have been detected 6 3 1 CCM ID The Protection Module has an internal detection circuit to identify the CCM module that is assembled within the Cassette If the CCM identity fails to match with that which is expected the Protection Module will set this trip There is currently one CCM version which is used for both 1100V and 3 3kV outlets If this trip occurs the Cassette should be returned for repair Ampcontrol Pty Ltd ABN 28 000 915 542 OCS USER MANUAL MAG 182 Version 2 AUG 15 6 3 2 MCF Battery Trip The Protection Module has an internal battery This is used to power the real time clock used to timestamp log messages as well has power the main contactor fail latch The health of this battery is monitored and if the battery condition is failing this trip will be set If this trip occurs the Protection Module should be returned to have the battery repaired or replaced 6 3 3 Internal Logic Error This trip will be set in the event that an internal fault has been detected I
24. certificate and the 1 5 rating will not be valid e Refer to the relevant section of the safety file for copies of certificates of conformity outlining the special conditions of the certification for the explosion protected equipment or components e The latest certificate and its associated attachments outlining the special conditions of the certification are maintained and available on the IEC Ex Website http iecex iec ch Ampcontrol Pty Ltd ABN 28 000 915 542 OCS USER MANUAL 182 Version 2 AUG 15 2 RECEIVING AND STORAGE 2 1 Receiving All possible precautions are taken to protect the equipment against damage or losses during shipment however before accepting delivery check all items against the packing list or bill of loading If there is evidence of physical damage notify Ampcontrol immediately Notify Ampcontrol immediately in case of any discrepancies to the packing list Keep a record of any 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 retain and store any approval documentation for your safety file as applic
25. communications Ampcontrol Pty Ltd ABN 28 000 915 542 OCS USER MANUAL 182 Version 2 AUG 15 1 SAFETY AND OTHER WARNINGS For safety reasons the OCS must be installed operated and serviced only by competent personnel Please read and understand this instruction manual completely before installing operating or servicing this equipment Failure to install or operate this instrument in accordance with the instructions contained in this manual may create hazardous operating conditions 1 1 Safe Use of Equipment The equipment supplied has been designed and manufactured to ensure safe operation The equipment must only be used within the design parameters The instructions within this manual must be observed as an aid towards achieving the safest possible installation Persons responsible for installation maintenance or operation must observe the following instructions 1 1 1 Changes to Equipment Changes in the design and modifications to the equipment are not permitted Unauthorised changes made to the hardware or operating firmware will void the manufacturer s warranty and may compromise the integrity of the system into which it is installed and other connected equipment 1 1 2 Equipment Knowledge Experience with or understanding of this equipment is essential for the safe installation and removal of the equipment Therefore please read and understand this manual prior to us
26. from the relay When power is restored the thermal memory would be at the same level had there been no loss of power The Thermal Accumulator shows the state of the thermal model 096 5 Cold 10096 lt Trip When a trip occurs it cannot be reset until the current is below the pick up level When the Protection Module is not in the running state if the thermal accumulator is not below the selected start block level a start block trip will occur This will automatically clear once the thermal accumulator drops to or is below the selected level This functionality is used to ensure adequate thermal capacity is available before another start is allowed If necessary it will force sufficient cooling time to allow the restoration of sufficient thermal reserve If for example the application required capability to permit a locked rotor start lasting up to 60 of the allowable cold locked rotor start time before tripping on Motor Overload the Start Block Level parameter would be set to 40 In order to allow an emergency restart on a hot motor a reset of the thermal memory is possible but the risk of permanent motor damage must be carefully considered before taking this step CAUTION Incorrect motor protection setup or thermal memory resets may cause or lead to motor failure or permanent motor damage 8 2 Short Circuit Table 18 Protection Module Short Circuit Trip Characteristics
27. trailing cable This is in accordance with AS NZS 2081 2011 The pilot is also used to transfer data when a remote termination unit RTX is used to achieve machine communication The Cassette Protection Module can be configured to operate in either diode or RTX mode This determines what terminating device the relay is looking for on the pilot NOTE S The RTX will only be recognised by the Cassette Protection Module and will not be seen as a diode by other earth continuity devices CAUTION l Cable parameters are important to the correct operation of the Pilot E C function Resistance amp capacitance values can determine the length of cable that the relay can drive The relay measures the resistance of the pilot earth loop and the leakage between the pilot and earth Ampcontrol Pty Ltd ABN 28 000 915 542 OCS USER MANUAL MAG 182 Version 2 AUG 15 AMPCONTROL o conductors These measurements are known as the series earth continuity resistance and the shunt earth continuity resistance respectively The shunt measurement ensures that a pilot to earth fault is detected If the pilot earth loop is not healthy series resistance greater or shunt resistance lower that their respective trip settings a trip occurs which in turn opens the main contactor control circuit The trip can be configured as latching or non latching This allows the user to determine if the trip is manually or automa
28. whenever the IECEx ITA 12 0032X Certificate is presented Special Conditions Applicable to the RTX Module 1 Input Output Parameters Pilot Earth Connector J1 18 8nF Negligible mH other connections RTX 1 Are for connection to voltage free contacts temperature sensors and suitable segregated from non intrinsically safe circuits when the apparatus is considered to be Intrinsically safe 2 The apparatus is not capable of withstanding a 500 V insulation test This must be taken in to account in any installation 3 Careful consideration should be given when connecting the system to multiple earth points to prevent earth loops potential differences between the different earth connections of the RTX and IPX units This may be achieved by ensuring that all intrinsically safe earths are infallible connected to one point only 4 copy of drawings 14 amp IPXA003 Sheet 1 is to be provided to the user
29. with no loose screw terminals or DIN rail terminals not fitted to rails etc e If required apply electrical contact grease to cassette contacts to reduce wear 10 1 3 Offsite Overhaul In line with AS NZS 2290 2014 for continued reliable and safe performance Ampcontrol recommends that each Cassette is overhauled to AS NZS 3800 and Ampcontrol s work instructions at intervals not exceeding that as recommended by the standard Ampcontrol Pty Ltd ABN 28 000 915 542 OCS USER MANUAL MAG 182 Version 2 AUG 15 10 2 Equipment Maintenance The OCS has no user serviceable parts WARNING All repairs must be carried out by Ampcontrol only P If a fault develops return the Cassette to Ampcontrol for repair It is q essential that no attempt be made to repair the Cassette as any attempt to dismantle or repair the Cassette can seriously compromise the safety of the unit and voids product warranty It is recommended that the electrical protection system incorporating the OCS 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 Leakage injection tests Earth Continuity tests Earth Fault Lockout tests Overcurrent injection tests CAUTION When conducting insulation tests on the outgoing power circuits ensure that the Cable Connecti
30. 06 172 212 25 0 204 424 14 2 13 6 750 45 13 50 77 27 0 109 54 141 108 173 216 25 0x 205 432 13 9x 14 6 875 46 13 75 78 2751110 55 1421110 174 220 25 0 206 440 13 6x 15 7 000 47 14 00 79 28 0 111 56 1431112 175 224 25 0 207 448 13 4 16 7 125 48 14 25 80 28 5 112 57 144 1114 176 228 25 0 208 456 13 2x 17 7 250 49 14 50 81 2901113 58 1451116 177 232 25 0 209 464 12 9x 18 7 375 50 14 75 82 29 5 114 59 1461118 178 236 25 0 210 472 12 7 19 7 500 51 15 00 83 30 0 115 60 1471120 179 240 25 0 211 480 12 5x 20 7 625 52 15 25 84 30 511116 61 148 122 180 244 24 6 212 488 12 3x 21 7 750 53 15 50 85 31 0 1117 62 149 124 1181 248 24 2 213 496 12 1x 22 7 875 54 15 75 86 31 5 1 118 63 150 126 182 252 23 8 214 504 11 9 23 8 000 55 16 00 87 32 0 1119 64 151 128 1183 256 23 4 215 512 11 7x 24 8 250 56 16 50 88 33 0 120 66 152 132 184 264 22 7 216 528 11 4x Ampcontrol Pty Ltd ABN 28 000 915 542 OCS USER MANUAL QUU MAG 182 Version 2 AUG 15 Protection Module Full Load Current Selection Table Amps 1000 1 and Max effective SC Level
31. 28 000 915 542 OCS USER MANUAL 182 Version 2 AUG 15 8 CURRENT RELATED PROTECTION FUNCTIONS Three current transformers within the Cassette are used to measure the three line currents The measured currents are used to implement the following protection functions Inverse time protection Over Current or Motor Overload Short circuit Under current Phase current balance The Full Load Current Range setting determines the base current for all of the phase current related functions the measured currents are normalized based on the selected value The range is selectable from 5 125A to 640A 8 1 Inverse Time Protection The Over Current Curve setting is used to select one of three Inverse Time Current characteristics e Very Inverse Over Current e Extremely Inverse Over Current e Motor Overload NOTE When the Motor Overload parameter is set the Short Circuit functionality is also modified to better suit motor starting transients See KS the Short Circuit section Section 8 2 for further information The Over Current Time Multiplier setting TMS scales the basic trip time for the basic over current characteristics to the desired response time Values are provided from 0 05 to 30 refer to Appendix A for the full list of values For cross reference the nominal trip times are listed for each TMS value for each of the curve options at 10x FLC 8 1 1 Over Current Table 16 Protec
32. 450mA Trip Settings 1096 500mA Inst 50ms 75ms 100ms 150ms 200ms 250ms 300ms 350ms 400ms 450ms 500ms Trip Time 0 20 CT Failure AMPCONTROL gt Ampcontrol Pty ABN 28 000 915 542 OCS USER MANUAL MAG 182 Version 2 AUG 15 Earth Continuity Series Trip 30 Shunt Trip Trip Time Earth Fault Lockout IS Test HV Insulation Test AS NZS2081 2011 Protection Functions 100 150 200 250 300 350 400 450 1 10058 150ms 200ms 250115 300105 35015 400 5 45015 5008 1 all phases in parallel OFF 2 5 5 10 20 50MO Contactor Protection Loss of Coil Voltage 100ms Loss of Vacuum 15 Frozen Contactor 100ms Loss of Contactor Control Back EMF Time 25 55 108 15s 20s Loss of Control 18 LOV Level 25VAC 50VAC Current Related Functions Over Current Protection Very Inverse as per IEC 60255 151 B Curve or Extremely Inverse as 2015 60255 151 C Curve Current Range See Protection Module Full Load Current Selection Table Appendix A Time Multiplier 0 05 30 See Protection Module TMS Table Motor Thermal Overload Full Load Current See Protection Module Full Load Current Selection Table Appendix A Time Multiplier 0 05 30 See Protection Module TMS Table Cooling Multiplier 1 0 1 5 2 0 2 5 3 0 4 0 5 0 Star
33. 542 OCS USER MANUAL MAG 182 Version 2 AUG 15 Protection Module Over Current Time Multiplier Settings TMS including nominal trip time in seconds at 10 PU Current 10 x trip time 10 x trip time 10 x trip time Value TMS Value TMS Ext Inv amp MOL 25 0 32 0 259 0 480 55 3 2 2 59 4 80 26 0 35 0 283 0 525 56 3 5 2 83 5 25 27 0 38 0 307 0 570 57 3 8 3 07 5 70 28 0 42 0 339 0 630 58 4 2 3 39 6 30 29 0 46 0 372 0 690 59 4 6 3 72 6 90 AMPCONTROL o Ampcontrol Pty Ltd ABN 28 000 915 542 APPENDIX B DRAWINGS OCS USER MANUAL MAG 182 Version 2 AUG 15 The drawings in this appendix are as per the below table Drawing Number Drawing Title Page Number 2 Typical Connection Diagram 55 IPXEO14 I S System Diagram 56 IPXA003 Protection Module Mechanical Details 57 14 Overcurrent and Short Circuit Curves 58 13 Motor Overload and Short Circuit Curves 59 OCS USER MANUAL MAG 182 Version 2 AUG 15 Ampcontrol Pty Ltd ABN 28 000 915 542 AMPCONTROL 9 9 v 2 L V Jo L 398 51 8 60 20 200 3 azs Y 0 im n TENEO 17 Wd lee
34. 60255 151 C Curve The trip time and reset in seconds for current follows the characteristic defined by 1 TMS 1 28 t D TMS 801 Where 11 the idealised trip time the input current ratio relative to the full load current set point ie per unit current TMS the Over Current Time Multiplier Setting tR 1 2 the idealised reset time 1 The per unit current is clipped to a maximum of 125095 Therefore the trip time for input currents above this level will not decrease any further i e the trip characteristic flat lines beyond 125096 of the selected full load current 2 Independent of the selected curve and TMS setting the minimum trip times for the Over Current functions are nominally 100ms 3 The trip times calculated from the above formulae are idealised The trip calculations are executed every 20ms so there is an additional delay and uncertainty of 25ms 15ms See Overcurrent Curves drawing 14 in Appendix B When the Protection Module is not in the running state if the thermal accumulator is not below the selected start block level a start block trip will occur This will automatically clear once the thermal accumulator drops to or is below the selected level Note however that generally this will happen quickly when the inverse overcurrent modes are selected Ampcontrol Pty Ltd ABN 28 000 915 542 OCS USER MANUAL
35. 8 500 17 00 34 011121 68 153 136 185 272 22 1 217 544 11 0x 26 8 750 58 17 50 90 35 0 122 70 154 140 186 280 21 4 218 560 10 7x 27 9 000 59 18 00 91 36 0 123 72 155 144 187 288 20 8 219 576 10 4x 28 9 250 60 18 50 92 37 0 124 74 156 148 188 296 20 3x 220 592 10 1x 29 9 500 61 19 00 93 38 0 125 76 157 152 189 304 19 7 221 608 9 9x 30 9 750 62 19 50 94 39 01 126 78 158 156 190 312 19 2 222 624 9 6x 31 10 00 63 20 00 95 40 0 127 80 159 160 191 320 18 8 223 640 9 4 Ampcontrol Pty Ltd ABN 28 000 915 542 OCS USER MANUAL MAG 182 Version 2 AUG 15 A2 Protection Module TMS Table Protection Module Over Current Time Multiplier Settings TMS including nominal trip time in seconds at 10 PU Current 10 x trip time 10 x trip time 10 x trip time Value TMS Value TMS Ext Inv Value TMS Ext Inv 2 amp MOL amp MOL 0 0 050 0 040 0 075 30 0 50 0 404 0 750 60 5 0 4 04 7 50 1 0 055 0 044 0 083 31 0 55 0 444 0 825 61 5 5 4 44 8 25 2 0 060 0 048 0 090 32 0 60 0 485 0 900 62 6 0 4 85 9 00 3 0 065 0 053 0 098 33 0 65
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37. Figure 3 1 Ampcontrol Outlet Cassette System 11 Figure 3 2 Ampcontrol Fixed Cassette System 12 Figure 4 1 2 Way OCS Dimensions Pictured with 2 Cassettes e 16 Figure 4 2 3 Way OCS Dimensions Pictured with 3 Cassettes 16 Figure 4 3 FCS Dimensions Pictured with 5 Cassettes stalled Mr 12 Figure 4 4 Remote Termination Unit 18 Figure 6 1 Actuator position within 5 5 28 TABLE OF TABLES Table 1 7 Table 2 Event Log Entry 00 23 Table 3 Outlet Parameter 26 Table 4 Load Parameter 27 Table 5 Protection Module Earth Leakage Trip Characteristics 29 Table 6 Protection Module Earth Leakage CT Failure Trip ge T m 30 Table 7 Protection Module Earth Continuity Series Trip Characteristics 31 Table 8 Protection Module Earth Continuity Shunt Trip iHi io ENTRE RET 31 Table 9 Protection Module Earth Fault Lockout EFLO Trip cinia cio 32 Table 10
38. N MODULE LOAD CURRENT TABLES A1 Protection Module Full Load Current Table Protection Module Full Load Current Selection Table Amps 1000 1 CT and Max effective SC Level 0 15 125 32 10 25 64 20 55 96 41 128 82 160 164 25 0 192 328 18 3x 1 5 250 33 10 50 65 21 01 97 42 1129 84 161 168 25 0 193 336 17 9x 2 15 375 34 10 75 66 21 5 98 43 130 86 162 172 25 0 194 344 17 4x 3 15 500 35 11 00 67 220 99 44 131 88 163 176 25 0 195 352 17 0x 4 5 625 36 11 25 68 22 5 100 45 132 90 164 180 25 0 196 360 16 7x 5 15 750 37 11 50 69 23 0 101 46 133 92 165 184 25 0x 197 368 16 3x 6 5 875 38 11 75 70 23 5 1 102 47 134 94 166 188 25 0 198 376 16 0x 7 16 000 39 12 00 71 24 01 103 48 135 96 167 192 25 0 199 384 15 6x 8 6 125 40 12 25 72 24 511104 49 136 98 168 196 25 0 200 392 15 3x 9 6 250 41 12 50 73 25 0 105 50 137 100 169 200 25 0 201 400 15 0 10 6 375 42 12 75 74 25 5 106 51 138 102 170 204 25 0 202 408 14 7x 11 6 500 43 13 00 75 26 0 1107 52 139 104 171 208 25 0x 203 416 14 4 12 6 625 44 13 25 76 26 5 108 53 140 1
39. a general reset after a failed test Trip Actions Prevent Main Contactor from closing Active Period Single test performed during the start sequence Optionally can be disabled Logging Always logs the measured test result Trip events are logged separately Parameters Trip Level Monitoring Last test value stored If an insulation trip level has been selected an automatic High Voltage DC Insulation Test is carried out after an Intrinsically Safe Earth Fault Lockout Test has been passed During the Insulation Test the Protection Module generates a high DC voltage approaching the peak system voltage which is applied between each phase and earth The Protection Module measures the voltage on the line and calculates the meg ohm resistance to earth for all three phases If the resistance value is above the pre set threshold the Protection Module will close its MCR output closing the outlet The insulation test takes 4 seconds The results of the insulation test should only be used as a guide to confirm that insulation remains above the pre set threshold Insulation tests apart from the generated insulation test via the Protection Module should be still carried out on a regular basis for maintenance purposes Ampcontrol Pty Ltd ABN 28 000 915 542 OCS USER MANUAL 182 Version 2 AUG 15 7 4 Main Contactor Protection There are four main contactor protection functions Each of the
40. able prior to wrapping being discarded 2 2 Inspection Equipment that is found to be damaged or has been modified away from its published specification must not be used Please contact Ampcontrol if the equipment is suspected to be different than that ordered or if it does not match the published specifications 2 3 Storage after Delivery When the equipment 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 between 0 40 C preferably on shelves and protected from moisture and sunlight 2 4 Unpacking of Equipment The method of packing used will depend 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 The disposal of packaging materials replaced parts or components ENVIRO must comply with environmental restrictions without polluting the soil air or water e Ensure that any timber and cardboard used as packaging is disposed of in a safe and environmentally responsible manner Where possible dispose of all waste products i e oils metals plastic and rubber products by using an approved recycling service centre amp Ampcontrol Pty Ltd ABN 28 000 915 542 OCS USER MANUAL AMPCONTHROL MAG 182 Version 2 AUG 15 3 PRODUCT OVERVIEW The Ampcontrol Out
41. al does not cover system commissioning the full scope of commissioning tests should be determined during the risk assessment or FMEA covering the design of the electrical protection system The following test can provide guidance on checking the correct operation of the Cassette Protection Module during commissioning These tests should be performed on each individual Cassette within the installed OCS This is not intended to provide an exhaustive commissioning checklist but should be considered to be a minimum set of tests 5 1 Earth Leakage Test the correct operation of earth leakage circuits by injecting a fault current through the Earth Leakage CT Ensure that all relevant tripping circuits operate successfully and that latched trips may be reset in the appropriate manner Disconnect the toroid from the Cassette Protection Module and ensure that an EL CT fault trip is issued with similar effect 5 2 Earth Fault Lockout Test the correct operation of Earth Fault Lockout protection by connecting suitably rated test resistors to the power conductors Attempt to energise the outlet and confirm that the Cassette Protection Module trips on Earth Fault Lockout WARNING 4 If the Earth Fault Lockout does not trip during this test full system voltage and power may be subsequently applied to the test 1 resistors 5 3 Earth Continuity Test that the Earth Continuity protection is operational by creating an open circuit on
42. and authenticity of this certificate be verified by visiting the Official IE CEx Website certificate issued by TUV Rheinland Australia Pty Ltd 4 6 Second Street Bowden SA 5007 Australia T VRheinland Ampcontrol Pty Ltd ABN 28 000 915 542 OCS USER MANUAL arnt MAG 182 Version 2 AUG 15 IECEx Certificate IEC of Conformity Certificate No IECEx ITA 12 0032X Date of Issue 2013 01 11 Issue No 0 Page 2 of 4 Manufacturer Ampcontrol CSM Pty Itd 7 Billbrooke Close Cameron Park NSVY Australia 2285 Australia Additional Manufacturing location sy This certificate is issued as verification that a sample s representative of production was assessed and tested and fund to comply with the IE C Standard list below and that the manufacturer s quality system relating to the Ex products covered by this certificate was assessed and found to comply with the IECE x Quality system requirements This certificate is granted subject to the conditions as set out in IECEx Scheme Rules IE CEx 02 and Operational Documents as amended STAHDARDS The electrical apparatus and any acceptable variations to it specified in the schedule ofthis certificate and the identified documents was found to comply with the following standards IEC 60079 0 2011 Explosive atmospheres Part 0 General requirements Edition 5 0 60079 11 2011 Explosive atmospheres Part 11 Equipm ent protection by intrinsic safety
43. ation Information Refer to drawing IPXE002 in Appendix B for electrical installation information 2 Ampcontrol Pty Ltd ABN 28 000 915 542 OCS USER MANUAL MAG 182 Version 2 AUG 15 4 5 External Accessories 4 5 1 Earth Leakage CT The Outlet Cassette Protection Module uses an Ampcontrol EL500 series current transformer for earth leakage measurements For the purposes of outlet identification tests during operation the earth leakage toroid is installed separately to the Cassette 4 5 2 Remote Termination Unit RTX The RTX is a microprocessor based module that replaces the diode at the end of the pilot conductor of the trailing cable It is powered by and communicates via the pilot line Its non volatile memory stores the parameters to configure the outlet as appropriate for the connected machine The RTX Module is pictured in Figure 4 4 All terminals are fully shrouded with the pilot and earth terminals being segregated from the other terminals The RTX provides remote start and stop facilities The circuitry involved in these functions is self diagnostic and will cause the outlet 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 PTC terminals are provided for a semiconduc
44. certainty of 25 mS 15 mS o u I u a I o I LE 222252002 Ampcontrol Pty Ltd ABN 28 000 915 542 AMPCONTROL gt ersion 2 APPENDIX C APPROVALS This appendix contains a copy of Issue No 0 of the IECEx ITA 12 0032X certificate of conformity and relevant attachments For the most up to date copy of this certification refer to the http iecex iec ch website Ampcontrol Pty Ltd ABN 28 000 915 542 OCS USER MANUAL M NTR MAG 182 Version 2 AUG 15 Certificate of Conformity INTERNATIONAL ELECTROTECHNICAL COMMISSION IEC Certification Scheme for Explosive Atmospheres for rules and details of the IECE x Scheme visit vwwwviecex com Certificate 12 0032X issue 0 Certificate history Status Current Date ofl ssue 2013 01 11 Page 1 of 4 Applicant Ampcontrol CSM Pty Ltd 7 Billbrooke Close Cameron Park NSW 2285 Australia Electrical Apparatus IP X Integrated Protection Relay System Optional accessory Type of Protection Ex ia Marking Ex ia 09 60 C IECEx ITA 12 0032 Approved for issue on be haf of the IECEx Parveen Akther Cert ication Body Postion Certification Authority for printed version Date 1 This certificate and schedule may only be reproduced in full 2 This certificate is not transferable and remainsthe property ofthe issuing body 3 The Status
45. connecting wiring passes through the hazardous area as part of a High Voltage pilot system 2 Input Output Parameters The following information must be taken into account during installation a Terminals 3 to 28 Um 132 Vac RMS phase to earth b Flying leads Um 2286 Vrms phase to earth c Pilot amp HV leads combined The interconnecting cabling that connects the Pilot Terminals 1 amp 2 and the HV flying leads combined to the RTX Module must not exceed the following Capacitance Inductance Inductance to UF Resistance Ratio L R 3 72 4 5 207 2 Ampcontrol Pty Ltd ABN 28 000 915 542 OCS USER MANUAL 182 Version 2 AUG 15 ATTACHMENT IECEx CERTIFICATE IECEx ITA 12 0032X Page 2 of 3 This Attachment forms an Integral Part of the IECEx Certificate and pages MUST be presented and read whenever the IECEx ITA 12 0032X Certificate is presented d Optional RDX Terminals 29 to 33 The capacitance and either the inductance or the inductance to resistance L R ratio of the hazardous area load connected the hazardous area connections must not exceed the following values Uo lo Po Co Lo L R V W UF 17 The above load parameters apply where i The external circuit contains no combined lumped inductance Lj or lumped capacitance greater than 196 of the above values OR ii The external circuit contains either only lumped inductanc
46. current EL is displayed as a of the trip level When the leakage reaches 100 for the selected time delay a trip occurs Ampcontrol Pty Ltd ABN 28 000 915 542 OCS USER MANUAL MAG 182 Version 2 AUG 15 7 1 3 Earth Leakage CT Failure Protection Table 6 Protection Module Earth Leakage CT Failure Trip Characteristics Parameter Action Power Cycle Trip status maintained Reset Requires a general reset after the trip condition has cleared Trip Actions Open Main Sonidetor Prevent Main Contactor from closing Active Period Always active Logging Always logged Parameters None Trip time and level is fixed Monitoring CT Detect trip status bit The Protection Module generates a CT Detection Signal to test the integrity of earth leakage circuit The CT Detection signal continually tests the earth leakage current transformer the wiring loop to the transformer and the input to the protection relay as required by AS NZS 2081 2011 The signal is fed from Pin 6 of the Protection Module Pass one loop through the earth leakage current transformer then back to Pin 7 The Earth Leakage CT Failure trip time is fixed at 500ms NOTE S The loop resistance of the CT Detection Signal circuit must remain below 10 7 2 Earth Continuity The earth continuity function tests for the continuity of the earth between the outlet and the machine via the pilot in the
47. d to the line and load contacts with the on board vacuum contactor switching the outlet In the earthed position the cassette is disconnected from the line bus and connects the load connections to earth These earth contacts are visible through viewing windows When in the earth position the supply to the actuator can be externally isolated to prevent operation to move the cassette away from the earth position 6 7 1 Actuator Actuators are used to transition the cassettes between the service and earth positions The actuator is controlled via PLC outputs and provides actuator healthy feedback to the PLC An analogue input corresponding with the position of the actuator rod is compared with the state of the limit switches by the PLC to indicate the position of the cassette NOTE Each actuator has a coloured band on each end of the cable to denote actuator position within the chassis as shown in Figure 6 1 Non matching colours will prevent operation of the actuator Position 1 Red p no 164891 L H Position 3 Blue p no 164893 Position 4 No Band p no 164894 Figure 6 1 Actuator position within chassis Ampcontrol Pty Ltd 28 000 915 542 OCS USER MANUAL 182 Version 2 AUG 15 7 ASINZS 2081 2011 PROTECTION FUNCTIONS The Protection Module housed within the Cassette provides a number of protection functions that meet the requiremen
48. e Competency based training courses are recommended and are available on request 1 1 3 Manual Handling 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 enclosures and gloves should be worn 1 1 4 Installation Correct operation and safety depend on the OCS 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 1 1 5 Operation As safety depends on the OCS functioning correctly it is highly recommended that all safety functions of the OCS be periodically tested to ensure correct operation Ampcontrol Pty Ltd ABN 28 000 915 542 OCS USER MANUAL AMPCONTHROL MAG 182 Version 2 AUG 15 1 1 6 Certification To comply with the Conditions of Certification ensure full serviceable life of the product and avoid nullifying the warranty it is essential to WARNING exercise great care with the installation use and storage of the system 4 components Failure to comply with the Conditions of Certification may seriously compromise the integrity of the system and or its components N and the consequence could be fatal The user must ensure that the Special Conditions outlined in the certificate and associated attachment is met or the
49. e Lj lumped capacitance in combination with a cable OR iii The inductance and capacitance are distributed as in a cable In all other situations e g the external circuit contains combined lumped inductance and capacitance up to 50 of each of the inductance and capacitance values are allowed 3 copy of drawings IPXEO14 8 Sheet 1 is to be provided to the user 4 The chassis of the apparatus is to be connected to the intrinsically safe earth via suitable terminations complying with the requirements of IEC 60079 7 clause 4 2 5 The installation is to be in accordance with the relevant installation Standards Code of Practice and manufacturers drawing IPXEO14 Careful consideration should be given when connecting the system to multiple earth points to prevent earth loops potential differences between the different earth connections of the RTX and IPX units This may be achieved by ensuring that all intrinsically safe earths are infallible connected to one point only 6 The IPX module contains a small battery and protective circuitry that has been considered to comply with IEC 60079 0 2011 amp IEC60079 11 201 1 only 2 Ampcontrol Pty Ltd ABN 28 000 915 542 OCS USER MANUAL MAG 182 Version 2 AUG 15 ATTACHMENT To IECEx CERTIFICATE IECEx ITA 12 0032X Page 3 of 3 n This Attachment forms an Integral Part of the IECEx Certificate and all pages MUST be presented and read
50. e unit that is installed within Outlet Cassette System OCS or Fixed Cassette System FCS There are two types FCS Cassettes and Cassette OCS Cassettes Each Cassette houses a Protection Module phase current transformers and main contactor components CB Circuit Breaker Main circuit breaker that controls power to all outlets Circuit Breaker Relay power relay within the Cassette Protection Module CBR to control the supply to the circuit breaker coil The Protection Module s CBR output is designed for use with under voltage tripping coils FCS FCS is the acronym for the Ampcontrol Fixed Cassette System Main Contactor the main power circuit opening device Installed within the MC Cassette the main contactor is opened and closed in order to turn the outlet on and off Main Contactor Relay power relay installed within the Cassette Protection MCHR Module to control the supply to the main contactor coil All trip times specified are to the opening of the MCR OCS OCS is the acronym for the Ampcontrol Outlet Cassette System A small memory device which is used to store setting information for the Parameter Dongle MEM and RTX modules which is attached to the wiring harness of the installation The Protection Module is installed in each Cassette providing a host of Module protection functions for the outlet Remote Termination Device Module that is installed at the machine end of RTX e D E the pilot to provide machine identification and
51. ed to allow the start sequence to be initiated from the load via the pilot signal In remote start mode the PLC cannot force the start of the outlet It can however prevent the outlet from starting The remote start setting requires the following sequence for a start to be triggered 1 2 3 4 10 All trips must be clear The PLC Comms enable bit must be enabled for a remote start condition to be possible and accepted The pilot resistance must be detected above 900 to ensure a start resistor is in place As soon as the resistance calculation drops below the EC series threshold a start is triggered Note that the EC series protection function will still be operating and the start will not be triggered if the EC measurement is above the set threshold If the EC resistance falls below 900 but remains above the EC series threshold it will result in a remote start error trip after 1 second The start sequence EFLO IT MC closing starts immediately after the trigger The start resistor must remain shorted out by the start button for the duration of the pre start tests If the EC resistance does not return to above 900 within 5 seconds after the outlet closes the Protection Module will trip on Remote Start Stuck After a start has been triggered the EC resistance must return above 900 before another start can be triggered The Remote Start Fault is automatically reset once the EC resistance returns above 900 An external r
52. endix H cover the requirements for back emf considerations for Frozen Contactor devices where large inertial loads are connected The trip level can be selected at 25VAC or 50VAC The trip time is less than 1sec amp Ampcontrol Pty Ltd ABN 28 000 915 542 OCS USER MANUAL MAG 182 Version 2 AUG 15 AMPCONTROL o 7 4 2 Frozen Contactor Table 12 Protection Module Frozen Contactor Trip Characteristics Parameter Action Power Cycle Trip status maintained Requires a physical reset after a trip The reset button is found on the Reset front cover of the Protection Module Trip Actions Open Circuit Breaker Prevent Main Contactor from closing Active Period When outlet is not running Logging Always Parameters No parameters Monitoring None AS NZS 2081 2011 Clause 9 2 2 states that the MC s auxiliary interlocks must be in agreement with the control signals being sent to the MC else tripping of the upstream CB shall commence Frozen contactor detection is while the MCR is open If the Protection Module detects that the main contactor has closed or remains closed after the MCR is opened for any reason it will result in a frozen contactor trip The frozen contactor protection activates in approximately 100ms 7 4 3 Close Fail Table 13 Protection Module Contactor Close Fail Trip Characteristics Parameter Action Power Cycle Trip status maintained Reset Requires
53. ents the motor being cold and 10096 means the motor has reached its maximum temperature and is therefore tripped The trip time is dependant not only on the present current level but also the prior current history Since motor currents typically vary widely during starting and running the actual trip time is also variable To facilitate co ordination of the protection with motor capabilities and upstream protection the trip time in seconds for a simple theoretical scenario of a fixed overload current of 116 given by 12 1 2 t I 5 729 In 42 2 n Fx Where 1 the idealised trip time the input current ratio relative to the full load current set point ie per unit current TMS the Over Current Time Multiplier Setting Ip the load current that was flowing long enough to reach thermal stability prior to the overload occurrence In the natural logarithm Ampcontrol Pty Ltd ABN 28 000 915 542 OCS USER MANUAL 182 Version 2 AUG 15 1 The per unit current is clipped to a maximum of 125096 Therefore the trip time for input currents above this level will not decrease any further ie the trip characteristic flat lines beyond 125096 of the selected full load current 2 Independent of the selected TMS setting the minimum trip times for NOTE the Overload function is nominally 100 ms 5 3 The trip times calculated from the above formulae ideal
54. eset is not required 7 3 Earth Fault Lockout The Cassette Protection Module can provide a two step insulation test as part of the Earth Fault Lockout protection function The initial test is the mandatory intrinsically safe test and can be followed by an automatic High Voltage Insulation Test 7 3 1 Intrinsically Safe EFLO Table 9 Protection Module Earth Fault Lockout EFLO Trip Characteristics Parameter Action Power Cycle Trip status maintained Reset Requires a general reset after a failed test Trip Actions Prevent Main Contactor from closing Active Period Single test performed during the start sequence Logging Logged when test fails Parameters No parameters oe The initial earth fault lockout function tests the resistance of the three phase lines to earth by applying an intrinsically safe signal prior to the closure of the main contactor in accordance with AS NZS 2081 2011 The test is initiated by starting the relay once all starting conditions are met This test takes 2 seconds If the value measured is less than the pre set level a trip occurs Ampcontrol Pty Ltd ABN 28 000 915 542 OCS USER MANUAL 182 Version 2 AUG 15 7 3 2 High Voltage Insulation Test Table 10 Protection Module High Voltage Insulation Test Characteristics Parameter Action Power Cycle Trip status maintained Reset Requires
55. f this trip occurs the Cassette should be returned for repair AMPCONTROL o 6 4 Events Log A real time clock calendar is included in the Protection Module This combines with the non volatile memory to provide a data logging feature This log sequentially records the time date and details of the Ampcontrol Pty Ltd ABN 28 000 915 542 OCS USER MANUAL MAG 182 Version 2 AUG 15 most recent event A chronological list of the previous 50 events is stored The following events are logged Table 2 Event Log Entry Types Event ID String Description 0 Unused Not a valid Message Should not be seen 1 Feed On Logs the Machine Type Data1 and Machine Number Data2 when the main contactor has been closed while in RTX mode 2 Insulation Test Record The results of an automatic HV insulation test 3 Earth Leakage Trip Earth leakage current was measured above the selected trip level 4 Series Earth Continuity The series resistance of the pilot was measured to Trip be above the selected trip level 5 Over current Overload The currents exceeded the bounds of the selected Trip trip characteristic 6 Short Circuit INST Trip An Instantaneous Short Circuit trip occurred 7 Close Failed After being requested to close the Main Contactor has not closed within 5 seconds As detected via the MCI 8 Main Contactor Relay The main contactor relay was closed
56. functions monitors the states of the outlets main contactor If a fault is detected the upstream circuit breaker is opened via the CBR output in order to remove power from the potentially faulty contactor 7 4 1 Voltage Detection Loss of Vacuum Table 11 Protection Module Voltage Detection Loss of Vacuum Trip Characteristics Parameter Action Power Cycle Trip status maintained Requires a physical reset after a trip The reset button is found on the front cover of the Protection Module Open Circuit Breaker Trip Actions Prevent Main Contactor from closing When outlet is not running and the Back emf timer has finished Active Period counting down Logging Logged when a trip occurs Trip Level Back emf Timer Parameters Monitoring Phase voltages are continuously updated Loss of Vacuum provides a mechanism for checking that voltage is not present on the outlet after the Main Contactor has opened The level at which the Main Contactor Failure should be initiated for residual voltages are outlined in AS NZS 2081 2011 Clause 9 2 1 The Loss of Vacuum protection cannot be enabled immediately after the outlet is stopped as there is the potential for back emf from the load to cause a trip Subsequently a back emf timer is provided and allowed to elapse after the outlet has stopped before the Loss of Vacuum protection can be operated AS NZS 2081 2011 Clause 9 3 and App
57. idealized trip time beyond 125096 of the selected full load current I isthe input current ratio relative to the full load current 2 Independent of the selected TMS setting the minimum trip set point ie per unit current times for the Overload function is nominally 100 mS TMS is the Over Current Time Multiplier Setting 3 The trip times calculated from the above formulae are iis tha ond aremt ete os Prid dd ce idealized The trip calculations are executed every 20 mS so ty p 5 there is an additional delay and uncertainty of 25 mS 15 mS o I u I I a I o 22024 Ampcontrol Pty Ltd ABN 28 000 915 542 OCS USER MANUAL MAG 182 Version 2 AUG 15 WY LC VT v10C v 6 o a lt sm A lt 1000 A 5 m 700 i 15 600 3 CO 500 400 e e ceu 100 XE Sec 5 8 80 200 5 70 E 8 60 auct 50 3 i og 40 er 5 FE 2 1 10 Sec Pn 8 5 81318 4 5 4 8 5 2 4 Es E Wee 10 2 Sec 52 98 KT Za 08 05 TMS 1 0 e 04 02 Short Circuit Trip Level
58. if the long term average current prior to an overload was 0 7PU the trip time for an over an overload from that starting point would be 56 96 of the trip time for the same overload current starting from cold Drawing 013 also shows the overload curve for various values of Ip The motor manufacturer s data should be consulted to select the time multiplier appropriate for the motor being protected Typically the capacity of a cold motor is given at six times its rated current The characteristic equation above can be used to select the TMS to match the motors overload capacity While the main contactor is closed the cooling output from the thermal model is calculated to achieve the necessary behaviour to match the characteristic above The Over Load Cooling Multiplier modifies the cooling output of the thermal model when the motor is Ampcontrol Pty Ltd ABN 28 000 915 542 OCS USER MANUAL 182 Version 2 AUG 15 stopped This can be used to account for reduced cooling capacity of the motor when it is not running Cooling multiplier of 1 means the cooling is independent of whether the motor is running or not eg a water cooled motor A setting of 2 5 may be appropriate for a fan cooled motor however for the best protection consult the motor manufacturer Values are provided from 1 0 to 5 0 The thermal model continues to simulate the motor s thermal behaviour even if the power is removed
59. isual and hands on checks 10 1 1 Visual Only Inspections A basic visual inspection focuses on looking at the installation for signs of physical damage water or dust ingress and the condition of cables and labels This type of inspection may involve opening cabinets to gain access to the OCS and other equipment This level of inspection may also include cleaning display windows that have become obscured by dirt Observations would typically be e Check that equipment enclosures cable trays conduits etc are in good order with no physical damage e Check that connected cables are free from cuts abrasions and obvious signs of damage Cable restraints are in good order and correctly fitted e Check that labels on equipment and cables are present and in good condition especially certification labels e Check that no modifications have been carried out to installed equipment 10 1 2 Hands On Detailed Inspections A more detailed inspection would include all of the elements of a visual inspection plus some checks that cover the integrity of connections fixtures and fittings In addition to basic visual observations more detailed integrity checks would involve e Verify that equipment housings and other mechanical fixtures are secured in place This includes terminal box lids tightness of cable glands integrity of mountings security of equipment fixing to walls DIN rails etc e Verify all electrical connections are secure
60. ized The p trip calculations are executed every 20 ms so there is an additional gt delay and uncertainty of 25 ms 15 ms 4 The above characteristic is equivalent to IEC 60255 8 equation below with the substitution of T TMS 72 9 This scaling aligns the trip time at 10 PU current with that of the Extremely Inverse curve above eg 808ms with a TMS of 1 0 Pap t Z 8 1 k 1 05 called the Service Factor 1 The base thermal model provides a thermal time constant of 72 9 seconds The TMS setting scales the basic thermal time constant allowing a maximum time constant of over 36 minutes TMS 30 Where in the Protection Module See Motor Overload Curves drawing 013 in Appendix B The TAC provides information about how much thermal capacity is left and therefore how long it will take to trip from given starting point and overload current If the motor current is constant and below 1 05PU the TAC will eventually settle to a value as follows I 2 _ 1009 100 For example if the long term average load current was 0 7PU the would settle at 4490 The relative trip time for a constant current as a function of the initial value of the TAC is given by 100 TAC Cold Trip Time Continuing the example above with the starting at 4496 the trip time would be 5696 of the cold trip time for the same current that is
61. l Pty Ltd ABN 28 000 915 542 OCS USER MANUAL MAG 182 Version 2 AUG 15 Key Features e Individual outlet isolation and earthing system OCS e Operations via HMI interface e Ethernet communications e Cassette Protection Module All electrical protection functions are provided by the new generation Cassette Protection Module and include Earth Leakage Earth Fault Lockout Earth Continuity including remote start mode Contactor Failure protection Motor thermal overload protection Short circuit protection Under current protection Current balance protection Under voltage protection Automatic HV insulation test prior to outlet closing Machine identification The following Control and Monitoring functions are accessed via the Ethernet IP communications Monitoring of key parameters for all protection functions Protection settings and parameter adjustments Statutory tests Resetting of protection trips Outlet control starting and stopping The status of all protection functions and control logic All control of outlet s is from the HMI screen Ampcontrol Pty Ltd ABN 28 000 915 542 OCS USER MANUAL 182 Version 2 AUG 15 4 INSTALLATION 4 1 General Warnings These instructions have been designed to assist users of the OCS with installation Before the OCS can be installed there are a number of things that need to be considered and understood to
62. let Cassette System OCS is a major advancement in control and protection technology The OCS combines the outlet contactor protection module current transformers and outlet test circuitry into a single replaceable unit This has the advantage of resulting in minimal down time in the event of a fault The Ampcontrol OCS is available in two types the standard OCS and the Fixed Cassette System FCS The OCS provides isolation and earthing of individual outlets via integrated actuators that are controlled at the touch of a button via a Human Machine Interface HMI screen In this manner operators are not exposed to potential electric shocks resulting from residual static charge on the cable This also eliminates a potential ignition source of an explosive atmosphere Figure 3 1 Ampcontrol Outlet Cassette System OCS Ampcontrol Pty Ltd ABN 28 000 915 542 Ac OCS USER MANUAL MAG 182 Version 2 AUG 15 o The FCS 1 1kV systems only sacrifices the remote isolation and earthing functionality of the OCS to provide a higher outlet density Due to the compact nature of the FCS 10 outlets are able to be installed in the same area used by a conventional 8 outlet system The FCS is designed as a fully bolted non withdrawable installation whilst still minimising downtime by providing fast and easy removal of the cassette protection components Figure 3 2 Ampcontrol Fixed Cassette System FCS Ampcontro
63. modified as follows 1 The primary instantaneous short circuit trip level is double the selected value therefore so it covers a range of 3 0 to 25 times full load current 2 Asecond time delayed short circuit element becomes active This element operates at the selected Short Circuit Trip Level but the trip time is the selected primary trip time plus 60ms There is a separate SC LT trip bit LT for long time amp event log to differentiate each of the short circuit elements This modified functionality allows the short circuit protection to be set just above the locked rotor current level without risking spurious trips due to initial transient offsets which can effectively double the initial inrush peak current The Short Circuit Output Relay setting is used to control which trip action a short circuit trip the trip can be directed to either the CBR preferred or the MCR WARNING 4 The circuit interrupting device tripped by the selected output relay for 62 the Short Circuit function MUST be rated to interrupt the full 1 prospective system short circuit current If the Short Circuit Output Relay setting is set to CBR when a short circuit trip occurs the circuit breaker is opened and the main contactor left closed for one second to allow the circuit breaker time to clear the fault Any other trips or control actions to open the contactor during this time except for earth leakage will be blocked
64. n run mode External open protection activates in approximately 1sec 7 4 5 Coil Voltage Detection Table 15 Protection Module Coil Voltage Detection Trip Characteristics Parameter Action Power Cycle 5 Reset Automatic Trip Actions Open Breaker Prevent Contactor from closing Active Period Always Logging Only logged if it results in the Protection Module stopping a running outlet Parameters No parameters Monitoring Coil voltage status bit The coil voltage is internally detected by sensing the voltage across terminals 12 amp 13 COIL SUPPLY 1 amp COIL SUPPLY 2 This additional functionality is provided so in the event of the Contactor coil voltage being lost while the outlet is running a nuisance Main Contactor Failure trip does not occur as the changing of state for the Main Contactor can be explained by the loss of coil voltage 7 4 6 MCF Latch AS NZS 4871 1 Clause 2 6 3 6 requires contactor related trips to be reset only by an authorised person To this end it is deemed that physical access inside the switchgear enclosure would be required to perform the relevant checks and as such the Main Contactor Failure reset is a push button on the Protection Module All trips bits that feed into the Main Contactor Failure Flag are individually logged in the Protection Module for event analysis in the instance of a Circuit Breaker Trip Ampcontrol Pty Ltd
65. n test can also be disabled via parameter settings e If the insulation test passes the start sequence moves to the closing state and the MCR output will be closed e Protection Module now waits for the MCI digital input to close This auxiliary feedback from the signal confirms that the main contactor has closed If the MCI does not follow the MCR within five seconds a close fail trip will occur and the start sequence will be cancelled e If the MCI digital input closes the Protection Module moves from the start sequence to the running state It will continue in the running state with the outlet closed until a stop command is received or any protection function trips e any point during the start sequence a stop command is received a protection function trips the start sequence is immediately cancelled and the MCR or CBR if appropriate output will be opened 6 2 Control of Resets All trip resets in the Protection Module are handled by positive edge reset signal events In this way continually driven reset signals will not reset faults Most trips are reset with a general reset Some trips have a dedicated reset to allow selective control of the reset functions and to provide a level of authority associated with resetting faults The trips that require additional reset commands include the Earth Leakage Thermal Memory for motor overload protection and Short Circuit Main Contactor Failure events generate a trip that
66. o diode mode the remote start function uses a 1000 series start resistor When remote start is enabled the PLC will not be able to initiate a start Insulation Test Trip Level Selects the trip level for or disables the automatic insulation test Under Voltage Trip Level Selects the trip level for or disables under voltage protection Back EMF Time Selects the back EMF timer period which inhibits loss of vacuum detection after the outlet is opened Ampcontrol Pty Ltd ABN 28 000 915 542 OCS USER MANUAL MAG 182 Version 2 AUG 15 6 6 Time and Date The time and date are used only to time stamp the events in the log which are recorded sequentially regardless of the time and date The time and date are not used for any control functions 6 7 Cassette Isolation amp Earthing OCS Only Through the use of remotely controlled actuators the OCS allows individual Outlet Cassettes to be moved between the service and earth positions This provides both a break between the outlet phase conductors and the incoming supply as well as visual earthing of the outlet cable without the requirement of a separate earthing outlet Each Cassette houses the line and load contacts vacuum contactor three current transformers and the Protection Module The cassette is driven between the service and earth positions by an electrically driven actuator When in the service position the cassette is connecte
67. on Module CCM in the Protection Module is disconnected Failure to do so may damage the Protection Module 10 3 Disposal ENVIRO The electronic equipment discussed in this manual must not be treated as general waste By ensuring that this product is disposed of e correctly you will be helping to prevent potentially negative Y consequences for the environment which could otherwise be caused by incorrect waste handling of this product Ampcontrol Pty Ltd ABN 28 000 915 542 OCS USER MANUAL 182 Version 2 AUG 15 11 SPECIFICATIONS 11 1 Cassette Specifications General Nominal System Voltage Up to 3 3kV Continuous Current Rating Up to 500A Thermal Protection Relay Outlet Cassette Protection Module Plug In Capability Yes 11 2 Protection Module Specifications 1 5 Parameters Combined Phase and Pilot RDX Port RTX Uo 28 0V Uo 17 3V Ui 28 0V lo 322mA lo 756mA Ci 18 8nF Po 2 25W Po 3 09W Li nil Co 3 721 Co 9 05 Ci 18 8nF Lo 816 Lo 4 5mH L R 134uH Ohm General Temperature Range 0 C lt lt 60 C Auxiliary Supply Voltage 24 VDC 20 30 W Sys Phase Phase Voltage 1100V 2095 3 3kV 20 Contact Ratings 110VAC 20 1000VA Power Factor 0 4 AS NZS2081 2011 Protection Functions Earth Leakage 100mA 150 200 250mA 300mA 350mA 400
68. ontrol Pty Ltd ABN 28 000 915 542 OCS USER MANUAL eas NTROL MAG 182 Version 2 AUG 15 gt Event ID String Description 35 Unknown Restart The system has powered up but cannot work out if Status the system powered down cleanly or if it had a restart 36 Short Circuit Trip Reset A short circuit trip was reset 37 Earth Leakage Trip An earth leakage trip was reset Reset 38 Fatal Clock Error The clock time was not able to be read from the Real Time Chip 39 MCF Battery Under The Battery which stores the Main Contactor Failure Voltage state and powers the Battery Back Ram is under Voltage eg the battery has reached the end of its life 40 Control Mask Changed Notes that the value of the control mask has been changed eg Test Relay has been closed Data stores the old mask value Data2 stores the new mask value 41 Invalid CCM Logs the fact an invalid CCM was attached to the Protection Module This is the logged version of a CCM ID trip 42 Internal Logic Error An Error has occurred in the operation of the code within the Protection Module The log is used to denote that the stack has grown too big or that the system has run out of RAM In normal operation neither of these things should occur 43 PTC Trip The outlet was stopped due to the RTX s PTC input exceeding its trip resistance level 44 RTX RTD Group 1 Trip The outlet was stopped due to one of the RTD inputs within group 1 going above the set
69. prevent incorrect or unsafe operation of the OCS or the system into which it is installed Along with relevant competence and an understanding of the target application the following points should be considered 4 1 1 Ensure that the information provided in this user manual is fully understood It is extremely important that the limitations and functionality of the OCS are understood to prevent incorrect installation and use from creating a potentially dangerous risk If in doubt as to the nature of the limitations or their implication refer to the installation s safety dossier or consult a competent authority such as a supervisor or Ampcontrol technical representative 4 1 2 Ensure that the application into which the OCS 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 choice of instrumentation logic solvers and actuators needed to implement the system Understanding the needs of the system will ensure proper selection of equipment 4 1 3 Ensure that the OCS will properly perform the required functions within the system design It is important to understand how the OCS is intended to interact with other equipment within a system For safe and reliable use it is c
70. rent reading needs to be above the trip level before the Protection Module trips Over Current Curve Selects if the over current protection will use one of the inverse current time curves or thermal motor protection curve This selection also impacts the short circuit functionality Over Current Time Multiplier TMS Determines the trip time characteristic for Over Current Motor Overload Over Load Cooling Multiplier Defines the cooling output of the thermal model when thermal motor protection is selected Over Load Start Block Level The thermal accumulator must be below this value to allow an outlet start Current Balance Trip Level Selects the trip level for or disables current balance protection Under Current Trip Level Selects the trip level for or disables under current protection Earth Leakage Trip Level Selects the trip level for earth leakage protection Earth Leakage Trip Time Selects the maximum trip time for earth leakage protection Earth Continuity Trip Level Selects the nominal series earth continuity trip level Earth Continuity Trip Time Selects the maximum trip time for both series and shunt earth continuity protection Earth Continuity Latch Selects whether earth continuity trips are latch requiring general reset or automatically reset when healthy Remote Start Enables remote start of the outlet via the pilot signal When the pilot is set t
71. rt Circuit protection by carrying out secondary primary injection on the CT inputs of the Cassette Protection Module Inject a current value relevant to the settings employed into one of the CT terminals and ensure that all relevant tripping circuits operate successfully in the time expected and that latched trips may be reset in the appropriate manner Repeat on the other CT terminals 5 7 Main Contactor Fail While the Cassette Protection Module is stopped that is the MCR output is open apply a voltage on the load side of the contactor The voltage must be greater than the selected trip level Ensure that a CBR trip is initiated by the Cassette Protection Module NOTE 4 Main Contactor Fail MCF trip can only be reset by pressing the MCF Reset Pushbutton on the front of the Outlet Cassette s Protection Module While the Cassette Protection Module is stopped close the MCI digital input Ensure that a CBR trip is initiated by the Cassette Protection Module 5 8 Voltage Measurement Validate the voltage measurement function of the Cassette Protection Module by checking the measured voltages via the PLC when the main contactor is closed 5 9 RTX Validate the correct operation of the RTX by making changes to load parameters moving the machine to a different outlet and ensuring that the correct settings are available on the new outlet Ampcontrol Pty Ltd ABN 28 000 915 542 OCS USER MANUAL
72. rucial that neither the OCS s logical operation nor its signalling be compromised by incompatibilities with connected equipment 4 1 4 Modifications of any form to the OCS are prohibited The OCS as supplied has been designed and manufactured to comply with the requirements of protection standards If modifications of any form are made to the OCS the equipment may no longer be fit for purpose If any modifications or damage to the OCS is evident do not use the equipment and contact Ampcontrol for advice AMPCONTROL Ampcontrol Pty Ltd ABN 28 000 915 542 7 OCS USER MANUAL MAG 182 Version 2 AUG 15 4 2 Mandatory Installation Practices The following information must be adhered to when installing the OCS Failure to adhere to this information may give rise to unsafe operation Using the OCS in a manner that exceeds its electrical functional or physical specifications or in a way that is contrary to its operating restrictions may create risks to personnel and or equipment resulting in injury or death The OCS is to be installed in an electrical system having a fault level equal to or less than as marked on the name plate The OCS s control supply must remain within the specified voltage range The installation of the OCS must be carried out by suitably trained and qualified personnel Identification labels fixed to the OCS must not be damaged removed or covered The installation is to be in accordance with the rele
73. t Block Level 20 30 40 50 60 70 80 90 we Ampcontrol Pty Ltd ABN 28 000 915 542 OCS USER MANUAL 182 Version 2 AUG 15 Current Related Functions Short Circuit Protection 1 5x to 12 5x in 0 25x increments in OC mode 3 0x to 25x when in MOL mode with addition slower trip element at Trip Settings 1 5x to 12 5x Multiples of Full Load Current Trip occurs at the level determined by selected Full Load Current x SC Level or 6 kA whichever is lesser 40ms 60ms 80ms 100ms 120ms 140ms 160ms 180ms 200ms All me times are 15ms Current Monitoring 0 Disabled 30 35 40 45 50 55 60 65 70 75 80 85 90 95 Current Balance 5 10 20 50 OFF Under Current Other Protection Functions Trip Settings Off 40 50 60 70 75 80 85 90 95 12 EQUIPMENT LIST Part Number Description 174431 OCS Cassette c w Protection Module 159325 Outlet Cassette Protection Module Spare Part 160292 Outlet Cassette Remote Termination Unit RTX 101649 Earth Leakage Toroid EL500 60 100T 500mA 60mmID 101650 Earth Leakage Toroid EL500 85 100T 500mA 85mmID 101654 Earth Leakage Toroid EL500 112 100T 50mA 112mmlD 2 Ampcontrol Pty Ltd 28 000 915 542 OCS USER MANUAL 182 Version 2 AUG 15 APPENDIX A PROTECTIO
74. th the IPX Integrated Protective Relay System IPX INTEGRATED PROTECTION RELAY IPXAD003Sheets 1 amp 2012114 CERTIFICATION MECHANICAL DETAILS 2 MEM Top PCB Caen amp 201 241 30 CCM PCB B 003Sheets 1 20124149 to 3 7 i1 20121730 PRENNE 0015 IPX RTXIS Board IPXE 011 201 21141923 IPX 1 5 System Diagram IPXE O14 1 201241 1923 Eee mamme RR Indicates Drawings Associated with the RTX Module Covered by EXTR AU ExTRITA 13 0001 00 2 Ampcontrol Pty Ltd ABN 28 000 915 542 OCS USER MANUAL 182 Version 2 AUG 15 ATTACHMENT To IECEx CERTIFICATE IECEx ITA 12 0032 Page 1 of 3 a This Attachment forms an Integral Part of the IECEx Certificate and all pages MUST be presented and read whenever the IECEx ITA 12 0032X Certificate is presented Special Conditions and Additional Information concerning the Ampcontrol IPX Integrated Protection Relay System Special Conditions amp System The following conditions of safe use must be applied in any installation 1 Location of Apparatus The IPX system comprises of an IPX Integrated Protection Relay Type IPX located in a non hazardous safe area and a RTX module also located in a non hazardous safe area and installed in strict accordance with the manufacturer s instructions The inter
75. the pilot conductor Ensure that all relevant tripping circuits operate successfully and that latched trips may be reset in the appropriate manner Repeat with a short circuit between pilot and earth These tests can be facilitated using earth continuity test relays built into the Cassette Protection Module These relays are controlled using the Cassette Protection Module s communications interface 5 4 Insulation Test High Voltage If the Earth Fault Lockout and Earth Continuity tests are successful check that an automatic HV insulation test is initiated by the Cassette Protection Module when the module is started WARNING 4 During this test the Cassette Protection Module will generate to 2700VDC from the 24 VDC input supply and apply this voltage to the 1 phase conductors Ampcontrol Pty Ltd ABN 28 000 915 542 OCS USER MANUAL 182 Version 2 AUG 15 5 5 Over Current Motor Overload Current Injection Test the Over Current Motor Overload protection by carrying out secondary primary injection on the CT inputs of the Cassette Protection Module Inject 2x Full Load Current FLC into one of the CT terminals and ensure that all relevant tripping circuits operate successfully in the time expected according to the settings employed and that latched trips may be reset in the appropriate manner Repeat on the other CT terminals 5 6 Short Circuit Current Injection Test the Sho
76. tically reset once the pilot earth loop is healthy 7 2 1 Pilot Series Table 7 Protection Module Earth Continuity Series Trip Characteristics Parameter Action Power Cycle Trip status maintained Requires a general reset after the trip condition has cleared Reset Alternatively the trip can be automatically reset depending on the status of the EC Latch parameter Trip Actions Open Main Contactor Prevent Main Contactor from closing Active Period Always active Logging Logged only if outlet is running Trip time Parameters Trip level Trip latch enable Monitoring Available as the raw ohms measurement resolution of 10 7 2 2 Pilot Shunt Table 8 Protection Module Earth Continuity Shunt Trip Characteristics Parameter Action Power Cycle Trip status maintained Requires a general reset after the trip condition has cleared Reset Alternatively the trip can be automatically reset depending on the status of the EC Latch parameter Trip Actions Open Main Contactor Prevent Main Contactor from closing Active Period Always active Logging Always logged Parameters Trip time Trip latch enable Monitoring Available as the raw ohms measurement resolution of 1000 Ampcontrol Pty Ltd ABN 28 000 915 542 OCS USER MANUAL 182 Version 2 AUG 15 7 2 3 Pilot Remote Start Remote start mode can be us
77. tion Module Over Current Trip Characteristics Parameter Action Power Cycle Reset Requires a general reset and all three measured phase currents must be below the 100 Open Main Contactor Prevent Main Contactor from closing Trip Actions Block restart if the thermal accumulator is not below the selected start block level Active Period When Over Current curve is set to Very Inverse or Extremely Inverse Logging Always Time Multiplier Full Load Current Monitoring Phase currents displayed as a percentage of selected full load current Thermal Accumulator TAC Ampcontrol Pty Ltd ABN 28 000 915 542 OCS USER MANUAL MAG 182 Version 2 AUG 15 The three phase currents are compared and the highest current is used to determine the trip time If the current exceeds the selected full load current an overcurrent trip accumulator TAC increases at a rate determined by the above function If the over current condition persists so that the trip accumulator reaches 10096 then a trip occurs If viewed during start up the trip accumulator can help determine if the over current settings are correct The Overcurrent curves provided are as follows 1 Very Inverse as per IEC 60255 151 B Curve The trip time and reset time in seconds for current follows the characteristic defined by 1 TMS 25 0 TMS gt 2 Extremely Inverse as IEC
78. tor switching thermistor These terminals are protected in a similar manner to the stop and start circuits If the remote start stop and PTC functions are not required each set of terminals must be bridged in order to start the Protection Module Five RTD inputs are provided for PT100 RTDs These terminals can also be used with resistor networks to provide digital information back to the Cassette Protection Module A parameter dongle allows an RTX to be replaced without needing to re program the parameters When installed this dongle should be firmly secured to the machine equipment Figure 4 4 Remote Termination Unit RTX 4 5 3 Parameter Dongle Parameters important to the running of the Protection Module and the safe operating of the outlet onto which it is connected are stored in the Protection Module Parameter Dongle The Parameter dongle is exchangeable between Protection Modules but it is intended to be physically tethered to the outlet that it controls Although the Protection Module and the RTX use the same hardware parameter dongle the parameters they store are different As such the parameter dongle is not interchangeable between the Protection Module and RTX Ampcontrol Pty Ltd ABN 28 000 915 542 OCS USER MANUAL MAG 182 Version 2 AUG 15 5 COMMISSIONING AND CALIBRATION Prior to being put into service the electrical protection system must be correctly commissioned This manu
79. trip level 45 RTX RTD Group 2 Trip The outlet was stopped due to one of the RTD inputs within group 2 going above the set trip level 46 Short Circuit LT Trip Short Circuit Long Time tripped 128 218 Parameter Modified To work out which parameter was modified minus 128 from the Event ID eg 130 means parameter 2 was modified Outlet parameters are numbered 0 29 Dongle Load parameters are numbered 30 59 and RTX Load parameters are numbered 60 89 The value which was changed from is stored in Data1 and the new value is in Data2 Ampcontrol Pty Ltd ABN 28 000 915 542 OCS USER MANUAL MAG 182 Version 2 AUG 15 6 5 Protection Module Parameters There are two distinct groups of parameters 6 5 1 Outlet Parameters Outlet Parameters relate to the particular outlet Protection Module Examples include the pilot mode outlet number and network settings These are always stored in the Parameter Dongle Table 3 Outlet Parameter Descriptions Name Description IP Address Byte 1 IP Address Byte 2 IP Address Byte 3 IP Address Byte 4 IP address for Ethernet communications with the PLC Subnet mask Byte 1 Subnet mask Byte 2 Subnet mask for Ethernet communications with the PLC Subnet mask Byte 3 Subnet mask Byte 4 Gateway Address Byte 1 Gateway Address Byte 2 Gateway address for Ethernet communications with the PLC Gateway Address Byte 3
80. ts of the AS NZS 2081 2001 standard This protection functions are e Earth Leakage e Earth Continuity e Earth Fault Lockout e Main Contactor Fail 7 1 Earth Leakage 7 1 1 Trip Characteristics Table 5 Protection Module Earth Leakage Trip Characteristics Parameter Action Power Cycle Trip status maintained Reset Requires an earth leakage reset after the trip condition has cleared Trip Actions Open Main Prevent Main Contactor from closing Active Period Always active Logging Always logged Parameters Trip dii Trip Time Monitoring Earth Leakage current displayed as 0 150 of selected trip level 7 1 2 Operation Summary The earth leakage protection function uses an Ampcontrol EL500 series toroid to measure the earth fault current This function is tested to AS NZS 2081 2011 A definite time operating characteristic is provided with adjustable trip sensitivity and an adjustable time delay NOTE Due to size restrictions and the coupling issues related with elongated La current transformers the Ampcontrol EL500 series earth leakage toroid KS is not integral to the Cassette and must be purchased separately When a fault occurs such that the trip level and time delays are exceeded a trip occurs The trip acts in the Main Contactor Relay MCR logic and is latched An earth leakage trip is considered a special fault and requires a specific reset function to be cleared The leakage
81. urrents displayed in Amps Under current protection monitors all three phase currents If any phase drop below the selected threshold the trip timer start counting The under current protection will trip after any phase current is below the threshold for 4 second Ampcontrol Pty Ltd 28 000 915 542 OCS USER MANUAL 182 Version 2 AUG 15 9 OTHER PROTECTION FUNCTIONS 9 1 Under Voltage Table 21 Protection Module Under Voltage Trip Characteristics Parameter Action Power Cycle Reset Automatic Active Period When outlet is running Logging Only if outlet is running Parameters Trip Level Monitoring Phase voltage displayed in Volts 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 voltage for 800ms then the outlet is stopped Ampcontrol Pty Ltd ABN 28 000 915 542 OCS USER MANUAL MAG 182 Version 2 AUG 15 10 SERVICE MAINTENANCE amp DISPOSAL 10 1 Equipment Service A number of external system based checks should be completed on a regular basis These routine inspections must be carried out by suitably trained people with knowledge of the OCS and the systems into which it is fitted Routine inspections may take the form of either visual only checks or v
82. vant installation Standards Codes of Practice Modifications must not be made to any part of the OCS 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 maintained as per the conditions as listed in the certification documentation NOTE If the OCS is to be used in a hazardous environment it must be installed within suitably certified flameproof enclosure The equipment is to be operated within an ambient temperature range of 20 C to 40 C Ampcontrol Pty Ltd ABN 28 000 915 542 OCS USER MANUAL MAG 182 Version 2 AUG 15 4 3 Mechanical Arrangement 4 3 1 OCS Dimensions The OCS is available in two sizes the 2 Way OCS and the 3 Way OCS These modules are designed to be stacked on top of each other allowing the best utilisation of the installation area 509 Figure 4 2 3 Way OCS Dimensions Pictured with 3 Cassettes Installed ao M Ampcontrol Pty Ltd ABN 28 000 915 542 OCS USER MANUAL NTHO MAG 182 Version 2 AUG 15 4 3 2 FCS Dimensions The FCS has a very high outlet density allowing more outlets to be installed with a smaller footprint 1160 Figure 4 3 FCS Dimensions Pictured with 5 Cassettes Installed 4 4 Electrical Install
83. while in run mode 19 RTX Parameter Error There was an error with the RTX parameter dongle 20 Shunt Earth Continuity The resistance of the pilot to earth was less that the Trip trip level 21 Thermal Memory Reset The thermal memory was overridden by user intervention amp reset to zero 22 RTX Stop The RTX stop input was activated causing an outlet stop 23 RTX Offline The RTX went offline causing an outlet trip 24 Insulation Trip The pre start high voltage insulation test failed 25 RTX Comms Timeout RTX is online but there was repeated data corruption 26 Power Up The system has powered up after a clean power down 27 Under Voltage Trip The phase voltage dropped below the trip level causing the outlet to drop out of run mode 28 Stopped General log denoting when the system completed the request to drop out of run mode 29 No Coil Voltage Trip Logs when a No Coil Supply trip occurred 30 CT Detection Error The earth leakage system could not detect an adequate toroid connection 31 Remote Start Stuck The remote start button was detected to be closed for longer that the trip limit 32 PLC Comms Timeout The PLC failed to provide heart beat 33 Start Disabled The Protection Module was disabled by the PLC 34 Earth Fault Lockout The resistance measured between the phases and Trip earth during an intrinsically safe EFLO test was below the set level Ampc

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