Ampcontrol OCS User Manual
Publicité
Publicité
OCS
OUTLET CASSETTE SYSTEM
User Manual
Version: 5, FEBRUARY/2020
Designed and manufactured in Australia by Ampcontrol Pty Ltd
Ampcontrol Pty Ltd
– ABN 28 000 915 542
OCS USER MANUAL
MAG-182 Version 5 – FEB/2020
WARNING!
The warning symbol highlights a potential risk of injury or death .
Please share these warnings with other operators.
CAUTION!
The caution symbol highlights a potential risk of damage to equipment .
Please share these cautions with other operators.
NOTE
The note symbol highlights key information .
Please share these notes with other operators.
ENVIRO
The enviro (environmental) symbol highlights areas which may have an impact on the surrounding fauna and/or flora .
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Copyright Notice
The Ampcontrol OCS 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 Outlet Cassette System.
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 +61 1300 267 373 | F +61 2 4903 4888
EMAIL: [email protected]
WEB: ampcontrolgroup.com
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TABLE OF CONTENTS
1 SAFETY AND OTHER WARNINGS .................................................................. 8
5 COMMISSIONING AND CALIBRATION ......................................................... 19
5.6 Over Current/Motor Overload Current Injection ........................................ 20
6.5 Protection Element Parameters ............................................................... 26
6.7 Cassette Isolation & Earthing (OCS Only) ................................................ 28
7 AS/NZS 2081:2011 PROTECTION FUNCTIONS ............................................ 30
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8 CURRENT RELATED PROTECTION FUNCTIONS ........................................ 39
9 OTHER PROTECTION FUNCTIONS .............................................................. 46
10 SERVICE, MAINTENANCE & DISPOSAL ..................................................... 47
11.2 Protection Element Specifications .......................................................... 49
APPENDIX A: PROTECTION ELEMENT LOAD CURRENT TABLES ................ 53
A1: Protection Element Full Load Current Table ............................................ 53
A2: Protection Element TMS Table ................................................................ 55
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TABLE OF FIGURES
Figure 3.1: Ampcontrol Outlet Cassette System (OCS) .......................................................................... 11
Figure 3.2: Ampcontrol Fixed Cassette System (FCS) ............................................................................ 12
Figure 4.1: 2-Way OCS Dimensions (Pictured with 2 Cassettes Installed) .............................................. 16
Figure 4.2: 3-Way OCS Dimensions (Pictured with 3 Cassettes Installed) .............................................. 16
Figure 4.3: FCS Dimensions (Pictured with 5 Cassettes Installed) ......................................................... 17
Figure 4.4: Remote Termination Unit (RTX) ........................................................................................... 18
Figure 6.1: Actuator position within chassis ............................................................................................ 29
TABLE OF TABLES
Table 1: Definitions ................................................................................................................................... 7
Table 2: Event Log Entry Types ............................................................................................................. 23
Table 3: Outlet Parameter Descriptions .................................................................................................. 26
Table 4: Load Parameter Descriptions ................................................................................................... 27
Table 5: Protection Element - Earth Leakage Trip Characteristics .......................................................... 30
Table 6: Protection Element - Earth Leakage CT Failure Trip Characteristics ........................................ 31
Table 7: Protection Element – Residual Voltage Trip Characteristics ..................................................... 31
Table 8 Protection Element - Earth Continuity Series Trip Characteristics .............................................. 33
Table 9: Protection Element - Earth Continuity Shunt Trip Characteristics .............................................. 33
Table 10: Protection Element - Earth Continuity Pilot Interlock Trip Characteristics ................................ 34
Table 11: Protection Element - Earth Fault Lockout (EFLO) Trip Characteristics .................................... 35
Table 12: Protection Element – High Voltage Insulation Test Characteristics ......................................... 35
Table 13: Protection Element – Voltage Detection (Loss of Vacuum) Trip Characteristics ...................... 36
Table 14: Protection Element – Frozen Contactor Trip Characteristics ................................................... 37
Table 15: Protection Element – Contactor Close Fail Trip Characteristics .............................................. 37
Table 16: Protection Element – External Open Trip Characteristics ........................................................ 38
Table 17: Protection Element – Coil Voltage Detection Trip Characteristics ........................................... 38
Table 18: Protection Element – Over Current Trip Characteristics .......................................................... 39
Table 19: Protection Element – Motor Overload Trip Characteristics ...................................................... 41
Table 20: Protection Element – Short Circuit Trip Characteristics ........................................................... 44
Table 21: Protection Element – Current Balance Trip Characteristics ..................................................... 45
Table 22: Protection Element – Under Current Trip Characteristics ........................................................ 46
Table 23: Protection Element – Under Voltage Trip Characteristics ........................................................ 46
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DEFINITIONS
Table 1: Definitions
Term
Cassette
CB
CBR
FCS
MC
MCR
Definition
A Cassette is the unit that is installed within Outlet Cassette System (OCS) or Fixed Cassette System (FCS). There are two types: FCS Cassettes and
OCS Cassettes.
Each Cassette houses a Protection Element, phase current transformers and main contactor components.
Circuit Breaker; Main circuit breaker that controls power to all outlets.
Circuit Breaker Relay; power relay within the Cassette Protection Element to control the supply to the circuit breaker coil. The Protection Element ’s
CBR output is designed for use with under voltage tripping coils.
FCS is the acronym for the Ampcontrol Fixed Cassette System.
Main Contactor; the main power circuit opening device. Installed within the
Cassette, the main contactor is opened and closed in order to turn the outlet on and off.
Main Contactor Relay; power relay installed within the Cassette Protection
Element to control the supply to the main contactor coil. All trip times specified are to the opening of the MCR.
OCS OCS is the acronym for the Ampcontrol Outlet Cassette System
Parameter Dongle
A small memory device which is used to store setting information for the
MEM and RTX modules which is attached to the wiring harness of the installation.
Protection Element
The Protection Element is installed in each Cassette, providing a host of protection functions for the outlet.
RTX
Remote Termination Device; Module that is installed at the machine end of the pilot to provide machine identification and communications.
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1 SAFETY AND OTHER WARNINGS
For safety reasons, the OCS 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 OCS 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 OCS functioning correctly it is highly recommended that all safety functions of the OCS be periodically tested to ensure correct operation.
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1.1.6 Certification
WARNING!
To comply with the Conditions of Certification , ensure full serviceable life of the product, and avoid nullifying the warranty, it is essential to exercise great care with the installation, use and storage of the system components. Failure to comply with the Conditions of Certification may seriously compromise the integrity of the system and/or its components, and the consequence could be fatal. The user must ensure that the
"Special Conditions" outlined in the certificate and associated attachment is met or the certificate (and the I.S. rating) will not be valid.
Refer to the relevant section of the safety file for copies of certificates of conformity outlining the special conditions of the certification for the explosion protected equipment or components.
The latest certificate and its associated attachments outlining the special conditions of the certification are maintained and available on the IEC Ex Website: http://iecex.iec.ch.
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2 RECEIVING AND STORAGE
2.1 Receiving
All possible precautions are taken to protect the equipment against damage or losses during shipment, however before accepting delivery, check all items against the packing list or bill of loading. If there is evidence of physical damage, notify Ampcontrol immediately.
Notify Ampcontrol immediately in 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 040˚C, preferably on shelves and protected from moisture and sunlight.
2.4 Unpacking of Equipment
The method of packing used will depend on the size and quantity of the equipment. The following cautions should be interpreted as appropriate.
CAUTION!
Take care when unpacking crates as the contents may have shifted during transport .
ENVIRO
The disposal of packaging materials, replaced parts, or components must comply with environmental restrictions without polluting the soil, air or water.
Ensure that any timber and cardboard used as packaging is disposed of in a safe and environmentally responsible manner .
Where possible, dispose of all waste products i.e. oils, metals, plastic and rubber products by using an approved recycling service centre.
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3 PRODUCT OVERVIEW
The Ampcontrol Outlet Cassette System (OCS) is a major advancement in control and protection technology. The OCS combines the outlet contactor, protection element, current transformers and outlet test circuitry into a single replaceable unit. This has the advantage of resulting in minimal down-time in the event of a fault.
The Ampcontrol OCS is available in two types: the standard OCS and the Fixed Cassette System (FCS).
The OCS provides isolation and earthing of individual outlets via integrated actuators that are controlled at the touch of a button via a Human Machine Interface (HMI) screen. In this manner, operators are not exposed to potential electric shocks resulting from residual static charge on the cable. This also eliminates a potential ignition source of an explosive atmosphere.
Figure 3.1: Ampcontrol Outlet Cassette System (OCS)
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The FCS (1.1kV systems only) sacrifices the remote isolation and earthing functionality of the OCS to provide a higher outlet density. Due to the compact nature of the FCS, 10 outlets are able to be installed in the same area used by a conventional 8 outlet system. The FCS is designed as a fully bolted, nonwithdrawable installation, whilst still minimising downtime by providing fast and easy removal of the cassette protection components.
Figure 3.2: Ampcontrol Fixed Cassette System (FCS)
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Key Features:
Individual outlet isolation and earthing system (OCS)
Operations via HMI interface
Ethernet communications
Cassette Protection Element
All electrical protection functions are provided by the new generation OCS Protection Element and include:
Earth Leakage
Earth Fault Lockout
Earth Continuity (including remote start mode)
Contactor Failure protection
Motor thermal overload protection
Short circuit protection
Under current protection
Current balance protection
Under voltage protection
Automatic HV insulation test prior to outlet closing
Machine identification.
The following Control and Monitoring functions are accessed via the Ethernet/IP communications:
Monitoring of key parameters for all protection functions
Protection settings and parameter adjustments
Statutory tests
Resetting of protection trips
Outlet control (starting and stopping)
The status of all protection functions and control logic.
All control of outlet(s) is from the HMI screen.
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4 INSTALLATION
4.1 General Warnings
These instructions have been designed to assist users of the OCS with installation.
Before the OCS can be installed, there are a number of things that need to be considered and understood to prevent incorrect or unsafe operation of the OCS or the system into which it is installed.
Along with relevant competence, and an understanding of the target application, the following points should be considered:
4.1.1 Ensure that the information provided in this user manual is fully understood.
It is extremely important that the limitations and functionality of the OCS are understood to prevent incorrect installation and use from creating a potentially dangerous risk. If in doubt as to the nature of the limitations or their implication, refer to the installation’s safety dossier or consult a competent authority such as a supervisor or Ampcontrol technical representative.
4.1.2 Ensure that the application into which the OCS is being installed has been properly defined, designed and approved.
Any system intended to mitigate the risk of injury needs to be properly designed and implemented.
Such a system must be the result of structured risk analysis with the outcomes used to define the system requirements. These requirements, in turn, will guide the choice of instrumentation, logic solvers and actuators needed to implement the system. Understanding the needs of the system will ensure proper selection of equipment.
4.1.3 Ensure that the OCS will properly perform the required functions within the system design.
It is important to understand how the OCS is intended to interact with other equipment within a system.
For safe and reliable use, it is crucial that neither the OCS’s logical operation nor its signalling be compromised by incompatibilities with connected equipment.
4.1.4 Modifications of any form to the OCS are prohibited.
The OCS as supplied has been designed and manufactured to comply with the requirements of protection standards. If modifications of any form are made to the OCS, the equipment may no longer be fit for purpose. If any modifications or damage to the OCS is evident, do not use the equipment and contact Ampcontrol for advice.
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4.2 Mandatory Installation Practices
The following information must be adhered to when installing the OCS. Failure to adhere to this information may give rise to unsafe operation.
Using the OCS in a manner that exceeds its electrical, functional or physical specifications, or in a way that is contrary to its operating restrictions, may create risks to personnel and/or equipment resulting in injury or death.
The OCS is to be installed in an electrical system having a fault level equal to or less than as marked on the name plate.
The OCS ’s control supply must remain within the specified voltage range.
The installation of the OCS must be carried out by suitably trained and qualified personnel.
Identification labels fixed to the OCS must not be damaged, removed or covered.
The installation is to be in accordance with the relevant installation Standards/Codes of Practice.
Modifications must not be made to any part of the OCS. As supplied, the unit is built to, and complies with the relevant standards. Modifications to its construction will render the unit noncompliant.
Complete and accurate records of the installation must be kept as part of the site installation.
The equipment is to be maintained as per the conditions as listed in the certification documentation.
NOTE
If the OCS is to be used in a hazardous environment, it must be installed within suitably certified flameproof enclosure.
NOTE
The equipment is to be operated within an ambient temperature range of - 20°C to + 40°C.
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4.3 Mechanical Arrangement
4.3.1 OCS Dimensions
The OCS is available in two sizes: the 2-Way OCS and the 3-Way OCS. These modules are designed to be stacked on top of each other, allowing the best utilisation of the installation area.
509
683
449
Figure 4.1: 2-Way OCS Dimensions (Pictured with 2 Cassettes Installed)
509
683
750
Figure 4.2: 3-Way OCS Dimensions (Pictured with 3 Cassettes Installed)
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4.3.2 FCS Dimensions
The FCS has a very high outlet density, allowing more outlets to be installed with a smaller footprint.
1160
450 665
Figure 4.3: FCS Dimensions (Pictured with 5 Cassettes Installed)
4.4 Electrical Installation Information
Refer to drawing OCSE002in APPENDIX B: DRAWINGS for electrical installation information.
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4.5 External Accessories
4.5.1 Earth Leakage CT
The Outlet Cassette Protection Element uses an Ampcontrol EL500 series current transformer for earth leakage measurements. For the purposes of outlet identification tests during operation, the earth leakage toroid is installed separately to the Cassette.
4.5.2 Remote Termination Unit (RTX)
The RTX is a microprocessor based module that can be utilised to replace the diode at the end of the trailing cable pilot conductor. It is powered by and communicates via the pilot line. Its non-volatile memory stores the parameters to configure the outlet as appropriate for the connected machine. The
RTX Module is pictured in Figure 4.4.
All terminals are fully shrouded, with the pilot and earth terminals being segregated from the other terminals.
The RTX provides remote start and stop facilities. The circuitry involved in these functions is selfdiagnostic 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. It should be noted that these functions are operational only, and that any emergency stops should be wired directly into the pilot circuit.
PTC terminals are provided for a semiconductor ‘switching’ thermistor. These terminals are protected in a similar manner to the stop and start circuits. If the remote start, stop and PTC functions are not required, each set of terminals must be bridged in order to start the Protection Element.
Five RTD inputs are provided for PT100 RTDs. These terminals can also be used with resistor networks to provide digital information back to the Cassette Protection Element.
A parameter dongle allows an RTX to be replaced without needing to re-program the parameters.
When installed, this dongle should be firmly secured to the machine/equipment.
Figure 4.4: Remote Termination Unit (RTX)
4.5.3 Parameter Dongle
Parameters important to the running of the Protection Element and the safe operation of the outlet onto which it is connected are stored in the Protection Element Parameter Dongle. The Parameter Dongle is exchangeable between Protection Elements, but it is intended to be physically tethered to the outlet that it controls.
Although the Protection Element and the RTX use the same hardware parameter dongle the parameters they store are different. As such the parameter dongle is not interchangeable between the
Protection Element and RTX.
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5 COMMISSIONING AND CALIBRATION
Prior to being put into service, the electrical protection system must be correctly commissioned. This manual does not cover system commissioning; the full scope of commissioning tests should be determined during the risk assessment or FMEA covering the design of the electrical protection system.
The following test can provide guidance on checking the correct operation of the Cassette Protection
Element during commissioning. These tests should be performed on each individual Cassette within the installed OCS.
This is not intended to provide an exhaustive commissioning checklist, but should be considered to be a minimum set of tests.
5.1 Earth Leakage
Test the correct operation of earth leakage circuits by injecting a fault current through the Earth Leakage
CT. Ensure that all relevant tripping circuits operate successfully and that latched trips may be reset in the appropriate manner.
Disconnect the toroid from the Cassette Protection Element and ensure that an EL CT fault trip is issued with similar effect.
5.2 Residual Voltage
This is applicable to the Residual Voltage Protection Element Version only. Test the correct operation of residual voltage detection circuitry by injecting a residual voltage onto the phases. Ensure that all relevant tripping circuits operate successfully and that latched trips may be reset in the appropriate manner.
These tests can be facilitated using residual voltage test relays, built into the Cassette Protection
Element. These rel ays are controlled using the Cassette Protection Element’s communications interface.
5.3 Earth Fault Lockout
Test the correct operation of Earth Fault Lockout protection by connecting suitably rated test resistors to the power conductors. Attempt to energise the outlet and confirm that the Cassette Protection Element trips on Earth Fault Lockout.
WARNING!
If the Earth Fault Lockout does not trip during this test, full system voltage and power may be subsequently applied to the test resistors .
5.4 Earth Continuity
Test that the Earth Continuity protection is operational by creating an open circuit on the pilot conductor.
Ensure that all relevant tripping circuits operate successfully and that latched trips may be reset in the appropriate manner.
Repeat with a short circuit between pilot and earth.
These tests can be facilitated using earth continuity test relays, built into the Cassette Protection
Element. These relays are controlled using the Cassette Protection Element ’s communications interface.
5.5 Insulation Test (High Voltage)
If the Earth Fault Lockout and Earth Continuity tests are successful, check that an automatic HV insulation test is initiated by the Cassette Protection Element when the module is started.
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WARNING!
During this test the Cassette Protection Element will generate up to
2700VDC from the 24 VDC input supply and apply this voltage to the phase conductors .
5.6 Over Current/Motor Overload Current Injection
Test the Over Current/Motor Overload protection by carrying out secondary/primary injection on the CT inputs of the Cassette Protection Element.
Inject 2x Full Load Current (FLC) into one of the CT terminals and ensure that all relevant tripping circuits operate successfully, in the time expected according to the settings employed, and that latched trips may be reset in the appropriate manner. Repeat on the other CT terminals.
5.7 Short Circuit Current Injection
Test the Short Circuit protection by carrying out secondary/primary injection on the CT inputs of the
Cassette Protection Element.
Inject a current value relevant to the settings employed into one of the CT terminals and ensure that all relevant tripping circuits operate successfully, in the time expected, and that latched trips may be reset in the appropriate manner. Repeat on the other CT terminals.
5.8 Main Contactor Fail
While the Cassette Protection Element is stopped (that is, the MCR output is open), apply a voltage on the load side of the contactor. The voltage must be greater than the selected trip level. Ensure that a
CBR trip is initiated by the Cassette Protection Element.
NOTE
A Main Contactor Fail (MCF) trip can be reset by pressing the MCF
Reset Pushbutton on the front of the OCS Protection Element or through the communications protocol.
While the Cassette Protection Element is stopped, close the MCI digital input. Ensure that a CBR trip is initiated by the Cassette Protection Element.
5.9 Voltage Measurement
Validate the voltage measurement function of the Cassette Protection Element by checking the measured voltages via the PLC when the main contactor is closed.
5.10 RTX
Validate the correct operation of the RTX by making changes to load parameters, moving the machine to a different outlet and ensuring that the correct settings are available on the new outlet.
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6 PRODUCT OPERATION
6.1 Outlet Control
In a typical installation, the outlet contactor is directly controlled by the Protection Element. The supervising PLC will send commands to the Protection Element to start or stop the outlet. The Protection
Element will respond by controlling its MCR output accordingly. In the event of any trip condition occurring, the Protection Element will open the MCR output (or CBR output as appropriate) and prevent reclosing the output until the fault condition has cleared and the trip has been reset.
To close an outlet controlled by a Protection Element, the supervising PLC will send a start command.
The following start sequence will be followed:
If there are any active trips, the Protection Element will ignore any start command received.
If all trips are cleared, the Protection Element will initiate a start sequence.
An earth fault lockout test is conducted. This test checks for a cable fault to earth. The test voltage and current are limited to intrinsically safe levels. If the test fails, the start sequence will be cancelled and the Protection Element will report an earth fault lockout trip.
If the earth fault lockout test passes, the Protection Element may then conduct an optional high voltage DC insulation test on the cable. If the insulation test fails, the start sequence will be cancelled and the Protection Element will report an insulation test trip. The insulation test can also be disabled via parameter settings.
If the insulation test passes, the start sequence moves to the closing state and the MCR output will be closed.
The Protection Element now waits for the MCI digital input to close. This auxiliary feedback from the signal confirms that the main contactor has closed. If the MCI does not follow the MCR within five seconds a ‘close fail’ trip will occur and the start sequence will be cancelled.
If the MCI digital input closes, the Protection Element moves from the start sequence to the running state. It will continue in the running state with the outlet closed until a stop command is received or any protection function trips.
If at any point during the start sequence a stop command is received or a protection function trips the start sequence is immediately cancelled and the MCR (or CBR if appropriate) output will be opened.
6.2 Control of Resets
All trip resets in the Protection Element are handled by positive edge reset signal events. In this way, continually driven reset signals will not reset faults. Most trips are reset with a general reset. Some trips have a dedicated reset, to allow selective control of the reset functions and to provide a level of authority associated with resetting faults. The trips that require additional reset commands include the Earth
Leakage, Thermal Memory for motor overload protection, Short Circuit and MCF Reset.
Main Contactor Failure events generate a trip that can be reset by the PLC. These trips require an inspection of the switching equipment associated with the outlet controlling Protection Element and as such a reset push-button is accessible from the front of the Protection Element and can be operated with power off.
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6.3 Internal Trips
The Protection Element has a number of trip functions that are not directly associated with the protection of the outlet, but signal that other dangerous faults have been detected.
6.3.1 CCM ID
The Protection Element has an internal detection circuit to identify the CCM module that is assembled within the Cassette. If the CCM identity fails to match with that which is expected, the Protection
Element will set this trip. There is currently one CCM version which is used for both 1.1kV and 3.3kV outlets. If this trip occurs the Cassette should be returned for repair.
6.3.2 MCF Battery Trip
The Protection Element has an internal battery. This is used to power the real time clock (used to timestamp log messages) as well has power the main contactor fail latch. The health of this battery is monitored and if the battery condition is failing this trip will be set. If this trip occurs the Protection
Element should be returned to have the battery repaired or replaced.
6.3.3 Internal Logic Error
This trip will be set in the event that an internal fault has been detected. If this trip occurs the Cassette should be returned for repair.
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6.4 Events Log
A real time clock/calendar is included in the Protection Element. This combines with the non-volatile memory to provide a data-logging feature. This log sequentially records the time, date and details of the most recent event. A chronological list of the previous 50 events is stored.
The following events are logged:
Table 2: Event Log Entry Types
Event ID
0
String
Unused
Description
Not a valid Message. Should not be seen.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
Feed On
Close Failed
Main Contactor Relay
Closed
Logs the Machine Type (Data1) and Machine
Number (Data2) when the main contactor has been closed while in RTX mode.
Insulation Test Record The results of an automatic HV insulation test.
Earth Leakage Trip
Earth leakage current was measured above the selected trip level.
Series Earth Continuity
Trip
Over current\Overload
Trip
The series resistance of the pilot was measured to be above the selected trip level.
The currents exceeded the bounds of the selected trip characteristic.
Short Circuit INST Trip An Instantaneous Short Circuit trip occurred.
After being requested to close, the Main Contactor has not closed within 5 seconds. (As detected via the MCI)
The main contactor relay was closed.
Under Current Trip
General Trip Reset
Phase currents were measured to be below the selected trip level.
A Trip was cleared via a General Reset request.
Power Down
Unexpected Restart
The system has been powered down correctly.
Protection Element
Dongle Parameter Error
There was an error with the Protection Element parameter dongle.
The MEM Processor restarted without a clean power down (most likely due to the watchdog resetting the system).
Frozen Contactor
Loss of Vacuum
The MCI Detects the contactor is closed while the
Main Contactor is requested to be open.
Voltage was detected at the outlet while the Main
Contactor was open.
Current Balance Trip
The difference between the measured phase currents is greater that the selected trip level.
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Event ID
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
String
Thermal Memory Loss
Description
The system was unable to read the Thermal Memory value from Battery Backed up Ram while booting.
The Motor Overload value will be initialised to 100%.
Main Contactor Opened
The main contactor auxiliary contact opened while in run mode.
RTX Parameter Error There was an error with the RTX parameter dongle.
Shunt Earth Continuity
Trip
The resistance of the pilot to earth was less than the trip level.
Thermal Memory Reset
The thermal memory was overridden by user intervention & reset to zero.
RTX Stop
The RTX stop input was activated causing an outlet stop.
RTX Offline
Insulation Trip
RTX Comms Timeout
Power Up
Under Voltage Trip
The RTX went offline causing an outlet trip.
The pre-start high voltage insulation test failed.
RTX is online, but there was repeated data corruption.
The system has powered up after a clean power down.
The phase voltage dropped below the trip level causing the outlet to drop out of run mode.
Stopped
No Coil Voltage Trip
General log denoting when the system completed the request to drop out of run mode.
Logs when a ‘No Coil Supply’ trip occurred.
CT Detection Error
The earth leakage system could not detect an adequate toroid connection.
Remote Start Stuck
The remote start button was detected to be closed for longer that the trip limit.
PLC Comms Timeout The PLC failed to provide ‘heart beat’.
Start Disabled
Earth Fault Lockout
Trip
The Protection Element was disabled by the PLC
The resistance measured between the phases and earth during an intrinsically safe EFLO test was below the set level.
Unknown Restart
Status
The system has powered up, but cannot work out if the system powered down cleanly or if it had a restart.
Short Circuit Trip Reset A short circuit trip was reset.
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Event ID
37
38
39
40
41
42
43
44
String
Earth Leakage Trip
Reset
Description
An earth leakage trip was reset.
Fatal Clock Error
MCF Battery Under
Voltage
Control Mask Changed
Invalid CCM
Internal Logic Error
PTC Trip
RTX RTD Group 1 Trip
The clock time was not able to be read from the Real
Time Chip.
The Battery which stores the Main Contactor Failure state and powers the Battery Backed Ram is under
Voltage (e.g. the battery has reached the end of its life)
Notes that the value of the control mask has been changed (e.g. a Test Relay has been closed). Data1 stores the old mask value; Data2 stores the new mask value.
Logs the fact an invalid CCM was attached to the
Protection Element. This is the logged version of a
‘CCM ID’ trip.
An Error has occurred in the operation of the code within the Protection Element. The log is used to denote that the stack has grown too big or that the system has run out of RAM. In normal operation neither of these things should occur.
The o utlet was stopped due to the RTX’s PTC input exceeding its trip resistance level.
The outlet was stopped due to one of the RTD inputs within group 1 going above the set trip level.
45
46
47
48
49
128 - 218
RTX RTD Group 2 Trip
Short Circuit LT Trip
The outlet was stopped due to one of the RTD inputs within group 2 going above the set trip level.
Short Circuit ‘Long Time’ tripped.
Residual Voltage Trip
Residual voltage was measured above the selected trip level.
Residual Voltage Reset A residual voltage trip was reset.
Pilot Interlock Trip
Parameter Modified.
The Fast element of the earth continuity detected resistance in excess of 100 Ohms for the selected trip time.
To work out which parameter was modified, minus
128 from the Event ID (eg 130 means parameter 2 was modified) Outlet parameters are numbered 0-
29, Dongle Load parameters are numbered 30-59 and RTX Load parameters are numbered 60-89. The value which was changed from is stored in Data1 and the new value is in Data2.
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6.5 Protection Element Parameters
There are two distinct groups of parameters:
6.5.1 Outlet Parameters
Outlet Parameters relate to the particular outlet/Protection Element. Examples include the pilot mode, outlet number and network settings. These are always stored in the Parameter Dongle.
Table 3: Outlet Parameter Descriptions
Name Description
IP Address Byte 1
IP Address Byte 2
IP Address Byte 3
IP Address Byte 4
Subnet mask Byte 1
IP address for Ethernet communications with the PLC.
Subnet mask Byte 2
Subnet mask Byte 3
Subnet mask Byte 4
Gateway Address Byte 1
Subnet mask for Ethernet communications with the PLC.
Gateway Address Byte 2
Gateway address for Ethernet communications with the PLC.
Gateway Address Byte 3
Gateway Address Byte 4
Pilot mode Selects the pilot termination method; diode or RTX.
Loss Of Vacuum Level Trip level for loss of vacuum protection.
Voltage Level
SC Output Relay
Defines the system voltage level.
Selects which output relay the short circuit trips.
6.5.2 Load Parameters
Load Parameters relate to the properties of different loads that may be connected to the Outlet
Cassette. Examples include the motor current, EC trip latch, and remote control. Load parameters can be stored in the Parameter Dongle of either the RTX (if present) or the Protection Element.
NOTE
Parameters cannot be changed while the Protection Element is running.
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Load Parameter Name
Load Machine Type
Load Machine ID
Table 4: Load Parameter Descriptions
Description
Text describing the type of machine. (RTX only)
Number identifying the machine. (RTX only)
Full Load Current Range
Short Circuit Trip Level
Short Circuit Trip Time
Over Current Curve
Defines the full load current the Protection Element expects to see. This determines the scaling of current readings, the base current for motor overload or inverse time over current protection and the trip levels for short circuit protection.
Defines the short circuit trip level as a multiple of the full load current setting.
Determines how long the current reading needs to be above the trip level before the Protection Element trips.
Selects if the over current protection will use one of the inverse current-time curves or thermal motor protection curve. This selection also impacts the short circuit functionality.
Over Current Time Multiplier
(TMS)
Over Load Cooling Multiplier
Over Load Start Block Level
Determines the trip time characteristic for Over Current/Motor
Overload.
Defines the cooling output of the thermal model, when thermal motor protection is selected.
The thermal accumulator must be below this value to allow an outlet start.
Selects the trip level for or disables current balance protection Current Balance Trip Level
Under Current Trip Level
Earth Leakage Trip Level*
Earth Leakage Trip Time*
Selects the trip level for or disables under current protection
Selects the trip level for earth leakage protection
Selects the maximum trip time for earth leakage protection
Residual Voltage Trip Level** Selects the trip level for residual voltage protection
Residual Voltage Trip Time** Selects the maximum trip time for residual voltage protection
Earth Continuity Trip Level Selects the nominal series earth continuity trip level
Earth Continuity Trip Time***
Pilot Interlock Trip Time****
Earth Continuity Latch
Remote Start
Insulation Test Trip Level
Selects the maximum trip time for both series and shunt earth continuity protection
Selects the maximum trip time for shunt and open circuit earth continuity protection
Selects whether earth continuity trips are latch (requiring general reset) or automatically reset when healthy
Enables remote start of the outlet via the pilot signal. When the pilot is set to diode mode, the remote start function uses a 100Ω series start resistor. When remote start is enabled, the PLC will not be able to initiate a start.
Selects the trip level for or disables the automatic insulation test.
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Load Parameter Name
Under Voltage Trip Level
Description
Selects the trip level for or disables under voltage protection
Back EMF Time
Selects the back EMF timer period which inhibits loss of vacuum detection after the outlet is opened.
’*’ - Setting is not available in the Residual Voltage Protection Element version.
’**’ - Setting is only available in the Residual Voltage Protection Element version.
*** - This setting is only used for series EC protection in the Residual Voltage Protection Element version.
****’ - Setting is only available in the Residual Voltage Protection Element version. Controls the Shunt
Trip Time and the Open Circuit (>100 Ω) Trip Time.
6.6 Time and Date
The time and date are used only to time stamp the events in the log (which are recorded sequentially regardless of the time and date). The time and date are not used for any control functions.
6.7 Cassette Isolation & Earthing (OCS Only)
Through the use of remotely controlled actuators, the OCS allows individual Outlet Cassettes to be moved between the service and earth positions. This provides both a break between the outlet phase conductors and the incoming supply, as well as visual earthing of the outlet cable without the requirement of a separate earthing outlet.
Each Cassette houses the line and load contacts, vacuum contactor, three current transformers, Earth
Leakage CT and the Protection Element. The cassette is driven between the service and earth positions by an electrically driven actuator. When in the service position the cassette is connected to the line and load contacts with the on-board vacuum contactor switching the outlet. In the earthed position the cassette is disconnected from the line bus and connects the load connections to earth. These earth contacts are visible through viewing windows.
When in the earth position the supply to the actuator can be externally isolated to prevent operation to move the cassette away from the earth position.
6.7.1 Actuator
Actuators are used to transition the cassettes between the service and earth positions. The actuator is controlled via PLC outputs and provides ‘actuator healthy’ feedback to the PLC. An analogue input corresponding with the position of the actuator rod is compared with the state of the limit switches by the PLC to indicate the position of the cassette.
NOTE
Each actuator has a coloured band on each end of the cable to denote actuator position within the chassis
Non matching colours will prevent operation of the actuator .
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Position 1
Red (p/no 164891)
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Position 2
White (p/no 164892)
Position 3
Blue (p/no 164893)
Position 4
No Band (p/no 164894)
Figure 6.1: Actuator position within chassis
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7 AS/NZS 2081:2011 PROTECTION FUNCTIONS
The Protection Element, housed within the Cassette, provides a number of protection functions that meet the requirements of the AS/NZS 2081:2011 standard. This protection functions are:
Earth Leakage*
Earth Continuity
Earth Fault Lockout
Main Contactor Fail
* - Not Available on Residual Voltage OCS Protection Element
7.1 Earth Leakage
7.1.1 Trip Characteristics
Table 5: Protection Element - Earth Leakage Trip Characteristics
Parameter Action
Power Cycle
Reset
Trip status maintained
Trip Actions
Active Period
Logging
Parameters
Monitoring
Requires an earth leakage reset after the trip condition has cleared
Open Main Contactor
Prevent Main Contactor from closing
Always active
Always logged
Trip Level
Trip Time
Earth Leakage current displayed as 0-150% of selected trip level
7.1.2 Operation Summary
The earth leakage protection function uses an Ampcontrol EL500 series toroid to measure the earth fault current. This function is tested to AS/NZS 2081:2011. A definite time operating characteristic is provided with adjustable trip sensitivity and an adjustable time delay.
NOTE
Due to size restrictions and the coupling issues related with elongated current transformers, the Ampcontrol EL500 series earth leakage toroid is not integral to the Cassette and must be purchased separately .
When a fault occurs such that the trip level and time delays are exceeded, a trip occurs. The trip acts in the Main Contactor Relay (MCR) logic and is latched. An earth leakage trip is considered a special fault and requires a specific reset function to be cleared.
The earth leakage current (EL) is displayed as a % of the trip level. When the leakage reaches 100% for the selected time delay a trip occurs.
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7.1.3 Earth Leakage CT Failure Protection
Table 6: Protection Element - Earth Leakage CT Failure Trip Characteristics
Parameter Action
Power Cycle Trip status maintained
Reset
Trip Actions
Active Period
Logging
Parameters
Monitoring
Requires a general reset after the trip condition has cleared
Open Main Contactor
Prevent Main Contactor from closing
Always active
Always logged
None (Trip time and level is fixed)
CT Detect trip status bit
The Protection Element generates a CT Detection Signal to test the integrity of earth leakage circuit.
The CT Detection signal continually tests the earth leakage current transformer, the wiring loop to the transformer and the input to the protection relay as required by AS/NZS 2081: 2011.
The signal is fed from Pin 6 of the Protection Element. Pass one loop through the earth leakage current transformer then back to Pin 7.
The Earth Leakage CT Failure trip time is fixed at 4.5 seconds.
NOTE
The loop resistance of the CT Detection Signal circuit must remain below 1Ω .
7.2 Residual Voltage
7.2.1 Trip Characteristics
Table 7: Protection Element – Residual Voltage Trip Characteristics
Parameter Action
Power Cycle
Reset
Trip Actions
Active Period
Logging
Parameters
Monitoring
Trip status maintained
Requires a residual voltage reset after the trip condition has cleared
Open Main Contactor
Prevent Main Contactor from closing
Always active
Always logged
Trip Level
Trip Time
Residual Voltage displayed as voltage
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7.2.2 Operation Summary
The residual voltage protection element is a designated unit for use on installations utilising a high impedance NER. A definite time operating characteristic is provided with adjustable trip sensitivity and an adjustable time delay.
When a fault occurs such that the trip level and time delays are exceeded, a trip occurs. The trip acts in the Main Contactor Relay (MCR) logic and is latched. A residual voltage trip is considered a special fault and requires a specific reset function to be cleared.
The residual voltage (RV) is displayed as the voltage detected. When the leakage reaches the relative trip level for the selected time delay a trip occurs.
The Label of the Residual Voltage Protection Element has been modified to easily distinguish the two types apart. The Residual Voltage Protection Element label has been coloured yellow, as opposed to the Standard Protection Element’s orange label. The two protection elements are not mechanically keyed, which means the relays can be interchanged, however the protection element will remain in a tripped state and prevent the outlet from being energised. The Residual Voltage Protection Element does not require the EL CT to be connected and disables the EL CT detection trip.
NOTE
The Residual Voltage Protection Element and the Standard Protection
Element can be interchanged, however the outlet will not be able to energise .
7.3 Earth Continuity
The earth continuity function tests for the continuity of the earth between the outlet and the machine, via the pilot in the trailing cable. This is in accordance with AS/NZS 2081: 2011. The pilot is also used to transfer data when a remote termination unit (RTX) is used to achieve machine communication.
The Protection Element can be configured to operate in either diode or RTX mode. This determines what terminating device the relay is expecting on the pilot.
NOTE
The RTX will only be recognised by an OCS Protection Element 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 cable that the relay can drive .
The relay measures the resistance of the pilot - earth loop and the leakage between the pilot and earth conductors. These measurements are known as the series earth continuity resistance and the shunt earth continuity resistance, respectively. The shunt measurement ensures that a pilot to earth fault is detected. If the pilot - earth loop is not healthy (series resistance greater or shunt resistance lower than their respective trip settings) a trip occurs which in turn opens the MCR to interrupt the main contactor control circuit.
The trip can be configured as latching or non-latching. This allows the user to determine if the trip is manually or automatically reset once the pilot - earth loop is healthy.
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The trip settings alter slightly for the Residual Voltage Protection Element version. In this version, the existing trip time and level (although extended in available values) settings are utilised for the series earth continuity resistance only. The shunt trip time setting becomes the Pilot Interlock Trip Time Setting.
The Pilot Interlock Trip Time setting is also used for open circuit trip conditions (>100Ω). This means that the EC settings that have a set trip point (shunt and open circuit faults) can have a separate trip time that is significantly faster than the series EC setting, which is more commonly used for touch potential protection.
7.3.1 Pilot Series
Table 8 Protection Element - Earth Continuity Series Trip Characteristics
Parameter Action
Power Cycle
Reset
Trip Actions
Active Period
Logging
Parameters
Monitoring
Trip status maintained
Requires a general reset after the trip condition has cleared.
Alternatively the trip can be automatically reset depending on the status of the EC Latch parameter.
Open Main Contactor Relay
Prevent Main Contactor from closing
Always active
Logged only if outlet is running
Trip time
Trip level
Trip latch enable
Available as the raw ohms measurement, resolution of 1 Ω.
7.3.2 Pilot Shunt
Table 9: Protection Element - Earth Continuity Shunt Trip Characteristics
Parameter Action
Power Cycle
Reset
Trip Actions
Active Period
Logging
Parameters
Monitoring
Trip status maintained
Requires a general reset after the trip condition has cleared.
Alternatively the trip can be automatically reset depending on the status of the EC Latch parameter.
Open Main Contactor Relay
Prevent Main Contactor from closing
Always active
Always logged
Trip time
Trip latch enable
Available as the raw ohms measurement, resolution of 100 Ω.
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7.3.1 Pilot Interlock
Table 10: Protection Element - Earth Continuity Pilot Interlock Trip Characteristics
Parameter Action
Power Cycle
Reset
Trip Actions
Active Period
Logging
Parameters
Monitoring
Trip status maintained
Requires a general reset after the trip condition has cleared.
Alternatively the trip can be automatically reset depending on the status of the EC Latch parameter.
Open Main Contactor Relay
Prevent Main Contactor from closing
Always active
Always logged
Trip time
Trip latch enable
Resolution of Series and Shunt measurements is as per 7.3.1 & 7.3.2.
7.3.2 Pilot Remote Start
Remote start mode can be used to allow the start sequence to be initiated from the load via the pilot signal. In remote start mode, the PLC cannot force the start of the outlet. It can however prevent the outlet from starting.
The remote start setting requires the following sequence for a start to be triggered:
1. All trips must be clear.
2. The PLC Comms enable bit must be enabled for a remote start condition to be possible and accepted.
3. The pilot resistance must be detected above 90Ω to ensure a start resistor is in place.
4. As soon as the resistance calculation drops below the EC series threshold a start is triggered.
(Note that the EC series protection function will still be operating, and the start will not be triggered if the EC measurement is above the set threshold).
5. If t he EC resistance falls below 90Ω, but remains above the EC series threshold it will result in a remote start error trip after 1 second.
6. The start sequence (EFLO, IT, MC closing) starts immediately after the trigger.
7. The start resistor must remain shorted out by the start button for the duration of the pre-start tests.
8. If the EC resistance does not return to above 90 Ω within 5 seconds after the outlet closes, the
Protection Element will trip on “Remote Start Stuck”.
9. After a start has been triggered, the EC resistance must return above 90 Ω before another start can be triggered.
10. The Remote Start Fault is automatically reset once the EC resistance returns above 90
Ω. (An external reset is not required)
7.4 Earth Fault Lockout
The Protection Element 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’.
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7.4.1 Intrinsically Safe EFLO
Table 11: Protection Element - Earth Fault Lockout (EFLO) Trip Characteristics
Parameter Action
Power Cycle Trip status maintained
Reset
Trip Actions
Active Period
Logging
Parameters
Monitoring
Requires a general reset after a failed test
Prevent Main Contactor from closing
Single test performed during the start sequence
Logged when test fails
No parameters
Last test value stored, for each phase. Value stored is from 0-150%, where 100% is 1M Ω (all phases in parallel).
The initial earth fault lockout function tests the resistance of the three phase lines to earth by applying an intrinsically safe signal prior to the closure of the main contactor in accordance with AS/NZS 2081:
2011. The test is initiated by starting the relay once all starting conditions are met. This test takes 2 seconds. If the value measured is less than the pre-set level a trip occurs.
7.4.2 High Voltage Insulation Test
Table 12: Protection Element – High Voltage Insulation Test Characteristics
Parameter
Power Cycle
Action
Reset
Trip Actions
Trip status maintained
Requires a general reset after a failed test
Prevent Main Contactor from closing
Active Period
Logging
Parameters
Monitoring
HV Test Voltage
Single test performed during the start sequence. Optionally can be disabled.
Always logs the measured test result. Trip events are logged separately
Trip Level
Last test value stored.
900VDC (1.1kV System) or 2700VDC (3.3kV System)
If an insulation trip level has been selected, an automatic High Voltage DC ‘Insulation Test’ is carried out after an Intrinsically Safe Earth Fault Lockout Test has been passed.
During the ‘Insulation Test’ the Protection Element generates a high DC voltage, approaching the peak system voltage, which is applied between each phase and earth. The Protection Element measures the voltage on the line and calculates the meg-ohm resistance to earth for all three phases. If the resistance value is above the pre-set threshold the Protection Element will close its MCR output, allowing the main contactors control circuit to energise. The insulation test takes 4 seconds.
The results of the insulation test should only be used as a guide to confirm that insulation remains above
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7.5 Main Contactor Protection
There are four main contactor protection functions. Each of the functions monitors the states of the outlets main contactor. If a fault is detected the upstream circuit breaker is opened (via the CBR output) in order to remove power from the potentially faulty contactor.
7.5.1 Voltage Detection (Loss of Vacuum)
Table 13: Protection Element – Voltage Detection (Loss of Vacuum) Trip Characteristics
Parameter Action
Power Cycle
Reset
Trip Actions
Active Period
Logging
Parameters
Monitoring
Trip status maintained
Communication reset or physical reset after a trip. The physical reset button is found on the front cover of the Protection Element
Open Circuit Breaker
Prevent Main Contactor from closing
When outlet is not running and the Back EMF timer has finished counting down
Logged when a trip occurs
Trip Level
Back EMF Timer
Phase voltages are continuously updated.
Loss of Vacuum provides a mechanism for checking that voltage is not present on the outlet after the
Main Contactor has opened. The levels at which the Main Contactor Failure should be initiated for residual voltages are outlined in AS/NZS 2081:2011 Clause 9.2.1.
The Loss of Vacuum protection cannot be enabled immediately after the outlet is stopped as there is the potential for Back EMF from the load to cause a trip. Subsequently, a Back EMF timer is provided and allowed to elapse after the outlet has stopped, before the Loss of Vacuum protection can be operated.
AS/NZS 2081:2011 Clause 9.3 and Appendix H cover the requirements for Back EMF considerations for
Frozen Contactor devices where large inertial loads are connected.
The trip level can be selected at 25VAC or 50VAC. The trip time is less than 1sec.
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7.5.2 Frozen Contactor
Table 14: Protection Element – Frozen Contactor Trip Characteristics
Parameter Action
Power Cycle Trip status maintained
Reset
Trip Actions
Communication reset or physical reset after a trip. The physical reset button is found on the front cover of the Protection Element
Open Circuit Breaker
Prevent Main Contactor from closing
When outlet is not running Active Period
Logging
Parameters
Monitoring
Always
No parameters
None
AS/NZS 2081:2011 Clause 9.2.2 states that the MC ’s auxiliary interlocks must be in agreement with the control signals being sent to the MC, else tripping of the upstream CB shall commence.
Frozen contactor detection is while the MCR is open. If the Protection Element detects that the main contactor has closed (or remains closed after the MCR is opened for any reason), it will result in a frozen contactor trip.
The frozen contactor protection activates in approximately 100ms.
7.5.3 Close Fail
Table 15: Protection Element – Contactor Close Fail Trip Characteristics
Parameter Action
Power Cycle Trip status maintained
Reset
Trip Actions
Active Period
Communication reset or physical reset after a trip. The physical reset button is found on the front cover of the Protection Element
Open Circuit Breaker
Prevent Main Contactor from closing
After closing MCR, prior to receiving confirmation from the MCI
Logging Always
Parameters No parameters
Monitoring None
AS/NZS 2081:2011 Clause 9.2.
2 states that the MC’s auxiliary interlocks must be in agreement with the control signals being sent to the MC, else tripping of the upstream CB shall commence.
Close fail detects the event when the Protection Element attempts to close the output by closing its MCR output, but receives no confirmation of the close output contactor via the MCI digital input.
Close fail protection activates in approximately 1sec.
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7.5.4 External Open
Table 16: Protection Element – External Open Trip Characteristics
Parameter Action
Power Cycle
Reset
Trip Actions
Active Period
Logging
Parameters
Monitoring
Trip status maintained
Communication reset or physical reset after a trip. The physical reset button is found on the front cover of the Protection Element
Open Circuit Breaker
Prevent Main Contactor from closing
While running
Always
No parameters
None
An External Open trip occurs if the main contactor is detected as having been opened while the system is in run mode.External open protection activates in approximately 1sec.
7.5.5 Coil Voltage Detection
Table 17: Protection Element – Coil Voltage Detection Trip Characteristics
Parameter Action
Power Cycle
Reset
Trip Actions
Active Period
Logging
Parameters
Monitoring
-
Automatic
Open Circuit Breaker
Prevent Main Contactor from closing
Always
Only logged if it results in the Protection Element stopping a running outlet
No parameters
Coil voltage status bit
The coil voltage is internally detected by sensing the voltage across terminals 12 & 13 (COIL-SUPPLY-1
& COIL-SUPPLY-2). This additional functionality is provided so in the event of the Contactor coil voltage being lost while the outlet is running a nuisance Main Contactor Failure trip does not occur, as the changing of state for the Main Contactor can be explained by the loss of coil voltage.
7.5.6 MCF Latch
AS/NZS 4871.1 Clause 2.6.3.6 requires contactor related trips to be reset only by an authorised person.
To this end it is deemed that physical access inside the switchgear enclosure would be required to perform the relevant checks, and as such the Main Contactor Failure can be reset by the push-button on the Protection Element or alternatively over comms. All trip bits that feed into the Main Contactor Failure
Flag are individually logged in the Protection Element for event analysis in the instance of a Circuit
Breaker Trip.
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8 CURRENT RELATED PROTECTION FUNCTIONS
Three current transformers within the Cassette are used to measure the three line currents. The measured currents are used to implement the following protection functions:
Inverse time protection - Over-Current or Motor Overload
Short circuit
Under current
Phase current balance
The ‘Full Load Current Range’ setting determines the base current for all of the phase current related functions: the measured currents are normalized based on the selected value. The range is selectable from 5.125A to 640A.
8.1 Inverse Time Protection
The ‘Over Current Curve’ setting is used to select one of three Inverse Time-Current characteristics:
Very Inverse Over Current
Extremely Inverse Over Current
Motor Overload
NOTE
When the Motor Overload parameter is set, the Short Circuit functionality is also modified to better suit motor starting transients. See
the Short Circuit section (Section 8.2) for further information.
The Over Current Time Multiplier setting (TMS) scales the basic trip time for the basic over current characteristics to the desired response time. Values are provided from 0.05 to 30; refer to Appendix A for the full list of values. For cross reference, the nominal trip times are listed for each TMS value, for each of the curve options at 10x FLC.
8.1.1 Over Current
Table 18: Protection Element – Over Current Trip Characteristics
Parameter Action
Power Cycle -
Reset
Trip Actions
Requires a general reset (and all three measured phase currents must be below the 100%).
Open Main Contactor
Prevent Main Contactor from closing
Block restart if the thermal accumulator is not below the selected start block level.
When Over Current curve is set to Very Inverse or Extremely Inverse. Active Period
Logging
Parameters
Monitoring
Always
Time Multiplier
Full Load Current
Phase currents displayed as a percentage of selected full load current
Thermal Accumulator (TAC)
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The three phase currents are compared and the highest current is used to determine the trip time. If the current exceeds the selected full load current, an overcurrent trip accumulator (TAC) increases at a rate determined by the above function. 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 the over-current settings are correct.
The Overcurrent curves provided are as follows:
1. Very Inverse as per IEC 60255-151 B Curve. The trip time and reset time in seconds for current I follows the characteristic defined by : 𝑡(𝐼) = 𝑇𝑀𝑆 ∙ (
13.5
𝐼 − 1
) 𝑡
𝑅
1.69
(𝐼) = 𝑇𝑀𝑆 ∙ (
1 − 𝐼
)
2. Extremely Inverse as per IEC 60255-151 C Curve. The trip time and reset time in seconds for current I follows the characteristic defined by :
80 𝑡(𝐼) = 𝑇𝑀𝑆 ∙ (
𝐼 2 − 1
) 𝑡
𝑅
1.28
(𝐼) = 𝑇𝑀𝑆 ∙ (
1 − 𝐼 2
)
Where: t(I) = the idealised trip time,
I = the input current ratio relative to the full load current set point – ie per unit current,
TMS = the Over Current Time Multiplier Setting, t
R
(I) = the idealised reset time.
NOTE
1. The per unit current is clipped to a maximum of 1250%. Therefore the trip time for input currents above this level will not decrease any further i.e. t he trip characteristic ‘flat lines’ beyond 1250% of the selected full load current.
2. Independent of the selected curve and TMS setting, the minimum trip times for the Over Current functions are nominally 100ms.
3. The trip times calculated from the above formulae are idealised.
The trip calculations are executed every 20ms, so there is an additional delay and uncertainty of 25ms +/-15ms.
See Overcurrent Curves, drawing OCSB001in APPENDIX B: DRAWINGS.
When the Protection Element is not in the ‘running’ state and the thermal accumulator is not below the selected start block level, a start block (trip) will occur. This will automatically clear once the thermal accumulator drops to, or is below the selected level. Note however that generally this will happen quickly when the inverse overcurrent modes are selected.
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8.1.2 Motor Overload
Table 19: Protection Element – Motor Overload Trip Characteristics
Parameter Action
Power Cycle
Reset
Trip Actions
Active Period
Logging
Parameters
Monitoring
Trip Status maintained
Requires a general reset (and all three measured phase currents must be below the 100%).
Open Main Contactor
Prevent Main Contactor from closing
Block restart if the thermal accumulator is not below the selected start block level.
When Over Current curve is set to Motor Overload.
Always
Time Multiplier
Full Load Current
Cooling Multiplier
Phase currents displayed as a percentage of selected full load current
TAC.
This protection scheme uses a simple first order thermal model of the motor to determine the tripping characteristic. It is fundamentally different to the Over Current protection outlined above in that it all current levels contribute to the model heating, and the effects of that heating persist in the model, where as in the Over Currents functions, the trip accumulator resets relatively quickly if the current falls below the selected full load current level.
The three measured phase currents are squared and added together to provide the heating input into the thermal model. The cooling is assumed to be proportional to the model’s ‘temperature’ at any given time.
The Thermal Accumulator ( TAC) is the model’s ‘temperature’ where 0% represents the motor being cold, and 100% means the motor has reached its maximum temperature (and is therefore tripped).
The trip time is dependant not only on the present current level, but also the prior current history. Since motor currents typically vary widely during starting and running, the actual trip time is also variable. To facilitate co-ordination of the protection with motor capabilities (and upstream protection), the trip time in seconds for a simple (theoretical) scenario of a fixed overload current of I is given by: 𝑡(𝐼) = 𝑇𝑀𝑆 ∙ 72.9 ∙ 𝑙𝑛 (
𝐼 2 − 𝐼 2 𝑝
𝐼 2 − 1.05
2
)
Where: t(I) = the idealised trip time,
I = the input current ratio relative to the full load current set point – ie per unit current,
TMS = the Over Current Time Multiplier Setting,
Ip = the load current that was flowing (long enough to reach thermal stability) prior to the overload occurrence. ln = the natural logarithm.
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NOTE
1. The per unit current is clipped to a maximum of 1250%. Therefore the trip time for input currents above this level will not decrease any further: ie, the trip characteristic ‘flat lines’ beyond 1250% of the selected full load current.
2. Independent of the selected TMS setting, the minimum trip times for the Overload function is nominally 100 ms.
3. The trip times calculated from the above formulae are idealized. The trip calculations are executed every 20 ms, so there is an additional delay and uncertainty of 25 ms +/-15 ms.
4. The above characteristic is equivalent to IEC 60255-8 (equation below) with the substitution of 𝝉 =TMS • 72.9. This scaling aligns the trip time at 10 PU current with that of the Extremely Inverse curve above (e.g. 808ms with a TMS of 1.0). 𝑡 = 𝜏 ∙ ln (
𝐼 2 − 𝐼 2 𝑝
𝐼 2 − (𝑘 ∙ 𝐼
𝐵
) 2
)
Where in the Protection Element: k = 1.05, called the
‘Service Factor’
IB = 1.
The base thermal model provides a thermal time constant of 72.9 seconds. The TMS setting scales the basic thermal time constant, allowing a maximum time constant of over 36 minutes (TMS = 30).
See Motor Overload Curves drawing OCSB002in APPENDIX B: DRAWINGS.
The TAC provides information about how much thermal capacity is left, and therefore how long it will take to trip from a given starting point and overload current. If the motor current I is constant (and below
1.05PU), the TAC will eventually settle to a value as follows:
𝐼
𝑇𝐴𝐶 = (
1.05
)
2
∙ 100 %
For example, if the long term average load current was 0.7PU, the TAC would settle at 44%.
The relative trip time for a constant current as a function of the initial value of the TAC is given by: 𝑡(𝑇𝐴𝐶) = ( 100% − 𝑇𝐴𝐶 ) ∙ 𝐶𝑜𝑙𝑑 𝑇𝑟𝑖𝑝 𝑇𝑖𝑚𝑒
Continuing the example above, with the TAC starting at 44%, the trip time would be 56% of the cold trip time (for the same current), that is, if the long term average current (Ip) prior to an overload was 0.7PU, the trip time for an over an overload from that starting point would be 56 % of the trip time for the same overload current starting from cold. Drawing OCSB002also shows the overload curve for various values of Ip.
The motor manufacturer’s data should be consulted to select the time multiplier appropriate for the motor being protected. Typically, the capacity of a cold motor is given at six times its rated current. The characteristic equation above can be used to select the TMS to match the motors overload capacity.
While the main contactor is closed, the cooling output from the thermal model is calculated to achieve the necessary behaviour to match the characteristic above.
The Over Load Cooling Multiplier modifies the cooling output of the thermal model when the motor is
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MAG-182 Version 5 – FEB/2020 stopped. This can be used to account for reduced cooling capacity of the motor when it is not running. A
Cooling multiplier of 1 means the cooling is independent of whether the motor is running or not – e.g. a water-cooled motor. A setting of 2.5 may be appropriate for a fan-cooled motor, however for the best protection consult the motor manufacturer. Values are provided from 1.0 to 5.0.
The thermal model continues to simulate the motor’s thermal behaviour even if the power is removed from the relay. When power is restored the thermal memory would be at the same level had there been no loss of power.
The “Thermal Accumulator” shows the state of the thermal model: 0% = Cold, 100% = Trip. When a trip occurs it cannot be reset until the current is below the pick-up level.
When the Protection Element is not in the ‘running’ state, if the thermal accumulator is not below the selected start block level, a ‘start block’ (trip) will occur. This will automatically clear once the thermal accumulator drops to, or is below the selected level. This functionality is used to ensure adequate thermal capacity is available before another start is allowed. If necessary it will force sufficient cooling time to allow the restoration of sufficient thermal reserve. If for example the application required capability to permit a locked roto r start lasting up to 60% of the allowable ‘cold’ locked rotor start time
(before tripping on Motor Overload), the ‘Start Block Level’ parameter would be set to 40%.
In order to allow an emergency restart on a hot motor, a reset of the thermal memory is possible – but the risk of permanent motor damage must be carefully considered before taking this step.
CAUTION!
Incorrect motor protection setup, or thermal memory resets may cause or lead to motor failure or permanent motor damage .
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8.2 Short Circuit
Table 20: Protection Element – Short Circuit Trip Characteristics
Parameter Action
Power Cycle
Reset
Trip Actions
Active Period
Logging
Parameters
Monitoring
Trip Status maintained
Specific short circuit reset
Open selected output – circuit breaker or main contactor
Prevent Main Contactor from closing
Always
When a fault occurs
Short Circuit Output Relay
Short Circuit Trip Level
Short Circuit Trip Time
Phase currents displayed as a percentage of selected full load current.
The short circuit function has a definite time characteristic. If the current exceeds the selected level for the pre-set time then a trip occurs.
The short circuit trip level is adjustable from 1.5 to 12.5 times (full load current) in 0.25 increments. Note however that there is also an upper limit in the current measuring system of 6kA (RMS). This limit will effectively over ride selections where the combination of the selected full load current and the selected short circuit level exceeds 6kA. For example, if 640A is selected, the short circuit will trip at 9.4PU
(940%) even if the short circuit level is set to 9.5x or above. The per unit current at which the 6kA limit
The trip time is selectable from 40 to 200ms.
If the Over Current function is set to Motor Overload, the short circuit functionality is modified as follows:
1. The primary ‘instantaneous’ short circuit trip level is double the selected value: therefore, so it covers a range of 3.0 to 25 times full load current.
2. A second ‘time delayed’ short circuit element becomes active. This element operates at the selected Short Circuit Trip Level, but the trip time is the selected (primary) trip time plus 60ms.
There is a separate ‘SC-LT’ trip bit (LT for ‘long time’) & event log to differentiate each of the short circuit elements.
This modified functionality allows the short circuit protection to be set just above the locked rotor current level without risking spurious trips due to initial transient offsets (which can effectively double the initial inrush peak current).
The Short Circuit Output Relay setting is used to control which trip action a short circuit trip: the trip can be directed to either the CBR (preferred) or the MCR.
WARNING!
The circuit interrupting device tripped by the selected output relay for the Short Circuit function MUST be rated to interrupt the full prospective system short circuit current .
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If the Short Circuit Output Relay setting is set to ‘CBR’, when a short circuit trip occurs, the circuit breaker is opened and the main contactor left closed for one second to allow the circuit breaker time to clear the fault. Any other trips or control actions to open the contactor during this time – except for earth leakage, will be blocked.
8.3 Current Balance
Table 21: Protection Element – Current Balance Trip Characteristics
Parameter Action
Power Cycle Trip Status maintained
Reset
Trip Actions
Active Period
General reset
Open Main Contactor
Prevent Main Contactor from closing
Always
Logging Always
Parameters Trip Level
Monitoring Phase currents displayed in Amps.
The current balance measurement is available and is calculated as: 𝑖 𝑏𝑎𝑙
=
𝑀𝐴𝑋 ∆ 𝑖 × 100% 𝑖 𝑎𝑣
Where: iav = the average of the 3 phase currents
MAX ∆ i = the maximum deviation of a phase current from the average.
The trip level is selectable at 5%, 10%, 20%, and 50% and off.
The phase current balance protection is inhibited until the average current exceeds both 20% of the selected full load current and the selected balance trip level.
If the trip level is exceeded, a timer is triggered. If the imbalance remains above the set level for more than two seconds the relay trips.
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8.4 Under Current
Table 22: Protection Element – Under Current Trip Characteristics
Parameter Action
Power Cycle
Reset
Trip Actions
Active Period
Logging
Parameters
Monitoring
-
Automatic
Open Main Contactor
Prevent Main Contactor from closing
When outlet is running
When a fault occurs
Trip Level
Phase currents displayed in Amps.
Under current protection monitors all three phase currents. If any phase drop below the selected threshold, the trip timer start counting. The under current protection will trip after any phase current is below the threshold for 4 second.
9
OTHER PROTECTION FUNCTIONS
9.1 Under Voltage
Table 23: Protection Element – Under Voltage Trip Characteristics
Parameter Action
Power Cycle
Reset
Active Period
Logging
Parameters
Monitoring
-
Automatic
When outlet is running
Only if outlet is running
Trip Level
Phase voltage displayed in Volts.
Under Voltage protection is enabled as soon as the main contactor is closed (indicated by closing the
MCI input). If any of the phase voltages drop below the selected trip setting of the nominal line voltage for 800ms then the outlet is stopped.
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10 SERVICE, MAINTENANCE & DISPOSAL
10.1 Equipment Service
A number of external system based checks should be completed on a regular basis. These ‘routine inspections’ must be carried out by suitably trained people with knowledge of the OCS and the systems into which it is fitted. Routine inspections may take the form of either visual-only checks, or visual and
‘hands-on’ checks.
10.1.1 Visual Only Inspections
A basic visual inspection focuses on looking at the installation for signs of physical damage, water or dust ingress and the condition of cables and labels. This type of inspection may involve opening cabinets to gain access to the OCS and other equipment. This level of inspection may also include cleaning display windows that have become obscured by dirt.
Observations would typically be:
Check that equipment enclosures, cable trays, conduits, etc. are in good order with no physical damage.
Check that connected cables are free from cuts, abrasions and obvious signs of damage. Cable restraints are in good order and correctly fitted.
Check that labels on equipment and cables are present and in good condition (especially certification labels).
Check that no modifications have been carried out to installed equipment.
10.1.2 Hands-On (Detailed) Inspections
A more detailed inspection would include all of the elements of a visual inspection, plus some checks that cover the integrity of connections, fixtures and fittings.
In addition to basic visual observations, more detailed integrity checks would involve:
Verify that equipment housings and other mechanical fixtures are secured in place. This includes terminal box lids, tightness of cable glands, integrity of mountings, security of equipment fixing to walls/DIN rails etc.
Verify all electrical connections are secure with no loose screw terminals or DIN rail terminals not fitted to rails etc.
If required, apply electrical contact grease to cassette contacts to reduce wear.
10.1.3 Offsite Overhaul
In line with AS/NZS 2290:2014, for continued reliable and safe performance, Ampcontrol recommends that each Cassette is overhauled to AS/NZS 3800 and Ampcontrol’s work instructions at intervals not exceeding that as recommended by the standard.
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10.2 Equipment Maintenance
WARNING!
The OCS has no user-serviceable parts.
All repairs must be carried out by Ampcontrol only .
If a fault develops, return the Cassette to Ampcontrol for repair. It is essential that no attempt be made to repair the Cassette as any attempt to dismantle or repair the Cassette can seriously compromise the safety of the unit and voids product warranty .
It is recommended that the electrical protection system incorporating the OCS be subject to regular functional tests at intervals determined by risk assessment or FMEA. These intervals typically coincide with periodic maintenance checks and will cover (but not limited to) tests such as:
Earth Leakage injection tests
Earth Continuity tests
Earth Fault Lockout tests
Overcurrent injection tests
CAUTION! When conducting insulation tests on the outgoing power circuits, ensure that the Cable Connection Module (CCM) in the Protection
Element is disconnected . Failure to do so may damage the
Protection Element .
10.3 Disposal
ENVIRO The electronic equipment discussed in this manual must not be treated as general waste . By ensuring that this product is disposed of correctly you will be helping to prevent potentially negative consequences for the environment which could otherwise be caused by incorrect waste handling of this product.
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11 SPECIFICATIONS
11.1 Cassette Specifications
General
Nominal System Voltage Up to 3.3kV
Continuous Current Rating Up to 500A (Thermal)
Protection Relay
Plug-In Capability
Outlet Cassette Protection Element
Yes
11.2 Protection Element Specifications
I.S. Parameters
Combined Phase and Pilot
Uo: 28.0V
Io: 322mA
Po: 2.25W
Co: 3.72μF
Ci: 18.8nF
Lo: 4.5mH
General
RDX Port
Uo: 17.3V
Io: 756mA
Po: 3.09W
Co: 9.05μF
Lo: 816μH
L/R: 134μH/Ohm
RTX
Ui: 28.0V
Ci: 18.8nF
Li: nil
Temperature Range
Auxiliary Supply Voltage
0°C < Ta < 60°C
24 VDC ± 20%, 30 W
Sys. Phase-Phase Voltage 1100V ± 20%, 3.3kV ± 20%
Contact Ratings 110VAC 20A, 1000VA, Power Factor 0.4
AS/NZS2081:2011 Protection Functions
Earth Leakage
Trip Settings +/-10%
(Standard OCS Protection Element Only)
100mA, 150mA, 200mA, 250mA, 300mA, 350mA, 400mA, 450mA,
500mA
Trip Time +0% -20%
CT Failure
Inst., 50ms, 75ms, 100ms, 150ms, 200ms, 250ms, 300ms, 350ms,
400ms, 450ms, 500ms
4.5s
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AS/NZS2081:2011 Protection Functions
Residual Voltage
Trip Settings +/-10%
(Residual Voltage OCS Protection Element Only)
150V, 200V, 250V, 300V, 350V, 400V, 450V, 500V, 600V, 700V, 800V,
900V, 1000V, 1100V, 1200V, 1300V, 1400V, 1500V
Trip Time +0% -20% 600ms, 800ms, 1 s, 1.5s, 2s, 3s, 4s, 5s,
Earth Continuity
Series Trip +/-3 Ω
Shunt Trip
10 Ω, 15Ω, 20Ω, 25Ω, 30Ω, 35Ω, 40Ω, 45Ω
1.5k
Ω
Pilot Interlock Trip
(Residual Voltage
Version Only)
100
Ω
Trip Time
Additional Trip Times for Residual Voltage
Version only
100ms, 150ms, 200ms, 250ms, 300ms, 350ms, 400ms, 450ms, 500ms
600ms, 800ms, 1s, 1.5s, 2s, 2.5s, 3s, 3.5s, 4s, 4.5s, 5s, OFF
Pilot Interlock Trip /
Shunt Trip Time
(Residual Voltage
Version Only)
100ms, 150ms, 200ms, 400ms, 500ms, OFF
Earth Fault Lockout
IS Test 1M Ω (all phases in parallel)
OFF, 2.5M
Ω, 5MΩ, 10MΩ, 20MΩ, 50MΩ HV Insulation Test
Contactor Protection
Loss of Coil Voltage < 100ms
Loss of Vacuum < 1s
< 100ms Frozen Contactor
Loss of Contactor
Control
Back EMF Time
Loss of Control
LOV Level
< 1s
2s, 5s, 10s, 15s, 20s
< 1s
25VAC, 50VAC
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Current Related Functions
Over Current Protection
Curves
Current Range
Time Multiplier
Motor Thermal Overload
Full Load Current
Time Multiplier
Cooling Multiplier
Start Block Level
Short Circuit Protection
Trip Settings
Very Inverse as per IEC 60255-151 B Curve, or Extremely Inverse as per IEC 60255-151 C Curve
See Protection Element Full Load Current Selection Table (Appendix A)
0.05-30 (See Protection Element TMS Table)
See Protection Element Full Load Current Selection Table (Appendix A)
0.05-30 (See Protection Element TMS Table)
1.0, 1.5, 2.0, 2.5, 3.0, 4.0, 5.0
20%, 30%, 40%, 50%, 60%, 70%, 80%, 90%
1.5x to 12.5x in 0.25x increments in OC mode,
3.0x to 25x when in MOL mode with addition slower trip element at
1.5x to 12.5x (Multiples of Full Load Current)
Trip occurs at the level determined by selected Full Load Current x SC
Level or 6 kA, whichever is lesser.
Trip Time
Current Monitoring
Under Current
Current Balance
40ms, 60ms, 80ms, 100ms, 120ms, 140ms,160ms, 180ms, 200ms (All times are +/- 15ms)
0% (Disabled), 30%,35%, 40%, 45%, 50%, 55%, 60%, 65%, 70%, 75%,
80%, 85%, 90%, 95%
5%, 10%, 20%, 50%, OFF
Other Protection Functions
Under Voltage Protection
Trip Settings
Trip Time
Off, 40%, 50%, 60%, 70%, 75%, 80%, 85%, 90%, 95%
850ms
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178819
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101650
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12 EQUIPMENT LIST
Part Number
173694
159689
Description
Fixed OCS Cassette c/w Standard OCS Protection Element (EtherNet/IP)
Withdrawable OCS Cassette c/w Standard OCS Protection Element
(EtherNet/IP)
Standard OCS Protection Element (Spare Part) (EtherNet/IP)
Standard OCS Protection Element (Spare Part) (Modbus TCP)
Residual Voltage OCS Protection Element (Spare Part) (Modbus TCP)
Outlet Cassette Remote Termination Unit (RTX)
Earth Leakage Toroid – EL500/60/100T 500mA 60mmID
Earth Leakage Toroid
– EL500/85/100T 500mA 85mmID
Earth Leakage Toroid – EL500/112/100T 50mA 112mmID
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APPENDIX A: PROTECTION ELEMENT LOAD CURRENT TABLES
A1: Protection Element Full Load Current Table
Protection Element Full Load Current Selection Table – Amps (1000:1 CT), and Max effective
SC Level
Value Amps
0 5.125
1 5.250
2 5.375
3 5.500
4 5.625
5 5.750
6 5.875
7 6.000
8 6.125
9 6.250
10 6.375
11 6.500
12 6.625
13 6.750
14 6.875
15 7.000
16 7.125
17 7.250
18 7.375
19 7.500
20 7.625
21 7.750
22 7.875
23 8.000
24 8.250
Value Amps
32 10.25
33 10.50
34 10.75
35 11.00
36 11.25
37 11.50
38 11.75
39 12.00
40 12.25
41 12.50
42 12.75
43 13.00
44 13.25
45 13.50
46 13.75
47 14.00
48 14.25
49 14.50
50 14.75
51 15.00
52 15.25
53 15.50
54 15.75
55 16.00
56 16.50
Value Amps
64 20.5
65 21.0
66 21.5
67 22.0
68 22.5
69 23.0
70 23.5
71 24.0
72 24.5
73 25.0
74 25.5
75 26.0
76 26.5
77 27.0
78 27.5
79 28.0
80 28.5
81 29.0
82 29.5
83 30.0
84 30.5
85 31.0
86 31.5
87 32.0
88 33.0
Value Amps
96
97
98
99
41
42
43
44
100 45
101 46
102 47
103 48
104 49
105 50
106 51
107 52
108 53
109 54
110 55
111 56
112 57
113 58
114 59
115 60
116 61
117 62
118 63
119 64
120 66
Value Amps
128 82
129 84
130 86
131 88
132 90
133 92
134 94
135 96
136 98
137 100
138 102
139 104
140 106
141 108
142 110
143 112
144 114
145 116
146 118
147 120
148 122
149 124
150 126
151 128
152 132
Value Amps SC max
160 164 25.0x
161 168 25.0x
162 172 25.0x
163 176 25.0x
164 180 25.0x
165 184 25.0x
166 188 25.0x
167 192 25.0x
168 196 25.0x
169 200 25.0x
170 204 25.0x
171 208 25.0x
172 212 25.0x
173 216 25.0x
174 220 25.0x
175 224 25.0x
176 228 25.0x
177 232 25.0x
178 236 25.0x
179 240 25.0x
180 244 24.6x
181 248 24.2x
182 252 23.8x
183 256 23.4x
184 264 22.7x
Value Amps SC max
192 328 18.3x
193 336 17.9x
194 344 17.4x
195 352 17.0x
196 360 16.7x
197 368 16.3x
198 376 16.0x
199 384 15.6x
200 392 15.3x
201 400 15.0x
202 408 14.7x
203 416 14.4x
204 424 14.2x
205 432 13.9x
206 440 13.6x
207 448 13.4x
208 456 13.2x
209 464 12.9x
210 472 12.7x
211 480 12.5x
212 488 12.3x
213 496 12.1x
214 504 11.9x
215 512 11.7x
216 528 11.4x
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Protection Element Full Load Current Selection Table – Amps (1000:1 CT), and Max effective
SC Level
Value Amps Value Amps Value Amps Value Amps Value Amps Value Amps SC max Value Amps SC max
25 8.500 57 17.00 89 34.0 121 68 153 136 185 272 22.1x 217 544 11.0x
26 8.750 58 17.50 90 35.0 122 70 154 140 186 280 21.4x 218 560 10.7x
27 9.000 59 18.00 91 36.0 123 72 155 144 187 288 20.8x 219 576 10.4x
28 9.250 60 18.50 92 37.0 124 74 156 148 188 296 20.3x 220 592 10.1x
29 9.500 61 19.00 93 38.0 125 76 157 152 189 304 19.7x 221 608 9.9x
30 9.750 62 19.50 94 39.0 126 78 158 156 190 312 19.2x 222 624 9.6x
31 10.00 63 20.00 95 40.0 127 80 159 160 191 320 18.8x 223 640 9.4x
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A2: Protection Element TMS Table
Protection Element Over Current Time Multiplier Settings (TMS) including nominal trip time in seconds at 10 PU Current
10 x trip time 10 x trip time 10 x trip time
Value TMS
Ext Inv.
& MOL
Very
Inv.
Value TMS
Ext Inv.
& MOL
Very
Inv.
Value TMS
Ext Inv.
& MOL
Very
Inv.
0 0.050 0.040 0.075 30 0.50 0.404 0.750 60 5.0 4.04 7.50
1 0.055 0.044 0.083 31 0.55 0.444 0.825 61 5.5 4.44 8.25
2 0.060 0.048 0.090 32 0.60 0.485 0.900 62 6.0 4.85 9.00
3 0.065 0.053 0.098 33 0.65 0.525 0.975 63 6.5 5.25 9.75
4 0.070 0.057 0.105 34 0.70 0.566 1.050 64 7.0 5.66 10.50
5 0.075 0.061 0.113 35 0.75 0.606 1.125 65 7.5 6.06 11.25
6 0.080 0.065 0.120 36 0.80 0.646 1.200 66 8.0 6.46 12.00
7 0.085 0.069 0.128 37 0.85 0.687 1.275 67 8.5 6.87 12.75
8 0.090 0.073 0.135 38 0.90 0.727 1.350 68 9.0 7.27 13.50
9 0.10 0.081 0.150 39 1.0 0.808 1.50 69 10.0 8.08 15.0
10 0.11 0.089 0.165 40 1.1 0.889 1.65 70 11.0 8.89 16.5
11 0.12 0.097 0.180 41 1.2 0.970 1.80 71 12.0 9.70 18.0
12 0.13 0.105 0.195 42 1.3 1.05 1.95 72 13.0 10.51 19.5
13 0.14 0.113 0.210 43 1.4 1.13 2.10 73 14.0 11.31 21.0
14 0.15 0.121 0.225 44 1.5 1.21 2.25 74 15.0 12.12 22.5
15 0.16 0.129 0.240 45 1.6 1.29 2.40 75 16.0 12.93 24.0
16 0.17 0.137 0.255 46 1.7 1.37 2.55 76 17.0 13.74 25.5
17 0.18 0.145 0.270 47 1.8 1.45 2.70 77 18.0 14.55 27.0
18 0.19 0.154 0.285 48 1.9 1.54 2.85 78 19.0 15.35 28.5
19 0.20 0.162 0.300 49 2.0 1.62 3.00 79 20.0 16.16 30.0
20 0.22 0.178 0.330 50 2.2 1.78 3.30 80 22.0 17.78 33.0
21 0.24 0.194 0.360 51 2.4 1.94 3.60 81 24.0 19.39 36.0
22 0.26 0.210 0.390 52 2.6 2.10 3.90 82 26.0 21.01 39.0
23 0.28 0.226 0.420 53 2.8 2.26 4.20 83 28.0 22.63 42.0
24 0.30 0.242 0.450 54 3.0 2.42 4.50 84 30.0 24.24 45.0
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Protection Element Over Current Time Multiplier Settings (TMS) including nominal trip time in seconds at 10 PU Current
10 x trip time
Value TMS
Ext Inv.
& MOL
Very
Inv.
25 0.32 0.259 0.480
26 0.35 0.283 0.525
27 0.38 0.307 0.570
28 0.42 0.339 0.630
29 0.46 0.372 0.690
Value TMS
55
56
57
58
59
3.2
3.5
3.8
4.2
4.6
10 x trip time
Ext Inv.
& MOL
Very
Inv.
Value TMS
2.59 4.80
2.83 5.25
3.07 5.70
3.39 6.30
3.72 6.90
10 x trip time
Ext Inv.
& MOL
Very
Inv.
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APPENDIX B: DRAWINGS
The drawings in this appendix are as per the below table.
Drawing Number Drawing Title
OCSE002
OCSE001
OCSA001
OCSB001
OCSB002
Typical Connection Diagram
I.S. System Diagram
Protection Element Mechanical Details
Overcurrent and Short Circuit Curves
Motor Overload and Short Circuit Curves
Page Number
58
59
60
61
62
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APPENDIX C: APPROVALS
This appendix contains a copy of Issue No. 1 of the IECEx ITA 12.0032X certificate of conformity and relevant attachments. For the most up-to-date copy of this certification refer to the http://iecex.iec.ch/ website.
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