Ice AP902 User manual

Instruction manual –AP902 Arc Protection Unit 2 (35)
A1008B
Revision
Date
Changes
Written by
Checked by
A
31/10/2017
First issue
ASI
RBI
B
28/05/2018
Update
HWE
GBI
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Read these instructions carefully and inspect the equipment to become familiar with it
before trying to install, operate, service or maintain it.
Electrical equipment should be installed, operated, serviced, and maintained only by
qualified personnel. Local safety regulations should be followed. No responsibility is
assumed by ICE for any consequences arising out of the use of this material.
We reserve right to changes without further notice.

Instruction manual –AP902 Arc Protection Unit 3 (35)
A1008B
TABLE OF CONTENTS
1ABBREVIATIONS ............................................................................................................. 5
2GENERAL......................................................................................................................... 6
2.1 Arc protection unit AP902 features........................................................................... 7
2.2 Simplified block diagram .......................................................................................... 8
3OPERATION AND CONFIGURATION.............................................................................. 9
3.1 LED indicator functions ............................................................................................ 9
3.2 LED Operation Quick Guide................................................................................... 10
3.3 Push-button description.......................................................................................... 11
3.3.1 Auto configuration (system setup)..................................................................... 11
3.4 Reset ..................................................................................................................... 11
3.5 Dipswitch settings .................................................................................................. 12
3.5.1 Scheme select dip-switch settings .................................................................... 14
3.6 Non-volatile memory .............................................................................................. 15
4ARC SENSORS .............................................................................................................. 16
4.1 Sensor Type Dependencies ................................................................................... 16
5SYSTEM SELF-SUPERVISION ...................................................................................... 17
6APPLICATION EXAMPLES ............................................................................................ 18
6.1 MV or LV application with current and light condition.............................................. 18
6.2 Circuit breaker failure protection (CBFP)................................................................ 19
7CONNECTIONS.............................................................................................................. 20
7.1 Outputs .................................................................................................................. 21
7.1.1 Trip relays T1 and T2........................................................................................ 21
7.1.2 Trip relays T3 and T4........................................................................................ 21
7.1.3 Binary output BO1 ............................................................................................ 21
7.1.4 System failure relay SF..................................................................................... 21
7.2 Inputs ..................................................................................................................... 22
7.2.1 Arc fiber optic loop sensor channels S1, S2, S3 ............................................... 22
7.2.2 Binary inputs BI1 and BI2 ................................................................................. 22
7.3 Auxiliary voltage..................................................................................................... 23
8WIRING DIAGRAM ......................................................................................................... 24
9DIMENSIONS AND INSTALLATION............................................................................... 25
10 TESTING ........................................................................................................................ 27
10.1 Carrying out testing in light only mode.................................................................... 27
10.2 Carrying out testing in light and current mode ........................................................ 28

Instruction manual –AP902 Arc Protection Unit 4 (35)
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10.3 Testing the CBFP function ..................................................................................... 29
10.4 Testing arc flash protection unit operation time ...................................................... 29
10.5 Test plan example.................................................................................................. 30
11 TROUBLESHOOTING GUIDE ........................................................................................ 31
12 TECHNICAL DATA ......................................................................................................... 32
12.1 Protection............................................................................................................... 32
12.2 Auxiliary voltage..................................................................................................... 32
12.3 Trip relays T1, T2, T3, T4....................................................................................... 32
12.4 Binary Output BO1 ................................................................................................. 32
12.5 Binary Inputs BI1, BI2............................................................................................. 32
12.6 Disturbance tests ................................................................................................... 33
12.7 Voltage tests .......................................................................................................... 33
12.8 Mechanical tests .................................................................................................... 33
12.9 Casing and package .............................................................................................. 33
12.10Environmental conditions ....................................................................................... 34

Instruction manual –AP902 Arc Protection Unit 5 (35)
A1008B
1ABBREVIATIONS
CB –Circuit breaker
CBFP –Circuit breaker failure protection
EMC –Electromagnetic compatibility
EPROM –Erasable programmable read only memory
HW –Hardware
LED –Light emitting diode
LV –Low voltage
ms –Millisecond
MV –Medium voltage
NC –Normally closed
NO –Normally open
SF –System failure
SW –Software
uP - Microprocessor

Instruction manual –AP902 Arc Protection Unit 6 (35)
A1008B
2GENERAL
AP902 is a sophisticated micro-processor based arc flash protection unit including
complete self-supervision functionality. It is designed to minimize the damage caused by
an arcing fault (arc flash) by tripping the circuit breaker sourcing the fault current. The
AP902 complete system self-supervision function provides the highest level of
dependability by continuously monitoring all internal system functions along with external
connections.
AP902 is designed according to the latest protection relay standards and is hence suitable
for installations in rough environments, such as utility, traditional or renewable power
plants, off shore, marine, oil and gas, mining, steel or any other heavy industry
applications and as well commercial and institutional electrical systems. AP902 is suitable
for either medium voltage or low voltage switchgear and motor control center applications
in both new and retrofit installations.

Instruction manual –AP902 Arc Protection Unit 7 (35)
A1008B
2.1 ARC PROTECTION UNIT AP902 FEATURES
AP902 is a multipurpose arc flash protection unit and can be applied for variety of
applications. AP902 can be used as a stand-alone unit or as part of a more complex arc
protection system through the binary bus. Main features of AP902:
-80-265Vac/dc auxiliary power supply or optional 18-72Vdc power supply
-3 arc fiber loop channel
-2 binary inputs (nominal voltage of 24 or 110 or 220Vdc)
-3 normally open trip relay outputs (direct trip circuit rated)
-1 normally open or optionally normally closed (electronic lock-out) trip relay
output (direct trip circuit rated)
-1 binary output (24Vdc)
-1 system failure relay output
-11 Indication LEDs
-Push-button
Figure 2-1 Arc protection unit AP902

Instruction manual –AP902 Arc Protection Unit 8 (35)
A1008B
2.2 SIMPLIFIED BLOCK DIAGRAM
AP902 simplified block diagram in Figure 2-2 shows the main components of the AP902
unit.
Figure 2-2 AP902 simplified block diagram

Instruction manual –AP902 Arc Protection Unit 9 (35)
A1008B
3OPERATION AND CONFIGURATION
3.1 LED INDICATOR FUNCTIONS
AP902 contains 11 indication LEDs. A user definable text pocket can be slid in for
identifying each LED function (except Power and Error LEDs). LED’s are located at the
front plate of the unit for clear viewing without a need for opening doors.
During power up the unit performs a LED-test. All LEDs are turned on for 2 seconds and
then back off. Only the blue power LED will remain on. When powered up, the unit goes
in 50ms into protection mode even while the LED test is being performed.
In normal operation only the blue power LED is ON.
The fiber sensor LEDs in inactive condition are off. If an arc fiber sensor is activated the
corresponding sensor channel LED will turn on if the activation is longer than 1.5ms. The
sensor LED activation function is latched (steady light). To clear the LED the “SET” button
should be pressed.
In case that a fiber sensor connection drops off or configuration mismatch situation is
detected by system self-supervision function (new sensor connected without running auto-
configuration system setup, see chapter 3.3.1) the corresponding LED will start flashing
and the ERROR LED will activate.
The Binary I/O LEDs are indicating the I/O-lines status. If any of the lines become active
for more than 1.5ms the corresponding LED will turn on (latch).
In trip situation the corresponding trip LED will turn on. Trip outputs are controlled by
dipswitch settings. (See chapter 3.5.)
All activation and trip indication LEDs are latched, even if the dipswitch setting is in non-
latched mode. They have to be cleared by pushing the “SET” button.
LED indications are stored in non-volatile EPROM memory for identifying the trip
information in case the auxiliary power is lost. When re-powering the unit after power
supply loss the actual LED status can be visualized from the front of the unit.

Instruction manual –AP902 Arc Protection Unit 10 (35)
A1008B
3.2 LED OPERATION QUICK GUIDE
LED
OFF
STEADY
ON
BLINKING
ACTION IF ABNORMAL
POWER
Blue
Auxiliary supply
disconnected
Auxiliary power
connected
N/A
Check the power source
ERROR
Red
System healthy
System failure
Configuration
mismatch.
Protection partly
operational
Verify system condition. see chapters 11:
Troubleshooting guide and 5: System self-
supervision
T1,T3,T4
Red
Normal status
Trip relays
T1,T3,T4
activated
N/A
Check the reason for trip. Clear the fault and reset
indications by pushing SET button
T2, T4
Red
Normal status
Trip relays T2,
T4 activated
N/A
Check the reason for trip. Clear the fault and reset
indications by pushing SET button
S1
Amber
Normal status
Fiber sensor
channel
activated
Fiber sensor drops
off or system set-
up not performed
Check why sensor activated or check the sensor
continuity or perform system set-up (see
chapter:3.3.1 Auto configuration (system setup)
S2
Amber
Normal status
Fiber sensor
channel
activated
Fiber sensor drops
off or system set-
up not performed
Check why sensor activated or check the sensor
continuity or perform system set-up (see
chapter:3.3.1 Auto configuration (system setup)
S3
Amber
Normal status
Fiber sensor
channel
activated
Fiber sensor drops
off or system set-
up not performed
Check why sensor activated or check the sensor
continuity or perform system set-up (see
chapter:3.3.1 Auto configuration (system setup)
QD
Amber
Normal status
Quenching
Device channel
activated
Fiber connection
to quenching
system drops off
or system set-up
not performed
Check the fiber connection and/or the system
configuration.
BI1
Amber
Normal status
Binary input 1
activated
Binary input 1
loose connection
Check the binary input wiring.
BI2
Amber
Normal status
Binary input 2
activated
Binary input 2
loose connection
Check the binary input wiring.
BO1
Amber
Normal status
Binary Output
activated
N/A
Table 3-1: LED operation quick guide

Instruction manual –AP902 Arc Protection Unit 11 (35)
A1008B
3.3 PUSH-BUTTON DESCRIPTION
AP902 contains one single push-button (SET) that can be used for all operational
functions of the unit. The push-button is utilized for auto-configuration of the system (see
chapter 3.3.1) and for resetting the indicators and latched output relays.
3.3.1 AUTO CONFIGURATION (SYSTEM SETUP)
When all sensors and binary lines have been connected an auto-configuration procedure
must be executed. The initialization sequence is performed by pressing the “SET”-button
for 2 seconds, and the AP902 sensor LEDs and BI1/BI2 LEDs start blinking. The unit
scans these inputs to see if they are connected and when input is detected the
corresponding LEDs are lit up to mark that a connection was found. The inputs without
connection continue blinking during the remaining 3 seconds. After total time of 5
seconds, all LEDs are turned off. During this system setup the dipswitch setting are also
stored in non-volatile memory.
All sensor inputs will remain operational even when not auto-configured. The auto-
configuration is only used for self-supervision purposes.
Note: in order to redo auto-configuration for a unit containing less connections (binary
inputs/outputs or sensors) than in previous memorized set-up a dip-switch (anyone) must
be moved back and forth prior to performing auto-configuration. Timeout allowing new
configuration is 1 minute. Reconfiguration with more connections is allowed without
moving the dip-switch.
3.4 RESET
All LED indications and latched trip relays are reset by pressing the “SET” button for 1
second. Otherwise the latched trip relays will remain activated until auxiliary power is
disconnected. All LED indications will remain active until reset is performed by the
operator even when auxiliary power supply is disconnected (see chapter 3.6 Non-volatile
memory).

Instruction manual –AP902 Arc Protection Unit 12 (35)
A1008B
3.5 DIPSWITCH SETTINGS
AP902 functionality such as tripping logic is configured using dipswitch settings. Different
trip schemes can be easily programmed by selecting the appropriate dipswitch positions.
This gives users the flexibility to change settings dependent on the demand of application.
Tripping may be selected based on arc light only or arc light and current thresholds (or
other tripping criterion such as undervoltage, or similar). Current thresholds or other
tripping criterion may be applied to binary input BI1 for blocking trip caused by natural light
sources. Also the CBFP time can be selected by dipswitch setting according to the
requirement of the CBFP function. Dipswitches are located at the back of the unit for easy
access. See Figure 3-1 AP902 dipswitches and Table 3-2 AP902 dipswitch setting for
details of settings.
Figure 3-1 AP902 dipswitches

Instruction manual –AP902 Arc Protection Unit 13 (35)
A1008B
Dipswitch
Function selection
ON (LEFT
POSITION)
OFF (RIGHT POSITION)
8
L> / L>+I>
Fiber sensor channels S2
and S3 trip criteria
Trip on light only (L>).
Trip on light and overcurrent (L> +
I>).
Both signals are required
simultaneously to trip.
7
S1: L> / L>+I>
Sensor channel S1 trip
criteria
Trip on light only (L>).
Trip on light and overcurrent (L> +
I>).
Both signals are required
simultaneously to trip.
6
Latch / non-latch
Latch or non-latch for trip
relays T1 and T2
T1 and T2 operate as
latched.
T1 and T2 operate as non-latched.
Note: Trip relays T3 and T4 are always latched. Binary output BO1
function is always non-latched.
5
100 / 150ms
CBFP time setting
CBFP time is set to 100ms.
CBFP time is set to 150ms.
4
Scheme select
Scheme selection
Refer to chapter 3.5.1 and 6
Refer to chapter 3.5.1 and 6
3
Scheme select
Scheme selection
Refer to chapter 3.5.1 and 6
Refer to chapter 3.5.1 and 6
2
Scheme select
Scheme selection
Refer to chapter 3.5.1 and 6
Refer to chapter 3.5.1 and 6
1
Scheme select
Scheme selection
Refer to chapter 3.5.1 and 6
Refer to chapter 3.5.1 and 6
Table 3-2 AP902 dipswitch setting selection
The chapter 3.5.1 shows AP902 internal logic and dipswitch selections. For inputs and
outputs descriptions refer to chapter 7.

Instruction manual –AP902 Arc Protection Unit 14 (35)
A1008B
3.5.1 SCHEME SELECT DIP-SWITCH SETTINGS
This chapter describes the available schemes that are configured using the Scheme
Select 1…4 dip-switches.
Logic scheme 0
The AP902 logic scheme 0 can be not only applied as stand-alone arc protection unit, but
also widely used as non-selective outgoing feeder compartment protection. Depend on
this scheme, user can either select light only mode or arc light + overcurrent mode to trip
all circuit breakers. The detailed instruction is described in “AP SAS™Standard Arc
Schemes - Instruction booklet”.
Figure 3-2: AP902 logic scheme 0

Instruction manual –AP902 Arc Protection Unit 15 (35)
A1008B
Logic scheme 1
The AP902 logic scheme I is mainly utilized in selective arc protection solution. The fiber
sensor S1 monitors the outgoing feeder cable compartment. The fiber sensor S2 monitors
the corresponding feeder breaker compartment and busbar compartment. Trip contact T1
is responsible for tripping circuit breaker of the outgoing feeder. The detailed instruction is
described in “AP SAS™Standard Arc Schemes - Instruction booklet”.
Figure 3-3: AP902 logic scheme I
3.6 NON-VOLATILE MEMORY
All critical system data including dipswitch settings and auto-configuration file described in
chapter 3.3.1 are stored in EPROM non-volatile memory to ensure correct operation and
full self-supervision even if auxiliary power is lost temporarily.
Also all LED indications described in chapter 3.1 are stored in non-volatile memory in
order to provide quick recovery of the system status indication even if auxiliary power is
lost temporarily. This feature is especially important if auxiliary power is lost after tripping.
Non-volatile memory does not require a power supply to maintain information and will
retain settings and indications permanently without power.

Instruction manual –AP902 Arc Protection Unit 16 (35)
A1008B
4ARC SENSORS
AP900 series provides choice of different types of arc sensors to be utilized in different
units and different switchgear types according to specific application requirements.
Available sensor types are arc light point sensors and arc light fiber optic loop sensors.
Arc light point sensors are typically installed in metal clad compartments providing quick
accurate location of the faulted area. Arc light fiber loop sensors are installed typically to
cover a wider protected area with one fiber when no need for more exact fault location
exists. The detailed instructions are described in “Arc Sensors Series - Instruction
booklet”.
4.1 SENSOR TYPE DEPENDENCIES
Different sensor types can be utilized with the AP902 arc flash protection unit. The table
below describes the dependencies.
AS01
AS02
AS06
AS07
AP902
No
No
Yes
Yes
Table 4-1: Arc sensor dependencies

Instruction manual –AP902 Arc Protection Unit 17 (35)
A1008B
5SYSTEM SELF-SUPERVISION
AP902 includes an extensive self-supervision feature. Self-supervision includes both
internal functions and external connections. The self-supervision module monitors power
supply, HW and SW malfunctions and binary input connection and sensor problems.
Dipswitch settings are also supervised by comparing actual value with stored Non-volatile
memory data (see chapter 3.3.1 Auto configuration (system setup))
In a healthy condition the power LED is on and the System Failure (SF) relay is energized.
If the self-supervision function detects a faulty condition or the power supply fails the self-
supervision relay is released and the ERROR LED is lit.
If a fiber sensor failure occurs, the unit will go into ERROR mode. The error LED will turn
on, the SF relay will release and the corresponding faulty fiber sensor channel LED will
start blinking. In this situation the unit is still in protection mode, but with the faulty fiber
sensor channel blocked. If the error is resolved the unit will automatically clear the SF-
status. This means that SF relay will energize and the error led will turn off. If one or more
of the sensors are disconnected the healthy sensors remain in use and unit remains
operational accordingly. The AP902 will remain in error mode until the disconnected
sensors are repaired.
If a dip switch setting is changed after the auto-configuration function (see chapter 3.3.1
Auto configuration) has been executed, the unit will go into SF-alarm mode. The
configured (stored) setting is however still valid and the unit is still operational.

Instruction manual –AP902 Arc Protection Unit 18 (35)
A1008B
6APPLICATION EXAMPLES
AP902 may be applied to a variety of power switchgear and controlgear layouts and
technologies. Some typical applications are described in this section. Please consult your
nearest ICE representative for a solution to your particular application.
6.1 MV OR LV APPLICATION WITH CURRENT AND LIGHT CONDITION
AP902 may be applied requiring both overcurrent and arc light conditions for trip. In this
case tripping is performed only if both conditions are fulfilled simultaneously. Typically the
overcurrent condition is obtained from the AP910 unit and the trip relay will be activated in
7ms. The overcurrent condition may be monitored by non-ICE products also (e.g. generic
feeder protection relay) and the total operation time is then dependent on device feeding
the overcurrent signal to AP902.
The sensor channel S1 can be set to operate on light only even if other channels operate
on both conditions of arc light and overcurrent.
Figure 6-1 shows an example of a system applying both overcurrent and arc light for
tripping from the fiber sensor channels S2 and S3 activations and arc light only from fiber
sensor channel S1 activation. S1 channel is monitoring the transformer feeder bus duct
above the current monitoring point. S2 channel is monitoring the main breaker and the
busbar. S3 channel is monitoring each feeder. For the maximum length of each fiber
sensor type refer to “Arc Sensors Series - Instruction booklet”.
The current monitoring signal is in this application coming from an external overcurrent
relay.

Instruction manual –AP902 Arc Protection Unit 19 (35)
A1008B
Figure 6-1: LV or MV stand-alone application .
Figure 6-1: LV or MV application example with light and current tripping criteria for fiber
sensor channels S2 and S3. The sensor channel S1 monitoring the zone before CT is set
to operate on light only. The current threshold monitoring signal may come either from an
external overcurrent relay or from AP910 arc protection unit. In this example an
overcurrent relay (50/51) is applied to monitor the overcurrent condition.
6.2 CIRCUIT BREAKER FAILURE PROTECTION (CBFP)
AP902 includes a selective circuit breaker failure function which can be enabled by
dipswitch setting (see chapter 3.5 Dipswitch settings). When enabled, the breaker failure
function activates when the tripped breaker fails to operate. Breaker failure function is
activated if AP902 detects the presence of light after a set operate time. When AP902 is
set to operate on light and current both parameters must persist to activate CBFP.
Breaker failure can be set to operate either on 100ms or 150ms delay (see chapter 3.5
Dipswitch settings).

Instruction manual –AP902 Arc Protection Unit 20 (35)
A1008B
7CONNECTIONS
Figure 7-1: AP902 terminals at rear plate