ELV-PRO MAG-219 V5 Earth Leakage Relay User Manual

ELV-PRO MAG-219 V5 Earth Leakage Relay User Manual

Copyright Notice
The Ampcontrol Earth Leakage Relay ELV-PRO 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 ELV-PRO Relay.

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

Table 1: Definitions

1 SAFETY AND OTHER WARNINGS

For safety reasons, the ELV-PRO must be installed, operated and serviced only by competent personnel. Please read and understand this instruction manual completely before installing, operating or servicing this equipment. Failure to install or operate this instrument in accordance with the instructions contained in this manual may create hazardous operating conditions.

1.1 Safe Use of Equipment
The equipment supplied has been designed and manufactured to ensure safe operation. The equipment must only be used within the design parameters.

The instructions within this manual must be observed as an aid towards achieving the safest possible installation.
Persons responsible for installation, maintenance, or operation, must observe the following instructions:

1.1.1 Changes to Equipment
Changes in the design and modifications to the equipment are not permitted. Unauthorised changes made to the hardware or operating firmware will void the manufacturer’s warranty, and may compromise the integrity of the system into which it is installed and other connected equipment.

1.1.2 Equipment Knowledge
Experience with, or understanding of, this equipment is essential for the safe installation and removal of the equipment. Therefore, please read and understand this manual prior to use. Competency based training courses are recommended and are available on request.

1.1.3 Manual Handling
Precautions have been taken to ensure all equipment is safe to handle and free from sharp edges. However, care should always be taken when handling enclosures and gloves should be worn.

1.1.4 Installation
Correct operation and safety depend on the relay being installed correctly. Mechanical and or electrical installation and maintenance of plant and equipment must only be carried out by appropriately qualified personnel and must be tested thoroughly prior to operation.

1.1.5 Operation
As safety depends on the relay functioning correctly, it is highly recommended that all safety functions of the relay be periodically tested to ensure correct operation.

2 RECEIVING AND STORAGE

2.1 Receiving
All possible precautions are taken to protect the equipment against damage or losses during shipment; however, before accepting delivery, check all items against the packing list or bill of loading. If there is evidence of physical damage, notify Ampcontrol immediately.

Notify Ampcontrol immediately in the case of any discrepancies to the packing list. Keep a record of any claims and correspondence. Photographs are recommended.

Where practicable do not remove protective covers prior to installation unless there are indications of damage. Boxes opened for inspection and inventory should be carefully repacked to ensure protection of the contents or else the parts should be packaged and stored in a safe place. Examine all packing boxes, wrappings and covers for items attached to them, retain and store any approval documentation for your safety file as applicable prior to wrapping being discarded.

2.2 Inspection
Equipment that is found to be damaged or has been modified away from its published specifications must not be used. Please contact Ampcontrol if the equipment is suspected to be different than that ordered or if it does not match the published specifications.

2.3 Storage after Delivery
When the equipment is not to be installed immediately, proper storage is important to ensure protection of equipment and validity of warranty.

All equipment should be stored indoors between 0-40˚C, preferably on shelves and protected from moisture and sunlight.

2.4 Unpacking of Equipment
The method of packing used will depend on the size and quantity of the equipment. The following cautions should be interpreted as appropriate.

3 PRODUCT OVERVIEW

3.1 Description
Ampcontrol’s ELV-PRO is a high performance, microprocessor based, wide bandwidth earth leakage protection relay that is capable of measuring and analysing power and switching frequency currents flowing in IT power systems. The ELV-PRO uses patented technology (US20130258537) to characterise earth leakage currents giving superior fault discrimination.

The ELV-PRO relay is designed for use in systems that may exhibit circulating earth currents and complex earth leakage currents typically associated with variable speed drives in mining environments.

3.2 Key Features
The ELV-PRO has the following key features:

• Compliance to AS/NZS 4871 and AS/NZS 2081

• Patented earth leakage analysis method*

• Fail safe operation

• Wide range Earth Leakage Current Measurement (20 Hz to 8 kHz)

• Wideband, Narrowband and Weighted Frequency Response Modes

• Adjustable trip level and trip times

• On board memory logs last 1000 data logs and 50 events

• CIP over EtherNet/IP for control and Monitoring

• Modbus TCP

• Continuous Toroid Connection Monitoring

• DIN rail mounted

• International patent application number PCT/AU2011/000705

3.3 Application
The ELV-PRO is intended for use at transformer NER connection points as a BUEL Protection relay. The relay is not limited to be used in this configuration only, and can be utilised on any individual outlet if desired. This would allow greater earth leakage current data to be captured relating to a specific outlet, rather than the entire system connected to the transformers secondary that the NER is protecting.

The ELV-PRO provides data logging to assist in fault finding. On each event trigger, the relay stores system data two seconds before and two seconds after the event including system time, earth leakage current, phase current and zero crossing of the phase current.

Ethernet connection to the ELV-PRO relay provides the ability to monitor the device parameters and real time measured current from an internet browser. All data logs stored on the unit can also be viewed.

4 INSTALLATION

4.1 General Warnings
These instructions have been designed to assist users of the ELV-PRO with installation.

Before the ELV-PRO can be installed, there are a number of things that need to be considered and understood to prevent incorrect or unsafe operation of the relay 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 relay are understood to prevent incorrect installation or use, creating a potentially dangerous risk. If in doubt as to the nature of the limitations or their implication, consult a competent authority such as a supervisor or Ampcontrol technical representative.

4.1.2 Ensure that the application into which the relay 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 relay will properly perform the required functions within the system design.
It is important to understand how the relay is intended to interact with other equipment within a system. For safe and reliable use, it is crucial that neither the logical operation nor its signalling be compromised by incompatibilities with connected equipment.

4.1.4 Modifications of any form to the relay are prohibited.
If modifications of any form are made to the relay, the equipment may no longer be fit for use. If any modifications or damage to the relay is evident, do not use the equipment and contact Ampcontrol for advice.

4.2 Mandatory Installation Practices
The following information must be adhered to when installing the ELV-PRO. Failure to adhere to this information may give rise to unsafe operation.

Using the relay in a manner that exceeds its electrical or functional 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 ELV-PRO must be supplied by a regulated voltage within the specified range.
• The installation of the ELV-PRO must be carried out by suitably trained and qualified personnel.
• Identification labels fixed to the ELV-PRO 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 ELV-PRO. Modifications to its construction will render the unit non-compliant.
• Complete and accurate records of the installation must be retained for warranty purposes.

4.3 Mechanical Installation Information

Figure 4-1: ELV-PRO Dimensions

The ELV-PRO metal enclosure is rated at IP20. It is DIN Rail mounted and measures 135mm x 135mm and 107mm deep as per Figure 4-1. The terminal layout and description is shown in Figure 4-2 and Table 2 respectively.

Figure 4-2: ELV-PRO Terminal Layout

Table 2: ELV-PRO Terminal Designators

4.4 Electrical Installation Information
A typical installation diagram of the ELV-PRO is shown below, Figure 4-3. The following sub-sections provide a more detailed description of each of the individual circuit elements.

Figure 4-3: Electrical Connections – ELV-PRO Circuit Diagram

4.4.1 Power Supply (Plug 3)
The ELV-PRO requires a regulated 24VDC power supply. There are two input supply connections for both the 0V and +24VDC inputs. These connections are internally connected. Terminals P3_1 & P3_2 are the positive supply inputs. Terminals P3_3 & P3_4 are the negative supply inputs.

Figure 4-4: Electrical Connections – ELV-PRO Power Supply (Plug 3)

4.4.2 Trip Reset and Digital Inputs (Plug 2 & Plug 4)
The trip reset and digital inputs are split across two plugs; Plug 2 and Plug 4 (see Figure 4-5). Plug 2 (right) is a dedicated digital input and Trip Reset 24V supply. All terminals of plug 2 are internally connected. Plug 4 (left) is a dedicated input plug; terminals P4_1 – P4_5 are assignable digital inputs, with terminal P4_6 the Reset input. The Trip Reset Input allows the ELV-PRO to be reset remotely.

Figure 4-5: Electrical Connections – Trip Resent and Digital Inputs (Plugs 2 & 4)

4.4.3 Earth Leakage CT, CT Test, Zero Crossing Input Connections (Plug 6)
The Earth Leakage protection is achieved through the use of a core balance CT. The connections to the CT are terminals P6_1 & P6_2. Terminal P6_3 is the screen termination point for the cable connecting the EL CT to the relay. For further details see Section 4.4.9.

Figure 4-6: Electrical Connections – EL CT, CT Test and Zero Crossing Connections (Plug 6)

4.4.4 Phase CT Input (Plug 5)
The ELV-PRO relay has an optional phase CT input (Any suitable toroid with a secondary rating of 5A) which is captured only during a logged event if available. The CT is connected to terminals P5_1 & P5_2. Terminal P5_3 is the screen termination point for the cable connecting the phase CT to the relay. Typical connection is shown in Figure 4-7.

Figure 4-7: Electrical Connections – Phase CT Input (Plug 5)

4.4.5 Control Contact Output Connections (Plug 1 Terminals 1,2,3,4 & 5)
The ELV-PRO has two control contact output Relays.

Figure 4-8: Electrical Connections – Control Contact Outputs Connections (Plug 1)

4.4.6 ELV-PRO Dongle Input (Dedicated Dongle Slot)
The ELV-PRO has a dedicated dongle input, item 2 of Figure 4-10. The dongle is keyed and therefore has a specific orientation. Refer to Figure 4-9.

Figure 4-9: ELF-PRO Parameter Dongle

4.4.7 Ethernet Input (Dedicated Ethernet Socket)
The ELV-PRO has an Ethernet socket to allow the ELV-PRO to be connected to a network switch or directly to a PC or Ethernet device, see item 1 of Figure 4-10.

Figure 4-10: Ethernet and Dongle Connections

4.4.8 Removal of ELV-PRO Relay
The ELV-PRO can be removed by simply removing the plugs and dislodging the Analyser from the DIN rail. Each plug is secured to the ELV-PRO through two screws on either end to prevent the plugs becoming loose during operation or transport.

4.4.9 ELV-PRO Current Transformer Location and Selection
The ELV-PRO relay has been designed for compliance to AS/NZS 2081:2011 for use on earth fault limited systems. There are generally two locations where the ELV-PRO may be installed:

1. Core balance protection performs the primary protection in an installation by protecting the outlet supplying power to a machine. In this application the relay’s operation time is typically set at instantaneous. The three power phases are passed symmetrically through the centre of the toroid. If there is no earth fault present, the vector sum of the currents in a three-phase supply is zero. If current from any phase flows to earth, the toroid flux becomes unbalanced, allowing the toroid to produce an output, which in turn trips the relay.
   A test current is injected through the window of the toroid to test the operation of the relay.

2. Series neutral protection is the backup protection method and may have an operation time up to a maximum of 500ms. In this method the neutral to earth connection is passed through the toroid. An earth fault on any of the phase conductors causes an earth current which returns, through the neutral, to the star point of the transformer and is detected by the toroid.
   A test circuit can connect a test resistor between a phase and earth or inject a current through the toroid as previously described.

Figure 4-11: ELV-PRO Toroid Installation Examples

The ELV-PRO relay is designed for use with Ampcontrol 100/1A EL500S series Toroids. They are available with window sizes 25, 60, & 112mm.

4.4.10 ELV-PRO Phase Monitoring Toroid
The ELV-PRO has provision for the connection of a suitable toroid, with a secondary rating of 5A, to monitor a phase current in the system.

5 PRODUCT OPERATION

The ELV-PRO’s advance analysis ability does not prevent the relay operating as an effective Earth Leakage Protection Relay. This section will discuss the various features of the relay.

5.1 Earth Leakage Protection
The Earth Leakage (EL) protection used in the ELV-PRO is based upon the ELV wideband EL Protection relay. The relay is designed to AS/NZS 2081:2011 Section 6. The ELV-PRO, like the ELV, uses patented technology (AU2011264414) to characterise earth leakage currents giving superior fault discrimination, particularly in applications involving switching power electronics and variable speed drives.

The earth fault current is measured using a toroid, with the trip time and trip threshold being able to be independently adjusted through the web interface. When a fault occurs above the relays trip level and time delay settings, the relay’s trip function is activated. A trip will de-energise the trip contacts connected in the system control circuit. The trip condition is latched and requires a reset input to clear, either through the web interface, Ethernet IP or Modbus IP. A local reset is also provided on the fascia of the relay.

The user has the ability to switch the relay between wideband (up to 8 kHz), narrowband (power frequency) and weighted frequency mode (up to 8 kHz, high frequency compensated).

The ELV Relay has been designed and tested for use on fault-limited systems. To ensure maximum protection, the earth leakage system should be used in conjunction with the other protection systems covered by AS/NZS 2081. The collective systems are designed to limit touch and step potentials.

The relay is also suitable for industry where equipment or system earth leakage protection is required. The relay is not suitable for personal protection, which requires trip levels of 20-30mA, with instantaneous operation (refer to AS/NZS 3190).

The ELV-PRO has three operating modes:

• Wideband mode: The relay will see all currents between 20 Hz and 8 kHz and trips if the true RMS level of leakage current is above the trip level (adjustable from 50mA to 5A). This mode is compliant with AS/NZS 2081:2011 and would be used in most cases.
• Narrowband (power frequency) mode: The relay will see all currents between 20 Hz and 100 Hz and trips if the true RMS level of leakage current is above the trip level (adjustable from 50mA to 5A). This mode operates as a traditional earth leakage relay.
• Weighted frequency mode: This mode sets a modified form of wideband operation for demanding applications; these settings allow increased trip levels at higher frequencies to take into account the reduced sensitivity of the human body to touch potentials at these frequencies.

5.2 Earth Leakage Analysis Tool
The ELV-PRO offers real time analysis of the earth leakage current and also provides a logging function that allows the data to be analysed later.

The real time analysis consists of three live graphs; an Oscilloscope graph, RMS Graph and a Fast Fourier Transform Graph.

• OSC (Oscilloscope) graph: Plots the instantaneous values of earth leakage current measured by the ELV-PRO. At every update, it displays the last 80ms of data.
• RMS graph: In this view, Root Mean Square values of the measured current are shown. The user is able to select the time interval on the graph by selecting from the buttons below the graph.
• FFT graph: This plot shows the frequency content of the past 80ms worth of instantaneous measurements.

For further details on navigating these graphs and utilising the analysis tools refer to Section 6.

5.3 Data Logging
Data logs are triggered by a trip or alarm event, a trigger from a digital input, or can be set to happen periodically. On each event trigger, the ELV- PRO stores system data for two seconds before and two seconds after the event. This includes:

• System time,
• Earth leakage current,
• Phase current (with connection of a toroid, 5A secondary connection, within ±5% of full-scale),
• Zero crossing of the phase current (with connection of a 110Vac supply), and
• Temperature

The last 1000 events are stored in the unit. The internal storage cannot be overwritten by the user. When the unit’s memory reaches capacity the oldest entries are overwritten.

Besides being triggered by a trip, logging can be initiated in three other ways:

• Digital Inputs: By a signal at digital inputs 1-5.
• Periodically: Logging initiated by the ELV-PRO software at a regular interval.
• Alarm level logging: The user selects a trip level and delay below that of the unit’s main trip settings; typically those of the downstream protection. This allows the user to see the operation of the downstream protection. A cool down time can also be selected to prevent the unit from continuously logging.

5.4 Real Time Clock (RTC)

Recorded data is stored on the ELV-PRO with a time stamp, indicating the system time when the log was made. For the purposes of aligning recorded data with other records, it is important that the user regularly checks that the time on the RTC reflects a level of accuracy acceptable to the user.

Without regular synchronisation, the RTC may become different from actual time. The ELV-PRO does not have an on board battery to maintain the RTC settings.

If the relay is not configured to use a NTP server, on power-up the relay will look at the last event stored in the memory, add 30 seconds, and use this time as the current time. When a change is made to the relay’s time, an event is recorded, capturing the relative time with reference to the power-up time, and a second event is captured with a time stamp of the new configured time.

By doing this any events that occur between power-up and time synchronism can be manually timestamped to the correct time relative to the configured time change. The ELV-PRO can be configured to utilise an NTP server on a connected network. Refer to Section 6.2.6 for further information. This allows the relay to automatically update the time. Similarly to a manual time change, if the NTP server causes the ELV-PRO to adjust its time configuration, the previously mentioned events will be captured.

5.5 IP Configuration
The Ethernet connection can be configured in two ways, Static IP or DHCP configurations.
If there is a DHCP server running on your local network, the DHCP setting should be selected in the relays settings page, Section 6.2.6Error! Reference source not found.. Alternatively if you wish to manually configure a static IP address, this can also be adjusted in the settings page.

•  DHCP: Requires no further user configuration.
• Static IP: Requires the user to manually set up the required network parameters. These include IP address, subnet mask and gateway address. These are typically specified by your network administrator.

Connection to the ELV-PRO’s internal web server requires access to a web browser on a connected PC or GUI that has access to HTTP port 80. Network settings will need to be configured correctly to successfully connect to the ELV-PRO web server. If there are multiple ELV-PRO relays used on a single network switch, initial configuration through a dedicated connection may be required before you can access through a network switch.

5.5.1 Configuration through a Dedicated Connection
First time operation and operation after an IP Reset may require configuration through a dedicated connection. After connecting the ELV-PRO directly your computer, the red cross over the wireless/hardwired icon on your task bar icon should disappear. If the wireless icon was displayed prior to connecting, the icon will change to the hardwired icon. There will likely be a yellow triangle with an exclamation mark over the hardwired icon, as shown in Figure 5-1. The triangle symbol simply means that internet access is unavailable.

Figure 5-1: Taskbar Icon: Wired Connection Available

You will need to configure the network adapter settings by right-clicking on this icon and selecting “Open
Network and Sharing Center”. The following should appear:

Figure 5-2: Network and Sharing Center

Click on “Local Area Connection” for the status page to appear as in Figure 5-3.

Figure 5-3: Local Area Connection Status (left) and Properties (right)

Click the “ Properties” button for the “Local Area Connection Properties” window to appear as in Figure 5-3.
Double click on “Internet Protocol Version 4 (TCP/IPv4)”. The following should appear:

Figure 5-4: Internet Protocol Versions 4 (TCP/IPv4) Properties

Assign the following IP address and Subnet mask:

• IPv4 Address = 10.1.1.xxx , where xxx is a value between 1 and 250 excluding address 10 (The ELV-PRO default setting is 10 so will cause a clash)
• IPv4 Subnet Mask = 255.255.255.0.

Once you have configured the network adapter settings, open up a web browser and type the following IP address into the browsers address bar:

10.1.1.10

The ELV-PRO Web Interface should appear as detailed in Section 6.

5.6 Protection Settings

The modifiable settings of the ELV-PRO include the following:

• Earth Leakage Trip Level
• Earth Leakage Trip Time
• Earth Leakage Alarm Trip Level
• Earth Leakage Alarm Time
• Alarm Cool Down
• Earth Leakage Mode
• Digital Input Settings

5.6.1 Earth Leakage Trip Level

This defines the leakage current which will cause an Earth Leakage trip. The current is detected via the Earth Leakage CT and is given in RMS. The setting can be any value between 50mA and 5000mA inclusive. The web server however has used values in set intervals to make adjustment easier and quicker. These values can be seen below, Table 3.

Table 3: Earth Leakage Trip level

5.6.2 Earth Leakage Trip Time
This defines how quickly the Earth Leakage trip will occur when the current through the CT is greater than the Earth Leakage Trip Level. These values are the maximum trip time, not the minimum (that is a trip is guaranteed to occur in less than 100ms when set to 100ms). The setting can be any value between 50ms and 500ms inclusive. The web server however has used values in set intervals to make adjustment easier and quicker. These values can be seen below.

Table 4: Earth Leakage Trip Time

5.6.3 Earth Leakage Alarm Trip Level
The setting can be any value between 50mA and 5000mA inclusive. The web server however has used values in set intervals to make adjustment easier and quicker. These values are identical to the EL Trip Level, as shown in Table 3.

5.6.4 Earth Leakage Alarm Time
This can be set to any value between 1ms and 1500ms inclusive. The web server however has used values in 50ms intervals to make adjustment easier and quicker.

5.6.5 Alarm Cool Down
This is the number of seconds that needs to have elapsed before the alarm can re-trigger. The value can be set to any value between 5 seconds and 300 seconds inclusive. The web server however has used values in set intervals of 5 seconds to make adjustment easier and quicker.

5.6.6 Digital Input Settings
The five (5) digital inputs are individually configured to suit the user’s application requirements. The following settings can be selected.

Table 5: Digital Input Settings

5.7 ELV-PRO CIP over EtherNet/IP Interface
The ELV-PRO has included EIP protocol to allow external equipment (capable of communicating in this protocol) to monitor and reset the ELV-PRO, such as a PLC. The EIP commands and configuration can be seen in APPENDIX C: ELV-PRO CIP OVER ETHERNET/IP.

5.8 ELV-PRO Modbus TCP Interface
The ELV-PRO has included a Modbus IP protocol to allow external equipment (capable of communicating in this protocol) to monitor and reset the ELV-PRO, such as a PLC. The Modbus IP commands and configuration can be seen in APPENDIX D: ELV-PRO Modbus TCP.

6 OPERATIONAL INTERFACE
This section provides information relating to the interfacing of the ELV-PRO. All interfacing elements will be defined here including the front Facia, Web server, Ethernet IP and Modbus IP.

6.1 ELV-PRO Facia Interface
The ELV-PRO has a basic interface on the front of the relay. The relay has been specifically designed to operate through a PC or web server when connected to a network. The ELV-PRO interface is shown in Figure 6-1.

The front of the relay has two buttons and two indicators. The ‘Reset’ button, Item 3 in Figure 6-1, functions as a local reset button allowing a trip to be reset, provided the fault has cleared. The ‘IP Reset’ button, Item 4 in Figure 6-1, is used to reset the IP address to the factory default setting (10.1.1.10). An IP Reset requires a ‘press and hold’ operation for 8 seconds. A successful IP Reset, will be confirmed through the front LED indication sequence as indicated in Table 6.

Figure 6-1: ELV-PRO Relay Fascia Interface

Table 6: ELV-PRO Relay Fascia LED Operation

6.2 ELV-PRO Web Interface

The ELV-PRO Web Interface allows the user to remotely access the information stored within the ELV-PRO.
This includes live data, event and data logs, device information and settings. The ELV-PRO has
six main tabs, accessible from the left-hand side of the page. These are:

• Live Graphs
• Data Logs
• Event Logs
• Device Info
• Settings
• About

6.2.1 Connecting to the ELV-PRO Web Interface
In order to connect to the ELV-PRO Web Interface, the user must type the IP address of the Analyser that they wish to connect to into their web browsers address bar. To view the Web Interface, the computer that is accessing the Analyser must be connected to the same network as the Analyser. For more information on IP configuration, refer to Section 5.5.

The Live Graphs tab is the default landing page and will automatically be displayed upon accessing the Web Interface. Refer to Section 6.2.2 for more information on the Live Graphs.

The web interface has a number of features that are common to all views. These features are identified in Figure 6-2 by numbered circles. Items identified by these numbered circles are explained in further detail in the following sub- sections.

Figure 6-2: ELV-PRO Web Interface – Overview

6.2.1.1 Item 1: Selected Tab
This name of the tab that is currently visible is displayed here.
When the relay is tripped, the web server reset button is also displayed next to the tab name (see Section 6.2.9).

6.2.1.2 Item 2: IP Address | Temperature | Unit Date and Time
This area of the Web Interface displays:

• The relay description/name
• The IP address of the ELV-PRO
• The temperature that the ELV-PRO is currently operating at
• The Hardware status
•  Trip Level
• Trip Time
• EL Current

The relay description in the top of the screen is defined in the ELV-PRO dongle settings (see Section 6.2.6 Error! Reference source not found. ). This description is also used to correctly identify the connected ELV-PRO relay.

6.2.1.3 Item 3: ELV-PRO Analyser Status Indicators
The ELV-PRO Status Indicators display the status of the Web Interface network connection to the Analyser and the status of the Relay. The functionality of these indicators is outlined in Table 7

Table 7: Web Interface Status Indicators.

6.2.1.4 Item 4: Tab Selection Panel
The Tab Selection Panel allows the user to switch between the different views in the ELV-PRO Web Interface. To move between tabs, simply mouse over the desired tab and select it with the left mouse button.

6.2.1.5 Item 5: Tab Viewing Area
This area of the Web Interface will display the information that is relevant to the tab that has been selected. The area outside of this zone will remain constant.

6.2.2 Live Graphs Tab
Figure 6-3 shows the ELV-PRO Live Graphs interface. By default, the Live Graphs tab displays the RMS graph of the past 30 seconds. The graphs in this tab are refreshed every second; provided the Live Update button (Item 2 of Figure 6-3) is activated (default is ON). With the Live Update button disabled the plot is static which can allow for better inspection of the data shown using the interactive features of the plots (described in Section 6.2.8). The buttons above the graphs (item 1 of Figure 6-3) allow the graph to alternate between the three possible options. These are:

•  OSC (Oscilloscope) graph: Plots the instantaneous values of earth leakage current measured by
  the ELV-PRO. At every update, it displays the last 80ms of data. Figure 6-4.

• RMS graph: In this view, Root Mean Square (RMS) values of the measured current are shown. The user is able to select the time interval on the graph by selecting from the buttons below the graph. Figure 6-3.

• FFT graph: This plot shows the frequency content of the past 80ms worth of instantaneous measurements. Figure 6-5.

For information on navigating the interactive graphs see Section 6.2.8. There is also a Help button below the plots, item 4 of Figure 6-4, which allows access to online help information.

Figure 6-3: ELV-PRO Web Interface – Live Graphs (RMS)

Figure 6-6: ELV-PRO Web Interface – Data Logs

Figure 6-7: ELV-PRO Web Interface – Data Logs (OSC)

Figure 6-8: ELV-PRO Web Interface – Data Logs (RMS)

Figure 6-9: ELV-PRO Web Interface – Data Logs (FFT)

6.2.4 Event Logs Tab
This tab shows the 50 most recent user changes made at the unit, see Figure 6-10. To export this list, use the link above the log (item 1) to show the log entries in a separate popup window for printing or copy-pasting. The Event log descriptions can be found in Table 8 below.

Figure 6-10: ELV-PRO Web Interface – Event Logs

Table 8: Event ID Descriptions

6.2.5 Device Information Tab
The Device Information Tab (Figure 6-11) shows settings, states and measurements relating to the hardware and software of the Analyser. The information is updated once a second and includes:

• Trip Settings
• Network Settings
• NTP Settings
• ADC Settings
• Software Information
• General Settings
• Systems Trips
• Digital Input Settings
• Hardware Status

Figure 6-11: ELV-PRO Web Interface – Device Info

6.2.6 Settings Tab
The settings Tab (Figure 6-12) allows for configuration of the following:

• Trip Settings
• Network Settings
• NTP Settings
• Date and Time
• Digital Input Settings
• Unit Configuration
• ADC Settings
• Passwords

To access the Settings page, the user will be prompted to enter a Username and Password. The default login details are shown in Table 9 below. Once the desired settings have been changed, select “Save Settings” to save and return to the Home page.

Table 9: Login Details

Figure 6-12: ELV-PRO Web Interface – Settings

When the ELV-PRO has been installed and powered up for the first time in an installation, it is recommended that the user press the ‘Calibrate ADC’ button on the settings page. When doing this the outlet or outlets the relay is protecting should not be energised. This will allow the relay to factor in the cable wiring, toroid differences and any influences due to the installation and location of the equipment for the application/installation.

6.2.7 About Tab
The About Tab (Figure 6-13) provides contact details and licensing information about the device and website.

Figure 6-13: ELV-PRO Web Interface – About

6.2.8 Interactive graph navigation
The graphs shown on the website are interactive. The user can zoom, pan, and display values:

• To zoom in, click on the graph and drag either horizontally (as shown in Figure 6-14) or vertically. Alternatively, for touchscreen devices pinch out to zoom in.
• To zoom out, double click the graph area (or pinch in on touchscreen devices)
• To pan around, shift-click and drag (mouse driven devices) or swipe (touchscreen devices)
• To display signal values, simply mouse over the plot to show the extended legend in the top right of the graph area (not available on touchscreen devices).

In the Oscilloscope and RMS graphs of a historic data log, time intervals can be determined by marking the start and end time with single clicks and then reading off the selected range from the box in the top left of the plot. To remove the marked range, click the box. To refine the selection, use single clicks near either end of the marked range to move the markers.

Figure 6-14: ELV-PRO Web Interface – Interactive Graph Navigation

6.2.9 Protection Function Trip
Should a trip occur, the trip indicator illuminates red (Item 3 of Figure 6-15) and the header block (Item 1 of Figure 6-15) and page background changes to red. The Reset pin code entry and button will also appear, see Item 2 in Figure 6-15. To reset, simply enter the pin and select the reset button.

Figure 6-15: ELV-PRO – Web Interface – Protection Function Trip

7 SERVICE, MAINTENANCE & DISPOSAL

7.1 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 ELV-PRO 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.

7.1.1 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 relay 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 sealed wall boxes are free from water and dust ingress internally. Door seals are in good condition.
• 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, wall boxes and cables are present and in good condition (especially certification labels).
• Check that no modifications have been carried out to installed equipment.

7.1.2 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, wall boxes and other mechanical fixtures are secured in place. This includes terminal box lids, tightness of cable glands, integrity of wall-box 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.

7.1.3 Electrical Testing / Commissioning
Prior to being put into service, the electrical protection system must be correctly commissioned. This manual does not cover system commissioning; the scope of commissioning tests should be determined during the risk assessment or FMEA covering the design of the electrical protection system.

The following points can provide guidance on checking the correct operation of ELV-PRO during commissioning. This is not intended to provide an exhaustive commissioning checklist, but should be considered to be a minimum.

• Ensure that the system is connected in accordance with the manufactures’ instructions, and conforms to the intended design.
• In the case of monitoring the NER circuit, ensure that no alternate earth paths exist that bypass the NER.
• Perform an earth leakage test by injecting a current through the primary (window) of the EL toroid and verify that the unit behaves as expected and that when it trips it also operates the intended circuit breaking device.
• The ADC settings should be calibrated through the web server interface on each installation or routine maintenance.

7.2 Equipment Maintenance

It is recommended that the electrical protection system incorporating the ELV- PRO be subject to regular functional tests at intervals determined by risk assessment of FMEA. These intervals typically coincide with periodic maintenance checks and will cover (but not limited to) tests such as earth continuity tests.

7.3 Disposal

8 SPECIFICATIONS

9 EQUIPMENT LIST

APPENDIX A: MINING EARTH LEAKAGE PROTECTION WITH VARIABLE SPEED DRIVES
The mining working environment presents a range of unique challenges for electrical distribution systems due to the equipment used and associated hazards. As such, various protection schemes have evolved to prevent damage to equipment and injury to personnel. In particular, these include:

a) Earth fault current limitation, usually consisting of a resistor connected between the supply transformer star point and earth, commonly referred to as a Neutral Earthing Resistor (NER).
b) Earth continuity monitoring devices.
c) Earth leakage protection devices.
d) Earth fault lockout protection.

As described in Appendix C of AS/NZS 4871.1:2012, the protection scheme is

Intended to ensure that when persons are exposed to touch potentials, the level of voltage and time exposed before protection systems trip is limited to an acceptable level

The acceptable levels are given in Figure C1 of the standard for 50 Hz touch voltages.

These protection systems were originally devised to protect against touch potential hazards cause by earth fault currents driven by the power supply (50 Hz). Consider, for example, that an earth fault occurs in a mobile machine powered by a trailing cable. The earth fault current will flow through the fault to the machine frame and return to the supply transformer star point via the trailing cable earth conductors. The voltage drop caused will result in a potential rise above earth on the frame, presenting a touch potential hazard. As described in AS/NZS 4871.1:2012 the system assessment must determine the earth fault limitation current that will protect people based on the achievable earth leakage clearance times and knowledge of the system in which it is installed.

A1 Variable Speed Drives
Variable speed drives (VSDs) are now finding wide use in mining applications. Most of these drives use variable frequency outputs that are produced by rectifying the supply to dc and then inverting this voltage back into ac using a high frequency carrier and pulse width modulation (PWM) to produce variable frequency currents in the motor. They complicate the situation in several ways:

1. VSDs introduce a new and complex voltage source into the power system. This may mean that earth faults can now be direct current (dc) in nature or may be driven by the inverter of the drive and so have a frequency that is primarily that of the drive PWM carrier frequency (1000Hz for example).

2. To minimise interference with protection and control systems, many drives employ electromagnetic compatibility (EMC or EMI) filters that consist primarily of a capacitive circuit between the input of the drive and earth. This provides a path for the earth currents that represents an alternative path to the NER, as shown in the figure below. In fact, it is the intention of the filter to provide this alternative path for the high frequency currents that flow (through the motor and cable stray capacitances) to earth under normal conditions. They will also provide an alternative path under fault conditions, particularly if the fault is driven by the high switching frequency drive output.
   It has also been shown that when one or more drives and filters are in use, and an earth fault occurs, there can be circulating currents between the drives and filters and/or the fault location. The fault current magnitudes may then greatly exceed the nominal current limitation value (typically 5A) determined by the NER. These large currents may cause touch potentials that greatly exceed the expected values.

3. Most earth leakage protection relays approved for use in mining applications are designed to detect 50 Hz currents, not dc or high frequency currents so the relays may not trip, or if they do trip they may take longer than expected.

The overall result is that with standard earth leakage protection relays and electrical system assessments based only on consideration of faults driven by the supply system (50 Hz), protection performance is unlikely to be adequate when variable speed drives are used in mining applications.

A2 Improving Protection
The design of earth leakage relays used in mining applications in Australia and New Zealand must comply with AS/NZS 2081. The latest version of this standard (AS/NZS 2081:2011) better recognises that system protection needs to be assessed in accordance with AS/NZS 4871.1:2010 and with the changes in the mining electrical environment.

The following extracts from AS/NZS 2081:2011 provide some key statements of interest:

1.1 Scope
Whereas this standard is based upon 50 Hz supply systems, it is envisaged that the equipment described may also be installed in systems with higher, lower or variable frequencies, or in dc supplied systems.
AS/NZS 60479, Part 1 and 2 should be referenced for consideration of the effects at other supply frequencies upon the human body.

Appendix B:
The diversity of operating conditions and equipment addressed by this Standard precludes reliance solely on explicitly prescribed trip levels or fault current levels, and their duration, in order to ensure a safe working environment. Rather, the onus is placed on the system designer to ensure appropriate touch voltage/operating times when integrating the protection devices addressed by this Standard.

B2 Voltage/duration Thresholds
Design criteria for the protection devices have been chosen to enable compliance to the touch voltage/operating times for systems operating at 50 Hz as described by Figure B1.

B3 Systems at other than 50 Hz Cyclic Frequency
Where equipment is installed and operated within systems at other than a constant 50 Hz cyclic frequency, the characteristics in paragraph B2 are not immediately applicable. In such instances, individual calculation to determine requirements at the frequency or frequencies in question will be required.
Standards AS/NZS 60479.1 and AS/NZS 60479.2 should be referenced in relation to the effects upon the human body of other supply frequencies.

What this means is that when VSDs (or other non 50Hz sources) are used in a mining electrical system then the standard approach needs to be interpreted to ensure that protection is adequate. The key factors to consider are as follows:

1. The sensitivity of the human body to electric shock varies with frequency. In general, for a given exposure time, the allowable touch voltage magnitude increases with frequency. For example, at 10 kHz, the “let go” voltage is about 5 times that level at 50 Hz.
2. When EMC filters are used, this forms a path for earth currents alternative to the NER. When considering touch potentials at a mobile machine for example, strictly speaking the impedance of the filter at the frequency of interest should be examined in order to determine the earth fault current that will flow when a fault occurs in the machine. The earth leakage trip time must then be used to ensure that the touch voltage and exposure time guarantee a safe system. Care must be taken when multiple filters are connected to a single supply, as this presents many modes of possible earth fault that need to be considered and actual earth fault currents may exceed the current seen by any single filter.
3. An earth leakage relay must be able to accurately sense earth fault currents of any frequency from dc to the maximum frequency of interest.

It can be seen that this is not a trivial matter and it is likely that the industry will need to adapt to this new and complex environment.

APPENDIX B: ELV PRO CURRENT TRANSFORMERS
B1 Earth Leakage Toroids
Toroids (current transformers) are not ideal devices and if correct procedures are not followed during installation nuisance tripping can result. Consider, for example, a single-phase earth leakage system where active and neutral pass through a toroid then at all times currents in the two wires are equal and opposite so that the net current through the toroid is zero. An ideal toroid would have all of the flux from each wire contained in the core and so would accurately add the opposing fluxes to get a net result of zero. A real toroid has “leakage fluxes”. That is, a very small proportion of the total flux from each cable is not contained in the core but in the space outside it and as a result it may link some turns but not others, depending on the positioning of the cables. The effect of this is that a small output may be obtained from the toroid where none would arise if the device were ideal.

The size of the error may vary from toroids of the same type because of slight differences in the core and the symmetry of the winding. Problems caused in this way increase as the toroid size increases, as currents increase and symmetry decreases. Nuisance tripping tends to occur when the total current rises, such as when a large motor is started. The following guidelines would help to avoid such problems.

B2 Toroid selection

1. Select the smallest internal diameter toroid, which will allow the cables to fit through. Avoid very large toroids (>200mm aperture) or toroids with square apertures.
2. Only use approved toroids specified by Ampcontrol as these have been designed to minimise problems.

B3 Toroid installation guidelines

1. Keep cables as close to the center of the toroid as possible. Do not tie them to one side of the toroid. Remember to aim for symmetry.
2. Do not bring the cables back past the toroid within one diameter of the toroid. Trying to cram cables into a small space reduces symmetry and may lead to problems.
3. Avoid placing the toroid near any device that produces magnetic fields. This includes bus bars, transformers or other cables. Try to maintain several toroid diameters clearance.
4. Many small cables tend to be worse than say, three large ones. Try to position the toroid in the circuit with this in mind.
5. Toroids used for core balance earth leakage protection cannot have bus bars passed through them.
6. To prevent possible nuisance tripping it is suggested that the conductor screen of the earth leakage toroid should be earthed at one end only, the relay end. If both ends are earthed the possibility exists for the shield to become an earth loop, having finite resistance and injecting noise into the toroid leads

APPENDIX C: ELV PRO CIP OVER ETHERNET/IP

The ELV-PRO communicates with a PLC, implementing CIP (Common Industrial Protocol) over EtherNet/IP.

C1 ELEMENTARY DATA TYPES
The elementary data types used within this document are taken from table C-2.1 from the CIP Specification, and are as follows.

Character String Data Types
The declaration of a variable of type STRING is equivalent to declaring a structured data type for the variable which allocates a UDINT variable containing the current size of the string in characters and an array of declared character size elements.

C2 LIVE DATA SEGMENT DEFINITION

C2.1 Trip Mask 1

C2.2 Status Mask 1

C2.3 Digital IO

C3 CONTROLS
This is a Write Only Class 1 service.

C3.1 Reset Control
This reset bit should only be set by an authorised person. An EL Trip requires investigation by a suitably trained electrician before being reset. The reset requests occur on the zero to one bit transition. Transitions from one to zero have no effect. This mask will always read as zero.

C4 EXPLICIT MESSAGES
C4.1 ELV-PRO Settings
Class Code: 70 hex
Class Attributes

Implemented Instances: 1
Instance Attributes

Digital Input Settings

Common Services

Get_Attributes_All Response Data – Instance Level

C4.2 ELV-Pro Firmware
Class Code: 71 hex
Class Attributes

Implemented Instances: 1
Instance Attributes

Common Services

C5 EVENT LOGS
The ELV-PRO stores the last 50 events. The events are stored from new to old; as a new event is created an old event is deleted (provided that the 50 event spaces are full). To allow the PLC to access these events, the ELV-PRO presents them as 5 instances, each containing 10 encoded event structures. Instance 1 contains the most recent event logs (with the first attribute containing the most recent event log). All events stored within an instance can be read using the ‘Get_Attributes_All’ service as described below.

Class Code: 72 hex
Class Attributes

Implemented Instances: 5
Instance Attributes

EVENT STRUCT

Common Services

Get_Attributes_All Response Data – Instance Level

*NOTE: N ranges from 1-5.

APPENDIX D: ELV PRO Modbus TCP
D1 Modbus Commands
The following Modbus commands are supported:

Table 10: Modbus Commands

Valid read registers are in the range from 4 to 109. An attempt to read a register outside this range will result in an exception scan. Supported Modbus exception responses are:

Table 11: Modbus Exception

D2 Modbus Status

Table 12: Modbus Status

D3 Read Modbus Address Table

D4 Uint16 Encoded String
To help with efficient data transfer, all strings transmitted via Modbus have been ‘compressed’ to contain two characters per 16bit word, with the upper byte containing the first character and the lower byte containing the second character. The characters themselves are encoded using the ASCII encoding standard and are terminated with a NULL character. Note: data returned after the NULL character should be ignored as its value is undefined.

Eg the string ‘Hello’ will be encoded as
0x4865, 0x6c6c, 0x6f00

D5 Write Modbus Address Table

APPENDIX E: ELV PRO Default Settings
The following settings are considered the factory default settings. Default settings will be utilised on an ELV-PRO that is booted with no dongle installed or when booted with a brand new dongle installed. If the ELV-PRO is booted with a brand new dongle installed, settings will not be saved to the dongle until a setting is modified. When a brand new dongle is installed into a powered and running ELV-PRO, the dongle will only be updated once a setting is modified.
If a dongle has been configured or has been initialised from another ELV-PRO, then the settings may not match those in the table below. If a dongle is removed when in operation the settings will not be altered.

ELV-PRO MAG-219 V5 Earth Leakage Relay User Manual – Original PDF
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