Ampcontrol IPD User manual

IPD 11 kV INTEGRATED PROTECTION
RELAY - USER MANUAL
Issue: R4 Oct 2011
CRN: 8874
Ampcontrol User Manual Part No: 141559
Designed and Manufactured in Australia by Ampcontrol CSM Pty Limited.

IPD 11 kV RELAY MANUAL
Issue: R4, Date: 10/2011, CRN: 8874
IPDB012 R4 IPD 11kV User Manual Page 1
Ampcontrol CSM Contact details:
7 Billbrooke Close, Cameron Park, NSW, 2285
P [phone] | F [phone]
EMAIL: [e-mail]
WEB: www.ampcontrolgroup.com
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.

IPD 11 kV RELAY MANUAL
Issue: R4, Date: 10/2011, CRN: 8874
IPDB012 R4 IPD 11kV User Manual Page 2
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 IPD 11kV Integrated Protection Relay.
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.

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Table of Contents:
Ampcontrol CSM Contact details:.................................................................................................................................. 1
Safety and other Warnings............................................................................................................................................ 1
Copyright Notice............................................................................................................................................................ 2
Disclaimer...................................................................................................................................................................... 2
Before You Begin .......................................................................................................................................................... 2
1Receiving, Storage & Maintenance...................................................................................................................... 5
1.1 Receiving ........................................................................................................................................................ 5
1.2 Storage after Delivery ..................................................................................................................................... 5
1.3Unpacking of Equipment ................................................................................................................................. 5
2Safety................................................................................................................................................................... 6
2.1 Personnel Safety Warnings............................................................................................................................. 6
2.1.1 Relevant Personnel............................................................................................................................. 6
2.1.2 Safety Communication ........................................................................................................................ 6
2.2 Safe Use of Equipment ................................................................................................................................... 6
2.2.1 Changes to Equipment........................................................................................................................ 6
2.2.2 Work in Hazardous Areas ................................................................................................................... 6
2.2.3 Equipment Knowledge ........................................................................................................................ 6
3Overview of Equipment........................................................................................................................................ 7
3.1 Introduction ..................................................................................................................................................... 7
3.2 Remote Display Module .................................................................................................................................. 8
3.2.1 Trip / Status Messages:....................................................................................................................... 9
3.2.2 Last Trip Status Messages:............................................................................................................... 11
4Machine Communication ................................................................................................................................... 12
4.1 Remote Termination Unit .............................................................................................................................. 12
4.2 Machine Type Codes .................................................................................................................................... 13
4.3 Machine Type Number.................................................................................................................................. 14
5Earth Protection Functions................................................................................................................................. 14
5.1 Earth Leakage............................................................................................................................................... 14
5.2 Earth Fault Lockout....................................................................................................................................... 15
5.2.1Intrinsically Safe EFLO Test.............................................................................................................. 15
5.2.2 Automatic Insulation Test.................................................................................................................. 15
5.2.3 Manual Insulation Test ...................................................................................................................... 17
5.3 Earth Continuity............................................................................................................................................. 18
6Current Related Functions ................................................................................................................................. 19
6.1 Basic Over-current Protection Functions....................................................................................................... 19
6.2 Over-current Characteristics ......................................................................................................................... 19
6.3 Motor Overload Characteristic....................................................................................................................... 20
6.4 Short Circuit .................................................................................................................................................. 21
6.5 Phase Current Balance ................................................................................................................................. 22
7Voltage Related Functions................................................................................................................................. 22
7.1 Main Contactor Fail Protection...................................................................................................................... 22
7.2 Under Voltage Trip........................................................................................................................................ 23
7.3 Voltage Metering........................................................................................................................................... 23

IPD 11 kV RELAY MANUAL
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8Fan Control ........................................................................................................................................................ 23
8.1 Fan Interlocking............................................................................................................................................. 23
8.2 Interlocking Sequence................................................................................................................................... 24
9User Adjustable Settings.................................................................................................................................... 24
9.1 Parameter Groups......................................................................................................................................... 24
9.2 Changing Settings......................................................................................................................................... 26
10 System Control .................................................................................................................................................. 27
10.1 Digital Inputs .............................................................................................................................................. 27
10.2 Output Relays ............................................................................................................................................ 27
10.3 Open Collector Outputs ............................................................................................................................. 27
10.4 Outlet Control............................................................................................................................................. 27
10.4.1 RTU Mode:........................................................................................................................................ 28
10.4.2 Remote Operation in Diode Mode:.................................................................................................... 28
10.5 Operational Sequence ............................................................................................................................... 28
11 Event Log........................................................................................................................................................... 29
12 Time & Date....................................................................................................................................................... 30
13 Remote Data Communications .......................................................................................................................... 31
14 Installation & Wiring Instructions........................................................................................................................ 31
14.1 Installation.................................................................................................................................................. 32
14.1.1 IPD Integrated Protection Relay........................................................................................................ 32
14.1.2 Remote Display Module (RDM)......................................................................................................... 32
14.1.3 EFLO Test Module 11kV & HV Test Module 11kV............................................................................ 32
14.1.4 Overload & Earth Leakage Toroids................................................................................................... 33
14.1.5 Toroid Installation Guide Lines.......................................................................................................... 34
14.2 Wiring Installation....................................................................................................................................... 34
14.2.1 Earthing............................................................................................................................................. 34
14.2.2 Intrinsically Safe Circuits: .................................................................................................................. 34
14.2.3 Low Voltage Signals.......................................................................................................................... 35
14.2.4 High Voltage Circuits......................................................................................................................... 35
15 IPD Equipment List ............................................................................................................................................ 36
16 IPD-11kV Specifications .................................................................................................................................... 37
17 Trouble Shooting................................................................................................................................................ 38
18 Maintenance & Disposal .................................................................................................................................... 40
18.1 Equipment Maintenance ............................................................................................................................ 40
18.2 Disposal of System Parts........................................................................................................................... 40
19 Drawings – Appendix A...................................................................................................................................... 41
20 Approvals – Appendix B..................................................................................................................................... 56

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1 Receiving, Storage & Maintenance
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
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 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.
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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2 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 Work in Hazardous Areas
No work on the equipment shall be carried out in a hazardous area unless that work complies with the guide lines
contained in HB13-2007 (Standards Australia Handbook-Electrical equipment for hazardous areas) and any relevant
standards referenced therein.
2.2.3 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.

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3 Overview of Equipment
The Ampcontrol IPD Integrated Protection Relay (IPD-11kV) is an intelligent protection relay based on
microprocessor technology.
The Installation, Operation and Maintenance Manual is intended for technical and non-technical personnel to assist
in the day to day operation of the IPD-11kV as well as installation.
3.1 Introduction
The integrated relay provides the necessary functions required for protecting electrical outlets supplying underground
mining machinery. 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 IPD Relay can provide machine communication through the use of a Remote Termination Unit (RTU-D)
connected between the pilot and earth at the machine end of the trailing cable. Through the use of the RTU-D
Remote Termination Unit the relay parameters are automatically up loaded from a remote machine when a cable is
inserted into a power outlet.
The earth fault lockout function tests the resistance of the 3 phase lines to earth by applying an intrinsically safe
signal prior to the closure of the main contactor in accordance with AS/NZS 2081.4 2002. The test is initiated once
all starting conditions are met. If the resistance is above the preset level then an automatic high voltage DC
“Insulation Test” to earth can be carried out. If the result of the Insulation Test is above the preset resistance level,
the IPD’s MCR relay energises, which in turn closes the main contactor. A manual “Insulation Test” is provided as a
maintenance/fault finding tool. (When this test is performed the MCR relay does not close at completion of a healthy
test).
The Insulation Test allows cable insulation levels to be trended as an aid to preventative maintenance.
The IPD Relay has 5 Digital inputs, which feed into a microprocessor unit. The microprocessor has been
programmed to control four output relays. Relay MCR for the main contactor and Relay CBR for the circuit breaker.
Relay RL3 is not used in the 11kV IPD. Relay RL4 when closed applies 110V to the HV Test Module for the
Insulation Test. All of the tripping logic and outlet control is performed by the microprocessor, so that virtually no
external control is required (See Typical Connection Diagram IPD-E-015).
Extensive information display and monitoring features are included to facilitate fault finding and system trending. This
information can be read locally on the Remote Display Module (RDM-D) or remotely via a communication link.

IPD 11 kV RELAY MANUAL
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Opto isolated outputs are available for connection to optional LED or Relay Modules to provide additional “run and
trip” indications. The Ampcontrol Relay Output Module (ROU) enables these indications to be interfaced with a PLC.
Direct connections to the Opto isolated outputs can also be made for remote monitoring with no additional interfacing
required. The maximum voltage for these outputs is 30V with an internal impedance of 4.7kΩ.
The protection functions provided by the IPD are:
Earth Leakage Section 5.1
Earth Fault Lockout- Section 5.2
Earth Continuity Section 5.3
Over Current/Overload Section 6
Short Circuit Section 6.4
Contactor Fail Section 7.1
Protection trips are stored in a non-volatile memory requiring a reset function before power can be restored to the
load. This remains the case even if a power down occurs following a trip condition.
3.2 Remote Display Module
This module (Ampcontrol RDM-D) consists of a two line - 16 character LCD display, LED status indicators and a
tactile keypad.
The display level is changed with the Up/Down arrow keys and the display position is changed with the Left/Right
arrow keys. The display map (Drawing IPD-B-009) shows the layout of the various display screens. The module is
approved to Ex ia Intrinsic Safety Standards so that it can be installed outside of a flameproof enclosure.
The healthy LED located top centre of the module flashes at 3 Hz to indicate healthy communications with the relay.
(A flash rate of 1 Hz indicates that the module is powered, but is not receiving data).
The module displays the following information:
1. IPD Status.
2. Software version and serial number.
3. Operational information from the protection functions, e.g. earth leakage current, earth continuity resistance
etc.
4. System information including the line voltage and current.
5. Status of digital inputs and relay outputs.
6. Protection trip settings, which can be viewed at any time. Authorised personnel can modify these settings
via the RDM, thus eliminating the need to open the flameproof enclosure.
7. Data logging information. The 120 most recent events are logged, with time and date, in a non-volatile
memory, for example power-up, trip, reset, close etc.
A review of the first few log events is a useful tool for fault finding.

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The IPD 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. The Status display is the default screen on power up and indicates what the IPD Relay
requires in order to allow the outlet to close. These messages are useful to unskilled personnel. If more than one
message is active the display cycles around all active messages showing them for 1 second each.
Through the use of the serial communications port, PLC’s and SCADA Systems can be configured to display the
same messages that appear on the Remote Display Module. This helps to provide consistent information to
operators.
3.2.1 Trip / Status Messages:
The following table shows a list of the twenty-eight status messages and the type of message (category). Messages
are cleared according to their message category.
Type 1
Messages are cleared by either pressing the <ENT> key while on the Status Display Page or by starting a
new starting sequence i.e. EFLO test started.
Type 2
Messages are enabled and cleared automatically.
Type 3
Messages are triggered by the respective trip functions and are cleared by resetting the trip function.

IPD 11 kV RELAY MANUAL
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Message Type Explanation
Tripped-No Volts
1 Voltage on load side of contactor is too low
MC Close Fail
1 MCI input did not close within 5 Sec of MCR relay closing
External MC Open 1
IPD detected (via MCI input) that MC was opened – not initiated
by the IPD relay
Insulation Alarm
1 Test result at alarm level (1.5 x selected trip level)
Last T: ---------
1 Shows ‘Last Trip’ record
Need IPD Start
2 Awaiting IPD start digital input
Need RTU Start
2 Awaiting RTU start digital input
Outlet Paused
2 IPD waits 10 Sec between running (or testing) and re-testing
Closing MainCont
2 MCR closed, waiting for MCI feedback (5 Sec max)
. . EFLO Testing
2 In process of EFLO Test (3 seconds)
Insulat. Testing
2 In process of Insulation Test (4 seconds)
Manual Ins. Test
2 In process of manual Insulation Test
IPD Memory Error
3 Corrupted memory in relay’s stored settings
RTU Memory Error
3 IPD detected errors in set up data received from RTU
Trip-RTU Offline
3 IPD can’t communicate with RTU
Stopped-RTU PTC
3 RTU PTC input Tripped (open)
I Balance Trip
3 Phase Current Balance Function Tripped
Locked Out - Fan
3 Fan interlock system is locking out IPD
Stopped IPD
3 IPD Stop Digital input activated (closed)
Earth Leak. CT Fail
3 Earth Leakage CT/Connection fail Trip
Earth Leak. Trip
2 Earth Leakage Function Tripped
Earth Cont. Trip
3 Earth Continuity Function Tripped
E/F Lockout Trip
3 Earth Fault Lockout Function Tripped
OverCurrent Trip
3 Over Current Function Tripped
Short Circ. Trip
3 Short Circuit Function Tripped
Main Cont. Fail
3 Main Contactor Fail Function Tripped
Insulation Fail
3 Insulation Test Function Tripped
Running: ----Amps
3 Outlet Closed: shows average of 3 phase currents (in amps)

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3.2.2 Last Trip Status Messages:
The IPD Relay has several functions which can stop/trip the outlet and then self-clear. The IPD Relay therefore
saves the non-latched trip codes in a register and displays the ‘Last Trip’ messages in the Status Message Page.
Note that the stop/trip record also appears in the Event Log.
There are 10 Messages that are displayed at Last T: ---------
Message Explanation
EC Leak T
E/C Leakage Trip that provides additional information for E/C Trip
EC ΩTrip
E/C Ohms Trip that provides additional information for E/C Trip
Fan I Stop
Fan interlock Stop
I bal-Trp
Current Balance Trip – Differentiates balance trip from basic over
current trip
MC Opened
Main contactor opened – opening not initiated by the IPD Relay
RTU mem. E
RTU Memory error – Errors in set up data from RTU
RTU Off L
RTU Off Line – IPD can’t communicate with RTU
RTU ptc T
RTU PTC input tripped
Stopped
IPD Stop Input Tripped
UVOLT Trp
Under Voltage trip – voltage on load side too low

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4 Machine Communication
4.1 Remote Termination Unit
The Remote Termination unit is a microprocessor based fully encapsulated 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 that machine.
All terminals are fully shrouded, with the pilot and earth terminals being kept segregated from the other terminals.
(See RTU-D General Case Dimensions on Drawing IPD-A-015)
The Remote Termination Unit (RTU-D) provides remote stop, start facilities of the IPD Relay’s controlled outlet. The
circuitry involved for these functions are 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.
WARNING!
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 semiconductor thermistor connection. These terminals are protected in a similar
manner to the stop and start circuits.
CAUTION!
If the remote stop, start and PTC functions are not required, each set of terminals must
be bridged, or the IPD Relay will not energise.
Four RTD inputs are provided for PT 100 temperature measuring devices. These terminals could also be used with
resistor networks to provide digital information back at the IPD Relay.
RX, TX and 0V terminals are no longer required.
On/Off Line Status, machine type, machine number, software version and input status of the Remote Termination
Unit can be examined by selecting “Machine Module Information” (Level 2, Positions 1-2). RTD temperature is
available, Level 2, Position 4.

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4.2 Machine Type Codes
There are 26 selectable machine type codes available for use in the Remote Termination Unit. The descriptive code
is transmitted to the IPD Relay to identify the type of machine connected to the outlet. The codes are selected using
the Remote Display Module (Level 9, Position 1).
Message Explanation
Belt
Conveyor
SHRr
Shearer
S-Ld
Stage Loader
Hpmp
Hydraulic Pump
Wpmp
Water Pump
cMnr
Continuous Miner
sCar
Shuttle Car
Bk/F
Breakfast Feeder
Crsh
Crusher
Fan
Fan
DCB
Distribution Control Box
BLANK
iFan
Fan with Interlocking
AFCm
Armoured Face Conveyor Main Gate
AFCt
Armoured Face Conveyor Tail Gate
M-BE
Mobile Boot End
Bolt
Bolter
HRMr
Hard Rock Miner
Winc
Winch
J-bo
Face Boring Machine
bBlt
Transfer Belt
Stak
Stacker
aCar
Add Car
IGG
Inert Gas Generator
tBlt
Transfer Belt
Dplg
Dummy Plug

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4.3 Machine Type Number
Machine numbers 1 to 40 can be assigned to machines. These numbers are programmed using the Remote Display
Module (Level 9, Position 2).
5 Earth Protection Functions
5.1 Earth Leakage
The earth leakage protection function uses an Ampcontrol EL500 series toroid to measure the earth fault current.
This function is tested to AS/NZS 2081.3 - 2002. A definite time operating characteristic is provided with adjustable
trip sensitivity and an adjustable 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 operating and holding the lock button closed and then
closing the reset button.
When a trip occurs, the “EL” LED on the remote display module is illuminated and the open collector output on the
relay is switched on to provide remote monitoring if required.
The leakage current (EL) is displayed on the RDM “Earth Fault Information” page as a % of the trip level. When the
leakage reaches 100% for the selected time delay a trip occurs.
The trip level is adjustable in 100 mA increments. Range 200 to 1000 mA.
The time delay is adjustable. Range: Instantaneous (<50mS) 100mS, then 150 to 470mS in 40mS increments.
The IPD generates a CT Detection Signal continuously to test the integrity of earth leakage circuit. The CT Detection
signal continually tests the toroidal current transformer, the wiring loop to the toroid and the input to the protection
relay, as required by AS/NZS 2081.3 - 2002.
The signal is generated by pins 32 and 33 as a 40mA signal at 200Hz. It must be fed from pin 32, three loops
through the toroid then back to pin 33. The Ct detectection signal can be monitored by pushing the ‘Enter’ switch
when viewing the ‘Earth FaultInformation’ on Level 3 position 1 of the Remote Digital Unit. When the trip occurs the
remote display module “EL” LED will flash and the open collector output on the relay is switched on to provide remote
monitoring if required.
The CT detect signal level can be displayed by pressing <ENT> on the RDM – while the
key is active, the CT level will appear instead of the EL current level.
The trip time is derived from the main EL trip time, but is constrained to a minimum of 80mS (4 x 20mS cycles).
CAUTION!
The loop resistance of the CT Detection Signal circuit connected to pins 32 and 33 must
remain below 0.5Ω.

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5.2 Earth Fault Lockout
The IPD Relay 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’. A
manual ‘Insulation Test’ is also provided.
An EFLO Test Module 11kV is a resistive isolation device used to interface the power conductors to the IPD relay.
This allows the IPD to measure the line voltages and to perform line insulation tests.
The HV Test Module 11kV is a high voltage generator (5000V) which is used in conjunction with the EFLO Test
Module 11kV to perform high voltage line insulation tests. The HV Test Module 11kV must be used when the
‘Insulation Test’ function is required.
When EFLO-11kV None is selected the IPD Relay does not provide an EFLO or a HV Test’, or any of the voltage
functions, including under voltage checking.
WARNING!
The ‘EFLO-11kV:
None’ Mode MUST NOT BE USED in applications where EFLO is
required by mining regulations.
5.2.1 Intrinsically Safe EFLO Test
The initial earth fault lockout function tests the resistance of the 3 phase lines to earth by applying an intrinsically safe
signal prior to the closure of the main contactor in accordance with AS/NZS 2081.4 2002. The test is initiated by
closure of the start button once all starting conditions are met (See Section 10.5, Operational Sequence). This test
takes 3 seconds.
If the value is less than the preset level (See Specifications, Section 16) a trip occurs. The “EF” LED on the Remote
Display Module is illuminated and the open collector output on the relay is switched on to provide remote monitoring
if required. To reset the relay following an earth fault lockout trip, operate the reset button.
The earth fault leakage level (EF) of the three phases is displayed on the RDM “Earth Fault Information” page as a %
of the trip level and relates to the last earth fault lockout test performed
5.2.2 Automatic Insulation Test
If ‘EFLO-11kV : Yes’ Mode has been selected, in the Group 1 Settings, an automatic High Voltage DC ‘Insulation
Test’ is carried out following a successful Intrinsically Safe Earth Fault Lockout Test.
The HV ‘Insulation Test’ is initiated when the IPD Relay closes its relay output, RL4, - for 4 seconds. This applies
110VAC to the HV Test Module 11kV which generates 5000Vdc that is applied between each phase and earth.
The IPD Relay measures the combined line leakage current and calculates the meg-ohm resistance to earth. At the
end of the test the result is stored in the Event Log as ‘it -- . - MΩ’. If the resistance value is above the preset
threshold the MCR Relay picks up allowing the outlet to be energised. Additionally, if the result is equal to or below
an Alarm Level (typically 1.5 times the selected trip level, see Table 5.2.2.i, following) the status message ‘Insulation
Alarm’ is displayed on the Status Page (level 0, position 0). The alarm message is displayed until a new EFLO Test
is initiated or the <ENT> key is pressed while on the status page. ‘Insul. Alm’ is also recorded in the Event Log.

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Ins . TstT: Selection
M
Ω
Alarm Level
M
Ω
15 25
20 35
25 40
30
45
35
50
50 80
80 120
100 150
None None
Table 5.2.2.i
If the value is less than the preset trip level a trip occurs and is latched and saved in non-volatile memory. The “EF”
LED on the Remote Display Module is illuminated and the open collector output on the relay is switched on to
provide remote monitoring if required. An Insulation Trip shares the “EF” LED on the Remote Display Module with an
EFLO trip but has dedicated trip messages on the Status Page. To reset the relay following an insulation test fail trip,
operate the reset button.
At the completion of a test the leakage is retained in memory until the next test is carried out. This can be viewed on
the Remote Display Module RDM (Level 3, Position 3).
Resistance readings between 10MΩand 200MΩwill be displayed. A fault condition (e.g. HV Test Module not
working) is displayed as 0MΩ.
If the ‘Insulation Test’ is not selected by either selecting ’EFLO-11kV None’ or setting ‘Ins.TstT:’ value to ‘None’ then
the MCR Relay closes at the completion of a healthy EFLO Test.
The accuracy of the insulation test and expected trip ranges are outlined in table 5.2.2.ii following. The results from
insulation test should only be used as a guide to confirm that insulation remains above the preset threshold.
Insulation tests apart from the generated insulation test via the IPD should be still carried out on a regular basis for
maintenance purposes.
Actual Fault Resistance (MΩ)
Trip Setting
Minimum
Maximum
15
13.5
16.5
20 18 22
25 22.5 27.5
30 27 33
35 31.5 38.5
50 45 55
80 72 88
100
90
110
Table 5.2.2.ii

IPD 11 kV RELAY MANUAL
Issue: R4, Date: 10/2011, CRN: 8874
IPDB012 R4 IPD 11kV User Manual Page 17
The values in the expected fault resistance range (up to 100MΩ) represent ±10% of the nominal value. This
tolerance is not guaranteed above 100MΩ.
Trip settings above 100MΩare not supported. Values above 100MΩare for indication only and should not be
considered accurate.
The start input must be held closed for the duration of the test.
5.2.3 Manual Insulation Test
A manual “Insulation Test” is provided as a maintenance/fault finding tool. The manual test can only be carried out
when the load is not energized. When this test is performed the MCR relay is prevented from closing at the
completion of a healthy test.
Before a manual Insulation Test can be performed the following conditions must apply:
1. The Remote Display Module must be online with the Insulation Test page being displayed. This is located
on the ‘EARTH FAULT INFORMATION’ Page, level 3, position 2.
2. Pilot must be healthy (and any previous trips reset).
3. EFLO function must not be tripped.
4. Insulation Test function must not be tripped.
5. Outlet must not be running.
6. Outlet must not be in the process of ‘closing’.
7. Outlet must not be ‘Paused’
8. The ‘Lock’ digital input must be closed.
When the above conditions are met the <ENT> key must be pressed and held (for the duration of the test). After 3
seconds the EFLO test will commence. If the test result is healthy the manual insulation test is initiated. The test
voltage is applied to the outgoing feeder while ever the above conditions are held (including holding the <ENT> key).
The test results are continuously calculated and displayed. The operator should maintain the test at least long
enough for the readings to stabilize, this being a function of the cable length. When the test is completed (usually by
releasing the <ENT> key) the results are held in memory until another insulation test is commenced, which may be
as part of the starting sequence, manually, or because IPD control power is lost.
The manual test can be carried out even if the ‘Ins.TstT:’ selection is
set to ‘none’ (i.e. the automatic insulation test in the starting
sequence is turned off).

IPD 11 kV RELAY MANUAL
Issue: R4, Date: 10/2011, CRN: 8874
IPDB012 R4 IPD 11kV User Manual Page 18
The status of the manual insulation test is shown on the Insulation Test Information Page (level 3, position 3). A
single letter following ‘Mt:’ indicates the status of the test:
Mt:x: Manual Test is blocked - by any one or more of the conditions 1 to 8 above.
Mt:e: Only the <ENT> key is required to initiate the manual test.
Mt:t: The manual test is timing through the enabling period (3 seconds).
Mt:A: The manual test is Active. The display will show measured values.
5.3 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. This is in accordance with AS/NZS 2081.2 2002. The pilot core is also used to transfer
data when a Remote Termination Unit is used to achieve machine communication.
The IPD relay can be configured to operate in either diode or RTU mode. The mode is selected in “Pilot Type”,
(Level 8, Position 1) and determines what terminating device the relay is looking for on the pilot.
CAUTION!
The Remote Termination Unit will only be recognised by an IPD Relay and will not be
seen as a diode by other earth continuity devices.
CAUTION!
Cable parameters are important to the correct operation of the Pilot E/C function
Resistance & capacitance values can determine the length of the cable that the relay can
drive. (See Specifications, section 16. IPD specifications)
The relay measures the resistance of the pilot - earth loop and the leakage between the pilot and earth conductors.
The leakage measurement ensures that pilot to earth faults are detected. If the pilot - earth loop is not healthy a trip
occurs (See Specifications, Section 16) which in turn opens the main contactor control circuit. The fault can be
configured as latching or non-latching. This allows the user to determine if the fault is manually or automatically reset
once the pilot - earth loop is healthy. The selection is either “Pilot Latch: On” or “Pilot Latch: Off” (Level 9, Position
11). To manually reset the relay, operate the reset button.
The “EC” LED on the Remote Display Module is illuminated and the open collector output on the relay is switched on
to provide remote monitoring if required.
The earth continuity resistance (ECR) of the pilot – earth loop and the leakage (L) between the pilot and earth
conductors is displayed on the RDM “Earth Fault Information” page as a % of the trip levels. When either value
reaches 100% a trip occurs.
The trip level of the earth continuity resistance is available in the following resistances: 10, 15, 20, 25, 30 and 45Ω.
Pilot Trip Time is adjustable to allow for operation in noisy electrical environments. The following trip times are
available: 80,120, 160, 200, 300, 400 and 500mS.
A setting of 120mS should be suitable for most installations. Long time delays (>200 ms) should only be used where
necessary.
WARNING!
Consequence of long trip times should be thoroughly assessed from a safety point of
view before using the higher values.

IPD 11 kV RELAY MANUAL
Issue: R4, Date: 10/2011, CRN: 8874
IPDB012 R4 IPD 11kV User Manual Page 19
6 Current Related Functions
6.1 Basic Over-current Protection Functions
Two current transformers are used to measure the three line currents. The measured currents are used to
implement the following protection functions:
(a) Over-current or Motor Overload
(b) Short Circuit
(c) Phase Current Balance
Full load settings cover a range from 7.5 Amps to 464 Amps. A current range and current multiplier are utilised to
select and store the full load current value in the non-volatile memory. This forms the basic reference level for the
over current protection functions.
The current range is selectable in 4 Amp increments between 60 and 116 Amps. The current multiplier is selectable
at 1/8, 1/4, 1/2, 1, 2, 4 times (See Section 9.1, Parameter Groups).
Example - Over-current Setting:
To obtain a full load current of 152 Amps select a current range of 76 Amps and a multiplier of 2.
Two curve types can be selected and a time multiplier modifies the basic trip time characteristic. There are eighteen
(18) multiplier settings that can be selected ranging from 0.005 times to 1.0 times (See Section 7.1, Fan Interlocking).
It should be noted that settings 0.005, 0.01, 0.015, 0.02, 0.03 and 0.04 are positioned after setting 1.0 in the stored
setting’s list (Level 9, Position 4).
The instantaneous current in each of the three phases can be displayed on the RDM (Level 5, Position 1). The three
phase currents are displayed, as a % of the overload set current. The average current value is expressed in Amps
and is displayed at Level 5 and the Status Page (Level 0, Position 0).
Following a trip condition the following conditions must be met to achieve a reset:
(a) The IPD reset input must be closed
(b) The trip accumulator must be less than 80%
6.2 Over-current Characteristics
If the selected over current type is “vInv”, then a very inverse over current characteristic set of curves are available
for selection. (See “vInv” Curves, Drawing IPC-B-004).
The three phase currents are compared and the highest current is used to calculate the trip time. If the current
exceeds the selected full load current an “over current trip accumulator” increases at a rate determined by the current
and the selected curve. This can be displayed on the RDM (Level 5, Position 2). When the current falls below the
selected full load current the trip accumulator reduces towards zero rapidly, however, if the over current condition
persists so that the trip accumulator reaches 100% then a trip occurs. If viewed during start up the trip accumulator
can help determine if over current settings are correct.
If a trip occurs the “OC” LED on the Remote Display Module is illuminated and concurrently the open collector output
on the relay is switched on to provide remote monitoring if required.
To reset the relay following an over current trip, operate the reset button.