Ampcontrol IPM V2 User manual

Revision: 15, May 2018
Designed and manufactured in Australia by Ampcontrol Pty Ltd
IPM V2
INTEGRATEDPROTECTIONRELAY
UserManual

Ampcontrol Pty Ltd –ABN 28 000 915 542
IPM V2 USER MANUAL
IPM2B003 Revision 15 –MAY/18
Uncontrolled Copy - Refer to Ampcontrol Website for Latest Version
Page 2 of 83
APPROVED FOR EXTERNAL DISTRIBUTION –PROPERTY OF AMPCONTROL PTY LTD –NOT TO BE REPRODUCED IN PART
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.

Ampcontrol Pty Ltd –ABN 28 000 915 542
IPM V2 USER MANUAL
IPM2B003 Revision 15 –MAY/18
Uncontrolled Copy - Refer to Ampcontrol Website for Latest Version
Page 3 of 83
APPROVED FOR EXTERNAL DISTRIBUTION –PROPERTY OF AMPCONTROL PTY LTD –NOT TO BE REPRODUCED IN PART
Copyright Notice
The Ampcontrol relay 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 IPM V2 Integrated Protection Relay.
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: customerserv[email protected]
WEB: ampcontrolgroup.com

Ampcontrol Pty Ltd –ABN 28 000 915 542
IPM V2 USER MANUAL
IPM2B003 Revision 15 –MAY/18
Uncontrolled Copy - Refer to Ampcontrol Website for Latest Version
Page 4 of 83
APPROVED FOR EXTERNAL DISTRIBUTION –PROPERTY OF AMPCONTROL PTY LTD –NOT TO BE REPRODUCED IN PART
TABLE OF CONTENTS
1 SAFETY AND OTHER WARNINGS..................................................................9
1.1 Safe Use of Equipment..............................................................................9
2 RECEIVING AND STORAGE..........................................................................10
2.1 Receiving.................................................................................................10
2.2 Inspection................................................................................................10
2.3 Storage after Delivery..............................................................................10
2.4 Unpacking of Equipment..........................................................................10
3 PRODUCT OVERVIEW ..................................................................................11
3.1 IPM V2 Relay...........................................................................................11
3.2 Accessories.............................................................................................14
4 INSTALLATION...............................................................................................16
4.1 General Warnings....................................................................................16
4.2 Mandatory Installation Practices ..............................................................16
4.3 Mechanical Installation Information..........................................................17
4.4 Electrical Installation Information .............................................................20
5 COMMISSIONING AND CALIBRATION .........................................................28
5.1 Earth Leakage .........................................................................................28
5.2 Earth Continuity.......................................................................................28
5.3 Insulation test ..........................................................................................28
5.4 Over Current / Motor Overload Current Injection......................................28
5.5 Short Circuit Current Injection..................................................................28
5.6 Current Detection in CTs .........................................................................28
5.7 Main Contactor Fail (MCF).......................................................................29
5.8 Voltage Measurement..............................................................................29
5.9 RS485 Interface.......................................................................................29
5.10 RTM (if Installed) ...................................................................................29
5.11 Lock, Reset, Aux, Ex-Stop, Ex-Start & MCI Inputs.................................29
6 EARTH PROTECTION FUNCTIONS..............................................................30
6.1 Earth Leakage .........................................................................................30
6.2 Insulation Test .........................................................................................31
6.3 Earth Continuity.......................................................................................34
7 CURRENT RELATED FUNCTIONS................................................................36
7.1 Overload Protection.................................................................................37
7.2 Short Circuit Protection............................................................................38
7.3 Phase Current Balance............................................................................38
7.4 Residual Current Signal...........................................................................39

Ampcontrol Pty Ltd –ABN 28 000 915 542
IPM V2 USER MANUAL
IPM2B003 Revision 15 –MAY/18
Uncontrolled Copy - Refer to Ampcontrol Website for Latest Version
Page 5 of 83
APPROVED FOR EXTERNAL DISTRIBUTION –PROPERTY OF AMPCONTROL PTY LTD –NOT TO BE REPRODUCED IN PART
7.5 Undercurrent Trip.....................................................................................39
8 VOLTAGE RELATED FUNCTIONS ................................................................40
8.1 Main Contactor Fail Protection.................................................................40
8.2 Undervoltage Trip....................................................................................40
8.3 Voltage Metering......................................................................................41
9 MACHINE COMMUNICATION........................................................................42
9.1 Remote Termination Module....................................................................42
9.2 Machine Type Codes...............................................................................42
9.3 Machine Type Number.............................................................................42
10 FAN BURP FUNCTION.................................................................................43
11 PUMP SNORE FUNCTION...........................................................................43
11.1 Basic Operation.....................................................................................43
11.2 Setup Procedure for Snore Function......................................................44
12 PRODUCT OPERATION...............................................................................45
12.1 Basic Display Operation.........................................................................45
12.2 Trip/Status Messages............................................................................46
12.3 Last Trip Status Messages.....................................................................48
12.4 Communications....................................................................................49
12.5 Remote IPM Control ..............................................................................50
12.6 System Control......................................................................................53
12.7 Analogue Output....................................................................................55
12.8 IPM Alarm Functions..............................................................................55
12.9 Event Log ..............................................................................................56
12.10 Time and Date.....................................................................................57
13 USER ADJUSTABLE SETTINGS..................................................................58
13.1 Parameter Groups.................................................................................58
13.2 Changing Settings .................................................................................60
14 SERVICE, MAINTENANCE & DISPOSAL.....................................................61
14.1 Equipment Service.................................................................................61
14.2 Equipment Maintenance ........................................................................62
14.3 Disposal.................................................................................................62
15 SPECIFICATIONS ........................................................................................63
16 EQUIPMENT LIST ........................................................................................64
APPENDIX 1: IPM Earth Leakage Tripping Curves............................................65
Tripping Curves for Instantaneous Trip Time Setting.....................................65
Tripping Curves for 25mA Trip Level Setting..................................................65
APPENDIX 2: IPM Full Load Current Selection Table (100:1 CT) ......................66

Ampcontrol Pty Ltd –ABN 28 000 915 542
IPM V2 USER MANUAL
IPM2B003 Revision 15 –MAY/18
Uncontrolled Copy - Refer to Ampcontrol Website for Latest Version
Page 6 of 83
APPROVED FOR EXTERNAL DISTRIBUTION –PROPERTY OF AMPCONTROL PTY LTD –NOT TO BE REPRODUCED IN PART
APPENDIX 3: IPM Full Load Current Selection Table (1000:1 CT) ....................67
APPENDIX 4: IPM Menu Structure.....................................................................68
APPENDIX 5: IPM Modbus Address Table ........................................................70
APPENDIX 6: Drawings .....................................................................................74

Ampcontrol Pty Ltd –ABN 28 000 915 542
IPM V2 USER MANUAL
IPM2B003 Revision 15 –MAY/18
Uncontrolled Copy - Refer to Ampcontrol Website for Latest Version
Page 7 of 83
APPROVED FOR EXTERNAL DISTRIBUTION –PROPERTY OF AMPCONTROL PTY LTD –NOT TO BE REPRODUCED IN PART
TABLE OF FIGURES
Figure 3.1: IPM Integrated Protection Relay................................................................................11
Figure 3.2: IPM Block Diagram ...................................................................................................12
Figure 3.3: Insulation Test Module..............................................................................................14
Figure 3.4: Phase Current Transformers.....................................................................................14
Figure 3.5: Earth Leakage Toroid................................................................................................15
Figure 3.6: Remote Termination Module.....................................................................................15
Figure 4.1: IPM Relay Dimensions..............................................................................................17
Figure 4.2: IPM Relay Rear Panel Details...................................................................................18
Figure 4.3: Current Transformer 45mm I.D. (Part: 101272) Dimensional Details.........................18
Figure 4.4: Current Transformer 88mm I.D. (Part: 101703) Dimensional Details.........................19
Figure 4.5: RTM Dimensions ......................................................................................................19
Figure 4.6: IPM Connection Block Diagram.................................................................................20
Figure 4.7: IPM Relay Electrical Connections: Digital Inputs.......................................................21
Figure 4.8: IPM Relay Electrical Connections: Phase Current Transformers...............................22
Figure 4.9: IPM Relay Electrical Connections: Earth Leakage Toroid .........................................23
Figure 4.10: IPM Relay Electrical Connections: Earth Leakage Toroid........................................24
Figure 4.11: IPM Relay Electrical Connections: ITM ...................................................................25
Figure 4.12: IPM Relay Electrical Connections: RS485 Connections..........................................25
Figure 4.13: IPM Relay Electrical Connections: Analogue Output...............................................26
Figure 4.14: IPM Relay Electrical Connections: Output Relays...................................................26
Figure 4.15: IPM Relay Electrical Connections: Power Supply....................................................27
Figure 6.1: AS/NZS 4871 Safe Touch Potential Levels (Figure C1 from the standard)................30
Figure 6.2: Instantaneous trip times for a selection of device trip level settings...........................31
Figure 6.3: ITM Insulation Test Connections...............................................................................32
Figure 6.4: Earth Continuity Connections....................................................................................34
Figure 7.1: IPM Phase CT Connections......................................................................................36
Figure 8.1: IPM Voltage Monitoring Connections........................................................................40
Figure 12.1: IPM Relay Fascia and Display.................................................................................45

Ampcontrol Pty Ltd –ABN 28 000 915 542
IPM V2 USER MANUAL
IPM2B003 Revision 15 –MAY/18
Uncontrolled Copy - Refer to Ampcontrol Website for Latest Version
Page 8 of 83
APPROVED FOR EXTERNAL DISTRIBUTION –PROPERTY OF AMPCONTROL PTY LTD –NOT TO BE REPRODUCED IN PART
TABLE OF TABLES
Table 1: Pre-set Resistance and Alarm Thresholds ....................................................................32
Table 2: Status Indication............................................................................................................45
Table 3: Trip/Status Message.....................................................................................................46
Table 4: Last Trip Messages.......................................................................................................48
Table 5: Modbus Commands......................................................................................................49
Table 6: Modbus Exception.........................................................................................................49
Table 7: Modbus Status..............................................................................................................50
Table 8: Events...........................................................................................................................56
Table 9: User Adjustable Settings...............................................................................................58
Table 10: User Adjustable Settings.............................................................................................59

Ampcontrol Pty Ltd –ABN 28 000 915 542
IPM V2 USER MANUAL
IPM2B003 Revision 15 –MAY/18
Uncontrolled Copy - Refer to Ampcontrol Website for Latest Version
Page 9 of 83
APPROVED FOR EXTERNAL DISTRIBUTION –PROPERTY OF AMPCONTROL PTY LTD –NOT TO BE REPRODUCED IN PART
1 SAFETY AND OTHER WARNINGS
For safety reasons, the relay must be installed, operated and serviced only by competent personnel.
Please read and understand this instruction manual completely before installing, operating or servicing
this equipment. Failure to install or operate this instrument in accordance with the instructions contained
in this manual may create hazardous operating conditions.
1.1 Safe Use of Equipment
The equipment supplied has been designed and manufactured to ensure safe operation. The equipment
must only be used within the design parameters.
The instructions within this manual must be observed as an aid towards achieving the safest possible
installation.
Persons responsible for installation, maintenance, or operation, must observe the following
instructions:
1.1.1 Changes to Equipment
Changes in the design and modifications to the equipment are not permitted. Unauthorised changes
made to the hardware or operating firmware will void the manufacturer's warranty, and may
compromise the integrity of the system into which it is installed and other connected equipment.
1.1.2 Equipment Knowledge
Experience with, or understanding of, this equipment is essential for the safe installation and removal of
the equipment. Therefore, please read and understand this manual prior to use. Competency based
training courses are recommended and are available on request.
1.1.3 Manual Handling
Precautions have been taken to ensure all equipment is safe to handle and free from sharp edges.
However, care should always be taken when handling enclosures and gloves should be worn.
1.1.4 Installation
Correct operation and safety depend on the relay 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 relay functioning correctly it is highly recommended that all safety functions
of the relay be periodically tested to ensure correct operation.

Ampcontrol Pty Ltd –ABN 28 000 915 542
IPM V2 USER MANUAL
IPM2B003 Revision 15 –MAY/18
Uncontrolled Copy - Refer to Ampcontrol Website for Latest Version
Page 10 of 83
APPROVED FOR EXTERNAL DISTRIBUTION –PROPERTY OF AMPCONTROL PTY LTD –NOT TO BE REPRODUCED IN PART
2 RECEIVING AND STORAGE
2.1 Receiving
All possible precautions are taken to protect the equipment against damage or losses during shipment,
however before accepting delivery, check all items against the packing list or bill of loading. If there is
evidence of physical damage, notify Ampcontrol immediately.
Notify Ampcontrol immediately in case of any discrepancies to the packing list. Keep a record of any
claims and correspondence. Photographs are recommended.
Where practicable do not remove protective covers prior to installation unless there are indications of
damage. Boxes opened for inspection and inventory should be carefully repacked to ensure protection of
the contents or else the parts should be packaged and stored in a safe place. Examine all packing
boxes, wrappings and covers for items attached to them, retain and store any approval documentation
for your safety file as 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.