IPM v2 User Manual

IPM V2
INTEGRATED PROTECTION RELAY

User Manual
Revision: 16, MARCH 2020

Designed and manufactured in Australia by Ampcontrol Pty Ltd
Ampcontrol Pty Ltd – ABN 28 000 915 542
IPM V2 USER MANUAL
IPM2B003 Revision 16 – MARCH/2020
WARNING!
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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.
NOT TO BE REPRODUCED IN PART
NOTE
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Please share these notes with other operators.
ENVIRO
–
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PROPERTY OF AMPCONTROL PTY LTD
impact on the surrounding fauna and/or flora.

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APPROVED FOR EXTERNAL DISTRIBUTION
Uncontrolled Copy - Refer to Ampcontrol Website for Latest Version Page 2 of 83

IPM V2 USER MANUAL
Copyright Notice
The Ampcontrol relay described in this document is the property of AMPCONTROL PTY LTD. It is
furnished under a license agreement and is to be used only in accordance with the terms of the
agreement.
No part of the hardware or documentation may be reproduced, transmitted, transcribed, stored in a
retrieval system, or translated into any language or computer language, in any form or by any means,
without prior written permission of AMPCONTROL PTY LTD.
Disclaimer
While every effort has been made to assure the accuracy and clarity of this document, AMPCONTROL
PTY LTD assumes no liability resulting from any omissions in this document, or from misuse of the
information obtained herein. The information in this document has been carefully checked and is
believed to be entirely reliable with all of the necessary information included. AMPCONTROL PTY LTD
reserves the right to make changes to any products described herein to improve reliability, function, or
design, and reserves the right to revise this document and make changes from time to time in content
hereof with no obligation to notify any persons of revisions or changes. AMPCONTROL PTY LTD does
not assume any liability arising out of the application or any use of any product or circuit described
herein; neither does it convey license under its patent rights or the rights of others.
Before You Begin

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Thank you for purchasing the Ampcontrol IPM V2 Integrated Protection Relay.
WARNING!
In the interests of safety and correct equipment operation, please
take the time to read and understand the content in this manual.
Ampcontrol Contact Details

–
7 Billbrooke Close, Cameron Park, NSW, 2285

P +61 1300 267 373 | F +61 2 4903 4888

EMAIL: customerservice@ampcontrolgroup.com
WEB: ampcontrolgroup.com

IPM V2 USER MANUAL
TABLE OF CONTENTS
1 SAFETY AND OTHER WARNINGS ..................................................................9
1.1 Safe Use of Equipment ..............................................................................9
2 RECEIVING AND STORAGE .......................................................................... 10
2.1 Receiving ................................................................................................. 10
2.2 Inspection ................................................................................................ 10
2.3 Storage after Delivery .............................................................................. 10
2.4 Unpacking of Equipment .......................................................................... 10
3 PRODUCT OVERVIEW .................................................................................. 11
3.1 IPM V2 Relay ........................................................................................... 11
3.2 Accessories ............................................................................................. 14

4 INSTALLATION ............................................................................................... 16
4.1 General Warnings .................................................................................... 16
4.2 Mandatory Installation Practices .............................................................. 16
4.3 Mechanical Installation Information .......................................................... 17
4.4 Electrical Installation Information ............................................................. 20
5 COMMISSIONING AND CALIBRATION ......................................................... 28
5.1 Earth Leakage ......................................................................................... 28
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5.2 Earth Continuity ....................................................................................... 28

5.3 Insulation test .......................................................................................... 28

5.4 Over Current / Motor Overload Current Injection ...................................... 28
5.5 Short Circuit Current Injection .................................................................. 28
5.6 Current Detection in CTs ......................................................................... 28
5.7 Main Contactor Fail (MCF) ....................................................................... 29
5.8 Voltage Measurement .............................................................................. 29
5.9 RS485 Interface ....................................................................................... 29
5.10 RTM (if Installed) ................................................................................... 29
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5.11 Lock, Reset, Aux, Ex-Stop, Ex-Start & MCI Inputs ................................. 29
6 EARTH PROTECTION FUNCTIONS .............................................................. 30

6.1 Earth Leakage ......................................................................................... 30
6.2 Insulation Test ......................................................................................... 31
6.3 Earth Continuity ....................................................................................... 34
7 CURRENT RELATED FUNCTIONS ................................................................ 36
7.1 Overload Protection ................................................................................. 37
7.2 Short Circuit Protection ............................................................................ 38
7.3 Phase Current Balance ............................................................................ 38
7.4 Residual Current Signal ........................................................................... 39
IPM V2 USER MANUAL
7.5 Undercurrent Trip..................................................................................... 39

8 VOLTAGE RELATED FUNCTIONS ................................................................ 40
8.1 Main Contactor Fail Protection ................................................................. 40
8.2 Undervoltage Trip .................................................................................... 40
8.3 Voltage Metering...................................................................................... 41
9 MACHINE COMMUNICATION ........................................................................ 42
9.1 Remote Termination Module .................................................................... 42
9.2 Machine Type Codes ............................................................................... 42
9.3 Machine Type Number............................................................................. 42
10 FAN BURP FUNCTION ................................................................................. 43
11 PUMP SNORE FUNCTION ........................................................................... 43

11.1 Basic Operation ..................................................................................... 43
11.2 Setup Procedure for Snore Function ...................................................... 44
12 PRODUCT OPERATION............................................................................... 45
12.1 Basic Display Operation ......................................................................... 45
12.2 Trip/Status Messages ............................................................................ 46
12.3 Last Trip Status Messages..................................................................... 48
12.4 Communications .................................................................................... 49
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12.5 Remote IPM Control .............................................................................. 50

12.6 System Control ...................................................................................... 53

12.7 Analogue Output .................................................................................... 55
12.8 IPM Alarm Functions.............................................................................. 55
12.9 Event Log .............................................................................................. 56
12.10 Time and Date ..................................................................................... 57
13 USER ADJUSTABLE SETTINGS .................................................................. 58
13.1 Parameter Groups ................................................................................. 58
13.2 Changing Settings ................................................................................. 60
14 SERVICE, MAINTENANCE & DISPOSAL ..................................................... 61
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14.1 Equipment Service ................................................................................. 61

14.2 Equipment Maintenance ........................................................................ 62
14.3 Disposal ................................................................................................. 62
15 SPECIFICATIONS ........................................................................................ 63
16 EQUIPMENT LIST ........................................................................................ 64
APPENDIX 1: IPM Earth Leakage Tripping Curves ............................................ 65
Tripping Curves for Instantaneous Trip Time Setting ..................................... 65
Tripping Curves for 25mA Trip Level Setting.................................................. 65
APPENDIX 2: IPM Full Load Current Selection Table (100:1 CT) ...................... 66

IPM V2 USER MANUAL
APPENDIX 3: IPM Full Load Current Selection Table (1000:1 CT) .................... 67
APPENDIX 4: IPM Menu Structure ..................................................................... 68
APPENDIX 5: IPM Modbus Address Table ........................................................ 70
APPENDIX 6: Drawings ..................................................................................... 74
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IPM V2 USER MANUAL
TABLE OF FIGURES
Figure 3.1: IPM Integrated Protection Relay................................................................................11
Figure 3.2: IPM Block Diagram ...................................................................................................12
Figure 3.3: Insulation Test Module ..............................................................................................14
Figure 3.4: Phase Current Transformers .....................................................................................14
Figure 3.5: Earth Leakage Toroid................................................................................................15
Figure 3.6: Remote Termination Module .....................................................................................15
Figure 4.1: IPM Relay Dimensions ..............................................................................................17
Figure 4.2: IPM Relay Rear Panel Details ...................................................................................18
Figure 4.3: Current Transformer 45mm I.D. (Part: 101272) Dimensional Details .........................18
Figure 4.4: Current Transformer 88mm I.D. (Part: 101703) Dimensional Details .........................19
Figure 4.5: RTM Dimensions ......................................................................................................19
Figure 4.6: IPM Connection Block Diagram.................................................................................20

Figure 4.7: IPM Relay Electrical Connections: Digital Inputs .......................................................21
Figure 4.8: IPM Relay Electrical Connections: Phase Current Transformers ...............................22
Figure 4.9: IPM Relay Electrical Connections: Earth Leakage Toroid .........................................23
Figure 4.10: IPM Relay Electrical Connections: Earth Leakage Toroid........................................24
Figure 4.11: IPM Relay Electrical Connections: ITM ...................................................................25
Figure 4.12: IPM Relay Electrical Connections: RS485 Connections ..........................................25
Figure 4.13: IPM Relay Electrical Connections: Analogue Output ...............................................26
Figure 4.14: IPM Relay Electrical Connections: Output Relays ...................................................26
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Figure 4.15: IPM Relay Electrical Connections: Power Supply ....................................................27

Figure 6.1: AS/NZS 4871 Safe Touch Potential Levels (Figure C1 from the standard) ................30
Figure 6.2: Instantaneous trip times for a selection of device trip level settings ...........................31
Figure 6.3: ITM Insulation Test Connections ...............................................................................32
Figure 6.4: Earth Continuity Connections ....................................................................................34
Figure 7.1: IPM Phase CT Connections ......................................................................................36
Figure 8.1: IPM Voltage Monitoring Connections ........................................................................40
Figure 12.1: IPM Relay Fascia and Display.................................................................................45
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IPM V2 USER MANUAL
TABLE OF TABLES
Table 1: Pre-set Resistance and Alarm Thresholds ....................................................................32
Table 2: Status Indication............................................................................................................45
Table 3: Trip/Status Message .....................................................................................................46
Table 4: Last Trip Messages .......................................................................................................48
Table 5: Modbus Commands ......................................................................................................49
Table 6: Modbus Exception.........................................................................................................49
Table 7: Modbus Status ..............................................................................................................50
Table 8: Events ...........................................................................................................................56
Table 9: User Adjustable Settings ...............................................................................................58
Table 10: User Adjustable Settings .............................................................................................59
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IPM V2 USER MANUAL
1 SAFETY AND OTHER WARNINGS

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

The equipment supplied has been designed and manufactured to ensure safe operation. The equipment
must only be used within the design parameters.
The instructions within this manual must be observed as an aid towards achieving the safest possible
installation.
Persons responsible for installation, maintenance, or operation, must observe the following
instructions:
1.1.1 Changes to Equipment

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

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

Precautions have been taken to ensure all equipment is safe to handle and free from sharp edges.
However, care should always be taken when handling enclosures and gloves should be worn.
1.1.4 Installation
Correct operation and safety depend on the relay and associated equipment being installed correctly.
Mechanical and or electrical installation and maintenance of plant and equipment must only be carried
out by appropriately qualified personnel and must be tested thoroughly prior to operation.
1.1.5 Operation
As safety depends on the relay functioning correctly it is highly recommended that all safety functions
of the relay be periodically tested to ensure correct operation.
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IPM V2 USER MANUAL
2 RECEIVING AND STORAGE

2.1 Receiving
All possible precautions are taken to protect the equipment against damage or losses during shipment,
however before accepting delivery, check all items against the packing list or bill of loading. If there is
evidence of physical damage, notify Ampcontrol immediately.
Notify Ampcontrol immediately in case of any discrepancies to the packing list. Keep a record of any
claims and correspondence. Photographs are recommended.
Where practicable do not remove protective covers prior to installation unless there are indications of
damage. Boxes opened for inspection and inventory should be carefully repacked to ensure protection of
the contents or else the parts should be packaged and stored in a safe place. Examine all packing
boxes, wrappings and covers for items attached to them, retain and store any approval documentation
for your safety file as applicable prior to wrapping being discarded.
2.2 Inspection
Equipment that is found to be damaged or has been modified away from its published specification must
not be used. Please contact Ampcontrol if the equipment is suspected to be different than that ordered or
if it does not match the published specifications.
2.3 Storage after Delivery

When the equipment is not to be installed immediately, proper storage is important to ensure protection
of equipment and validity of warranty.
All equipment should be stored indoors between 0-40˚C, preferably on shelves and protected from
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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.
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The disposal of packaging materials, replaced parts, or components

must comply with environmental restrictions without polluting the soil,
ENVIRO
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.

IPM V2 USER MANUAL
3 PRODUCT OVERVIEW
3.1 IPM V2 Relay
The Ampcontrol IPM V2 Integrated Protection Relay is an intelligent protection relay based on
microprocessor technology. The IPM Integrated Relay provides the necessary functions required for
protecting electrical outlets supplying underground mining machinery, powered by reeling or trailing
cables, in the metalliferous industry. The relay can also be used to provide optimum overload protection
of motors used on conveyors, pumps, fans and compressors. All of the protection functions are
combined into a compact, plug-in unit, which can be easily changed out to minimise down time in the
event of a problem with the relay.
The IPM provides protection and control functions for:
 Earth Leakage
 Earth Continuity
 Insulation Testing
 Contactor Fail
 Under Voltage
 Overcurrent
 Short Circuit
 Under Current (Pump Snore Protection)
 Fan “Burp” Control
The IPM Integrated Protection Relay can provide Machine Data Transfer through the use of a Remote
Termination Module (RTM) connected between the pilot and earth at the machine end of the trailing
cable. Through the use of the RTM Remote Termination Module the relay parameters are automatically
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uploaded from a remote machine when a cable is inserted into a power outlet. The RTM also allows for
remote control (starting) of the IPM output.

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Figure 3.1: IPM Integrated Protection Relay

IPM V2 USER MANUAL
A RS485 Modbus communication port is available that can be connected to a PLC or a central
monitoring system for continuous monitoring and fault-finding.
The IPM Relay provides an isolated 4-20mA analogue output that can be configured to continuously
represent Average Current, Overload, Earth Leakage and the Insulation level of the relay.
The IPM Integration Protection Relay has 6 digital inputs (Lock, Reset, Aux, Ex-Stop, Ex-Start and MCI),
which feed into a microprocessor unit to be interpreted. The microprocessor has been programmed to
control three output relays, MCR (Main Contactor Relay), CBR (Circuit Breaker Relay) and ALM (Alarm
Relay).
All of the tripping logic and outlet control is performed by the microprocessor, so that virtually no external
control is required.
A four-line 20 character backlit LCD display combined with a keypad provides an easy to operate user
interface. The display provides easy access to all available information. A simple procedure allows
adjustment of the relay’s settings.
To Outlet Contactor
24V AC/DC
Power
Supply
Phase CT
RS485 External
Comms Communications
Phase CT
Device Device (e.g. PLC)
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Phase CT 4-20mA
Analogue
IPM Receiver
Relay
EL Toroid External
Digital
Inputs
ITM
Alarm Output Relay
CBR Output Relay
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Pilot MCR Output Relay 1

MCR Output Relay 2
M RTM Diode
(Optional) (Alternative)
Pilot Termination
Figure 3.2: IPM Block Diagram

IPM V2 USER MANUAL
3.1.1 Earth Leakage Protection

The IPM monitors the outlet’s earth leakage current through the use of an approved core balance
toroid. A Residual Current Device (RCD) operating characteristic is provided with adjustable trip
sensitivity and time delay. When a trip is initiated, the IPM will open its MCR output relay, opening the
outlet’s contactor.
For detailed information on the operation of the Earth Leakage protection function, refer to Section 6.1.
3.1.2 Earth Continuity Protection

The Earth Continuity function tests for the continuity of the earthing between the outlet and the
machine, via the pilot core in the trailing cable. The pilot core is also used to transfer data when a
Remote Termination Module (RTM) is used to achieve machine communication.
For detailed information on the operation of the Earth Continuity protection function, refer to Section
6.3.
3.1.3 Insulation Testing

The insulation testing function tests the resistance of the 3 phase lines to earth by applying a high
voltage DC signal to the phase conductors, via the Insulation Test Module (ITM). This test is initiated
once all starting conditions are met.
If the result of the Insulation Test is above the pre-set resistance level, the IPM’s MCR relay energises,
which in turn closes the main contactor. A manual “Insulation Test” is also provided as a
maintenance/fault finding tool. (When this test is performed the MCR relay does not close at completion
of a healthy test). The Insulation Test allows cable insulation levels to be trended as an aid to
preventative maintenance.
For detailed information on the operation of the Earth Fault Lockout protection function, refer to Section
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6.2.
3.1.4 Frozen / Failed Contactor Protection

The IPM relay provides failed contactor protection, initiating a back-trip to an upstream circuit breaker if
the contactor is deemed to have failed to open when required. The position of outlet’s contactor is
monitored via the Main Contactor Input (MCI). The state of the contactor is then compared to the state
of the IPM’s output relay. If the contactor is closed whilst the MCR is in the open position, a failed
contactor trip will be initiated.
The IPM also monitors the voltage on the load side of the outlet’s contactor, via the ITM module, whilst
the contactor is in the open position. If this voltage exceeds 10% of the rated line voltage, a failed
contactor trip will be initiated. When a trip is initiated, the IPM will open its CBR output relay, opening
the upstream circuit breaker.
For detailed information on the operation of the Frozen/Failed Contactor protection function, refer to
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Section 8.1.
3.1.5 Overcurrent / Overload Protection

The IPM relay monitors the outlet phase currents via three current transformers (CTs). The measured
current allows the IPM to implement overcurrent, thermal motor overload and phase imbalance
protection. When a trip is initiated, the IPM will open its MCR output relay, opening the outlet’s
contactor.
For detailed information on the operation of the Overcurrent and Overload protection functions, refer to
Section 0.
3.1.6 Short Circuit Protection

In addition to the overload protection functions, the IPM relay uses the currents measured from the
three phase CTs to provide short circuit protection. The IPM opens its CBR output when a short circuit

IPM V2 USER MANUAL
trip is initiated. In typical installations the CBR output is used to trip a circuit breaker upstream from the
outlet’s contactor.
For detailed information on the operation of the Short Circuit protection function, refer to Section 7.2.
3.1.7 Pump Snore Function

The IPM relay has a Pump Snore function that provides additional control functionality for pump
installations. The Snore function automatically stops the output upon detection of a low current
condition, avoiding damage to the pump components due to overheating. The outlet will be restarted
after a fixed or automatically adjustable time delay.
For detailed information on the operation of the Pump Snore function, refer to Section 11.
3.1.8 Fan Burp Function

The IPM relay has a Fan Burp function that provides additional control functionality for fan installations.
The Burp function allows for the progressive inflation of ventilation bags (tubes) by pulsing the motor
contactor controlling a ventilation fan, several times at start-up.

For detailed information on the operation of the Fan Burp function, refer to Section 10.
3.2 Accessories
The IPM relay requires a number of accessories to perform its protection functions. These accessories
will be introduced in the following subsections. Some accessories are marked as optional and are not
required for the IPM to perform its basic protection functions. Purchasing these optional items will,
however, expand the capabilities of the installation.
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3.2.1 Insulation Test Module (ITM)

The IPM is connected to the outlet’s phase conductors via a high

impedance Insulation Test Module (ITM). This allows the IPM to perform a
high voltage DC insulation test prior to the closing of the outlet’s contactor.
The IPM also uses the ITM to monitor the magnitude of the phase
voltages. This is used during the frozen contactor testing to ensure that
when the outlet’s contactor opens, voltage is removed from the outlet. The
ITM is available in a 415V model or a 1kV model.
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3.2.2 Phase Current Figure 3.3: Insulation

Transformers (CTs) Test Module
The IPM relay measures the
phase currents from all three of the outlet’s phases. Using
these measured current values, the IPM is able to implement
its overload and short circuit protections functions. The IPM
requires three (3) current transformers to measure the phase
currents. The phase current transformers are available in two
standard sizes: 45mm inner diameter (1000:1 & 500:5) and
88mm inner diameter (1000:1 only). The current transformers
are panel mounted units.
Figure 3.4: Phase Current Transformers
IPM V2 USER MANUAL
3.2.3 Earth Leakage Toroid

The IPM requires a summation toroid to be installed around the outlet’s
three phase conductors. This toroid allows the IPM to measure the
magnitude of outlet’s earth leakage current. Only one (1) earth leakage
toroid is required per IPM. The IPM’s earth leakage toroids are 1000:1 and
have an 88mm inner diameter.
Figure 3.5: Earth

3.2.4 Remote Termination Leakage Toroid

Module (RTM) (Optional)
The RTM is an optional component in the IPM system. It is
used to terminate the pilot cable in the motor enclosure
instead of a diode. When used, the RTM stores the IPM’s
Group 2 protection settings for that particular motor. This
means that the cable supplying the motor can be moved to
another outlet without the need to re-configure all of the
IPM’s protection settings. The RTM also offers a remote
Figure 3.6: Remote Termination Module start input.
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IPM V2 USER MANUAL
4 INSTALLATION
4.1 General Warnings
These instructions have been designed to assist users of the relay with installation.
Before the relay 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 and use from 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
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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 relays logical operation nor its signalling be
compromised by incompatibilities with connected equipment.
4.1.4 Modifications of any form to the relay or accessories are prohibited.

The relay, as supplied, has been designed and manufactured to comply with the requirements of
protection standards. 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

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The following information must be adhered to when installing the relay. Failure to adhere to this
information may give rise to unsafe operation.

Using the relay 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 relay must be powered within the specified voltage range.
 The installation of the relay must be carried out by suitably trained and qualified personnel.
 Identification labels fixed to the relay 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 relay. As supplied, the unit is built to, and
complies with the relevant standards. Modifications to its construction will render the unit non-
compliant.
 Complete and accurate records of the installation must be kept as part of the site installation.
IPM V2 USER MANUAL
4.3 Mechanical Installation Information

4.3.1 IPM V2 Integrated Protection Relay
The IPM relay is a panel mounted relay that requires a 135mm x 135mm square cut out.
There are four mounting brackets and four M5 screws that are supplied with the relay. These brackets
slide into the side of the relay after it has been inserted into the cut out. The screws are inserted into
the bracket and tightened to secure the IPM to the panel.
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Figure 4.1: IPM Relay Dimensions

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IPM V2 USER MANUAL
132
132
Figure 4.2: IPM Relay Rear Panel Details
4.3.2 Phase Current Transformers (CTs) & EL Toroid

The IPM uses 1000:1 or 500:5 current transformers to monitor the phase current of the outlet.
The IPM uses a 1000:1 current transformer installed around all three phases to monitor the earth
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leakage current of the outlet.

These current transformers are panel mounted.

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Figure 4.3: Current Transformer 45mm I.D. (Part: 101272) Dimensional Details

IPM V2 USER MANUAL
Figure 4.4: Current Transformer 88mm I.D. (Part: 101703) Dimensional Details
4.3.3 Remote Termination Module (RTM)

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Figure 4.5: RTM Dimensions

IPM V2 USER MANUAL
4.4 Electrical Installation Information

The IPM relay provides several protection functions and, due to this, has a number of different types of
electrical connections. This section will provide details on the wiring and terminations for each of these
different types of connections.
The following sub-sections are arranged as per the terminal numbering on the rear of the unit (refer to
Figure 4.2 for terminal arrangement).
For an alternate representation of the wiring for the IPM, refer to drawing IPM2E002 in APPENDIX 6:
Drawings.
To Outlet Contactor
24V AC/DC
Power
Supply
Phase CT
RS485 External
Comms Communications
Phase CT
Device Device (e.g. PLC)
Phase CT 4-20mA
Analogue
IPM Receiver
Relay
–
EL Toroid External
Digital
Inputs
ITM
Alarm Output Relay
CBR Output Relay
Pilot MCR Output Relay 1
MCR Output Relay 2
M
–
RTM Diode
(Optional) (Alternative)
Pilot Termination
Figure 4.6: IPM Connection Block Diagram

IPM V2 USER MANUAL
4.4.1 Digital Inputs (Terminals 1, 2, 3, 4, 5, 6, 7 & 8)

1
+Di Digital input reference power supply
2
Lock Locked pushbutton or contact input
3
Reset pushbutton or contact input
Reset (optional)
4
Auxiliary pushbutton or contact input
Aux
IPM (optional)
5
Relay Ex-Stop
External stop pushbutton or contact input
(optional)
6
External start pushbutton or contact input
Ex-Start (optional)
7
Main Contactor auxiliary contact input
MCI (for Frozen Contactor Protection)
8
DI Screen*
Note*: Required in areas of high

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electrical interference
Figure 4.7: IPM Relay Electrical Connections: Digital Inputs
The IPM has a number of digital inputs to allow external devices to interact with the relay. Each of
these inputs is activated when it is shorted to the DI+ terminal (1) by a normally open contact or
pushbutton.
The MCI input is a special input that is used to monitor the state of the outlet’s main contactor for the
IPM’s frozen contactor protection. Wire a normally open auxiliary contact from the main contactor to
this input to allow this function to operate correctly.
For a detailed explanation of the functions of each of these inputs, refer to Section 12.6.1.
The Digital Input (DI) Screen terminal is used to terminate the screens of the cables that are used for
the digital inputs.
–
NOTE
If the IPM is to be installed in areas of high electrical interference, it is
recommended that the wiring for the digital inputs be run in screened
cables.

IPM V2 USER MANUAL
4.4.2 Phase Current Transformers (Terminals 9, 10, 11 & 12)

Phase Conductors
A B C
9
CT-A S1 P1
Current TXF
1000/1 or
500/5
S2 P2
10
CT-B S1 P1
Current TXF
1000/1 or
IPM 500/5
S2 P2
Relay
11
CT-C S1 P1
Current TXF
12 1000/1 or
CT-COM 500/5
S2 P2
Internally
Earthed
Figure 4.8: IPM Relay Electrical Connections: Phase Current Transformers
The IPM relay measures the individual phase currents of the outlet, using current transformers, to
provide input for a number of its protection functions. Current transformers should be wired to the IPM
in twisted pairs with an overall screen.
–
Current transformers are not ideal devices and if correct procedures are not followed during installation,
nuisance tripping can result. An ideal CT would have all the flux from the wire contained in the core and
so would accurately detect any change in current. A real CT has “leakage fluxes”. That is, a very small
proportion of the total flux is not contained in the core, but in the space outside it and as result reduces
sensitivity of the CT. The positioning of the cables also plays a part in this effect.
The size of the error will vary from CT to CT, even those of the same type and size because of slight
differences in the core and symmetry of the windings.
To avoid nuisance tripping and false readings, consider the following during installation:
1. Keep cables as close to the centre of the toroid as possible. Do not tie them to one side of the
toroid. Remember to aim at symmetry.
2. Do not bring the cables back past the toroid within one diameter of the CT, trying to cram cables
–
into a small space reduces symmetry and may lead to problems, which are difficult to solve.
3. Avoid placing the CT near any device, which produces magnetic fields - whether it is a
transformer or other cables. Try to maintain several CT diameters clearance.
4. Many small cables tend to be worse than say three large ones. Try to position the CT in the
circuit with this in mind.
5. Select the smallest internal diameter CT to suit the cable size.
NOTE
The two CT-COM terminals (12 & 13) are internally connected and are
joined to earth.

IPM V2 USER MANUAL
4.4.3 Earth Leakage Toroid (Terminals 13 & 14)

Phase Conductors
A B C Optional EL Test Circuit
EL Test P/B
14
CT-EL
1000:1 CT
IPM 13
88mm I.D. AC Control
CTcom
Relay Supply
Internally
Earthed
Test Resistor
Figure 4.9: IPM Relay Electrical Connections: Earth Leakage Toroid
The IPM relay measures the earth leakage current using a summation toroid to provide input for the
earth leakage protection function. The toroid should be wired to the IPM using a twisted pair cable with
an overall screen.
–
NOTE
For general information on the installation of CTs and earth leakage

toroids, refer to Section 4.4.2.
The earth leakage protection function can be tested by connecting an AC supply through the earth
leakage toroid, via a test pushbutton and a resistor. The resistor must be selected to ensure that the
earth leakage protection trips as required.
–

IPM V2 USER MANUAL
4.4.4 Earth Continuity (Terminal 15)

EC Test P/B Phase Conductors
15 A B C
PILOT
IPM
EARTH
Relay
Supply Enclosure
Trailing Cable
Motor Enclosure
Emergency Stop IPM Diode Mode Pilot Connections

PILOT M Local Control:
Emergency
Start
Stop
INPUT* Stop
EARTH
Pilot
Remote Start RTM Earth

Selector
Note*: Input is ignored if IPM Remote Control:
Remote Start is set to ‘NO’ Not available in Diode Mode
–
Figure 4.10: IPM Relay Electrical Connections: Earth Leakage Toroid

The Pilot terminal (15) is to be wired to the pilot core of the outlet’s cable. The IPM monitors the
presence of either a termination diode, or an RTM, that is installed in the motor enclosure to ensure
that there is a continuous earth connection between the supply enclosure and the motor enclosure via
the outlet cable. The magnitude of the pilot/earth return loop impedance is also monitored via this
terminal.
In order for the earth continuity protection to function correctly, ensure that the earth connection is
correctly installed to the IPM.
If an RTM is connected, and the IPM set to remote start mode, then a remote start can be requested by
closing the input on the RTM. The input must remain closed whilst the motor is running. A stop will be
initiated if this input becomes open circuit.
–
WARNING! The Remote Input on the RTM is not to be used for an emergency stop
function. Emergency stop pushbuttons should be wired into the
pilot circuit. A normally closed contact with a contact monitoring block
should be considered.
NOTE
Remote Start is not available if the IPM is used in Diode Mode.

IPM V2 USER MANUAL
4.4.5 Terminals 15 & 16

Do not connect. These terminals are unused in this version of the IPM relay.
4.4.6 ITM Interface (Terminals 18, 19, 20, 21 & 22)

Phase Conductors
From Contactor
A B C
18
Vtest VTEST
19
0V Earth
IPM 20
ITM
Va Vcma Va
Relay
21
Vb Vcmb Vb
22
Vc Vcmc Vc
Flying Leads
Figure 4.11: IPM Relay Electrical Connections: ITM
The Insulation Test Module (ITM) is a resistor barrier, which interfaces between the power circuit and
the IPM relay. It also provides a manual and automatic High Voltage DC ‘Insulation Test’. The ITM is
housed in an encapsulated module.
Terminals 20, 21 and 22 provide the voltage measurement feedback for the IPM relay from the power
–
circuit.
Terminal 19 provides the earth connection between the IPM and the ITM.
Terminal 18 on the IPM is the ‘Vtest’ output of the IPM relay. The IPM will energise this output when
the high voltage DC insulation test is being undertaken, providing a source for the high voltage
generation in the ITM.
4.4.7 RS485 Communications Port (Terminals 23, 24 & 25)
23
RS485+ To RS485 Capable
24 External Communications
IPM Device (e.g. PLC)
RS485-
–
Relay
25
RS485 Common
Figure 4.12: IPM Relay Electrical Connections: RS485 Connections
RS485 connections should be wired in screened twisted pair. The screen of the twisted pair cable
should be terminated into terminal 25 of the IPM relay.
4.4.8 Terminal 26
Do not connect. This terminal is unused in this version of the IPM relay.

IPM V2 USER MANUAL
4.4.9 Analogue Output (Terminals 27 & 28)
External
4-20mA Receiver
27
Analogue Output + 7.5Vmin to 36Vmax
IPM
28 4-20mA
Relay Analogue Output - RL
Figure 4.13: IPM Relay Electrical Connections: Analogue Output

The IPM relay is provided with a 4-20mA analogue output. It is provided with a wide ranging DC
voltage input at 7.5VDC to 36VDC.
4.4.10 Output Relays (Terminals 29, 30, 31, 32, 33, 34, 35, 36, 37 & 38)
29
MCR-1 COM
30 Main Contactor Relay (MCR)
MCR-1 N/O The MCR output has two poles, one is a
changeover contact and the other is a
31
normally open contact.
MCR-2 N/O
–
Either of these contacts can be used to

32 trip the main contactor for the outlet.

MCR-2 COM The other MCR contact can then be used
33 as an indication output.
IPM MCR-2 N/C
Relay 34
ALM COM Alarm Relay (ALM)
The ALM output is a normally open
35 contact.
ALM N/O Function is programmable.
36
CBR COM Circuit Breaker Relay (CBR)
–
The CBR output is a changeover contact.

37
CBR N/C The CBR output is intended to initiate a
back-trip to an upstream circuit breaker
38
CBR N/O via a shunt or undervoltage coil.
Figure 4.14: IPM Relay Electrical Connections: Output Relays
The IPM relay has three (3) different types of output relays. The Main Contactor Relay (MCR) is
intended to open and close the outlet’s contactor as part of its control and protection functions. The
Alarm Relay (ALM) can be programmed to close at specified alarm points for different protection
functions. The Circuit Breaker Relay (CBR) is intended to provide a back-trip to an upstream circuit
breaker for faults such as frozen contactor and short circuit.
IPM V2 USER MANUAL
4.4.11 Power Supply (Terminals 39 & 40)
39
IPM Pwr+
IPM 24VDC or 24VAC
40 Supply
Relay IPM Pwr-
Figure 4.15: IPM Relay Electrical Connections: Power Supply
The IPM can be supplied by either 24VAC or 24VDC.
4.4.12 Chassis Earth Connection

The earth connection on the rear of the IPM relay is a bolted connection. An earth conductor should be
secured to the chassis of the IPM using a ring lug.
–
–

IPM V2 USER MANUAL
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 tests can provide guidance on checking the correct operation of the relay during
commissioning. 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 toroid. Ensure
that all relevant tripping circuits operate successfully and that latched trips may be reset in the
appropriate manner.
5.2 Earth Continuity

Test that the Earth Continuity protection is operational by creating an open circuit on the pilot wire.
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 the pilot and earth.
5.3 Insulation test

Ensure that a manual insulation test can be successfully conducted via the IPM.
Also check that an automatic insulation test is initiated by the IPM when a START signal is generated.
–
5.4 Over Current / Motor Overload Current Injection

Test the Over Current / Motor Overload protection by carrying out secondary injection on the CT
terminals of the IPM.
Where Over Current protection is employed, inject 2x FLC (Full Load Current) 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 second set of CT terminals and the third set of CT terminals.
If Motor Overload is used, check 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.
5.5 Short Circuit Current Injection

–
Test the Short Circuit protection by carrying out secondary injection on the CT terminals of the IPM.
Inject a current value relevant for 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 second set of CT terminals and the third set of CT terminals.
5.6 Current Detection in CTs

Ensure the integrity of the current-detection CTs by injecting primary current into the CT aperture and
validating the reading on the IPM screen.

IPM V2 USER MANUAL
5.7 Main Contactor Fail (MCF)

Validate the correct operation of the ITM and MCF protection by applying a voltage on the load side of
the contactor. The voltage must be >10% of the rated voltage of the ITM. Ensure that a CBR trip is
initiated by the IPM which can only be reset by performing a locked reset.
5.8 Voltage Measurement

Validate the voltage measurement function of the IPM by checking the measured voltages on the IPM
screen when the main contactor is closed.
5.9 RS485 Interface

The correct operation of the RS485 interface is determined by polling the IPM relay from a RS485
capable device.
5.10 RTM (if Installed)

Validate the correct operation of the RTM by making changes to Group 2 settings, moving the machine
to a different outlet and ensuring that the correct settings are available on the new outlet.
5.11 Lock, Reset, Aux, Ex-Stop, Ex-Start & MCI Inputs

Ensure that the digital inputs to the IPM are operating correctly by operating each of the inputs and
ensuring that the IPM functions as expected.
–
–

IPM V2 USER MANUAL
6 EARTH PROTECTION FUNCTIONS

The IPM relay provides the following earth protection functions:
 Earth Leakage
 Insulation Test
 Earth Continuity
6.1 Earth Leakage

6.1.1 Introduction
Protection systems are defined in AS/NZS 2081 for use in fault limited systems. This standard
describes the requirements of Earth Leakage protection to initiate a trip of the circuit interrupting device
when a selected value of earth fault current is exceeded for a certain amount of time.
All protection systems must comply with this standard as stated in AS/NZS 4871, which sets out the
general requirements for the design, construction and testing of electrical equipment directly associated
with mining and quarrying activities. Part of these requirements includes designing for electrical faults,
and the standard outlines the safe touch potential which must be considered in electrical protection
design. Acceptable touch potential levels are described using a series of curves as shown in Figure
6.1.
–
–
Figure 6.1: AS/NZS 4871 Safe Touch Potential Levels (Figure C1 from the standard)
The IPM V2 relay’s earth leakage protection function has been designed in accordance with AS/NZS
3190 – Approval and Test Specification – Residual Current Devices (current-operated earth-leakage
devices). Given this, it is important to consider the performance of the earth leakage protection provided
by the IPM V2 and assess how the relay’s performance compares with the requirements of AS/NZS
2081. Testing was completed to assess the ability of the IPM V2 relay to trip within acceptable levels.
The results for the earth leakage tripping times of the relay are detailed in APPENDIX 1: IPM Earth
Leakage Tripping Curves. These results show that the tripping times are well within those specified by
the relevant standards. The tripping times reduce for higher fault currents, improving the performance of
IPM V2 USER MANUAL
the relay.
Figure 6.2 summarises the trip times which can be expected when the trip time is set to be
‘Instantaneous’, for increasing fault currents at different trip levels.
300
250
200
Trip Time (ms)
25mA
150 50mA
100mA
100
200mA
50
500mA
0
100 1000
Fault Current (mA)
Figure 6.2: Instantaneous trip times for a selection of device trip level settings
6.1.2 Earth Leakage Protection Function

The earth leakage protection function uses a 1000:1 core balance toroid to measure the earth fault
–
current. A Residual Current Device (RCD) operating characteristic is provided with adjustable trip
sensitivity and time delay.

The % leakage current is displayed on the 'Current and Voltage Information’ page (Level 2, Screen 2)
as ‘Ie’ shown as a % of the selected trip level. When the leakage reaches 100% a trip occurs. For
timing of the trip refer to APPENDIX 1: IPM Earth Leakage Tripping Curves. As discussed above, the
higher the fault current measured the faster the trip response.
To reset the relay depends on the RCD Reset Lock setting (in group 1 settings page 8). If off, the user
can reset the relay by operating the reset key/digital input. If the setting is on, the user is required to
activate the lock input before operating the reset key/digital input.
The trip level is selected via the ‘RCD Trp. Level’ setting (Level 6, Screen 13) and is adjustable
between 25mA and 500mA and off.
The time delay is selected via the ‘RCD Trp. Time’ setting (Level 6, Screen 14). Settings are
–
instantaneous and adjustable between 50ms and 150ms.

6.2 Insulation Test
The IPM Relay can provide an automatic High Voltage ‘Insulation Test’. A manual ‘Insulation Test’ is
also provided.
An Insulation Test Module (ITM), which is a resistive isolation device, is used to interface the power
conductors to the IPM Relay. Modules are selected in the Group 1 Settings ‘ITM Module’ (Level 5,
Screen 2) for rated line voltages of 415V and 1000V.
The ITM is the preferred isolation module and must be used when the ‘Insulation Test’ function is
required.
When “None” is selected the IPM Relay does not provide ‘Insulation Test’, or voltage functions.

IPM V2 USER MANUAL
Phase Conductors
From Contactor
A B C
18
Vtest VTEST
19
0V Earth
IPM 20
ITM
Va Vcma Va
Relay
21
Vb Vcmb Vb
22
Vc Vcmc Vc
Flying Leads
Figure 6.3: ITM Insulation Test Connections
6.2.1 Automatic Insulation Test

If an ITM Module has been selected, in the adjustable Group 1 Settings and a trip level has been set in
the adjustable Group 2 settings, then an automatic High Voltage DC ‘Insulation Test’ is initiated by
operation of the start button once all starting conditions are met.
The HV DC ‘Insulation Test’ commences when the IPM Relay applies voltage to the ‘Vtest’ terminal of
the relay for a period of 2 seconds. This applies 30VDC to the ITM Module. A HV DC voltage is
generated in the ITM Module, which applies a voltage of 500V for 415V operation and 820V for 1000V
systems, between each phase and earth.
–
The IPM Relay measures the resistance to earth for all phases in parallel. At the end of the test the
result is stored in the Event Log as ‘It:X.XMΩ’ If the resistance value is above the pre-set threshold the
MCR Relay picks up allowing the outlet to be energised. Additionally, if the result is equal to or below
an Alarm Level (typically 1.5 times the selected trip level) the status message ‘Insulat.Test Alarm’ is
displayed on the Status Page (Level 1, Screen 1).
Table 1: Pre-set Resistance and Alarm Thresholds
Ins. Tst. Level: Selection MΩ Alarm Level MΩ

1.0 1.5
2.0 3.0
5.0 7.5
10 15
–
20 30
None None
If the value is less than the pre-set trip level a trip occurs and is latched and saved in a non-volatile
memory. To reset the relay following an insulation test fail trip, operate the reset button.
Insulation Test 3
---- Not Active ----

Last Test : 8.6MΩ
 L3: Indicates the status of the insulation test.

 L4: Displays the insulation resistance as a result of the test and is retained in memory until the
next test is carried out.
IPM V2 USER MANUAL
The trip level is set at ‘Ins.Tst.Level’ page (Level 6, Screen 18) and is selectable.
If the ‘Insulation Test’ is not selected by setting the ‘ITM Module’ value to “None” then the MCR Relay
closes by operation of the start button.
6.2.2 Manual Insulation Test

A manual “Insulation Test” is provided as a maintenance/fault finding tool. The manual test can only be
carried out when the load is not energised. A manual insulation test is also prevented when operating
in snore mode.
Before a manual Insulation Test can be performed the following conditions must apply:
1. The Insulation Test page being displayed. This is located on the ‘Insulation Test’ screen (Level 3,
Screen 2).
2. Pilot must be healthy (and any previous trips reset).
3. Insulation Test function must not be tripped.
4. Outlet must not be running.
5. Outlet must not be in the process of ‘closing’.

6. Outlet must not be ‘Paused’.
When the above conditions are met the <TEST> key must be pressed and held (for the duration of the
test). After 3 seconds the manual insulation test is initiated. The test voltage is applied to the outgoing
feeder while ever the above conditions are held (including holding the <TEST> key). The test results
are continuously calculated and displayed. The operator should maintain the test at least long enough
for the readings to stabilise, this being a function of the cable length. Once the test is completed
(usually by releasing the <TEST> key) the results are held in memory until another insulation test is
commenced either manually or as part of the starting sequence, or IPM control power is lost.
If the ‘ITM Module’ has been set to “None” then the manual test will not function.
–
The status of the manual insulation test is shown on the Insulation Test Screen (Level 3, Screen 2).
The three functions shown on the screen are ‘Not Active’, ‘Arming Man.Ins.Test’ and ‘Manual Insulat.
Test’.
The display will show the last measured value.
–

IPM V2 USER MANUAL
6.3 Earth Continuity

EC Test P/B Phase Conductors
15 A B C
PILOT
IPM
EARTH
Relay
Supply Enclosure
Trailing Cable
Motor Enclosure
Emergency Stop IPM Diode Mode Pilot Connections

PILOT M Local Control:
Emergency
Start
Stop
INPUT* Stop
EARTH
Pilot
Remote Start RTM Earth

Selector
Note*: Input is ignored if IPM Remote Control:
Remote Start is set to ‘NO’ Not available in Diode Mode
–
Figure 6.4: Earth Continuity Connections

The Earth Continuity function tests for the continuity of the earthing between the outlet and the machine,
via the pilot core in the trailing cable. The pilot core is also used to transfer data when a Remote
Termination Module is used to achieve Machine Data Transfer.
The IPM relay can be configured to operate in either diode or RTM mode. The mode is selected in ‘EC
Pilot Mode’ (Level 5, Screen 1) and determines what terminating device the relay is looking for on the
pilot.
NOTE
The Remote Termination Module will only be recognised by an IPM
Relay and will not be seen as a diode by other earth continuity devices.
–
The relay measures the resistance of the pilot - earth loop and the leakage between the pilot and earth
conductors. The leakage measurement ensures that pilot to earth faults are detected. If the pilot - earth
loop resistance exceeds 45Ω a trip occurs which in turn opens the main contactor control circuit. The
fault can be configured as latching or non-latching. This allows the user to determine if the fault is
manually or automatically reset once the pilot - earth loop resistance is less than 45Ω. The selection is
either ‘EC Trip Latch: On’ or ‘Off” (Level 6, Screen 17). To manually reset the relay, operate the reset
button.

IPM V2 USER MANUAL
Earth Continuity 3
R:27% L: 0% V#10
Load [WPump # 1]
 L3: Shows the earth continuity resistance (R) of the pilot – earth loop and the leakage (L)
between the pilot and earth conductors as a % of the trip levels. When either value reaches
100% a trip occurs. The version of the software is also indicated.
 L4: Shows the Load Type and Number (from the connected RTM unit).
Pilot Trip Time is adjustable to allow for operation in noisy electrical environments. The trip times can be
selected at ‘Pilot Trip t’ (Level 6, Screen 15) and can be set to 80, 120, 160, 200, 300, 400 and 500ms.
The leakage trip setting is fixed at 1850Ω.

Clause 5.3 of AS/NZS 2081 requires total clearance trip times <500mS, this includes interposing relays,
contactors and circuit breaker opening times. An EC trip time of up to 500mS is entirely appropriate
where touch potentials are managed appropriately, however in all cases the EC trip time should be as
low as is reasonably practical.
The purpose of earth continuity protection is to continuously monitor the integrity of the return earth
resistance. The earth continuity protection relay cannot explicitly monitor the return earth resistance
alone, and instead monitors the resistance of the pilot-earth loop. In all cases, the resistance of the pilot-
earth loop will be higher than the return earth resistance itself, and so is conservative. That is, the return
earth resistance can be no higher than the trip setting of the earth continuity relay.
–
There are two aspects to earth continuity monitoring:

(1) To actively remove power from an outlet in case of live uncoupling, and;
(2) To monitor incremental changes in the resistance of the earth return path to ensure that
leakage currents under both normal and fault conditions do not result in dangerous touch
voltages.
The IPM relay meets the requirements of AS/NZS2081 which sets a limit on the maximum clearance
time that can be utilised for earth continuity protection of 500ms. This specifically addresses the risk
associated with live uncoupling. That is, in restrained receptacles suitable for mining applications the
pilot pin disengages before the earth connection and the upper limit of 500ms removes power before a
user can practically complete disconnection and inadvertently come into contact with live exposed
connections or generate a hazardous electrical condition.
Similarly, incremental changes in the return earth resistance can occur over time through the normal
–
process of coupling and uncoupling electrical connections and the ingress of dust and contaminants as
mining progresses. The electrical distribution system will be designed so that the worst case touch
potential under fault conditions is developed with the upper limit of return earth resistance set by the
earth continuity trip resistance. It should be noted that a modest increase (even an increase above the
trip setting) of earth return resistance is not immediately dangerous in the majority of situations – a touch
potential is normally only generated in case of an earth fault. Unlike an earth leakage clearance time,
there is no requirement that the earth continuity trip time be instantaneous, nor is there a defined link
between EC clearance time and significantly improved safety outcomes. Under Australian Standards
earth continuity protection trip times <=500ms are generally acceptable and will normally meet the
requirements of (1) & (2) for most applications.
The trip time for earth continuity should be chosen in the same way as an earth leakage trip current
setting. In all cases, the earth leakage trip current should be as close as possible to the normal (non-
fault) EL current that does not cause a nuisance tripping. Similarly, the earth continuity trip time should
be as low as practical to not cause a nuisance trips. In low noise applications (eg: simple DOL motors
IPM V2 USER MANUAL
and linear loads) practically achievable clearance times will be less than 200ms. In higher noise
applications (eg: Soft starters, variable speed drives and non-linear loads) higher clearance times up to
500ms may be necessary and can be shown to be safe.
Please note, excessive noise on the pilot-earth loop (as monitored by the EC protection relay) can be
indicative of a standing touch potential or another undiagnosed operating difficulty. Where EC trip
settings above 200ms are required to avoid nuisance tripping Ampcontrol recommends the source of
noise (and so the electrical distribution system design) is properly investigated to ensure the system is
safe.
7 CURRENT RELATED FUNCTIONS

The IPM relay uses a current transformer on each of the three phases to monitor the line currents. The
measured currents are used to implement the following protection functions:
 Overload Protection
 Short Circuit Protection
 Phase Current Balance
 Residual Current Balance
 Under Current Trip
Phase Conductors
A B C
9
CT-A S1 P1
Current TXF
–
1000/1 or
500/5
S2 P2
10
CT-B S1 P1
Current TXF
1000/1 or
IPM 500/5
S2 P2
Relay
11
CT-C S1 P1
Current TXF
12 1000/1 or
–
CT-COM 500/5
S2 P2
Internally
Earthed
Figure 7.1: IPM Phase CT Connections

IPM V2 USER MANUAL
7.1 Overload Protection

The motor overload function is based on a thermal model of the motor. The three phase currents are
squared to provide the I2R heating input to the motor model. The selected ‘Stopped Cooling Ratio’
determines the cooling output for the model.
The state of the thermal model is shown by the ‘Thermal Accumulator’, which can be viewed on the
'Current/Volts Information' level on the display. The thermal accumulator represents the motor
temperature. When the accumulator reaches 100%, a Motor Overload Trip occurs.
The full load current is selected via the ‘100% Current’ setting (Level 6, Screen 2) and can be set
between 0.5125A and 640A in 448 steps. See the Appendix section of this manual for the respective Full
Load Current Selection tables for a 100:1 CT or 1000:1 CT.
The trip time is selected via the ‘O/L Trp t @ 6x’ setting (Level 6, Screen 6). It is a function of the current
and the selected trip time curve. Refer to APPENDIX 6: Drawings for details of the motor overload and
short circuit trip times.
The fifteen (15) motor overload curves allow trip settings from 3 to 40 seconds at six (6) times FLC and
are shown for both cold and hot conditions. The hot curve corresponds to the trip time after the motor
has been running at the selected full load current indefinitely.
The trip time can be calculated as follows:
 2 1.1238 A% 
I 
Trip Time  C x 31.53  ln  100 
 
 I 2  1.1238 
Where:
–
C = Curve Selected
I = Current (FLC = 1)
A% = Initial Thermal Accumulator Value
NOTE
For Cold Start A = 0% and on Hot Start, A = 89%.
The motor manufacturer's data should always be consulted to select the appropriate settings for the
–
motor being protected. Typically, the capacity of a cold motor is given at six times its rated current.
The IPM Relay's trip curves can then be used to select the trip time curve, which best suits the motors
overload capacity.
The motor overload trip latches once the thermal accumulator reaches 100% and can only be reset once
the thermal accumulator falls below a pre-set value. The pre-set value is selected via the ‘O/L Rst Level’
setting (Level 6, Screen 8) and can be set to 30%, 40%, 50%, 60%, 70%, 80%, 90%, A-30%, A-40%, A-
50%, A-60%, A-70%, A-80%, A-90%. The “A-“settings automatically reset a motor overload trip once the
thermal accumulator falls below the set value. Otherwise the trip has to be reset manually by pressing
the keypad ‘RESET’ button or activating the ‘RESET’ digital input once the thermal accumulator has
fallen below the set value.
An emergency restart on a hot motor can be achieved by zeroing the thermal accumulator
memory. This is done by closing the Lock input and Reset key/digital input simultaneously for
1.5 seconds.
IPM V2 USER MANUAL
CAUTION!
Repeated restart attempts in this condition may damage the motor
The ‘Stopped Cooling Ratio’ modifies the cooling output of the thermal model when the motor is stopped.
This can be used to account for reduced cooling capacity of the motor when it is not running (motor run
status monitored via MCI digital input).
The ratio is selected via the ‘O/L cool mult’ setting (Level 6, Screen 7) and is adjustable from 1.0 to 5.0.
A cooling multiplier of 1 means the cooling is independent of whether the motor is running or not – for
example, a water-cooled motor. Protection for a fan-cooled motor is based on a setting of 2.5, however,
for the best protection consult the motor manufacturer.
7.2 Short Circuit Protection

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 function trips the CBR relay (the CBR relay is
normally energised, and drops out when tripped).
The short circuit trip level is selected via the ‘Short Cct.Trip’ setting (Level 6, Screen 4) and is a multiple
of the selected full load current, from 3.0 to 10 times FLC, in steps of 0.5. The trip time is selected via the
‘Short Cct. t’ setting (Level 6, Screen 5) and is adjustable from 20ms to 160ms.
To reset the relay following a short circuit trip it is necessary operate the reset key/digital input.
–
7.3 Phase Current Balance

The current balance measurement ‘Ib’ is displayed on the ‘Voltage and Current Information’ page, Level
2, Screen 2.
If Iave is <100% the difference between the average current and each phase current is calculated. The
maximum difference is used as the current balance percentage.
If Iave is >= 100% then the current balance is calculated as:
MAX ΔI x 100%
𝐼𝑏𝑎𝑙 =
𝐼𝑎𝑣𝑒
Where:
Iave = Average of the 3 phase currents
–
MAX Δ I = The maximum deviation of a phase current from the average

Phase current balance protection is selected via the ‘Cur.Bal.trip’ setting (Level 6, Screen 9).
The trip level is selectable at 5%, 10%, 20%, 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 any phase drops below the selected trip setting for a period of 2 seconds then the outlet is stopped. To
reset the relay following a current balance trip, operate the reset key/digital input.
I A B C 2
Cur: 0% 0% 0%

IPM V2 USER MANUAL
Ave: 0 Amp Ir: 0%

Ibal: 0% Iel: 0%
7.4 Residual Current Signal

The three phase current signals are summed electronically in the IPM to produce a residual current
signal that can be used to detect earth fault currents. If the residual current signal exceeds the trip level
for the selected trip time, a trip occurs, tripping the MCR relay. The fault is latched.
To reset the relay following a residual current trip, operate the reset key/digital input.
 L2: Displays the 3 phase currents as a % of the FLC
 L3: Displays the average current and the % residual current as ‘Ir’
 L4: Displays the current balance and the % of leakage current
The trip level is selected via the ‘Residual iTrp’ setting (Level 6, Screen 11) and is adjustable from 10%
to 250% FLC and ‘off’. The trip time is selected via the ‘Res.trip time’ setting (Level 6, Screen 12) and is
adjustable from 100ms to 5 seconds. Setting the trip level to ‘off’ disables this function.
NOTE
The residual current function can be used even if a core balance toroid
is used for earth leakage protection. It can be used to provide some
detection of wiring/CT/internal relay faults.
–
7.5 Undercurrent Trip

Undercurrent protection is enabled as soon as the main contactor is closed (indicated by closing the MCI
input). Selecting a value of “None” will inhibit this function. If any phase drops below the selected trip
setting for a period of 4 seconds then the outlet is stopped. This raises the “Under Current Trip” alarm
and is recorded in the event log as “Und.I Trp”. To reset the relay, operate the reset button.
The trip level is selected via the ‘Under I Level’ setting (Level 6, Screen 10). The trip level is selectable at
32%, 40%, 48%, 56%, 64%, 72%, 80%, 88%, and 96%. Setting the trip level to “None” disables this
function.
NOTE
This function is used when in snore mode and must be set to an
appropriate level – note that there is a 4 second delay before a trip.
–

IPM V2 USER MANUAL
8 VOLTAGE RELATED FUNCTIONS

The IPM relay uses the Insulation Test Module (ITM) to monitor the magnitude of the voltage on the load
side of the outlet’s main contactor. The voltage measurement is used to implement the following
functions:
 Main Contactor Fail Protection
 Undervoltage Trip
 Voltage Metering
Phase Conductors
From Contactor
A B C
18
Vtest VTEST
19
0V Earth
IPM 20
Va Vcma ITM Va
Relay
21
Vb Vcmb Vb
22
Vc Vcmc Vc
Flying Leads
Figure 8.1: IPM Voltage Monitoring Connections

–
8.1 Main Contactor Fail Protection

The Main Contactor Fail (MCF) protection operates if the Main Contactor (MC) fails to function by either:
1. Failing to open when required. This is achieved by comparing the state of the main contactor (via
the Main Contactor Input MCI) against the state of the MCR relay output. This test provides
“Frozen Contactor Protection”.
2. Failing to maintain insulation across the contacts when the contactor is open. The Insulation Test
Module (ITM) is used to measure the voltage on the load side of the contactor. If this exceeds
10% of the rated line voltage, a trip will occur. This test provides “Loss of Vacuum Protection”.
This function is inhibited immediately after the main contactor opens to allow for back EMF
voltages generated by some motors to dissipate. The inbuilt time is selected via the ‘back EMF
time’ setting (Level 6, Screen 20). The settings are adjustable from 2 to 20 seconds.
A main contactor fail trip operates the CBR relay, which trips the circuit breaker.
–
To reset the relay following a main contact failure trip, operate the reset key/digital input.
The status of the MCI input can be viewed on the ‘IPM Relay and Keys’ screen, (Level 4, Screen 2).
8.2 Undervoltage Trip

The undervoltage 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 MCR relay is de-energised.
To reset the relay following an undervoltage trip, operate the reset key/digital input.
The trip level is selected via the ‘U/V Trp level’ setting (Level 6, Screen 19) and is adjustable between
40, 50, 60, 70, 75, 80, 85, 90, 95 & OFF. Setting the trip level to ‘OFF’ disables this function.

IPM V2 USER MANUAL
8.3 Voltage Metering

The Insulation Test Module (ITM) is also used to provide line voltage metering.
I&V A B C 2
Cur: 0% 0% 0%
Volts 0% 0% 0%
O/L: 0% MCF-t 100%
 L2: Displays the line current for each of the 3 phases.

 L3: Displays the line voltages for each of the 3 phases.
 L4: Displays the thermal accumulator and main contactor fail timer that counts down when a main
contactor fault is detected.
Line voltages of 415V and 1000V are configured when the appropriate Insulation Test Module is
selected in the ‘Group 1 Settings’ (Level 5, Screen 2).
–
–

IPM V2 USER MANUAL
9 MACHINE COMMUNICATION
The IPM provides the option of using the Remote Termination Module (RTM) to provide machine
communication. See Section 6.3 for connection diagram.
9.1 Remote Termination Module

The Remote Termination Module is a microprocessor based fully encapsulated module that replaces the
diode at the end of the pilot conductor of the trailing cable. It is powered by and communicates via the
pilot line. Its non-volatile memory stores the parameters to configure the outlet as appropriate for that
machine.
This allows the motor to be supplied from different outlets without the need for re-programming the
protection settings into the IPM each time.
Machine type and machine number are displayed on the Default and Earth Continuity Screens (Levels 1
and 3).
9.2 Machine Type Codes

There are fourteen (14) selectable machine type codes available for use in the Remote Termination
Module. The descriptive code is transmitted to the IPM Relay to identify the type of machine connected
to the outlet. The codes are programmed at the ‘RTM Mach. Type’ page (Level 6, Screen 1).
 J-bo Face Boring Machine
 Fan Ventilation Fan
 Drill Drill
 Pump Pump
 Hpmp Hydraulic Pump
–
 Wpmp Water Pump

 DCB Distribution Control Box

 Bolt Bolter
 HRMr Hard Rock Miner
 Belt Conveyor Belt
 Winc Winch
 Crsh Crusher
 Dplg Dummy plug
Spare
9.3 Machine Type Number

Machine numbers 1 to 40 can be assigned to machines. These numbers are programmed at the ‘RTM
Mach. Num.’ page (Level 6, Screen 2).
–

IPM V2 USER MANUAL
10 FAN BURP FUNCTION

The Burp Function of the IPM relay allows the progressive inflation of ventilation bags (tubes) by pulsing
the motor contactor, controlling the ventilation fan, several times at start up (see Section 12.6.5 for
operational sequence).
There are three configurable parameters that control the Burp Function at start up, ‘Burp Number of
Pulses’, ‘Burp Pulse On Time’ and ‘Burp Pulse Off Time’.
Selectable Settings:
 ‘# Burp Pulses’ (Level 6, Screen 25) - selectable at none and 1 to 6 (selection of “none” disables
the Burp Function).
 ‘Burp On Time’ (Level 6, Screen 26) and ‘Burp Off Time’ (Level 6, Screen 27) - selectable at 0.6,
0.8, 1.0, 1.2, 1.5, 2.0, 2.5 and 3.0 seconds.
11 PUMP SNORE FUNCTION

The purpose of the IPM Snore Function is to (optionally) add a timed re-start to the IPM Relay after an
undercurrent trip has been detected. Refer to Section 7.5 for more information on the operation of the
undercurrent trip function.
11.1 Basic Operation

The basic operation of the snore function is illustrated using the following scenario:
Assume a pump is the load device of the relay, which pumps a dam. When the water level drops below
the pump pickup, the load current will drop significantly enough to be detected as an undercurrent trip
–
(as set in the settings level 6) by the IPM.

The Snore Function (Snore-Process) will operate only after configuration and activation via the IPM
menus. The snore function will operate after undercurrent is detected and will permit the pump to restart
after a time delay (tSnoreDelay). After this off period the pump will restart. During the first 4 second ON
period (tSnoreOn) the pump will run, and only if the pump remains in an undercurrent state, the IPM will
extend tSnoreDelay by 1.5 times and switch off the output relay for the new setting of tSnoreDelay. This
process will continue until the time reaches a maximum of tSnoreDelay x 8.
The initial setting for tSnoreDelay is obtained from a menu configuration setting (tSnoreSet). The
available initial settings are OFF, 5, 10, 15, 20, 8F, 15F, 20F, 30F, 60F minutes (the “F” represents a
fixed delay that does not extend tSnoreDelay as described above. If a load is detected during tSnoreOn
(that is, no undercurrent is detected), the pump will remain on, but tSnoreDelay will be reduced to ¾ of
its present setting; but not below tSnoreSet (this does not apply to the “F” settings). In the case where
the new tSnoreDelay is less than tSnoreSet, then tSnoreDelay shall be set to tSnoreSet.
–
When in tSnoreDelay mode, and if a ‘Start’ is initiated from:

a) The ‘Start’ key (on the relay), or,

b) A pulse from the External Start input is detected
Then the relay will immediately abort the running tSnoreDelay and proceed through a power-on
sequence.
If a power failure occurs when the IPM is operating in Snore Mode, it will resume operating in Snore
Mode when power is restored. If Aux is open, or there is an EL fault on Power Up, the snore function will
wait for up to 15 seconds to start.

IPM V2 USER MANUAL
11.2 Setup Procedure for Snore Function

Setup of the Snore Function is done by settings throughout the menu structure. The additional settings
required to enable the Snore Function include:
 Start Mode must be set to ‘Snore’
 The Snore Delay parameter must not be set to none
 The ‘Under Current’ trip level must not be set to none
 The AUX External Digital input must be active
11.2.1 Relay Snore Mode Starting Procedure

When the ‘Snore’ start mode is selected, the relay can be initially started from different sources:
 Start key on facia, if and only if the aux input is closed,
 External start button, if and only if the aux input is closed.
Each operation of the ‘Start’ key will cause the relay to proceed through a power-on sequence
regardless of the status of the snore function.
11.2.2 Relay Stop Procedure

The relay will be stopped whenever the Stop key or the external Stop is actioned – regardless of the
Snore process. This will reset the snore delay timer.
If the AUX input opens at any time during operation in Snore mode, then a start is required to restart the
snore function. The Message ‘Snore – Need Aux’ will be displayed on the screen when in Snore mode
with the AUX open. This will reset the snore delay timer.
–
–

IPM V2 USER MANUAL
12 PRODUCT OPERATION
12.1 Basic Display Operation
The fascia of the IPM Integrated Protection Relay has a four line 20 character backlit Liquid Crystal
Display (LCD), Status LED and a tactile keypad. Figure 1 gives an overview of the fascia of the relay.
Figure 12.1: IPM Relay Fascia and Display

–
The layout of the display structure is shown on the ‘IPM Display Map’, APPENDIX 4: IPM Menu
Structure. The display level is changed with the Up/Down arrow keys and the Left/Right arrow keys
control the various display screens.
The ENT and ESC keys are used to modify settings and provide hyper jump access to the display
structure.
The Reset key allows a reset following a trip condition.
The Test key is used to activate a manual insulation test.
Start and Stop keys are provided for controlling the IPM which in turn controls the MC and MCB
The Status LED is a single bi-coloured LED that can be viewed some distance from the relay. Status
indication is as follows:
Table 2: Status Indication
–
IPM Status LED Colour LED Flash
OK (Run) Green 4Hz
OK (Stopped) Green 1Hz
Alarm Red 4Hz
Trip Red 1Hz

IPM V2 USER MANUAL
The IPM status display is one of the most useful features of the relay’s display system and should be
viewed as the first step in fault finding. The ‘Relay Status Page’ is the default screen on power up and
shows the current status of the IPM Protection Relay.
[ Need IPM Start ]
Load [Pump # 1 ]
I= 0 Amps V= 0 V
 Line 1: A one-line status message is displayed and if more than one message is active the
display cycles through all active messages at 1 second intervals.
 Line 2: IPM Software version appears here while the UP arrow key held.
 Line 3: Shows the Load Type and Number (from the connected RTM unit).
 Line 4: Shows the Load Current (3ϕ average) and Load Voltage (average ϕ - ϕ.)
Through the use of the Modbus communications port, PLC’s and SCADA systems can be configured to
display the same messages that appear on the display. This helps to provide consistent information to
operators.
12.2 Trip/Status Messages

The following table shows a list of the forty (40) status messages and the category (type) of the
–
messages. Messages are cleared according to their message category.

 Type 1: Messages are latched for display and are cleared by either pressing the <ENT> key while
on the Status Display Page or by starting a new starting sequence.
 Type 2: Messages are enabled and cleared automatically.
 Type 3: Messages are triggered by the respective trip functions and are cleared by resetting the
trip function.

Table 3: Trip/Status Message
Message and Type Comment
Tripped No Volts 1 Voltage on load side of contactor is too low

–
MC Close Fail 1 MCI input did not close within 5 sec of MCR relay
closing
External MC Open 1 IPM detected (via MCI input) that MC was opened –
not initiated by the IPM relay
Burp MCI Fail 1 MCI input fails to follow MCR relay output during burp
phase
Under Current Trip 1 Under Current function tripped

Last T:-------- 1 Shows ‘Last Trip’ record
OTS Mode Exit Stop 1 IPM has exited the OTS Test Mode

IPM V2 USER MANUAL
Outlet Paused 2 IPM waits 5 sec between running (or testing) and re-
testing
Need IPM Start 2 Awaiting IPM start digital input
Testing Insulation 2 In process of Insulation Test (2 seconds)
Closing Main Cont. 2 MCR closed, waiting on MCI feedback (5 sec max.)
Burp: MCR Closed 2 Burp Phase is on MCR closed
Burp: MCR Open 2 Burp phase is active – MCR is open
Running 2 Outlet closed

Snore 2 Snore function active
Snore – Close AUX 2 Aux digital input must be closed for Snore to function
High Current Alarm 2 High Current Alarm triggered
Thermal Trip Alarm 2 Thermal Trip Alarm triggered
Cur. Balance Alarm 2 Current Balance Alarm triggered
Under Cur. Alarm 2 Under Current Alarm triggered
Earth Leakage Alarm 2 Earth Leakage Alarm triggered

–
UnderVoltage Alarm 2 Under Voltage Alarm triggered
Insulat. Test Alarm 2 Insulation Test Alarm triggered

2 Shown when the digital input is closed but the IPM is
Need RTM Start
stopped
OTS Testing Mode 2 IPM operating in OTS Test Mode
Earth Leakage Trip 3 Earth Leakage function tripped
Earth Cont. Trip 3 Earth Continuity function tripped
Insulat. Fail Trip 3 Insulation Test function tripped

–
Over Current Trip 3 Over Current function tripped

Short Circuit Trip 3 Short Circuit function tripped
I Balance Trip 3 Phase Current Balance function tripped
Residual Cur. Trip 3 Residual Current function tripped
Main Contactor Fail 3 Main Contactor Fail function tripped
RTM-Offline Trip 3 IPM cannot communicate with RTM
IPM Memory Error (see 3

Corrupted memory in relay’s stored settings
Note 1)

IPM V2 USER MANUAL
RTM Memory Error (see 3

IPM detected errors in set up data received from RTM
Note 1)
Stopped - IPM 3 IPM Stop digital input activated (closed)
RTM CT Ratio Error (see 3 The attached RTM was set up using a different CT
Note 2) ratio than that of the IPM in use
3 The attached RTM does not support 100:1 CT

RTM Version Error
operation
Remote Stop 3 Shown whenever RTM’s digital input is open
2 Present when:
Start is set to Modbus.

Configuration Error
In snore mode; the delay or undercurrent trip level is
not set. Also if the remote start is set to ‘yes’ or ‘aux’
whilst in snore mode.
Stopped – Ext Stop 3 IPM Stop digital input externally activated (closed).
1. It is normal to see the IPM Memory Error Message when

NOTE switching between Diode/RTM Mode or when the RTM is first
–
connected to the pilot.

2. If the CT Ratio is changed the current setting must also be reset

(otherwise an Error Message of "RTM CT Ratio Error" will be
displayed).
12.3 Last Trip Status Messages

The IPM Relay has several functions, which can stop/trip the outlet and then self-clear. The IPM Relay
therefore saves the non-latched trip codes in a register and displays the ‘Last Trip’ messages in the
Status Message Page (note that the stop/trip function also appears in the Event Log).
Messages that are displayed at Last T: ---------
–
Table 4: Last Trip Messages
E/C Leakage Trip that provides additional

EC Leak T
information for E/C Trip
E/C Ohms Trip that provides additional

EC Ω Trip
information for E/C Trip
Main contactor opened – opening not initiated

MC Opened
by the IPM Relay

IPM V2 USER MANUAL
RTM Off Line – IPM cannot communicate with

RTM Off L
RTM
Und. I Trp Under Current trip caused outlet to stop
Stopped IPM Stop Input Tripped Locally
Ext. Stop IPM Stop Input Tripped Externally
12.4 Communications
The IPM Relay provides an industry standard RS485 Slave Modbus communication port. This allows
connection to a PLC or a SCADA system. APPENDIX 5: IPM Modbus Address Table provides detail on
Modbus addresses.
The baud rate is selected via the ‘Modbus:Baud /P’ setting (Level 5, Screen 4) and is selectable between
1200 and 19200 Baud, with even, odd, or no parity. One stop bit is used in conjunction with parity, while
two stop bits are used with no parity.
The half-duplex 3-wire RS485 communications interface allows up to 31 devices to be multi-dropped
onto a single master communication line. The IPM’s Modbus Slave address is selected via the ‘ModBus
Addr:’ setting (Level 5, Screen 3) and is adjustable between 1 and 31.
12.4.1 Modbus Commands

The following Modbus commands are supported:
–
Table 5: Modbus Commands

Modbus CMD Comment

03 Read Holding Registers
06 Store Single Register
Valid read registers are in the range from 1 to 96. An attempt to read a register outside this range will
result in an exception scan. Currently, only the first 78 registers contain valid data. Supported Modbus
exception responses are:
Table 6: Modbus Exception
Modbus Exception Comment

–
01 Illegal Function
02 Illegal Data Address

03 Illegal Data Value

IPM V2 USER MANUAL
12.4.2 Modbus Status

Table 7: Modbus Status
Status Comment
Address The Modbus slave address the IPM is set to
A solid block when a READ command is
Read
received
A solid block when a WRITE command is
Wrt
received
A solid block when an unsupported Modbus
Exc
command is received
A solid block when a checksum error is
CRC
detected
Par A solid block when a parity error is detected
NE A solid block when noise is detected

FE A solid block when a framing error is detected
Modbus 4
Address [01] Read[ÿ]
CRC[ ] NF[ ] Wrt.[ ]
Par[ ] FE[ ] Exc.[ ]
–
The Modbus Status can be viewed on Level 4, Screen 4.
12.5 Remote IPM Control

The IPM and RTM software have been changed to allow for the RTM digital input to be used to control
the IPM. This functionality is similar to that of the IPB/C/D.
The remote start can be set in two modes. In one mode it is always active and in the other mode it is
active only when the auxiliary digital input is closed. Remote start can also be disabled.
12.5.1 Function Overview

A previously unused parameter called ‘remote start’, originally intended to implement the remote start
functionality, is used to enable the remote start function. Setting it to ‘yes’ enables remote start. Setting
it to ‘no’ will disable remote start. Setting it to ‘Aux’ enables remote start only when the auxiliary digital
–
input is closed.
The remote input (on the RTM) is edge sensitive. This ensures that if there is an upstream trip, the IPM
will not restart automatically once the power is restored. It also allows the keypad and external digital
input stops to work sensibly so that if the IPM is stopped locally, it will not restart immediately after any
of the stop are released.
When remote start is active, the remote input is closed to start the IPM and must remain closed while
the IPM is running. The remote input is opened to stop the IPM.

IPM V2 USER MANUAL
12.5.2 Operating Modes
NOTE
The external digital stop input and the keypad stop will always stop the
IPM regardless of the start mode.
There are two modes in which the IPM relay can operate:
 Diode Mode- The remote start parameter has no effect when the IPM is set to diode mode.
 RTM Mode- The Remote start parameter has three possible options; ‘no’, ‘yes’ and ‘aux’.
12.5.2.1 Remote start - ‘no’
The remote input will be ignored. Starting the relay will depend on whatever start mode is selected
as per the existing operation.

12.5.2.2 Remote start - ‘yes’
1. Start mode - ‘K/Ext’ (Keypad or External)
Keypad and External start inputs are ignored. Remote input controls the IPM. Local stop
input will still stop the IPM. Local stop inputs will override the remote start if they are held
closed while a remote start is signalled.
2. Start mode - ‘Ext’ (External only)
As per ‘K/Ext’
3. Start mode - ‘K&Ext’ (Keypad and External)
As per ‘K/Ext’
–
4. Start mode - ‘Modbs’ and ‘Snore’

These modes will not operate when remote start is set to ‘yes’. The status display will
show “Configuration Err”.
12.5.2.3 Remote start - ‘Aux’
When an appropriate start mode is selected, changing the Auxiliary digital input will switch between
local (keypad or external digital start input) and remote (RTM digital input). It is allowable to change
the state of the Auxiliary input while the IPM is running.
If the RTM input is open and the IPM is running while the Auxiliary input is closed, the IPM will
immediately stop. If the RTM input is closed and the IPM is running while the Auxiliary input is
closed, the IPM will continue to run.
1. Start mode - ‘K/Ext’, ‘Ext’ and ‘K&Ext’
The IPM will change between remote start mode and local start mode depending on the
state of the ‘Aux’ digital input. When the input is closed the IPM will be controlled via the
–
RTM as described in Section 4.4.4.

When the ‘Aux’ digital input is open the control will revert to local mode. The start signal
required will depend on the Start mode parameter.
2. Start mode - ‘Modbs’ and ‘Snore’
These modes will not operate when remote start is set to ‘yes’. The status display will
show “Configuration Err”.

IPM V2 USER MANUAL
12.5.3 IPM/RTM Software Compatibility
NOTE
A ‘New IPM’ is considered to be version 9 or earlier; An ‘Old RTM’ is
version 2 or earlier (reported as ‘20’ on the IPM display).
 New RTM and New IPM - Nothing to consider.

 New RTM and Old IPM - The Old IPM will ignore the remote start setting.
 Old RTM and New IPM - The new IPM will check the version of the RTM (this is transmitted in
the pilot protocol). If the RTM has the ‘remote start’ parameter set, but the RTM version is too old,
the IPM will display “RTM Version Error”.
 Old RTM and Old IPM - Nothing to consider.
12.5.4 Status Messages

There are two new status messages - “Need RTM Start” and “Remote Stop”.
When in remote start mode, whenever the RTM’s digital input is open, the display will show “Remote
Stop”. If the digital input is closed but the IPM is stopped the display will show “Need RTM Start” to
indicate that the RTM’s digital input needs to be opened and then closed to generate a new edge.
NOTE This is most likely to happen if the RTM’s digital input is closed to allow
the IPM to run and then a local stop is used to stop the IPM. Because of
–
the edged triggered nature of the RTM digital input, the IPM will not
automatically restart.
–

IPM V2 USER MANUAL
12.6 System Control

12.6.1 Digital Inputs
The IPM provides six (6) voltage free digital inputs for correct operation. To activate an input a
connection needs to be made from '+DiPwr' terminal to the respective digital input’s terminal.
IPM Dig Inputs 4

ExtRst¡/¡ Lock¡_¡
ExtStp¡/¡ Aux¡/¡
ExtStr¡/¡ A/O 20.0mA
 L2: Displays the status of the external reset and the lock inputs.
 L3: Displays the status of the external stop and the auxiliary inputs.
 L4: Displays the external start input and the analogue output in mA.
The function of each input is as follows:
1. Lock: The lock input needs to be closed whenever changes to the relay settings are being made.
If the lock input is not closed then the settings cannot be changed.
The lock input must also be closed to reset the thermal memory to allow an emergency restart.
To perform a reset, the motor must be stopped (MCI open) and both the reset key and the lock
input must be held closed for 1.5 seconds. This will reset the ‘Thermal Accumulator’ and allow
the motor to be started immediately.
2. Reset: The reset digital input performs the same function as the keyboard reset allowing for
external/remote resetting of trips. To reset a trip, an open to close transition on the reset input (or
–
reset key) is required.

3. MCI: The Motor Contactor Interlock input provides the IPM relay with the status of the motor
contactor. Its status is used by the thermal modelling to activate the 'Cooling Multiplier' and also
provides the basis for Motor Contactor Fail (MCF) monitoring.
4. Digital: This is an auxiliary digital input.
5. Ex-Start: This input allows the installation of an external start button.
6. Ex-Stop: This input allows the installation of an external stop button.
12.6.2 Output Relays

The IPM provides three relay outputs for correct operation. All relay contacts are rated at 5A/190VAC.
1. MCR: (Main Trip Relay). This relay energises when there are no trips, and drops out whenever a
trip occurs. A normally open and a changeover set of contacts are provided.
2. ALM: (Alarm Relay). This relay energises whenever there are alarms active and drops out when
–
all alarms are clear. One changeover set of contacts is provided.

3. CBR: (CBR Relay). This relay is normally energised and drops out if there is a short circuit trip or
a motor contactor fail trip. One changeover set of contacts is provided.
IPM Relay & Keys 4

CBR:In. Tst MCR:out
ALM:out ¡/¡ MCI ¡/¡
Str¡/¡ Rst¡/¡ Stp¡/¡
 L2: Displays the status of the CBR and MCR Relays.
 L3: Displays the status of Alarm Relay, the Test key and the Main Contactor input.
 L4: Displays the status of the Start, Reset and Stop Keys.
IPM V2 USER MANUAL
12.6.3 Outlet Control

The outlet can be energised by local or remote operation depending on the ‘Remote Start’ option. The
selection is “Yes” or “No” (Level 6, Screen 16).
If “Yes” is selected the relay ignores the local start input thus allowing operation of the outlet from the
remote machine. Both the external and local stop buttons will turn off the outlet.
If “No” is selected the local start/stop buttons control the outlet.
12.6.4 Start Mode

The Start Mode is selected at (Level 5, Screen 3). The possible settings are K/Ext, Ext, K&Ext, Modbus
and Snore. The start/stop logic operates as follows:
1. The external stop digital input and the front keypad stop button will always stop the relay,
regardless of the settings for ‘Start Mode’. In all cases only one of the stop inputs needs to be
active to stop the relay.

2. K/Ext mode – Relay can be started with either an external start or the keypad.
3. Ext mode – Only the external start is used. The keypad start is disabled.
4. K&Ext mode – Both the external start and the front panel keypad start button needs to be active
to start the relay.
5. Modbus mode – Not implemented.
6. Snore mode – The parameters for Under Current Trip, Start Mode and the Snore time delay need
to be set for your application. Extra protection against accidentally selecting this mode is provided
by requiring the external digital input to be closed before this mode will start.
12.6.5 Operational Sequence (Insulation Test and Burp Function selected)

Before an outlet can be energised there should be no protection faults present.
–
Once the start button is operated an insulation test is performed. If the result of this test is satisfactory
the Burp Phase is initiated. When the Burp Phase is completed the IPM Relay goes into the run mode.
A time delay of 5 seconds is allowed for the Main Contactor Interlock (MCI) to close. If it does not
close within this time, then the run mode is exited.
If a stop input is closed while the relay is in run mode, the run is cleared, and the MCR relay de-
energises. The event log reads “Stopped”.
While the main contactor is closed, the MCI input is continuously monitored. If it opens, the run is
cleared and the MCR relay de-energises. In this case the event log records “MC Opened” which
indicates that the outlet was turned off by something other than the IPM Relay, for example, open
circuited main contactor coil or control supply.
It should be noted that if the main contactor does not close when the MCR relay closes and the
–
start/stop conditions are maintained, then the IPM will cycle through the following start sequence:
testing, run, stopped, pause then repeat the sequence while ever the start input is closed.

IPM V2 USER MANUAL
12.7 Analogue Output

The IPM Relay provides an isolated 4-20mA analogue output. The output continuously monitors Average
Current, Overload, Earth Leakage and the Insulation Level of the relay. The Monitor Output settings can
be selected at ‘4-20mA Output’ (Level 6, Screen 28). Settings available are O/L (0-100%), Iave (0-
250%), E/L (0-100%) and MΩ (0-40MΩ). The analogue output status in milliamps is shown on the ‘IPM
Relay and Keys’ screen, (Level 4, Screen 2).
12.8 IPM Alarm Functions

The IPM has several standard alarm functions. If any are triggered, the Alarm Relay (ALM) picks up.
Each has a selectable alarm level, and can be disabled. Generally the alarms are self-resetting once the
alarm condition is removed.
1. High Current Alarm - Is activated by the phase currents exceeding the selected threshold. It is
selected via the ‘High I alarm’ setting (Level 6, Screen 21) and is adjustable from 100% to 600%
FLC and ‘off’. The highest of the three phase currents is used. Time delay = 1 sec. Setting the
alarm level to ‘off’ disables this function.

2. Overload Alarm - Is activated by the thermal accumulator exceeding the selected threshold. It is
selected via the ‘O/L Alarm Lev’ setting (Level 6, Level 22) and is adjustable from 50% to 95%
and ‘off’. Time delay = 2 s. A motor overload trip overrides this alarm. Setting the alarm level to
‘off’ disables this function.
3. Under Cur. Alarm - Is activated by the phase current falling below the selected threshold. It is
selected via the ‘Under I Alarm’ setting (Level 7, Screen 10) and is adjustable from 32% to 96%
and ‘off’. This alarm is only activated when the motor is running (MCI input closed). Time delay =
2 sec. Setting the alarm level to ‘off’ disables this function.
4. Earth Leakage Alarm - Is activated when the earth leakage current exceeds a set level. The
alarm level is selected via the ‘E/L Alarm Lev’ setting (Level 6, Screen 24) and can be set to 20%,
–
50%, 80% and ‘off’. The earth leakage alarm has a time delay of 1 second and auto resets when
the earth leakage current falls below the selected level. Setting the alarm level to ‘Off’ disables
this function.
5. Insulat. Test Alarm - Is activated when the meg-ohm resistance of each phase to earth, as a
result of an insulation test, equals or falls below the alarm level. The alarm level is set at 1.5
times the trip setting.
The alarm message is displayed until a new test is initiated or the <ENT> key is pressed while displaying
the alarm message. The ‘Insulat. Test Alarm’ is also recorded in the Event Log.
–

IPM V2 USER MANUAL
12.9 Event Log

A real time clock/calendar is included in the IPM Relay. 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 event log can be viewed by using the right or left arrow keys to scroll the log.
Event Log 1
Record#01: Power Up
We 26/07 14:57:13.64
We 26/07 14:58:21
A typical display shows:

L2: Displays the event.

 L3: Indicates the time that the relay powered up on Wednesday, 26 July.
 L4: Indicates the present time.
Log 1 is always the most recent event. Each time a new log is recorded, the 50th log is removed from
the list.
The following events are logged:
Table 8: Events
Event Description
Power Up The instant that power is applied to the relay
–
Pwr Down Removal of power from the relay

MCR Close Closure of the Main Contactor Relay

Stopped Stopping of the outlet by operation of the local stop
button
Ext. Stop Stopping of the outlet by operation of the external
stop button
MC Opened Main Contactor has opened but not initiated by the
IPM Relay
MC Fail Main Contactor Fail Function Trip
CloseFail Indicates that the MCI Input did not close within 5
seconds of MCR closing
EC Ω Trip Pilot/Earth continuity loop exceeds 45 Ohms
–
EC Leak T Leakage resistance between the pilot and earth is

less than 1500 Ohms

EL Trip Earth leakage protection tripped
Burp Done Burp sequence completed
Burp Fail Burp sequence failed to complete
SC Trip Trip condition of short circuit protection
OC Trip Trip condition of overload protection
I bal-Trp Current balance trip condition
RESET Records resetting of a protection trip function
Setup Mod Records that set up data has been modified
Und.I Trp Under Current Trip caused outlet to stop
uvolt trp Records that voltage was not present on at least
IPM V2 USER MANUAL
Event Description
one outgoing phase when the main contactor was
closed
Ires.trip Residual E/L Trip condition
Tmem Loss The thermal memory data has been corrupted
T-mem Rst Thermal memory has been manually reset to zero
Mem.ERROR Records that the relay’s non-volatile parameter
memory has been corrupted
µ- P reset Internal microprocessor reset
RTM mem. E Records that the Remote Termination Module’s
non-volatile memory has been corrupted or Remote
Termination Module has gone off line while the
outlet is running.
Feeder On Records RTM machine code and number when

main contactor is closed (proceeded by MCR
closed). This log only appears when in RTM mode.
RTM Off L Indicates a loss of communications with the RTM.
Meg Ω Trp Insulation Test failed
IT: -- . -MΩ Records the result of the Insulation Test
Insul.Alm Result of Insulation Test is equal to or less than the
alarm level
o/l alarm Thermal accumulator has exceeded the selected
threshold
L-cur alm Phase current has dropped below the selected
–
threshold
H-cur.alm Phase current has exceeded the selected threshold

e/l alarm Earth leakage current exceeded the selected
threshold
RTM Stop In any of the remote start modes; the event log will
record when the IPM is stopped via the remote
digital input.
12.10 Time and Date
Clock Setup
–
We 26/07 14:58:21
If there is a need to adjust the real time clock, carry out the following procedure:
 Using the display’s keys select the time and date information page (Level 4, Screen 5) to display
the Day, Month, Year, Hours and Minutes.
 Press the ENTER key. A “v” will appear in the top line above the minute section. This indicates
the number to be changed.
 Use the left and right arrow keys to move the “v” to the desired position.
 Press the ENTER key. The “v” now changes to a “?” The right arrow key is used to increment the
allowable values, once the desired value is obtained, press the ENTER key again. The “?”
returns to a “v”.
IPM V2 USER MANUAL
 Repeat steps 3 and 4 until the correct time and date are displayed.
 With the “v” showing press the reset push button. The “v” then changes to “E” (this is a prompt to
press the ENTER key).
 Press the ENTER key. At that instant, the seconds are zeroed and the selected time/date
information is transferred to the internal clock.
If the battery voltage is low the time will zero and the date will reset to 1st January on power up.
NOTE The date and time are used only to time stamp the events in the log
(which are recorded sequentially regardless of the date/time). Date and
time data is not used for any control functions.
13 USER ADJUSTABLE SETTINGS

13.1 Parameter Groups
There are two groups of adjustable settings contained in the IPM relay’s non-volatile memory. Both
groups can be viewed and modified via the display and the up/down and left/right keys.
The first group of settings is always stored in the relay and relates to parameters, which are linked to the
system rather than the particular load connected to the outlet.
–
Table 9: User Adjustable Settings

Group 1 Setting Description

EC Pilot Mode Determines if the pilot is to be terminated with a
diode or Remote Termination Module
ITM Module Selects the Insulation Test Module to be used
with the IPM Relay
Start Mode Selects the inputs required to initiate a start
condition
ModBus Address Selects the Modbus Slave Address
ModBus Baud/P Sets the Modbus baud rate
ModBus Timeout Sets ModBus Error timing
–
CT RATIO Selects between 100:1 and 1000:1 toroids

The second group of settings consists of parameters that are related to the load connected to the
protected outlet. These settings are stored, retrieved to/from the memory in the IPM Relay or the
memory in the Remote Termination Module, depending on the “Pilot Mode” setting.
If Diode Mode is selected the IPM Relay reads and writes to and from the relay’s internal memory for the
group 2 settings.
If RTM Mode is selected, the settings are sent to and retrieved from the memory in the Remote
Termination Module.

IPM V2 USER MANUAL
Table 10: User Adjustable Settings
Group 2 Setting Description

RTM Mach. Type Selects the RTM descriptive code transmitted to
identify the machine connected to the outlet
RTM Mach. Num Selects the assigned machine number to be
transmitted by the Remote Termination Module
100% Current Sets the full load current
OC I mul Combines with OC range to define the full load
current
Short Cct. Trp Sets the short circuit trip level
Short Cct. t Sets the trip time for the short circuit function
O/L trp t @6x Modifies the basic overcurrent time curves to
achieve the desired trip times
O/L cool mult Allows the cooling rate of the thermal model to be
modified
O/L Rst. Level Sets the pre-set level to allow a reset of an O/L
trip
Cur. Bal. trp Adjusts current phase balance trip
Under I level Sets the under current threshold
Residual i Trp Selects the residual current trip threshold as a %
of FLC
Res. Trip time Sets the trip time for the residual current function
RCD Trp. Level Sets the sensitivity trip level for the earth leakage
protection
–
RCD Trp. Time Sets the trip time for the earth leakage protection
Pilot Trip t Sets the trip time for the earth continuity
protection
Remote Start When “Yes” is selected the IPM Relay ignores the
local start input. When “No” is selected the local
start/stop inputs control the relay
EC Trip Latch Determines whether earth continuity trips are self-
resetting or not
Ins. Tst. Level Sets the trip threshold or disables the insulation
test function
U/V Trp. Level Sets the under voltage threshold
Back emf time Adjustable time delay to inhibit main contactor
failure following opening of main contactor
–
High I alarm Selects the high current alarm threshold as a %

of FLC
O/L Alarm Lev Selects the overload alarm threshold as a % of
the thermal accumulator
Under I Alarm Selects the under current alarm threshold as a %
of FLC
E/L Alarm Lev Selects the alarm trip level for the earth leakage
protection
# Burp Pulses Sets the number of burp pulses
Burp on Time Sets the burp pulse on time
Burp Off Time Sets the burp pulse off time
4-20mA Output Sets the value to be transmitted
Snore Delay Sets the Snore Delay Value
IPM V2 USER MANUAL
13.2 Changing Settings

The procedure for adjusting the settings is independent of where the values are stored. The EC Pilot
Mode should be checked prior to making any other adjustments to be certain the changes are made to
the desired memory.
 Ensure the outlet is stopped.
 For Group 2 Settings in RTM Mode, ensure RTM is online.
 Display the parameter that has to be changed.
 Close and hold the lock input.
 Press the enter button to change the current parameter.
 Use the left and right arrows to step through the allowable values until the desired new setting is
displayed.
 Press the enter button to indicate that the value is the required setting.
 Once Saving indicator has finished on the display, open the lock input.
If the ESC key is operated at any stage during the procedure, the modifying sequence is aborted and the
setting reverts to its previously stored value.
When changes have been made to the stored values, the old value and the new value are stored in the
event log.
A separate log immediately proceeds this, recording the time and date that the change was made.
–
–

IPM V2 USER MANUAL
14 SERVICE, MAINTENANCE & DISPOSAL

14.1 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 relay 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.
14.1.1 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.
–
14.1.2 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.
–

IPM V2 USER MANUAL
14.2 Equipment Maintenance
The IPM V2 relay system has no user-serviceable parts.

WARNING! All repairs must be carried out by Ampcontrol only.
If a fault develops, return the product to Ampcontrol for repair. It is
essential that no attempt be made to repair the product as any
attempt to dismantle or repair the product can seriously compromise
the safety of the unit and voids product warranty.
It is recommended that the electrical protection system incorporating the relay 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 those listed in the
commissioning section (Section 5).
14.3 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.
–
–

IPM V2 USER MANUAL
15 SPECIFICATIONS
General
Auxiliary Supply Voltage 24 VDC ± 20%, <10W
Contact Ratings MCR (1 N/O, 1 C/O), CBR and ALM (1 C/O) 5A/190VAC 100VA max
RS485 Slave Modbus
Communications
Baud Rate: 1200 to 19200
Monitoring 4-20mA Analogue Output
Back EMF Timer
2, 5, 10, 15, 20 sec
Delay Settings
Machine Numbers Can be allocated from 1 to 40
Protection Functions
Earth Leakage
Trip Settings OFF, 25, 50, 100, 200, 500mA
Trip Delay Inst. (<80ms), 50ms, 100ms, 150ms
Alarm Setting OFF, 10%, 20%, 30%, 40%, 50%, 60%, 80%
Earth Continuity
Shunt Trip < 1850Ω
Operating Time 80, 120, 160, 200, 300, 400, 500ms
Trip Resistance > 45Ω
Reset Resistance < 45Ω
–
Earth Fault Lockout

Resistance NONE, 1, 2, 5, 10, 20MΩ (test time 2 sec)

Alarm Setting Trip setting x 1.5
Current Related Functions
Over Current Protection
0.5125 to 64 Amps (224 steps) 100:1 CT
Current Range
5.125 to 640 Amps (224 steps) 1000:1 CT
Trip Time (at 6xFLC) 3, 4, 5, 6, 7, 8, 10, 12, 14, 16, 20, 24, 28, 32, 40sec
Cooling Multiplier 1, 1.5, 2, 2.5, 3, 4, 5 times
30%, 40%, 50%, 60%, 70%, 80%, 90%, A-30%, A-40%, A-50%, A-
Overload Reset Level
60%, A-70%, A-80%, A-90%
Alarm Setting OFF, 50%, 60%, 70%, 75%, 80%, 85%, 90%, 95%
–
Short Circuit Protection

Trip Settings 3.0 to 10.0 times in 0.5 increments (x FLC)

Trip Time 20, 40, 60, 80, 100, 120, 160ms
Under Current
Trip Setting OFF, 32%, 40%, 48%, 56%, 64%, 72%, 80%, 88%, 96%
Alarm Setting OFF, 32%, 40%, 48%, 56%, 64%, 72%, 80%, 88%, 96%
Residual Current
OFF, 10%, 20%, 30%, 40%, 50%, 60%, 80%, 100%, 120%, 150%,
Trip Setting
200%, 250%
Trip Time OFF, 100ms, 200ms, 500ms, 1sec, 2, 3, 5sec

IPM V2 USER MANUAL
OFF, 100%, 108%, 120%, 140%, 160%, 200%, 240%, 280%, 320%,
High Current Alarm
360%, 400%, 500%, 600%
Current Balance
Trip Setting OFF, 5%, 10%, 20%, 50%
Trip Time 2sec
Other Protection Functions
Under Voltage Protection
Trip Settings 40%, 50%, 60%, 70%, 75%, 80%, 85%, 90%, 95%, OFF
Trip Time 800ms
Fan (Burp) Function
Number of Pulses None and 1 to 6 (selection of none disables the Burp Function)
Time On/Off 0.6, 0.8, 1.0, 1.2, 1.5, 2.0, 2.5 and 3.0sec
None, 5,10,15, 20, 8F,15F,20F, 30F, 60F

Pump (Snore) Function
Time in Minutes F= Fixed delay
16 EQUIPMENT LIST
Part Number Description
143794 IPM Integrated Protection Relay 24V
121504 ITM-415 Insulation Test Module
121505 ITM-1000V Insulation Test Module
143315 RTM Remote Termination Module
–
101703 88mm Earth leakage Toroid

141548 Current Transformer 100:1 [500:5] 45mm I.D.

101272 Current Transformer 1000:1 45mm I.D.
101108 40mm M5 Screw
171010 Support Bracket
–

IPM V2 USER MANUAL
APPENDIX 1: IPM Earth Leakage Tripping Curves

Tripping Curves for Instantaneous Trip Time Setting
The graph below shows the time taken for the IPM relay to trip for a given fault current when the relay is
set to a trip time of Instantaneous, and a selection of trip levels.
300
250
200
Trip Time (ms)
25mA
150 50mA
100mA
100
200mA
50 500mA
0
100 1000
Fault Current (mA)
Tripping Curves for 25mA Trip Level Setting

–
The graph below shows the relay trip times for a 25mA trip level setting, for different trip time settings.
200
180
160
140
Trip Time (ms)
120
INST
100
50ms
80
60 100ms
–
40 150ms
20
0
100 1000
Fault Current (mA)
NOTE
Similar graphs can be obtained for 50mA, 100mA, 200mA and
500mA trip levels.

IPM V2 USER MANUAL
APPENDIX 2: IPM Full Load Current Selection Table (100:1 CT)
IPM Full Load Current Selection Table – Amps (100:1 CT)

0.5125 1.025 2.05 4.1 8.2 16.4 32.8
0.5250 1.050 2.10 4.2 8.4 16.8 33.6
0.5375 1.075 2.15 4.3 8.6 17.2 34.4
0.5500 1.100 2.20 4.4 8.8 17.6 35.2
0.5625 1.125 2.25 4.5 9.0 18.0 36.0
0.5750 1.150 2.30 4.6 9.2 18.4 36.8
0.5875 1.175 2.35 4.7 9.4 18.8 37.6
0.6000 1.200 2.40 4.8 9.6 19.2 38.4
0.6125 1.225 2.45 4.9 9.8 19.6 39.2

0.6250 1.250 2.50 5.0 10.0 20.0 40.0
0.6375 1.275 2.55 5.1 10.2 20.4 40.8
0.6500 1.300 2.60 5.2 10.4 20.8 41.6
0.6625 1.325 2.65 5.3 10.6 21.2 42.4
0.6750 1.350 2.70 5.4 10.8 21.6 43.2
0.6875 1.375 2.75 5.5 11.0 22.0 44.0
0.7000 1.400 2.80 5.6 11.2 22.4 44.8
0.7125 1.425 2.85 5.7 11.4 22.8 45.6
0.7250 1.450 2.90 5.8 11.6 23.2 46.4
–
0.7375 1.475 2.95 5.9 11.8 23.6 47.2

0.7500 1.500 3.00 6.0 12.0 24.0 48.0

0.7625 1.525 3.05 6.1 12.2 24.4 48.8
0.7750 1.550 3.10 6.2 12.4 24.8 49.6
0.7875 1.575 3.15 6.3 12.6 25.2 50.4
0.8000 1.600 3.20 6.4 12.8 25.6 51.2
0.8500 1.700 3.40 6.8 13.6 27.2 54.4
0.8750 1.750 3.50 7.0 14.0 28.0 56.0
0.9000 1.800 3.60 7.2 14.4 28.8 57.6
0.9250 1.850 3.70 7.4 14.8 29.6 59.2
0.9500 1.900 3.80 7.6 15.2 30.4 60.8
–
0.9750 1.950 3.90 7.8 15.6 31.2 62.4

1.0000 2.000 4.00 8.0 16.0 32.0 64.0

IPM V2 USER MANUAL
APPENDIX 3: IPM Full Load Current Selection Table (1000:1 CT)
IPM Full Load Current Selection Table – Amps (1000:1 CT)
5.125 10.25 20.5 41 82 164 328

5.250 10.50 21.0 42 84 168 336
5.375 10.75 21.5 43 86 172 344
5.500 11.00 22.0 44 88 176 352
5.625 11.25 22.5 45 90 180 360
5.750 11.50 23.0 46 92 184 368
5.875 11.75 23.5 47 94 188 376
6.000 12.00 24.0 48 96 192 384
6.125 12.25 24.5 49 98 196 392

6.250 12.50 25.0 50 100 200 400
6.375 12.75 25.5 51 102 204 408
6.500 13.00 26.0 52 104 208 416
6.625 13.25 26.5 53 106 212 424
6.750 13.50 27.0 54 108 216 432
6.875 13.75 27.5 55 110 220 440
7.000 14.00 28.0 56 112 224 448
7.125 14.25 28.5 57 114 228 456
7.250 14.50 29.0 58 116 232 464
–
7.375 14.75 29.5 59 118 236 472

7.500 15.00 30.0 60 120 240 480

7.625 15.25 30.5 61 122 244 488
7.750 15.50 31.0 62 124 248 496
7.875 15.75 31.5 63 126 252 504
8.000 16.00 32.0 64 128 256 512
8.250 16.50 33.0 66 132 264 528
8.500 17.00 34.0 68 136 272 544
8.750 17.50 35.0 70 140 280 560
9.000 18.00 36.0 72 144 288 576
9.250 18.50 37.0 74 148 296 592
–
9.500 19.00 38.0 76 152 304 608

9.750 19.50 39.0 78 156 312 624

10.000 20.00 40.0 80 160 320 640

IPM V2 USER MANUAL
APPENDIX 4: IPM Menu Structure

Level Menu Level - Menu Message / Sub Menu Display Default
Screen Function
1 Need IPM 1.1 Start / Status / See Trip / Status Messages;
Start Error Messages Type 1 – Latched for Display
Type 2 – Enabled & Cleared Automatically
Type 3 – Triggered by Trip Function
1.2- Event Log : (last Pwr Up, Pwr Down, MCR Close, Stopped, Ext. Stop, MC Fail, Close Fail,
1.50 50 events) ECW Trip, EC Leak Trip, EL trip, Burp Done, Burp Fail, SC Trip, OC Trip,I
L2: Event, L3: bal-Trp, RESET, Set up Mod,
Time - Event,
L4 :Present Time
2 Earth 2.1 Current / Voltage

Leakage / Overload
2.2 All Currents; E/L, % Trip Level to 100% Trip, Current Balance
E/L, IB
3 Earth 3.1 Earth Continuity When either EC Res or Earth Loop Leakage reaches 100% a trip occurs
Continuity
3.2 Insulation Test 1MW, 2MW, 5MW, 10MW, 20MW (Alarm - 1.5 x Set Value)
Level Display shows last measured value
3.3 Status Indicator
–
Remote Input
4 IPM Relays & 4.1 IPM Relay & CBR, MCR, ALM, MCI, Str, Rst, Stp
Keys Keys
4.2 IPM Dig Inputs ExtRst, ExtStp, ExtStr, Lock, Aux, A/O 4.0mA
4.3 Modbus Status [Address, Read, Wrt, Exc, CRC, Par, NE, FE]
4.4 Clock Setup [Day, Mth, Yr, Hrs, Mins & Sec] (Time Stamp – Events Log)
5 Settings: 5.1 EC Pilot Mode [Diode, RTM] –Earth Loop Resist. < 45W
Grp1-IPM
5.2 ITM Module [415v / 1000v]
5.3 Start Mode [Selects Inputs Reqd. For Start Mode]
5.4 Modbus Addr [1 -31]
–
5.5 Modbus : Baud [12000,E,N, 24000,E,N, 48000,E,N, 96000,E,N, 192000,E,N] 96000

/P
5.6 Modbus T-out 0.5, 1.0, 2.0, 5.0, None 0.5 Sec
5.7 CT Ratio 100:1 and 1000:1
6 Settings: 6.1 RTM Machine [J-bo, Fan, Dril, Pump, Hpmp, Wpmp, DCB,
Grp2-RTM Type
Bolt, HRMr, Belt, Winc, Crsh, Dplg, Spare]
6.2 RTM Mach. [ 1 to 40 ]
Num.
6.3 100% Current [5.125A – 625A] 5.125A
6.4 Short Cct.Trp [Selectable; 3.0 to 10 Times FLC] 3.0 x
6.5 Short Cct.t [20, 40, 60,80,100, 120, 160 mSec] 20

IPM V2 USER MANUAL
Level Menu Level - Menu Message / Sub Menu Display Default

Screen Function
mSec
6.6 O/L trp t @ 6x 3, 4, 5, 6, 7, 8, 10, 12, 14, 16, 20, 24, 28, 32, 40 Sec 3 Sec
6.7 O/L cool mult [1.0 to 5.0] (ie 2.5 – Fan Cooled Mtr) 1.0
6.8 O/L Rst Level [30% - 90%, A30% - A 90%] “A- Auto Reset 30%
6.9 Cur.Bal Trip [5%, 10%, 20%, 50%, off] 5%
6.10 Under I Level [32%, 40%,48%, 56%,64%, 72%, 80%, 88%, 96%, None ] 32%
6.11 Residual i Trip [10, 20, 30, 40, 50, 60, 80, 100, 120, 150, 200, 250%] 10%
6.12 Res. trip time [100mS, 1, 2, 3, 5 Sec] 100 mS
6.13 RCD Trp. Level [25, 50 , 100, 200, 500mA] 25 mA
6.14 RCD Trp. Time [50, 100, 150mSec] 50mSec
6.15 Pilot Trip t [80, 120, 160, 200, 300, 400, 500mSec] (120mSec) 80mSec
6.16 Remote Start No, Yes, No
6.17 EC Trip Latch [On / Off] For Reset – Operate Reset Button On
6.18 Ins.Tst Level 1, 2, 5, 10, 20MW, None 1.0MW
6.19 U/V Trip level [40, 50, 60, 70, 75, 80, 85, 90, 95%, Off] 40%
6.20 back emf time [2 , 5, 10, 15, 20 Sec] 2 Sec
6.21 High I alarm [100 – 600% FLC & Off] 100%
(Delay – 1s)
6.22 O/L Alarm Lev 50%, 60%, 70%, 75%, 80%, 85%, 90%, 95%, Alarm Off 50%
(Delay – 2s)
–
6.23 Under I Alarm 32%, 40%, 48%, 56%, 64%, 72%,80%, 88%, 96%, Off 32%
(Delay – 2s)
6.24 E/L Alarm Lev 10%, 20%, 30%, 40%, 50%,60%, 80%, Off 10%
(Delay – 1s)
6.25 Burp Pulses [None, 1 to 6] None
6.26 Burp On Time [0.6, 0.8, 1.0, 1.2, 1.5, 2.0. 2.5. 3.0Sec] 0.6 Sec
6.27 Burp Off Time [0.6, 0.8, 1.0, 1.2, 1.5, 2.0. 2.5. 3.0Sec] 0.6 Sec
6.28 4-20 Ma Output [O/L : 0 – 100%, lave: 0-250%, E/L: 0 -100%, MW 0- 40MW O/L
6.29 Snore Delay Off, 5, 10, 15, 20, 8F, 15F, 20F, 30F, 60F (F= Fixed Delay) Off
Type 1 EC Leak T Type 2 Type 3

–
Tripped No Volts EC Ω Trip Outlet Paused Snore-Close Aux Earth Leakage Trip RTM –Off Line Trip
MC Close Fail MC Need IPM Start High Current Alarm Earth Cont. Trip IPM Memory Error
Opened
External MC Open RTM Off L Testing Insulation Thermal Trip Alarm Insulat. Fail Trip RTM Memory Error
Burp MCI Fail Und.I.Trp Closing Main Cont. Cur. Balance Alarm Over Current Trip Stopped – IPM
Under Current Trip Stopped Burp: MCR - Closed Under Cur. Alarm Short Circuit Trip
Last Trip Message Ext.Stop Burp: MCR - Open Earth Leakage Alarm I Balance Trip
Running UnderVoltage Alarm Residual Cur. Trip
Snore Insulat.Test Alarm Main Contactor Fail

IPM V2 USER MANUAL
APPENDIX 5: IPM Modbus Address Table

Modbus Modbus
Byte Name Bit Identification Byte Name Bit Identification
Address Address
0-3 Reserved Digital Inputs
Trip Status 1 0 = Spare
0 = Earth Leakage 1 = Spare
1 = Earth Continuity Trip 2 = Lock
2 = Insulat. test trip 3 = Reset
3 = Overload Trip 4 = Aux
4 = Short Circuit Trip 5 = External Stop
5 = Current Balance Trip 7 6 = External Start
6 = Residual Current Trip Note: 7 = MCI
4 Key Bits keys_control
7 = Main Contactor Fail 0-7 clear digital_inputs
Note: Bit trips_1
when key Keys
set when trips_2
tripped Trip Status 2 pressed 0 = Stop
0 = External Stop 1 = Start
1 = RTM Offline Trip 2 = Reset
2 = IPM Memory Error 3 = Test

3 = RTM Memory Error 4 = Spare
4 = Stopped - IPM 5 = Spare
5 = Modbus Timeout 6 = Spare
6 = Modbus Stop 7 = Spare
7 = RTM CT Ratio Error 8 Reserved
Soft Trip Status Pilot Forward Resistance as a
0 = Tripped No Volts Percentage (%) of the trip
1 = MC Close Fail 9 pilot_fwd level.
2 = External MC Open Note: The IPM aims to trip at
3 = Burp MCI Fail 36Ω (100%).
4 = Under Current Pilot Forward Resistance as a
5 = OTS Test Mode Exited 10 pilot_rev Percentage (%) of the trip
6 = Spare
–
5 level (nominally 2k).

7 = Last T: Insulat. Test Result
soft_trips
Note: Bit
set when alarms 0: 0.0MΩ
tripped Alarms 1-99: 0.1MΩ - 9.9MΩ
0 = High Current Alarm 11 meg_result
100-127: Invalid Values
1 = Thermal Acc Alarm 128-255: 0MΩ - 127MΩ
2 = Current Balance (Modbus register value -128)
3 = Under Cur. Alarm Control Keys
4 = Earth Leakage Alarm 0 = Up Key
5 = Under Voltage Alarm 1 = Down Key
6 = Insulation Test Alarm 2 = Left key
7 = Spare cur_gain_Leds
3 = Right key
Relay Status 12 keys_menu_ra
4 = Enter key
0 = Outlet Paused w (in high byte)
5 = ESC Key
1 = Need IPM Start 14 = Red LED
2 = Testing Insulation 15 = Green LED
3 = Closing Main Cont.
4 = Burp: MC Closed
–
Earth Leakage Current

5 = Burp: MC Open 13 el_cur
(0…250%)
6 = Running
6 7 = Manual Insulation Test A Phase Current
14 cur_a
Note: Bit ipm_stat2_byte (0…1000%)
set when ipm_stat_byte B Phase Current
active Relay Status 2 15 cur_b
0 = Snore (0…1000%)
1 = Snore – Close Aux C Phase Current
16 cur_c (0…1000%)
2 = RTM Version Error
3 = RTM Stop Current Balance
4 = Wait on RTM Start 17 current_bal (0…100%)
5 = Config Error Residual Current
6 = OTS Test Mode 18 ir_cur_high (0…1000%)
7 = Spare
OC Thermal Accum
19 (0…120%)
A Phase Voltage
20 volts_a
(0…120%)
IPM V2 USER MANUAL
Modbus Modbus
Address Address
B Phase Voltage Machine Type
21 volts_b
(0…120%) 0=----
C Phase Voltage 1 = J-bo - Jumbo
22 volts_c
(0…120%) 2 = Fan
Phase Voltage Average 3 = Drill
23 volts_average 4 = Pump
(BCD format)
Current Average 5 = Hpmp - Hydraulic Pump
24 current_ave
(0…250%) 45 machine_type
6 = Wpmp - Water Pump
25-29 7 = DCB
Reserved
8 = Bolt - Bolter
Serial Number High
30 serial_high 9 = HRMr - Hard Rock Miner
Top 16 bit of serial number
10 = Belt
Serial Number Low
31 Serial_low 11 = Winc - Winch
Lower 16 bit of serial number
12 = Crush - Crusher
IPM Software Version – 13 = DPlug – Dummy Plug
where 14 = Spare
32 mia_sw_ver
x = Top 3 bits (Hardware Ver.)
Machine Number
y = Bot 5 bits (Software Ver.) 0 = Invalid Data
33 sub_second Time Sub – Second 46 machine_num
1 …. 40
34 second Time – Second
35 minute Time – Minute FLC Setting (See OC
36 hour Time – Hour section)
Date 1..32 = 5.125..10.000A
37 date
eg. 1 = 1st, 15 = 15th 33..64 = 10.25..20.00A
Month cur_range_para
38 month 47 65..96 = 20.5..40.0A
eg. 1 = Jan, 6 = Jun m
97..128 = 41..80A
39 year Year (two digits only) 129..160 = 82..160A
Day 161..192 = 164..320A
40 day eg. 0 = Sunday, 193..224 = 328..640A
1 = Monday SC Trip Level (xFLC)
–
EC Pilot Mode 0 = Invalid Data

0 = Invalid Data
41 pilot_mode 1 = 3x
1 = RTM 2 = 3.5x
2 = Diode 3 = 4x
ITM Module 4 = 4.5x
0 = Invalid Data 5 = 5x
42 param_itm 1 = 415V 6 = 5.5x
short_cct_para
2 = 1000V 48 7 = 6x
m
3 = None 8 = 6.5x
Modbus Address 9 = 7x
43 param_mb_adr 0 = Invalid Data 10 = 7.5x
1……31 11 = 8x
Modbus Baud Rate 12 = 8.5x
0 = Invalid Data 13 = 9x
1 = 1200 Even Parity 14 = 9.5x
2 = 1200 Odd Parity 15 = 10x
3 = 1200 No Parity SC Trip Time
–
4 = 2400 Even Parity 0 = Invalid Data

5 = 2400 Odd Parity 1 = 20 ms

6 = 2400 No Parity 2 = 40 ms
param_mb_bau sc_trp_tm_para
44 7 = 4800 Even Parity 49 3 = 60 ms
d m
8 = 4800 Odd Parity 4 = 80 ms
9 = 4800 No Parity 5 = 100 ms
10 = 9600 Even Parity 6 = 120 ms
11 = 9600 Odd Parity 7 = 160 ms
12 = 9600 No Parity
13 = 19200 Even Parity
14 = 19200 Odd Parity
15 = 19200 No Parity

IPM V2 USER MANUAL
Modbus Modbus
Address Address
O/L Trip Time @ 6x FLC Ires Trip Level (%FLC)
0 = Invalid Data 0 = Invalid Data
1 = 3s 1 = 10%
2 = 4s 2 = 20%
3 = 5s 3 = 30%
4 = 6s 4 = 40%
5 = 7s 5 = 50%
6 = 8s 55 rc_lev_param 6 = 60%
time_mul_para
50 7 = 10s 7 = 80%
m
8 = 12s 8 = 100%
9 = 14s 9 = 120%
10 = 16s 10 = 150%
11 = 20s 11 = 200%
12 = 24s 12 = 250%
13 = 28s 13 = OFF
14 = 32s Ires Trip Time
15 = 40s 0 = Invalid Data

S-Cool Ratio 1 = 100ms
0 = Invalid Data 2 = 200ms
1 = 1.0 56 rc_tim_param 3 = 500ms
2 = 1.5 4 = 1 Sec
cool_mul_para
51 3 = 2.0 5 = 2 Sec
m
4 = 2.5 6 = 3 Sec
5 = 3.0 7 = 5 Sec
6 = 4.0 RCD Trip Level
7 = 5.0 0 = Invalid Data
O/L Reset Level 1 = 25mA
0 = Invalid Data 2 = 50mA
57 el_sens
1 = 30% 3 = 100mA
2 = 40% 4 = 200mA
–
3 = 50% 5 = 500mA
4 = 60% 6= OFF
5 = 70% RCD Trip Time

6 = 80% 0 = Invalid Data
52 ol_rst_param
7 = 90% 1 = Ins. (Instantaneous)
58 el_time
8 = A-30% 2 = 50ms
9 = A-40% 3 = 100ms
10 = A-50% 4 = 150ms
11 = A-60% Pilot Trip Time
12 = A-70% 0 = Invalid Data
13 = A-80% 1 = 80ms
14 = A-90% 2 = 120ms
Current Balance Trip 59 ectime_adj 3 = 160ms
0 = Invalid Data 4 = 200ms
1 = 5% 5 = 300ms
53 cur_bal_param 2 = 10% 6 = 400ms
3 = 20% 7 = 500ms
–
4 = 50% Remote Start

5 = OFF 0 = Invalid Data

Under I Trip 60 remote_control 1 = No
0 = Invalid Data 2 = Yes
1 = 32% 3 = Aux
2 = 40% Pilot Latch
4 = 56% 61 pilot_latch
54 p_und_cur 1 = On
5 = 64% 2 = OFF
6 = 72% Meg Level
8 = 88% 1 = 1.0M
9 = 96% 2 = 2.0M
10 = OFF 62 meg_level
3 = 5.0M
4 = 10M
5 = 20M
6 = None

IPM V2 USER MANUAL
Modbus Modbus
Address Address
Under Voltage Trip Level Earth Leakage Alarm
1 = 40% 1 = 10%
2 = 50% 2 = 20%
3 = 60% 3 = 30%
68 ec_alm_param
4 = 70% 4 = 40%
63 uv_lev_param
5 = 75% 5 = 50%
6 = 80% 6 = 60%
7 = 85% 7 = 80%
8 = 90% 8 = OFF
9 = 95% Number of Burp Pulses
10 = OFF 0 = Invalid Data
Back EMF Time 1 = None
0 = Invalid Data 2=1
1 = 2 Sec 69 p_burp_num 3=2
64 b_emf_time 2 = 5 Sec 4=3
3 = 10 Sec 5=4
4 = 15 Sec 6=5
5 = 20 Sec 7=6
High Current Alarm Burp On Time
1 = 100% 1 = 0.6 S
2 = 108% 2 = 0.8 S
3 = 120% 3 = 1.0 S
70 p_burp_on
4 = 140% 4 = 1.2 S
5 = 160% 5 = 1.5 S
6 = 200% 6 = 2.0 S
65 hc_alm_param
7 = 240% 7 = 2.5 S
8 = 280% 8 = 3.0 S
9 = 320% Burp Off Time
–

11 = 400%
1 = 0.6 S
12 = 500% 2 = 0.8 S
13 = 600% 3 = 1.0 S
71 p_burp_off
14 = OFF 4 = 1.2 S
O/L Alarm Level 5 = 1.5 S
0 = Invalid Data 6 = 2.0 S
1 = 50% 7 = 2.5 S
2 = 60% 8 = 3.0 S
3 = 70% 4-20mA Output
66 ta_alm_param 4 = 75% 0 = Invalid Data
5 = 80% 1 = O/L
72 p_4_20_op
6 = 85% 2 = Iave
7 = 90% 3 = lel
8 = 95% 4 = MΩ
9 = OFF 73-74 Reserved
Under Current Alarm Snore Delay
–

1 = 32% 1 = OFF
2 = 40% 2=5
3 = 48% 3 = 10
4 = 56% 4 = 15
67 uc_alm_param 75 _snoreIndex
5 = 64% 5 = 20
6 = 72% 6 = 8F
7 = 80% 7 = 15F
8 = 88% 8 = 20F
9 = 96% 9 = 30F
10 = Off 10 = 60F
RCD Reset Lock
0 = Invalid Data
76 RCD_rst_lock
1 = OFF
2 = ON
77-78 Reserved

IPM V2 USER MANUAL
APPENDIX 6: Drawings
The drawings listed in the below table appear in Section 6 in the same order.
Drawing No. Description
IPM2E002 Connection Diagram
IPM2A013 IPM2 Integrated Protection Relay Display Map
IPM2E008 Motor Overload & Short Circuit Trip Times
IPM2A017 IPM2 S/S Fascia Case Dimension Detail
IPM2A001 IPM Relay Backplane Connection Details
IPM2A002 IPM 415V ITM Dimension & Marking Details
IPM2A003 IPM 1kV ITM Dimension & Marking Details
IPM2A005 IPM RTM Remote Termination Module Dimension & Marking Details
IPM2A018 IPM Relay Current TXF Profiles
–
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IPM V2 USER MANUAL
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IPM V2

INTEGRATED PROTECTION RELAY

Revision: 16, MARCH 2020

CAUTION! The caution symbol highlights a potential risk of damage to

The enviro (environmental) symbol highlights areas which may have an

impact on the surrounding fauna and/or flora.

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Before You Begin

Ampcontrol Contact Details

7 Billbrooke Close, Cameron Park, NSW, 2285

P +61 1300 267 373 | F +61 2 4903 4888

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3.2 Accessories ............................................................................................. 14

5.2 Earth Continuity ....................................................................................... 28

5.3 Insulation test .......................................................................................... 28

6 EARTH PROTECTION FUNCTIONS .............................................................. 30

7.5 Undercurrent Trip..................................................................................... 39

11 PUMP SNORE FUNCTION ........................................................................... 43

12.5 Remote IPM Control .............................................................................. 50

12.6 System Control ...................................................................................... 53

14.1 Equipment Service ................................................................................. 61

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Figure 4.6: IPM Connection Block Diagram.................................................................................20

Figure 4.15: IPM Relay Electrical Connections: Power Supply ....................................................27

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1 SAFETY AND OTHER WARNINGS

1.1 Safe Use of Equipment

1.1.1 Changes to Equipment

1.1.2 Equipment Knowledge

1.1.3 Manual Handling

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2 RECEIVING AND STORAGE

2.3 Storage after Delivery

moisture and sunlight.

2.4 Unpacking of Equipment

The disposal of packaging materials, replaced parts, or components

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remote control (starting) of the IPM output.

Figure 3.1: IPM Integrated Protection Relay

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Pilot MCR Output Relay 1

MCR Output Relay 2

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3.1.1 Earth Leakage Protection

3.1.2 Earth Continuity Protection

3.1.3 Insulation Testing

3.1.4 Frozen / Failed Contactor Protection

3.1.5 Overcurrent / Overload Protection

3.1.6 Short Circuit Protection

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3.1.7 Pump Snore Function

3.1.8 Fan Burp Function

contactor controlling a ventilation fan, several times at start-up.

3.2.1 Insulation Test Module (ITM)

The IPM is connected to the outlet’s phase conductors via a high

3.2.2 Phase Current Figure 3.3: Insulation

3.2.3 Earth Leakage Toroid

Figure 3.5: Earth