Ampcontrol IKDV01 User manual

IKDV01 KEYPAD PUSH BUTTON SYSTEM
User Manual
Issue: R4 Mar 2020
ECN: 9436
Ampcontrol User Manual Part No: 110910
Designed and Manufactured in Australia by Ampcontrol CSM Pty Limited.

IKDV01 Keypad Push Button System
Issue: R4 Date: 03/2020, ECN: 9436
IKDB003 R4 IKD Keypad Pushbutton System User Manual.docx
Page 1
Safety and other Warnings
WARNING!
This safety alert symbol identifies important safety messages in this manual and
indicates a potential risk of injury or even death to the personnel. When you see
this symbol, be alert, your safety is involved, carefully read the message that
follows, and inform other operators.
CAUTION!
This safety alert symbol identifies important information to be read in order to ensure
the correct sequence of work and to avoid damage or even destruction of the
equipment, and reduce any potential risk of injury or death to the personnel.
Supplementary information not directly affecting safety or damage to equipment. Carefully
read the message that follows, and inform other relevant personnel.
Information concerning possible impact on the environment and actions required for
prevention and proper response.
If this document is being read via a computer the hyper links may be used (Press control and click on the blue
highlighted text to go to that topic).

IKDV01 Keypad Push Button System
Issue: R4 Date: 03/2020, ECN: 9436
IKDB003 R4 IKD Keypad Pushbutton System User Manual.docx
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Copyright Notice
No part of this publication may be reproduced, transmitted or transcribed into any language by any means without
the express written permission of Ampcontrol CSM Pty Ltd, 7 Billbrooke Close, Cameron Park. NSW 2285,
Australia.
Disclaimer
Ampcontrol CSM Pty Ltd will make no warranties as to the contents of this documentation and specifically disclaims
any implied warranties or fitness for any particular purpose.
Ampcontrol further reserves the right to alter the specification of the system and/or manual without obligation to notify
any person or organisation of these changes.
Before You Begin
We would like to take a moment to thank you for purchasing the IKDV01 Keypad Push Button System.
Ampcontrol Electronics Contact details:
Ampcontrol CSM Pty Ltd
7 Billbrooke Close, Cameron Park, NSW, 2285
P [phone] | F [phone]
EMAIL: [e-mail]
WEB: www.ampcontrolgroup.com
WARNING!
To ensure the correct and safe operation of this equipment the user is to
become completely familiar with the safety requirements and correct
operating procedures detailed in this user manual.

IKDV01 Keypad Push Button System
Issue: R4 Date: 03/2020, ECN: 9436
IKDB003 R4 IKD Keypad Pushbutton System User Manual.docx
Page 3
Table of Contents:
Safety and other Warnings............................................................................................................................................ 1
Copyright Notice............................................................................................................................................................ 2
Disclaimer...................................................................................................................................................................... 2
Before You Begin .......................................................................................................................................................... 2
Ampcontrol Electronics Contact details: ........................................................................................................................ 2
1Receiving and Storage......................................................................................................................................... 4
1.1 Receiving ........................................................................................................................................................ 4
1.2 Storage after Delivery ..................................................................................................................................... 4
1.3 Unpacking of Equipment ................................................................................................................................. 4
2General Safety..................................................................................................................................................... 5
2.1 Personnel Safety Warnings............................................................................................................................. 5
2.1.1Relevant Personnel............................................................................................................................. 5
2.1.2 Safety Communication ........................................................................................................................ 5
2.2 Safe Use of Equipment ................................................................................................................................... 5
2.2.1 Changes to Equipment........................................................................................................................ 5
2.2.2 Equipment Knowledge ........................................................................................................................ 5
2.3 Conditions of Conformity –IEC [Ex ia]............................................................................................................ 5
3Overview of the IKDV01 Keypad System............................................................................................................. 6
4Initial Power-up .................................................................................................................................................... 6
5Mode 1: Standard Operation................................................................................................................................ 7
5.1 Stop................................................................................................................................................................. 7
5.2 Start................................................................................................................................................................. 8
5.3 Lock................................................................................................................................................................. 8
5.4 Reset............................................................................................................................................................... 8
5.5 Earth Continuity (E/C) Test ............................................................................................................................. 8
5.6 Earth Fault Lockout (EFLO) Test .................................................................................................................... 8
5.7 Earth Leakage (E/L) Test ................................................................................................................................ 9
5.7.1 Switch 4 Settings:................................................................................................................................ 9
5.8 RL1.................................................................................................................................................................. 9
6Mode 2: PLC Control ........................................................................................................................................... 9
6.1 Description of Operation ............................................................................................................................... 10
7Specifications..................................................................................................................................................... 10
8Settings.............................................................................................................................................................. 10
8.1 Operation Mode Settings: ............................................................................................................................. 10
8.1.1 Mode 1 - Standard Operation............................................................................................................ 10
8.1.2 Mode 2 –PLC Control....................................................................................................................... 10
8.2 Earth Leakage Test Time Setting:................................................................................................................. 10
9Maintenance & Disposal .................................................................................................................................... 11
9.1 Equipment Maintenance ............................................................................................................................... 11
9.2 Disposal of System Parts.............................................................................................................................. 11
10 Part Numbers..................................................................................................................................................... 11
Appendix A –Drawings ............................................................................................................................................... 12
Appendix B –Approvals .............................................................................................................................................. 16

IKDV01 Keypad Push Button System
Issue: R4 Date: 03/2020, ECN: 9436
IKDB003 R4 IKD Keypad Pushbutton System User Manual.docx
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1 Receiving and Storage
1.1 Receiving
All possible precautions are taken to protect the equipment against damage or losses during shipment, however
before accepting delivery, check all items against the packing list or Bill of Lading. If there are shortages or evidence
of physical damage, notify Ampcontrol immediately.
Notify Ampcontrol within 7 days (maximum) in case of shortages or discrepancies, according to the packing list. This
action will help ensure a speedy resolution to any perceived problems. Keep a record of all claims and
correspondence. Photographs are recommended.
Where practicable do not remove protective covers prior to installation unless there are indications of damage.
Boxes opened for inspection and inventory should be carefully repacked to ensure protection of the contents or else
the parts should be packaged and stored in a safe place. Examine all packing boxes, wrappings and covers for
items attached to them, especially if the wrappings are to be discarded.
1.2 Storage after Delivery
Where 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 protected from the elements in a cool dry area. If storing on the ground,
ensure that the storage area is not an area where water will collect.
1.3 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.
Make sure that cable drums are securely attached to their shipping pallets before
attempting to move them (if applicable).
The disposal of packaging materials, replaced parts, or components must comply with
environmental restrictions without polluting the soil, air or water.
Ensure that any timber and cardboard used as packaging is disposed of in a safe and
environmentally responsible manner.
Where possible, dispose of all waste products i.e. oils, metals, plastic and rubber products
by using an approved recycling service centre.

IKDV01 Keypad Push Button System
Issue: R4 Date: 03/2020, ECN: 9436
IKDB003 R4 IKD Keypad Pushbutton System User Manual.docx
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2 General Safety
2.1 Personnel Safety Warnings
2.1.1 Relevant Personnel
Ensure all personnel directly responsible or involved with the installation, operation and maintenance of the
equipment reference this manual in conjunction with any relevant risk assessments to identify all foreseeable
hazards.
2.1.2 Safety Communication
All safety instructions and design requirements within this manual must be communicated to all users. These
requirements are necessary to identify and control any foreseeable risk associated with this piece of equipment. In
the event of any damage or malfunction that results in the potential to harm the health or safety of any person; the
owner/operator should notify the manufacturer immediately.
2.2 Safe Use of Equipment
Equipment supplied has been manufactured within the guide lines of the relevant Australian Standards and state
legislative requirements. Equipment identified within this manual has been designed for a specific intended purpose;
therefore any modification or damage must be reported to the manufacturer for repair.
The instructions within this manual must be observed as an aid towards achieving maximum safety during operation.
2.2.1 Changes to Equipment
Changes in the design and modifications to the equipment are not permitted
2.2.2 Equipment Knowledge
Experience with, or understanding of, this equipment is essential for the safe installation and removal of the
equipment. If in doubt, contact Ampcontrol immediately.
Mechanical and or Electrical installation, and maintenance of plant and equipment, must only be carried out by
appropriately trained, qualified and competent personnel.
2.3 Conditions of Conformity –IEC [Ex ia]
WARNING!
To comply with the Conditions of Certification, ensure full serviceable life of the product,
and avoid nullifying the warranty, it is essential to exercise great care with the
installation, use and storage of the System components. Failure to comply with the
Conditions of Certification (Appendix B –Approvals) may seriously compromise the
integrity of the system and/or its components, and the consequence can be fatal. The
user must ensure that the “Conditions of Safe Use” outlined in the certificate are met or
the certificate will not be valid.

IKDV01 Keypad Push Button System
Issue: R4 Date: 03/2020, ECN: 9436
IKDB003 R4 IKD Keypad Pushbutton System User Manual.docx
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3 Overview of the IKDV01 Keypad System
The Ampcontrol IKDV01 Keypad Push Button System is used in conjunction with the Ampcontrol range of Integrated
Protection Relays. The Keypad is approved to Ex ia Intrinsic Safety Standards so that it can be installed outside the
flameproof enclosure.
The use of the IS Keypad System eliminates the conventional flameproof buttons normally used on a Distribution
Control Box (DCB).
A faulty keypad can be changed out at the face, whereas a damaged flameproof actuator requires the DCB to be
removed from service for repairs.
CAUTION!
The user is responsible for assisting in the maintenance of the Ex ia Intrinsic Safety rating by
complying with the “Conditions of Safe Use” outlined in the certificate (Appendix B –
Approvals).
The keypad module consist of eight (8) push button keys, each fitted with acknowledge LEDs and associated
electronics.
The keypad module is connected to the IKDV01 Interface Module by a three-wire cable. The keypad module
receives power and communicates with the IKDV01 Interface via this cable. The setting of DIP Switches 2 and 3 will
configure the Interface Module for Standard Operation (See Mode 1 in Section 5) or PLC Control (See Mode 2 in
Section 6).
When a keypad key is operated the corresponding relay or opto-isolated output in the IKDV01 Interface Module
responds and activates its output.
A typical basic system is shown in Drawing IKDB001 in Appendix A –Drawings.
4 Initial Power-up
When power is applied to the IKDV01 Interface Module, the outputs remain off until communications with the keypad
is healthy and the Stop key has been pressed (only applies when Mode 1 is selected).
When power is first applied to the keypad (via the IKDV01 Interface) all LEDs on the push button keys will flash
simultaneously until communication is established. This flashing may continue if wiring to the keypad is faulty or the
Interface Module itself is faulty.

IKDV01 Keypad Push Button System
Issue: R4 Date: 03/2020, ECN: 9436
IKDB003 R4 IKD Keypad Pushbutton System User Manual.docx
Page 7
5 Mode 1: Standard Operation
To set the Interface for Standard operation set DIP Switch 2 OFF and Dip Switch 3 ON. The switches are located on
the IKDV01 Interface Module, see Drawing IKDA003in Appendix A –Drawings.
Standard IKD IS Keypad
5.1 Stop
Activation of the Stop key causes the Stop opto-isolated output to turn on. This output is connected to the stop input
(terminals 19 and 20) on the Integrated Protection Relay.
The Stop key also activates the stop relay output. The relay output is a normally open contact on an internal relay
and is normally directly connected in the main control circuit. The contact closes when the keypad and interface are
powered up. The contact will open if the Stop key is pressed.
To ensure the Stop key is functioning correctly, a special test function has been attached to this key. When power is
first applied to the system the stop LED on the IS Keypad flashes continuously. The Stop outputs on the IKDV01
Interface Module are held in an off state. This condition (indicated by the flashing stop LED) will remain until the Stop
key is pressed.
Once the Stop key is pressed, the Keypad and Interface Module go into the normal operating mode.

IKDV01 Keypad Push Button System
Issue: R4 Date: 03/2020, ECN: 9436
IKDB003 R4 IKD Keypad Pushbutton System User Manual.docx
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To add further safety to the Keypad / Interface system, a “watchdog timer”, continually tries to open the stop relay
output contact. If the keypad system is functioning correctly, the timer is being continually reset and the output
remains closed.
CAUTION!
To enable the additional safety feature of the “watchdog timer” to be fully utilised it is
important that the stop relay output contact be used in the control circuit.
5.2 Start
When the Start key is pressed the Start opto-isolated output turns on. This output is connected to the start input
(terminals 25 and 26) on the Integrated Protection Relay. This function is ignored unless the stop key has been
operated following power up.
5.3 Lock
Before the Lock key is operative the I.S. Digital Input must be closed to allow the lock key to function. The I.S. Digital
Input (located on the rear of the Keypad Module) is intended to be connected to a push button which is either locked
or behind a lockable cover, to prevent unauthorised operation.
Operation of the Lock key causes the lock opto-isolated output to turn on. This output is connected to the lock input
(terminals 21 and 22) on the Integrated Protection Relay.
5.4 Reset
Operation of the Reset key causes the reset opto-isolated output to turn on. This output is connected to the reset
input (terminals 23 and 24) on the Integrated Protection Relay.
5.5 Earth Continuity (E/C) Test
Operation of the E/C Test key triggers the test operation contacts, which are connected into the pilot circuit.
The test alternates between an open circuit and a short circuit on the pilot line. The alternations occur every 2
seconds. This can be observed by viewing the Earth Fault Information Pages on the Remote Display Unit of the
Integrated Protection Relay.
If the Stop key is pressed simultaneously with the E/C Test key, a diode is switched between the pilot and earth to
perform a “Relay Healthy” test. This allows the operator to determine if the fault is in the DCB or in the external
circuit.
When this test is performed the Stop relay remains off for 1.5 seconds after the E/C Test key is released.
5.6 Earth Fault Lockout (EFLO) Test
Operation of the EFLO Test key allows external test resistors to be switched between VcmA, VcmB, and VcmC
terminals (3, 4 and 5 on the Integrated Protection Relay) and earth.
To perform this test the Start key must be operated while holding the EFLO Test key operated.

IKDV01 Keypad Push Button System
Issue: R4 Date: 03/2020, ECN: 9436
IKDB003 R4 IKD Keypad Pushbutton System User Manual.docx
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5.7 Earth Leakage (E/L) Test
This test is to be performed with the outlet of the equipment energised to test the integrity of the trip circuitry.
Operation of the E/L Test key operates the internal E/L Test relay, which closes the output contact. The relay is
intended to be used to apply a test current through the earth leakage toroid. One side of the E/L Test relay output is
connected to the 110 Volt AC supply. This can be used as the injection source or can be used to operate an
auxiliary relay.
The relay contact closes for 150 ms or 600 ms, depending on the setting of DIP switch 4. This switch is located on
the IKDV01 Interface Module. See Drawing IKDA003 in Appendix A –Drawings.
5.7.1 Switch 4 Settings:
Off = 150 ms
On = 600 ms
The 150 ms selection should be used for testing earth leakage relays that provide primary protection.
5.8 RL1
Operation of the RL1 key operates the internal RL1 relay, which closes the output contact.
6 Mode 2: PLC Control
To set the Interface for PLC Control set DIP Switch 2 ON and Dip Switch 3 OFF. The switches are located on the
IKDV01 Interface Module. See Drawing IKDA003in Appendix A –Drawings.
When the IKDV01 Interface Module has been set to Mode 2 the Programmable Logic Controller controls the outlet of
the DCB. The main differences to the Standard Operation are as follows:
1. No stop reset is required on power up
2. Operation of the Start key causes RL1 output to close (while key is closed)
3. Operation of RL1 Key has no action
4. Start opto-output is disabled