Ampcontrol HPB User manual

Version: 9, March/2020
PN: 117829
Designed and manufactured in Australia by Ampcontrol Pty Ltd
HPB
IntegratedProtectionRelay
UserManual

Ampcontrol Pty Ltd –ABN 28 000 915 542
HPB USER MANUAL
HPBB012 Version 9 –March/2020
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WARNING!
The warning symbol highlights a potential risk of injury or death.
Please share these warnings with other operators.
CAUTION!
The caution symbol highlights a potential risk of damage to
equipment.
Please share these cautions with other operators.
NOTE
The note symbol highlights key information.
Please share these notes with other operators.
ENVIRO
The enviro (environmental) symbol highlights areas which may have an
impact on the surrounding fauna and/or flora.

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Copyright Notice
The Ampcontrol HPB 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 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 HPB.
WARNING!
In the interests of safety and correct equipment operation, please
take the time to read and understand the content in this manual.
Ampcontrol Contact Details
7 Billbrooke Close, Cameron Park, NSW, 2285
P [phone] | F [phone]
EMAIL: [e-mail]
WEB: ampcontrolgroup.com

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TABLE OF CONTENTS
1 SAFETY AND OTHER WARNINGS..................................................................7
1.1 Safe Use of Equipment..............................................................................7
2 RECEIVING AND STORAGE............................................................................8
2.1 Receiving...................................................................................................8
2.2 Inspection..................................................................................................8
2.3 Storage after Delivery................................................................................8
2.4 Unpacking of Equipment............................................................................8
3 PRODUCT OVERVIEW ....................................................................................9
3.1 Introduction................................................................................................9
3.2 Remote Display Module (HDM) ...............................................................10
4 INSTALLATION...............................................................................................12
4.1 General Warnings....................................................................................12
4.2 Mandatory Installation Practices ..............................................................12
4.3 Installation and Wiring Instructions...........................................................13
5 MACHINE COMMUNICATION........................................................................17
5.1 HPB Termination Unit (HTU)....................................................................17
5.2 Machine Type Codes...............................................................................17
5.3 Machine Number .....................................................................................18
5.4 Receiver Sensitivity .................................................................................18
6 EARTH PROTECTION FUNCTIONS..............................................................19
6.1 Earth Leakage .........................................................................................19
6.2 Earth Fault Lockout..................................................................................19
6.3 Earth Continuity.......................................................................................20
7 CURRENT RELATED FUNCTIONS................................................................23
7.1 Basic Over-Current Protection.................................................................23
7.2 Over-Current Characteristic.....................................................................23
7.3 Short Circuit.............................................................................................24
7.4 Phase Current Balance............................................................................24
8 VOLTAGE RELATED FUNCTIONS ................................................................25
8.1 Main Contactor Fail Protection.................................................................25
8.2 Under Voltage Trip...................................................................................25
8.3 Voltage Metering......................................................................................25
9 USER ADJUSTABLE SETTINGS....................................................................26
9.1 Parameter Groups...................................................................................26
9.2 Changing Settings ...................................................................................27
10 SYSTEM CONTROL.....................................................................................28

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10.1 Digital Inputs..........................................................................................28
10.2 Output Relays........................................................................................28
10.3 Open Collector Outputs .........................................................................28
10.4 Outlet Control.........................................................................................28
10.5 Operational Sequence...........................................................................28
11 EVENT LOG..................................................................................................29
12 TIME & DATE................................................................................................31
13 REMOTE DATA COMMUNICATIONS ..........................................................32
14 SPECIFICATIONS ........................................................................................33
15 EQUIPMENT LIST ........................................................................................35
16 TROUBLESHOOTING ..................................................................................36
16.1 Pilot Fault Finding Information ...............................................................38
APPENDIX A: DRAWINGS................................................................................40
APPENDIX B: APPROVALS..............................................................................59

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TABLE OF FIGURES
Figure 16-1: HPB - Pilot –Resistor & HTU Mode ...................................................................................39
TABLE OF TABLES
Table 1: HPB Display Messages ............................................................................................................10
Table 2: HPB Error Status Indicator........................................................................................................11
Table 3: Low Voltage Signals.................................................................................................................15
Table 4: Machine Type Codes................................................................................................................18
Table 5: Group 1 Settings.......................................................................................................................26
Table 6: Group 2 Settings.......................................................................................................................26
Table 7: Event Logs................................................................................................................................29

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1 SAFETY AND OTHER WARNINGS
For safety reasons, the HPB 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.
WARNING!
This equipment generated dangerously high voltage levels. Because of
the potential risks associated with this equipment it is essential that only
qualified and experienced personnel be permitted to work in or around
this equipment.
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 use. Competency based
training courses are recommended and are available on request.
1.1.3 Manual Handling
The transformers supplied with the CCMB-22kV are heavy. Care should be taken when transporting
and handling these transformers.
Precautions have been taken to ensure all equipment is safe to handle and free from sharp edges.
However care should always be taken when handling enclosures and gloves should be worn.
1.1.4 Installation
Correct operation and safety depend on the HPB and associated equipment being installed correctly.
Mechanical and or electrical installation and maintenance of plant and equipment must only be carried
out by appropriately qualified personnel and must be tested thoroughly prior to operation.
1.1.5 Operation
As safety depends on the HPB functioning correctly it is highly recommended that all safety functions of
the HPB be periodically tested to ensure correct operation.

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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 the 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 applicable 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.
ENVIRO
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.

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3 PRODUCT OVERVIEW
3.1 Introduction
The Ampcontrol HPB Integrated Protection Relay is an intelligent protection relay based on
microprocessor technology. The Relay has been specifically designed to operate with very high
interference to the pilot conductor that occurs on cables in open cut mining operations. This is more
prevalent on a non-symmetric position of the pilot and earth conductors.
The integrated relay provides the necessary function required for protection electrical outlets supplying
draglines, shovels, drills etc. All of the protection functions are combined into a compact, plug-in unit,
which can be easily changed out to minimise down time in the event of a problem with the relay.
The HPB Relay can provide machine communication through the use of a HPB Termination Unit (HTU-
1) connected between the pilot and earth at the machine end of the trailing cable. Through the use of the
HTU-1 Termination Unit the relay parameters are automatically uploaded from a remote machine when a
cable is inserted into a power outlet.
The relay can perform an automatic “H.V. Insulation” test on the cable prior to the closure of the main
contactor. The results of the test are displayed on the HPB Display Module (HDM-1) and can be
remotely monitored.
The HPB Relay has 5 digital inputs, which feed into a microprocessor unit. The microprocessor has been
programmed to control three output relays. Relay MCR for the main contactor and Relay CBR for the
circuit breaker. RL3 is used to control the supply to the Cable Connection Module enabling it to perform
the Earth Fault Lockout test. All of the tripping logic and outlet control is performed by the
microprocessor, so that only minimal external control is required. See Typical Connection Diagrams
HPBE006 and HPBE013, in APPENDIX A: DRAWINGS.
Extensive information display and monitoring features are included to facilitate fault finding and system
trending. This information can be read locally on the HPB Display Module (HDM-1) or remotely via a
communication link.
Opto-isolated outputs are available for connection to optional LED or Relay Modules to provide
additional “run” and “trip” indications (See Drawing IPAS005, in APPENDIX A: DRAWINGS). The
Ampcontrol Relay Output Module (ROU) enables these indications to be interfaced with a PLC (See
Drawing IPAA031, in APPENDIX A: DRAWINGS).
There are currently two HPB models available; the HPB 6.6kV, which is suitable for 6.6kV systems, and
the HPB 22kV, which is suitable for 11kV and 22kV systems.
Protection Functions
Earth Leakage Protection
Earth Fault Lockout Protection
Earth Continuity Protection
Over-Current/Overload Protection
Short Circuit Protection
Contactor Fail Protection
Protection trips are stored in a non-volatile memory requiring a rest function before power can be
restored. This remains the case even if a power down occurs following a trip condition.

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3.2 Remote Display Module (HDM)
The Ampcontrol HDM (Remote Display Module) communicates with the HPB Relay via a three-wire
connection. The Module consists of a two-line 16 character alpha-numeric liquid crystal display (LCD),
LED status indicators and a tactile keypad.
The various display pages are arranged on levels with each level having a number of positions. The
display level is changed with the Up/Down arrow keys and the Left/Right arrow keys control the display
position. An Enter key is used when programming the relay. The display map shows how the movement
is controlled between levels and positions (See Drawing HPBB004, in APPENDIX A: DRAWINGS).
The healthy LED located top centre of the module flashed at 3Hz (three times per second) to indicate
healthy communications with the relay. A flash rate of 1Hz (once every second) indicates that the
module is powered (15VDC), but no receiving data.
The module displays the following information:
a. Software version and serial number
b. HPB Status
c. Operational information from the protection functions, e.g. earth leakage current, earth continuity
resistance etc.
d. System information including the line voltage and current
e. Status of digital inputs and relay outputs
f. Protection trip settings, which can be viewed at any time. Authorised personnel can modify these
settings via that HDM Remote Display Module
g. Data logging information. The 120 most recent events and parameter changes are logged, with
time and date, in a non-volatile memory (e.g. power-up, trip, reset, close etc.).
NOTE
A review of the first few log events is a useful tool for fault finding.
The HPB Relay status display is one of the most useful features of the relay’s display system and should
be viewed as the first step in fault finding.
This display shows a list of 9 prompts in order of priority indicating what the HPB Relay requires to allow
the output to close. The prompts are listed as follows:
Table 1: HPB Display Messages
Display Message
Description
[RUNNING]
Outlet energised
[TESTING]
Performing EFLO Test
[TRIPPED]
Trip Condition (see HDM LEDs)
[HPB Mem Err]
HPB Relays non-volatile memory is corrupted
[HTU Mem Err]
HTU-1 non-volatile memory is corrupted
[HTU STOP]
Waiting for HTU-1 stop input to be closed
[HPB STOP]
Wating for HPB stop input to open
[HPB START?]
Waiting for the HPB Relay’s start input to close
[WAITING]
Pause between successive Megger Tests

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An error status indicator is also shown on the status page, which is normally zero; exceptions are as
follows:
Table 2: HPB Error Status Indicator
Display Message
Description
Error # 1
Indicates corruption in the Group 1 Settings (HPB Mem Error)
Error # 2
Indicated corruption in the Group 2 Settings (HTU Mem Error)
Error # 3
Is a combination of faults in both groups
For details of Groups see Section 9.1, Parameter Groups.

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4 INSTALLATION
4.1 General Warnings
These instructions have been designed to assist users of the HPB with installation and special wiring
techniques required to reduce induction from high voltage circuits.
Before the HPB can be installed, there are a number of things that need to be considered and
understood to prevent incorrect or unsafe operation of the HPB 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 HPB 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, consult a competent authority such as a supervisor or Ampcontrol
technical representative.
4.1.2 Ensure that the application into which the HPB 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 HPB will properly perform the required functions within the system
design.
It is important to understand how the HPB is intended to interact with other equipment within a system.
For safe and reliable use, it is crucial that neither the HPB’s logical operation nor its signalling be
compromised by incompatibilities with connected equipment.
4.1.4 Modifications of any form to the HPB are prohibited.
The HPB as supplied has been designed and manufactured to comply with the requirements of
protection standards. If modifications of any form are made to the HPB, the equipment may no longer be
fit for use. If any modifications or damage to the HPB is evident, do not use the equipment and contact
Ampcontrol for advice.
4.2 Mandatory Installation Practices
The following information must be adhered to when installing the HPB. Failure to adhere to this
information may give rise to unsafe operation.
Using the HPB 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 HPB must be powered within the specified voltage range.
The installation of the HPB must be carried out by suitably trained and qualified personnel.
Identification labels fixed to the HPB must not be damaged, removed or covered before, during or
after installation.
The installation is to be in accordance with the relevant installation Standards/Codes of Practice.

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Modifications must not be made to any part of the HPB. 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.
4.3 Installation and Wiring Instructions
4.3.1 Integrated Protection Relay
The HPB Relay has a powder coated sheet steel enclosure to be mounted into existing
enclosures of adequate IP rating.
The Relay is designed to operate when mounted either laid down flat or in a vertical position.
CAUTION!
Vent holes are provided at both the top and bottom of the relay to assist
in the cooling of the electronics inside the relay. These vents should not
be blocked or restricted in any way.
When installing the HPB Relay care should be taken to ensure sufficient space is allowed around the
relay for the ease of change out during routine maintenance.
Connections to the HPB Relay are made via a plug in base. The base is to be securely fastened to the
enclosure in which it is being installed. The base is clearly labelled for ease of terminal location and
identification.
4.3.2 Remote Display Module (HDM)
The Remote Display Module is housed in an IP55 polycarbonate enclosure. The Module has been
designed to be flush mounted, external to the switchgear it is controlling.
4.3.3 Cable Connection Module
CCMB –6.6kV (6.6kV systems)
The CCMB-6.6kV (Cable Connection Module type B –6.6kV) is a resistive isolation device, which
interfaces between the power circuit and the HPB Relay allowing the HPB to measure both the line
voltage and the insulation resistance to Earth. A 5kVDC voltage is generated within the CCMB, which
under normal operation, applies up to 2.5kVDC between each phase and earth. The CCMB-6.6kV is
housed in a polycarbonate enclosure.
CCMB-22kV (Cable Connection Module type B –22kV) is an isolated device that allows the HPB Relay
to interface with the power circuit to measure both the line voltage and the insulation resistance to
Earth. The CCMB-22kV connects to the 11kV or 22kV power circuit via 3 x voltage transformers
connected in a phase to earth through the CCMB-22kV. The line voltage is measured on the secondary
side of the voltage transformers and an insulation test is performed by lifting the primary star point from
earth and applying 5kVDC to the star point which passes through the primary windings and is applied
to all three phases in parallel.
CAUTION!
The CCMB and the HPB Relay must be earthed to the same earth
connection as the trailing cable on systems with separate earth grids.
Ensure that the earth connection are reliably installed, as this is the
basis of protection, for the isolation device.

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CAUTION!
When installing the CCMB –22kV, measure the resistance between the
transformer primary star point and earth before applying power. Ensure
that it is less that 10Ω.
4.3.4 Overload & Earth Leakage Toroids
Current transformers (CT) are not ideal devices and if correct procedures are not followed during
installation, nuisance tripping can result.
If using, for example, a single-phase earth leakage system where active and neutral pass through a
toroid then at all times currents in the two wires are equal and opposite so that the net current through
the toroid is zero. An ideal current transformer would have all the flux from each wire contained in the
core and so would accurately add the opposing fluxes to get a net result to zero. A real current
transformer has “leakage fluxes”. That is, a very small proportion of the total flux from each cable is not
contained in the core, but in the space outside it and as a result it may link some turns but not others,
depending on the positioning of the cables. The effect of this is that a small output may be obtained
from the CT when none would arise if the device was ideal.
The size of the error will vary from CT to CT of the same type because of slight differences in the core
and the symmetry of the winding.
Problems caused in this way become worse as CT sizes increase, as currents increase and a
decrease in the symmetry of the cables.
Nuisance tripping tends to occur when the total current rises, such as when a large motor is started.
To help avoid such problems, select to smallest internal diameter CT, which will allow the cables to fit
through.
4.3.5 Toroid Installation Guide Lines
a. Keep cables as close to the centre of the toroid as possible. Do not tie them to one side of the
toroid. Remember aim at symmetry.
b. Do not bring the cables back past the toroid within on diameter of the CT, trying to cram cables into
a small space reduces symmetry and may lead to problems, which are difficult to solve.
c. Avoid placing the CT near any device, which produces magnetic fields, whether it is a transformer
or other cables. Try to maintain several CT diameters clearance.
d. Many small cables tend to be worse than for example, three large ones. Try to position the CT in
the circuit with this in mind.
4.3.6 Wiring Installation
The connections to the HPB Relay consist of a mix of low and high voltage supplied and relay contact
circuits. To reduce induction from high voltages, care needs to be taken in the layout of the wiring and
the installation.
When using a 110V HPB a power supply filter, e.g. Schaffner FN612-1106 (1A, 250VAC chassis
mounted filter) or similar, should be installed adjacent to the HPB Relay. The earth should be
connected to Pin 7 on the relay as directly as possible.
4.3.7 Low Voltage Signals
Care must be taken to ensure these circuits cannot come into contact with higher voltages (e.g. via
insulation breakdown, or broken wires etc.). It is recommended that these circuits be run in a separate
loom from the “high” voltage circuits. To ensure that interference is kept to a minimum, the following
cabling is required.

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Table 3: Low Voltage Signals
Duty
Pin
Signal
Cable Type
Pilot Core
6
7
Pilot
Earth
Single core screened
# Screen = 0V
Serial Comms Port
8
9
10
11
12
+Vsc
FIO
TXD
RDI
OV
Four core screened
# Screen = 0V
Remote Display
13
14
12
Data
+Vdm
OV
Two core screened
# Screen = 0V
Earth Leakage Toroid
1
2
EL1
EL2
Two core screened
Screen = Earth
Cable Connection Module
3
4
5
7
VcmA
VcmB
VcmC
Earth
Three core screened
Screen = Earth
Current Protection Transformers
15
16
17
18
Ia1
Ia2
Ic1
Ic2
Two core screened
Screen = Earth
Local Stop Button
(digital input)
19
20
SpDig+
SpDig-
* Two core screened
Screen = Earth
Lock Switch
(digital input)
21
22
Lock+
Lock-
* Two core screened
Screen = Earth
Reset Switch
(digital input)
23
24
Reset+
Reset-
* Two core screened
Screen = Earth
Start Switch
(digital input)
25
26
Start+
Start-
* Two core screened
Screen = Earth
Motor Contactor Aux Contact
(digital input)
27
28
MCI+
MCI-
* Two core screened
Screen = Earth
NOTE
# The 0V is internally connected to the HPB Relay’s earth (Pin 7).
The screen therefore must NOT be earthed at any other point.
* The HPB Relay’s digital inputs could alternatively be run in a
screened multicore cable (Separate cable for each HPB in multiple
installations).

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Where these “low voltage” circuits need to connect near the power circuits (e.g. Current transformers,
cable connection module, main contactor auxiliaries etc.), care needs to be taken to ensure that the
circuits are adequately separately and restrained. This ensure that the separation is maintained, even if
a wire termination becomes loose etc.
4.3.8 High Voltage Circuits
The “high” voltage circuits of the HPB are the 110 VAC supply (110V version Pins 30, 31 only) and the
relay contacts. Apart from keeping these separate from other wiring to the relay, there are no special
requirements.
CAUTION!
The relay contacts of the HPB Relay must not be used to switch more
than 190 VAC, 5A or 100VA.
4.3.9 Earthing
The HPB has two earth connections. The earth pin 7 is for the communication and pilot circuits. The
earth on Pin 29 connects to the earth shield of the HPB Relay’s internal transformer (110V version
only) and chassis. The CCMB-6.6kV also has an earth connection and the CCMB-22kV has two earth
connection. The CCMB-22kV signal earth should be connected to the HPB pin 7. All other connections
should be run back separately to the main earth point.

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5 MACHINE COMMUNICATION
5.1 HPB Termination Unit (HTU)
The HTU-1 Remote Termination Unit is a microprocessor based module that is connected between the
pilot and earth at the remote end of the trailing cable to provide machine communication. It is powered
by and communicates via the pilot line. Its non-volatile memory stored the parameters to configure the
outlet as appropriate for that machine (See Drawing HPBM013, in APPENDIX A: DRAWINGS).
The HPB Termination Unit (HTU-1) provides remote stop of the HPB Relay’s controlled outlet by tripping
the Earth Continuity function. The EC LED on the HDM Remote Display Module is illuminated and the
Earth Continuity will need to be reset if “Pilot Latch:On” has been selected. Stop switches are connected
in series with a diode between the stop and earth terminals. Alternately the internal HTU-1 Termination
Module’s diode can be used to terminate the stop loop.
Machine stops can be differentiated from other pilot trips in the HPB Relay’s Event Log by connecting
machine stops into the HTU-1 Module’s “Stop” input instead of being connected in the pilot loop.
WARNING!
Emergency stops must be wired directly into the pilot circuit.
A transient protected internal diode is connected between the diode terminal and earth. When the pilot is
connected to the diode terminal the machine can be used with a conventional pilot protection relay such
as an Ampcontrol PCA Relay but will not operate when connected to a HPB Relay.
If the remote stop function is not required the stop terminal must be bridged to the diode terminal or the
HPB Relay will not energise. The status of the Remote “Stop” input is displayed “HTU: Online Run” or
“HTU: Online Stp” and can be viewed on the HDM Module’s “Pilot and HTU information” page (level 2,
position 1). Also displayed on this page is offline status and pilot information. The HTU-1 software
version and machine type is displayed on position 2.
Level 2, position 3 displays the EC trip count (ECR), the EC shunt/short trip count (ECS), a counter
(Stat) for the number of cycles the HTU has been online (max will depend on EC trip time) and the status
of the HTU run input (Run) where 0 = offline, 1 = run & 2 = stop.
The Remote termination settings are programmed via the HDM Remote Display Module (Section 9, User
Adjustable Settings).
5.2 Machine Type Codes
There are 5 selectable machine type codes available for use in the HTU-1 Termination Unit. The
descriptive code is transmitted to the HPB Relay to identify the type of machine connected to the outlet.
The codes are selected using the HDM Remote Display Module (level 9, position 1):

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Table 4: Machine Type Codes
Code
Description
DrgL
Drag Line
Shvl
Shovel
Dril
Drill
PSTx
Portable Transformer
Wpmp
Water Pump
5.3 Machine Number
Machine numbers 1 to 40 can be assigned to machines (1 to 40 for each machine type). These numbers
are programmed using the HDM Remote Display Module (level 9, position 2).
5.4 Receiver Sensitivity
The HPB allows the sensitivity of the HTU receiver to be adjusted to suit different installations. For
installations where multiple HPB’s are located close to each other the sensitivity can be reduces to
prevent crosstalk between the pilot signals. In installations with long trailing cables the sensitivity can be
increased.
The sensitivity can be adjusted from 1 –32, with larger values corresponding to decreased sensitivity.
For most installations starting with the sensitivity set to 8 should yield good results. If the HTU is
connected through a long trailing cable and the HTU is not coming online, try increasing the sensitivity.
Alternatively, if there are multiple relays installed near each other, and they do not behave as expected
try decreasing the sensitivity to prevent crosstalk.

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6 EARTH PROTECTION FUNCTIONS
6.1 Earth Leakage
The Earth Leakage protection function uses a toroid to measure the earth leakage current. A definite
time operating characteristic is provided with an adjustable trip sensitivity and time delay.
When a fault occurs and the trip level and time delay are exceeded; a trip occurs. The trip acts in the
Main Contactor Relay (MCR) logic and is latched. An earth leakage trip is treated as a special fault and
requires an authorised person to perform the reset function. This is achieved by holding the lock input
closed and then closing the reset button.
When an earth leakage trip occurs, the “EL” LED on the display module flashes and the open collector
output on the HPB Relay is switched on the provide additional monitoring if required.
The measured instantaneous leakage current (EL) is displayed on the HDM “Earth Fault Information”
page as a percentage of the trip level. When the leakage reaches 100% for the selected time delay a trip
occurs.
For the HPB 6.6kV and the HPB 22kV 200mA EL, the trip level is adjustable in 100mA increments over
the range 200mA-1000mA and for the standard HPB 22kV the trip level is selectable in 250mA
increments over the range 500mA-2500mA. The time delay is selectable as instantaneous (<80ms) or
adjustable in 40ms increments over the range of 150ms-470ms.
6.2 Earth Fault Lockout
6.2.1 HPB 6.6kV
On 6.6kV systems the earth fault lockout function tests the resistance of the 3 phase lines to earth by
applying a “megger test” prior to closing the main contactor. The test is initiated by closing the start input,
provided all other starting conditions are met (see Section 10.5, Operational Sequence). The HPB Relay
closes its relay output, RL3, which applies 100VAC to the CCMB-6.6kV (Cable Connection Module type
B –6.6kV). This is a resistive isolation device used to interface the HPB Relay to the power conductors.
A 5kVDC voltage is generated within the CCMB-6.6kV, which under normal operation applies up to
2.5kVDC between each phase and earth.
The HPB Relay measures the voltage on the line and calculates the meg-ohm resistance to earth of
each phase. At the end of the test, provided the value is above the pre-set threshold, the MCR relay
closes allowing the outlet to be energised. If the value is below the pre-set threshold, an Earth Fault Trip
occurs.
At the completion of a test, the resistance to earth of each phase is retained in memory until the next test
is carried out. This can be viewed on the HDM (Remote Display Module) (level3, position 2).
6.2.2 HPB 22kV
On 11kV and 22kV systems the earth fault lockout function tests the resistance of the 3 phase lines to
earth by applying a “megger test” prior to closing the main contactor. The test is initiated by closing the
start input (provided all other starting conditions are met (see Section 10.5, Operational Sequence). The
HPB Relay closes its relay output, RL3, which applies 48VDC to the CCMB-22kV (Cable Connecting
Module type B –22kV). The CCMB-22kV then disconnects the primary windings of its 3 x voltage
transformers from earth (they are connected to earth at all other times), and generates 5kVDC which is
applied to the primary star point, resulting in 5kVDC between all three phases and earth. The HPB Relay
then measures the current to earth and calculates the resistance of the line insulation to earth of all three
phases in parallel. Three seconds (3s) after the end of the test, if the calculated resistance is above the
present threshold, the MCR relay closes allowing the outlet to be energised. If the calculated resistance
is below the pre-set threshold, an Earth Fault Trip occurs.
At the completion of a test, the result is retained in memory until the next test is carried out. This can be

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viewed on the HDM (Remote Display Module) (level 3, position 2). An insulation test will yield one of the
following results:
a. “Hardware Fault” – The HPB cannot detect the presence of the CCMB. Check power supply to
the CCMB and all wiring
NOTE
An open circuit connection between the CMMB and power circuit
cannot be detected and will not display as “Hardware Fault”.
b. “< 10 MΩ” –The resistance between the power circuit and earth is less than 10MΩ.
c. A value between 10MΩand 120MΩ- The resistance between the power circuit and earth ±10%.
d. “> 120 MΩ” –The resistance between the power circuit and earth is greater than 120MΩ.
WARNING!
The CCMB generates 5kVDC. This high voltage DC is produced, and
applied to the 3 phase lines, even when the high voltage 3 phase
supply is not available. Care should therefore always be taken when
working close to high voltage 3 phase cables/bus etc. An audible tone is
generated whenever the CCMB is active, warning of the presence of
high voltage DC.
CAUTION!
Like all insulation tests, a faulty (open circuit) connection to the power
circuit will create the appearance of a high insulation resistance to
earth. To verify the connection to the power circuit it is recommended
that periodic insulation tests be performed, using the HPB, with a
known resistance (e.g. 50MΩ) or a short circuit to earth on the line.
This should be done on an isolated system (high voltage supply
disconnected) using control power only.
NOTE
The start input must be held closed for the duration of the test (including
the 3 s delay on HPB 22 kV) which is adjustable between 10 and 25
seconds to allow for the charging of cable capacitance.
Setting the “EFLR Test” Value to “off” disabled the Earth Fault test. If this is done, and the system is
ready to start, the MCR Relay closes as soon as the start input is closed.
6.3 Earth Continuity
The earth continuity function tests for the continuity of the earthing between the outlet and the machine,
via the pilot core in the trailing cable. The pilot core is also used to transfer machine data when a remote
HTU (HPB Termination Unit) is used to achieve machine communication. The pilot resistance is
measured with a DC signal and communications is achieved by a high frequency AC signal.
The HPB Relay can be configured to operate in either Resistor or HTU Mode. The mode is selected in
“Pilot Type”, (level 8, position 1) and defines the type of termination unit to be connected between the
pilot and earth at the machine end of the trailing cable being protected by the HPB Relay.
The advantage of using the resistor mode is that it uses a simple signal and a robust termination device
making the system easy to fault find.