Ampcontrol IPM V2 Operation & User’s Manual

Designed and manufactured in Australia by Ampcontrol Pty Ltd IPM V2 INTEGRATED PROTECTION RELAY User Manual

IPM V2 USER MANUAL IPM2B003 Revision 15 – MAY/18 Uncontrolled Copy - Refer to Ampcontrol Website for Latest Version Page 2 of 83 APPROVED FOR EXTERNAL DISTRIBUTION – PROPERTY OF AMPCONTROL PTY LTD – NOT TO BE REPRODUCED IN PART WARNING! The warning symbol highlights a potential risk of injury or death. Please share these warnings with other operators. CAUTION! The caution symbol highlights a potential risk of damage to equipment. Please share these cautions with other operators. NOTE The note symbol highlights key information. Please share these notes with other operators. ENVIRO The enviro (environmental) symbol highlights areas which may have an impact on the surrounding fauna and/or flora.

IPM V2 USER MANUAL IPM2B003 Revision 15 – MAY/18 Uncontrolled Copy - Refer to Ampcontrol Website for Latest Version Page 3 of 83 APPROVED FOR EXTERNAL DISTRIBUTION – PROPERTY OF AMPCONTROL PTY LTD – NOT TO BE REPRODUCED IN PART Copyright Notice The Ampcontrol relay described in this document is the property of AMPCONTROL PTY LTD. It is furnished under a license agreement and is to be used only in accordance with the terms of the agreement. No part of the hardware or documentation may be reproduced, transmitted, transcribed, stored in a retrieval system, or translated into any language or computer language, in any form or by any means, without prior written permission of AMPCONTROL PTY LTD. Disclaimer While every effort has been made to assure the accuracy and clarity of this document, AMPCONTROL PTY LTD assumes no liability resulting from any omissions in this document, or from misuse of the information obtained herein. The information in this document has been carefully checked and is believed to be entirely reliable with all of the necessary information included. AMPCONTROL PTY LTD reserves the right to make changes to any products described herein to improve reliability, function, or design, and reserves the right to revise this document and make changes from time to time in content hereof with no obligation to notify any persons of revisions or changes. AMPCONTROL PTY LTD does not assume any liability arising out of the application or any use of any product or circuit described herein; neither does it convey license under its patent rights or the rights of others. Before You Begin Thank you for purchasing the Ampcontrol IPM V2 Integrated Protection Relay. WARNING! In the interests of safety and correct equipment operation, please take the time to read and understand the content in this manual. Ampcontrol Contact Details 7 Billbrooke Close, Cameron Park, NSW, 2285 P +61 1300 267 373 | F +61 2 4903 4888 EMAIL: [email protected] WEB: ampcontrolgroup.com

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

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

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

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

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

IPM V2 USER MANUAL IPM2B003 Revision 15 – MAY/18 Uncontrolled Copy - Refer to Ampcontrol Website for Latest Version Page 9 of 83 APPROVED FOR EXTERNAL DISTRIBUTION – PROPERTY OF AMPCONTROL PTY LTD – NOT TO BE REPRODUCED IN PART 1 SAFETY AND OTHER WARNINGS For safety reasons, the relay must be installed, operated and serviced only by competent personnel. Please read and understand this instruction manual completely before installing, operating or servicing this equipment. Failure to install or operate this instrument in accordance with the instructions contained in this manual may create hazardous operating conditions. 1.1 Safe Use of Equipment The equipment supplied has been designed and manufactured to ensure safe operation. The equipment must only be used within the design parameters. The instructions within this manual must be observed as an aid towards achieving the safest possible installation. Persons responsible for installation, maintenance, or operation, must observe the following instructions: 1.1.1 Changes to Equipment Changes in the design and modifications to the equipment are not permitted. Unauthorised changes made to the hardware or operating firmware will void the manufacturer's warranty, and may compromise the integrity of the system into which it is installed and other connected equipment. 1.1.2 Equipment Knowledge Experience with, or understanding of, this equipment is essential for the safe installation and removal of the equipment. Therefore, please read and understand this manual prior to use. Competency based training courses are recommended and are available on request. 1.1.3 Manual Handling Precautions have been taken to ensure all equipment is safe to handle and free from sharp edges. However, care should always be taken when handling enclosures and gloves should be worn. 1.1.4 Installation Correct operation and safety depend on the relay and associated equipment being installed correctly. Mechanical and or electrical installation and maintenance of plant and equipment must only be carried out by appropriately qualified personnel and must be tested thoroughly prior to operation. 1.1.5 Operation As safety depends on the relay functioning correctly it is highly recommended that all safety functions of the relay be periodically tested to ensure correct operation.

IPM V2 USER MANUAL IPM2B003 Revision 15 – MAY/18 Uncontrolled Copy - Refer to Ampcontrol Website for Latest Version Page 10 of 83 APPROVED FOR EXTERNAL DISTRIBUTION – PROPERTY OF AMPCONTROL PTY LTD – NOT TO BE REPRODUCED IN PART 2 RECEIVING AND STORAGE 2.1 Receiving All possible precautions are taken to protect the equipment against damage or losses during shipment, however before accepting delivery, check all items against the packing list or bill of loading. If there is evidence of physical damage, notify Ampcontrol immediately. Notify Ampcontrol immediately in case of any discrepancies to the packing list. Keep a record of any claims and correspondence. Photographs are recommended. Where practicable do not remove protective covers prior to installation unless there are indications of damage. Boxes opened for inspection and inventory should be carefully repacked to ensure protection of the contents or else the parts should be packaged and stored in a safe place. Examine all packing boxes, wrappings and covers for items attached to them, retain and store any approval documentation for your safety file as applicable prior to wrapping being discarded. 2.2 Inspection Equipment that is found to be damaged or has been modified away from its published specification must not be used. Please contact Ampcontrol if the equipment is suspected to be different than that ordered or if it does not match the published specifications. 2.3 Storage after Delivery When the equipment is not to be installed immediately, proper storage is important to ensure protection of equipment and validity of warranty. All equipment should be stored indoors between 0-40˚C, preferably on shelves and protected from moisture and sunlight. 2.4 Unpacking of Equipment The method of packing used will depend on the size and quantity of the equipment. The following cautions should be interpreted as appropriate. CAUTION! Take care when unpacking crates as the contents may have shifted during transport. ENVIRO The disposal of packaging materials, replaced parts, or components must comply with environmental restrictions without polluting the soil, air or water. Ensure that any timber and cardboard used as packaging is disposed of in a safe and environmentally responsible manner. Where possible, dispose of all waste products i.e. oils, metals, plastic and rubber products by using an approved recycling service centre.

IPM V2 USER MANUAL IPM2B003 Revision 15 – MAY/18 Uncontrolled Copy - Refer to Ampcontrol Website for Latest Version Page 11 of 83 APPROVED FOR EXTERNAL DISTRIBUTION – PROPERTY OF AMPCONTROL PTY LTD – NOT TO BE REPRODUCED IN PART 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 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. Figure 3.1: IPM Integrated Protection Relay

IPM V2 USER MANUAL IPM2B003 Revision 15 – MAY/18 Uncontrolled Copy - Refer to Ampcontrol Website for Latest Version Page 12 of 83 APPROVED FOR EXTERNAL DISTRIBUTION – PROPERTY OF AMPCONTROL PTY LTD – NOT TO BE REPRODUCED IN PART 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. Figure 3.2: IPM Block Diagram M RS485 Comms Device RTM (Optional) 4-20mA Analogue Receiver Phase CT Phase CT EL Toroid External Communications Device (e.g. PLC) Pilot Diode (Alternative) To Outlet Contactor Pilot Termination CBR Output Relay MCR Output Relay 1 Phase CT ITM IPM Relay Alarm Output Relay MCR Output Relay 2 External Digital Inputs 24V AC/DC Power Supply

IPM V2 USER MANUAL IPM2B003 Revision 15 – MAY/18 Uncontrolled Copy - Refer to Ampcontrol Website for Latest Version Page 13 of 83 APPROVED FOR EXTERNAL DISTRIBUTION – PROPERTY OF AMPCONTROL PTY LTD – NOT TO BE REPRODUCED IN PART 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 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 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 IPM2B003 Revision 15 – MAY/18 Uncontrolled Copy - Refer to Ampcontrol Website for Latest Version Page 14 of 83 APPROVED FOR EXTERNAL DISTRIBUTION – PROPERTY OF AMPCONTROL PTY LTD – NOT TO BE REPRODUCED IN PART 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. 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. 3.2.2 Phase Current Transformers (CTs) 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 Figure 3.3: Insulation Test Module

IPM V2 USER MANUAL IPM2B003 Revision 15 – MAY/18 Uncontrolled Copy - Refer to Ampcontrol Website for Latest Version Page 15 of 83 APPROVED FOR EXTERNAL DISTRIBUTION – PROPERTY OF AMPCONTROL PTY LTD – NOT TO BE REPRODUCED IN PART 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. 3.2.4 Remote Termination 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 start input. Figure 3.5: Earth Leakage Toroid Figure 3.6: Remote Termination Module

IPM V2 USER MANUAL IPM2B003 Revision 15 – MAY/18 Uncontrolled Copy - Refer to Ampcontrol Website for Latest Version Page 16 of 83 APPROVED FOR EXTERNAL DISTRIBUTION – PROPERTY OF AMPCONTROL PTY LTD – NOT TO BE REPRODUCED IN PART 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 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 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 IPM2B003 Revision 15 – MAY/18 Uncontrolled Copy - Refer to Ampcontrol Website for Latest Version Page 17 of 83 APPROVED FOR EXTERNAL DISTRIBUTION – PROPERTY OF AMPCONTROL PTY LTD – NOT TO BE REPRODUCED IN PART 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. Figure 4.1: IPM Relay Dimensions

IPM V2 USER MANUAL IPM2B003 Revision 15 – MAY/18 Uncontrolled Copy - Refer to Ampcontrol Website for Latest Version Page 18 of 83 APPROVED FOR EXTERNAL DISTRIBUTION – PROPERTY OF AMPCONTROL PTY LTD – NOT TO BE REPRODUCED IN PART 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 leakage current of the outlet. These current transformers are panel mounted. Figure 4.3: Current Transformer 45mm I.D. (Part: 101272) Dimensional Details 132 132

IPM V2 USER MANUAL IPM2B003 Revision 15 – MAY/18 Uncontrolled Copy - Refer to Ampcontrol Website for Latest Version Page 19 of 83 APPROVED FOR EXTERNAL DISTRIBUTION – PROPERTY OF AMPCONTROL PTY LTD – NOT TO BE REPRODUCED IN PART Figure 4.4: Current Transformer 88mm I.D. (Part: 101703) Dimensional Details 4.3.3 Remote Termination Module (RTM) Figure 4.5: RTM Dimensions

IPM V2 USER MANUAL IPM2B003 Revision 15 – MAY/18 Uncontrolled Copy - Refer to Ampcontrol Website for Latest Version Page 20 of 83 APPROVED FOR EXTERNAL DISTRIBUTION – PROPERTY OF AMPCONTROL PTY LTD – NOT TO BE REPRODUCED IN PART 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. Figure 4.6: IPM Connection Block Diagram M RS485 Comms Device RTM (Optional) 4-20mA Analogue Receiver Phase CT Phase CT EL Toroid External Communications Device (e.g. PLC) Pilot Diode (Alternative) To Outlet Contactor Pilot Termination CBR Output Relay MCR Output Relay 1 Phase CT ITM IPM Relay Alarm Output Relay MCR Output Relay 2 External Digital Inputs 24V AC/DC Power Supply

IPM V2 USER MANUAL IPM2B003 Revision 15 – MAY/18 Uncontrolled Copy - Refer to Ampcontrol Website for Latest Version Page 21 of 83 APPROVED FOR EXTERNAL DISTRIBUTION – PROPERTY OF AMPCONTROL PTY LTD – NOT TO BE REPRODUCED IN PART 4.4.1 Digital Inputs (Terminals 1, 2, 3, 4, 5, 6, 7 & 8) 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 Relay Reset 3 Aux 4 5 Ex-Stop Lock 2 +Di 1 6 Ex-Start 7 MCI 8 DI Screen* Note*: Required in areas of high electrical interference Digital input reference power supply Locked pushbutton or contact input Reset pushbutton or contact input (optional) Auxiliary pushbutton or contact input (optional) External stop pushbutton or contact input (optional) Main Contactor auxiliary contact input (for Frozen Contactor Protection) External start pushbutton or contact input (optional)

IPM V2 USER MANUAL IPM2B003 Revision 15 – MAY/18 Uncontrolled Copy - Refer to Ampcontrol Website for Latest Version Page 22 of 83 APPROVED FOR EXTERNAL DISTRIBUTION – PROPERTY OF AMPCONTROL PTY LTD – NOT TO BE REPRODUCED IN PART 4.4.2 Phase Current Transformers (Terminals 9, 10, 11 & 12) 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. A B C Phase Conductors Current TXF 1000/1 or 500/5 Current TXF 1000/1 or 500/5 IPM Relay CT-B 10 CT-A 9 S1 S2 P1 P2 S1 S2 P1 P2 CT-C Current TXF 1000/1 or 500/5 11 12 S1 S2 P1 P2 Internally Earthed CT-COM

IPM V2 USER MANUAL IPM2B003 Revision 15 – MAY/18 Uncontrolled Copy - Refer to Ampcontrol Website for Latest Version Page 23 of 83 APPROVED FOR EXTERNAL DISTRIBUTION – PROPERTY OF AMPCONTROL PTY LTD – NOT TO BE REPRODUCED IN PART 4.4.3 Earth Leakage Toroid (Terminals 13 & 14) 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 Relay 14 13 A B C Phase Conductors AC Control Supply EL Test P/B Test Resistor Optional EL Test Circuit 1000:1 CT 88mm I.D. CTcom Internally Earthed CT-EL

IPM V2 USER MANUAL IPM2B003 Revision 15 – MAY/18 Uncontrolled Copy - Refer to Ampcontrol Website for Latest Version Page 24 of 83 APPROVED FOR EXTERNAL DISTRIBUTION – PROPERTY OF AMPCONTROL PTY LTD – NOT TO BE REPRODUCED IN PART 4.4.4 Earth Continuity (Terminal 15) 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 Relay PILOT 15 EARTH A B C Phase Conductors EC Test P/B RTM PILOT EARTH INPUT* M Trailing Cable Supply Enclosure Motor Enclosure Emergency Stop Start Note*: Input is ignored if IPM Remote Start is set to ‘NO’ Emergency Stop Pilot Earth Not available in Diode Mode Local Control: Remote Control: IPM Diode Mode Pilot Connections Stop Remote Start Selector

IPM V2 USER MANUAL IPM2B003 Revision 15 – MAY/18 Uncontrolled Copy - Refer to Ampcontrol Website for Latest Version Page 25 of 83 APPROVED FOR EXTERNAL DISTRIBUTION – PROPERTY OF AMPCONTROL PTY LTD – NOT TO BE REPRODUCED IN PART 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) 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) 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 Relay Va 20 Vb 21 22 Vc A B C Phase Conductors From Contactor ITM Vcma Vcmb Vcmc Va Vb Vc Flying Leads 0V 19 Vtest 18 Earth VTEST IPM Relay 23 RS485+ 24 RS485- 25 RS485 Common To RS485 Capable External Communications Device (e.g. PLC)

IPM V2 USER MANUAL IPM2B003 Revision 15 – MAY/18 Uncontrolled Copy - Refer to Ampcontrol Website for Latest Version Page 26 of 83 APPROVED FOR EXTERNAL DISTRIBUTION – PROPERTY OF AMPCONTROL PTY LTD – NOT TO BE REPRODUCED IN PART 4.4.9 Analogue Output (Terminals 27 & 28) 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) 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. External 4-20mA Receiver IPM Relay 27 Analogue Output + 28 Analogue Output - 4-20mA 7.5Vmin to 36Vmax RL IPM Relay MCR-2 N/O 31 MCR-2 COM 32 33 MCR-2 N/C MCR-1 N/O 30 MCR-1 COM 29 34 ALM COM 35 ALM N/O 36 CBR COM 37 CBR N/C 38 CBR N/O Main Contactor Relay (MCR) The MCR output has two poles, one is a changeover contact and the other is a normally open contact. Either of these contacts can be used to trip the main contactor for the outlet. The other MCR contact can then be used as an indication output. Alarm Relay (ALM) The ALM output is a normally open contact. Function is programmable. Circuit Breaker Relay (CBR) The CBR output is a changeover contact. The CBR output is intended to initiate a back-trip to an upstream circuit breaker via a shunt or undervoltage coil.

IPM V2 USER MANUAL IPM2B003 Revision 15 – MAY/18 Uncontrolled Copy - Refer to Ampcontrol Website for Latest Version Page 27 of 83 APPROVED FOR EXTERNAL DISTRIBUTION – PROPERTY OF AMPCONTROL PTY LTD – NOT TO BE REPRODUCED IN PART 4.4.11 Power Supply (Terminals 39 & 40) 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 Relay 39 IPM Pwr+ 40 IPM Pwr- 24VDC or 24VAC Supply

IPM V2 USER MANUAL IPM2B003 Revision 15 – MAY/18 Uncontrolled Copy - Refer to Ampcontrol Website for Latest Version Page 28 of 83 APPROVED FOR EXTERNAL DISTRIBUTION – PROPERTY OF AMPCONTROL PTY LTD – NOT TO BE REPRODUCED IN PART 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 IPM2B003 Revision 15 – MAY/18 Uncontrolled Copy - Refer to Ampcontrol Website for Latest Version Page 29 of 83 APPROVED FOR EXTERNAL DISTRIBUTION – PROPERTY OF AMPCONTROL PTY LTD – NOT TO BE REPRODUCED IN PART 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 IPM2B003 Revision 15 – MAY/18 Uncontrolled Copy - Refer to Ampcontrol Website for Latest Version Page 30 of 83 APPROVED FOR EXTERNAL DISTRIBUTION – PROPERTY OF AMPCONTROL PTY LTD – NOT TO BE REPRODUCED IN PART 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 IPM2B003 Revision 15 – MAY/18 Uncontrolled Copy - Refer to Ampcontrol Website for Latest Version Page 31 of 83 APPROVED FOR EXTERNAL DISTRIBUTION – PROPERTY OF AMPCONTROL PTY LTD – NOT TO BE REPRODUCED IN PART 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. 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. 0 50 100 150 200 250 300 100 1000 Trip Time (ms) Fault Current (mA) 25mA 50mA 100mA 200mA 500mA

IPM V2 USER MANUAL IPM2B003 Revision 15 – MAY/18 Uncontrolled Copy - Refer to Ampcontrol Website for Latest Version Page 32 of 83 APPROVED FOR EXTERNAL DISTRIBUTION – PROPERTY OF AMPCONTROL PTY LTD – NOT TO BE REPRODUCED IN PART 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 Relay Va 20 Vb 21 22 Vc A B C Phase Conductors From Contactor ITM Vcma Vcmb Vcmc Va Vb Vc Flying Leads 0V 19 Vtest 18 Earth VTEST

IPM V2 USER MANUAL IPM2B003 Revision 15 – MAY/18 Uncontrolled Copy - Refer to Ampcontrol Website for Latest Version Page 33 of 83 APPROVED FOR EXTERNAL DISTRIBUTION – PROPERTY OF AMPCONTROL PTY LTD – NOT TO BE REPRODUCED IN PART 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 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 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 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 IPM2B003 Revision 15 – MAY/18 Uncontrolled Copy - Refer to Ampcontrol Website for Latest Version Page 34 of 83 APPROVED FOR EXTERNAL DISTRIBUTION – PROPERTY OF AMPCONTROL PTY LTD – NOT TO BE REPRODUCED IN PART 6.3 Earth Continuity 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 Relay PILOT 15 EARTH A B C Phase Conductors EC Test P/B RTM PILOT EARTH INPUT* M Trailing Cable Supply Enclosure Motor Enclosure Emergency Stop Start Note*: Input is ignored if IPM Remote Start is set to ‘NO’ Emergency Stop Pilot Earth Not available in Diode Mode Local Control: Remote Control: IPM Diode Mode Pilot Connections Stop Remote Start Selector

IPM V2 USER MANUAL IPM2B003 Revision 15 – MAY/18 Uncontrolled Copy - Refer to Ampcontrol Website for Latest Version Page 35 of 83 APPROVED FOR EXTERNAL DISTRIBUTION – PROPERTY OF AMPCONTROL PTY LTD – NOT TO BE REPRODUCED IN PART 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 IPM2B003 Revision 15 – MAY/18 Uncontrolled Copy - Refer to Ampcontrol Website for Latest Version Page 36 of 83 APPROVED FOR EXTERNAL DISTRIBUTION – PROPERTY OF AMPCONTROL PTY LTD – NOT TO BE REPRODUCED IN PART 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 Figure 7.1: IPM Phase CT Connections A B C Phase Conductors Current TXF 1000/1 or 500/5 Current TXF 1000/1 or 500/5 IPM Relay CT-B 10 CT-A 9 S1 S2 P1 P2 S1 S2 P1 P2 CT-C Current TXF 1000/1 or 500/5 11 12 S1 S2 P1 P2 Internally Earthed CT-COM

IPM V2 USER MANUAL IPM2B003 Revision 15 – MAY/18 Uncontrolled Copy - Refer to Ampcontrol Website for Latest Version Page 37 of 83 APPROVED FOR EXTERNAL DISTRIBUTION – PROPERTY OF AMPCONTROL PTY LTD – NOT TO BE REPRODUCED IN PART 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: 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.               1238 .1 100 1238 % .1 .53 ln 31 2 2 I A I C x Time Trip

IPM V2 USER MANUAL IPM2B003 Revision 15 – MAY/18 Uncontrolled Copy - Refer to Ampcontrol Website for Latest Version Page 38 of 83 APPROVED FOR EXTERNAL DISTRIBUTION – PROPERTY OF AMPCONTROL PTY LTD – NOT TO BE REPRODUCED IN PART 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: 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 IPM2B003 Revision 15 – MAY/18 Uncontrolled Copy - Refer to Ampcontrol Website for Latest Version Page 39 of 83 APPROVED FOR EXTERNAL DISTRIBUTION – PROPERTY OF AMPCONTROL PTY LTD – NOT TO BE REPRODUCED IN PART 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 IPM2B003 Revision 15 – MAY/18 Uncontrolled Copy - Refer to Ampcontrol Website for Latest Version Page 40 of 83 APPROVED FOR EXTERNAL DISTRIBUTION – PROPERTY OF AMPCONTROL PTY LTD – NOT TO BE REPRODUCED IN PART 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 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 Relay Va 20 Vb 21 22 Vc A B C Phase Conductors From Contactor ITM Vcma Vcmb Vcmc Va Vb Vc Flying Leads 0V 19 Vtest 18 Earth VTEST

IPM V2 USER MANUAL IPM2B003 Revision 15 – MAY/18 Uncontrolled Copy - Refer to Ampcontrol Website for Latest Version Page 41 of 83 APPROVED FOR EXTERNAL DISTRIBUTION – PROPERTY OF AMPCONTROL PTY LTD – NOT TO BE REPRODUCED IN PART 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 IPM2B003 Revision 15 – MAY/18 Uncontrolled Copy - Refer to Ampcontrol Website for Latest Version Page 42 of 83 APPROVED FOR EXTERNAL DISTRIBUTION – PROPERTY OF AMPCONTROL PTY LTD – NOT TO BE REPRODUCED IN PART 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 IPM2B003 Revision 15 – MAY/18 Uncontrolled Copy - Refer to Ampcontrol Website for Latest Version Page 43 of 83 APPROVED FOR EXTERNAL DISTRIBUTION – PROPERTY OF AMPCONTROL PTY LTD – NOT TO BE REPRODUCED IN PART 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 IPM2B003 Revision 15 – MAY/18 Uncontrolled Copy - Refer to Ampcontrol Website for Latest Version Page 44 of 83 APPROVED FOR EXTERNAL DISTRIBUTION – PROPERTY OF AMPCONTROL PTY LTD – NOT TO BE REPRODUCED IN PART 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 IPM2B003 Revision 15 – MAY/18 Uncontrolled Copy - Refer to Ampcontrol Website for Latest Version Page 45 of 83 APPROVED FOR EXTERNAL DISTRIBUTION – PROPERTY OF AMPCONTROL PTY LTD – NOT TO BE REPRODUCED IN PART 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 IPM2B003 Revision 15 – MAY/18 Uncontrolled Copy - Refer to Ampcontrol Website for Latest Version Page 46 of 83 APPROVED FOR EXTERNAL DISTRIBUTION – PROPERTY OF AMPCONTROL PTY LTD – NOT TO BE REPRODUCED IN PART 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 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 IPM2B003 Revision 15 – MAY/18 Uncontrolled Copy - Refer to Ampcontrol Website for Latest Version Page 47 of 83 APPROVED FOR EXTERNAL DISTRIBUTION – PROPERTY OF AMPCONTROL PTY LTD – NOT TO BE REPRODUCED IN PART Message and Type Comment 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 Need RTM Start 2 Shown when the digital input is closed but the IPM is 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 Note 1) 3 Corrupted memory in relay‟s stored settings

IPM V2 USER MANUAL IPM2B003 Revision 15 – MAY/18 Uncontrolled Copy - Refer to Ampcontrol Website for Latest Version Page 48 of 83 APPROVED FOR EXTERNAL DISTRIBUTION – PROPERTY OF AMPCONTROL PTY LTD – NOT TO BE REPRODUCED IN PART Message and Type Comment RTM Memory Error (see Note 1) 3 IPM detected errors in set up data received from RTM Stopped - IPM 3 IPM Stop digital input activated (closed) RTM CT Ratio Error (see Note 2) 3 The attached RTM was set up using a different CT ratio than that of the IPM in use RTM Version Error 3 The attached RTM does not support 100:1 CT operation Remote Stop 3 Shown whenever RTM‟s digital input is open Configuration Error 2 Present when: Start is set to Modbus. 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). NOTE 1. It is normal to see the IPM Memory Error Message when 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 Message and Type Comment EC Leak T E/C Leakage Trip that provides additional information for E/C Trip EC Ω Trip E/C Ohms Trip that provides additional information for E/C Trip MC Opened Main contactor opened – opening not initiated by the IPM Relay

IPM V2 USER MANUAL IPM2B003 Revision 15 – MAY/18 Uncontrolled Copy - Refer to Ampcontrol Website for Latest Version Page 49 of 83 APPROVED FOR EXTERNAL DISTRIBUTION – PROPERTY OF AMPCONTROL PTY LTD – NOT TO BE REPRODUCED IN PART RTM Off L RTM Off Line – IPM cannot communicate with 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 IPM2B003 Revision 15 – MAY/18 Uncontrolled Copy - Refer to Ampcontrol Website for Latest Version Page 50 of 83 APPROVED FOR EXTERNAL DISTRIBUTION – PROPERTY OF AMPCONTROL PTY LTD – NOT TO BE REPRODUCED IN PART 12.4.2 Modbus Status Table 7: Modbus Status Status Comment Address The Modbus slave address the IPM is set to Read A solid block when a READ command is received Wrt A solid block when a WRITE command is received Exc A solid block when an unsupported Modbus command is received CRC A solid block when a checksum error is 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 IPM2B003 Revision 15 – MAY/18 Uncontrolled Copy - Refer to Ampcontrol Website for Latest Version Page 51 of 83 APPROVED FOR EXTERNAL DISTRIBUTION – PROPERTY OF AMPCONTROL PTY LTD – NOT TO BE REPRODUCED IN PART 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 IPM2B003 Revision 15 – MAY/18 Uncontrolled Copy - Refer to Ampcontrol Website for Latest Version Page 52 of 83 APPROVED FOR EXTERNAL DISTRIBUTION – PROPERTY OF AMPCONTROL PTY LTD – NOT TO BE REPRODUCED IN PART 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 IPM2B003 Revision 15 – MAY/18 Uncontrolled Copy - Refer to Ampcontrol Website for Latest Version Page 53 of 83 APPROVED FOR EXTERNAL DISTRIBUTION – PROPERTY OF AMPCONTROL PTY LTD – NOT TO BE REPRODUCED IN PART 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 IPM2B003 Revision 15 – MAY/18 Uncontrolled Copy - Refer to Ampcontrol Website for Latest Version Page 54 of 83 APPROVED FOR EXTERNAL DISTRIBUTION – PROPERTY OF AMPCONTROL PTY LTD – NOT TO BE REPRODUCED IN PART 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 IPM2B003 Revision 15 – MAY/18 Uncontrolled Copy - Refer to Ampcontrol Website for Latest Version Page 55 of 83 APPROVED FOR EXTERNAL DISTRIBUTION – PROPERTY OF AMPCONTROL PTY LTD – NOT TO BE REPRODUCED IN PART 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 key is pressed while displaying the alarm message. The „Insulat. Test Alarm‟ is also recorded in the Event Log.

IPM V2 USER MANUAL IPM2B003 Revision 15 – MAY/18 Uncontrolled Copy - Refer to Ampcontrol Website for Latest Version Page 56 of 83 APPROVED FOR EXTERNAL DISTRIBUTION – PROPERTY OF AMPCONTROL PTY LTD – NOT TO BE REPRODUCED IN PART 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 IPM2B003 Revision 15 – MAY/18 Uncontrolled Copy - Refer to Ampcontrol Website for Latest Version Page 57 of 83 APPROVED FOR EXTERNAL DISTRIBUTION – PROPERTY OF AMPCONTROL PTY LTD – NOT TO BE REPRODUCED IN PART 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 IPM2B003 Revision 15 – MAY/18 Uncontrolled Copy - Refer to Ampcontrol Website for Latest Version Page 58 of 83 APPROVED FOR EXTERNAL DISTRIBUTION – PROPERTY OF AMPCONTROL PTY LTD – NOT TO BE REPRODUCED IN PART  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 IPM2B003 Revision 15 – MAY/18 Uncontrolled Copy - Refer to Ampcontrol Website for Latest Version Page 59 of 83 APPROVED FOR EXTERNAL DISTRIBUTION – PROPERTY OF AMPCONTROL PTY LTD – NOT TO BE REPRODUCED IN PART 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 IPM2B003 Revision 15 – MAY/18 Uncontrolled Copy - Refer to Ampcontrol Website for Latest Version Page 60 of 83 APPROVED FOR EXTERNAL DISTRIBUTION – PROPERTY OF AMPCONTROL PTY LTD – NOT TO BE REPRODUCED IN PART 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 IPM2B003 Revision 15 – MAY/18 Uncontrolled Copy - Refer to Ampcontrol Website for Latest Version Page 61 of 83 APPROVED FOR EXTERNAL DISTRIBUTION – PROPERTY OF AMPCONTROL PTY LTD – NOT TO BE REPRODUCED IN PART 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 IPM2B003 Revision 15 – MAY/18 Uncontrolled Copy - Refer to Ampcontrol Website for Latest Version Page 62 of 83 APPROVED FOR EXTERNAL DISTRIBUTION – PROPERTY OF AMPCONTROL PTY LTD – NOT TO BE REPRODUCED IN PART 14.2 Equipment Maintenance WARNING! The IPM V2 relay system has no user-serviceable parts. 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 IPM2B003 Revision 15 – MAY/18 Uncontrolled Copy - Refer to Ampcontrol Website for Latest Version Page 63 of 83 APPROVED FOR EXTERNAL DISTRIBUTION – PROPERTY OF AMPCONTROL PTY LTD – NOT TO BE REPRODUCED IN PART 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 Communications RS485 Slave Modbus Baud Rate: 1200 to 19200 Monitoring 4-20mA Analogue Output Back EMF Timer Delay Settings 2, 5, 10, 15, 20 sec 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 Current Range 0.5125 to 64 Amps (224 steps) 100:1 CT 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 Overload Reset Level 30%, 40%, 50%, 60%, 70%, 80%, 90%, A-30%, A-40%, A-50%, A- 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 Trip Setting OFF, 10%, 20%, 30%, 40%, 50%, 60%, 80%, 100%, 120%, 150%, 200%, 250% Trip Time OFF, 100ms, 200ms, 500ms, 1sec, 2, 3, 5sec

IPM V2 USER MANUAL IPM2B003 Revision 15 – MAY/18 Uncontrolled Copy - Refer to Ampcontrol Website for Latest Version Page 64 of 83 APPROVED FOR EXTERNAL DISTRIBUTION – PROPERTY OF AMPCONTROL PTY LTD – NOT TO BE REPRODUCED IN PART High Current Alarm OFF, 100%, 108%, 120%, 140%, 160%, 200%, 240%, 280%, 320%, 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 Pump (Snore) Function None, 5,10,15, 20, 8F,15F,20F, 30F, 60F 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 IPM2B003 Revision 15 – MAY/18 Uncontrolled Copy - Refer to Ampcontrol Website for Latest Version Page 65 of 83 APPROVED FOR EXTERNAL DISTRIBUTION – PROPERTY OF AMPCONTROL PTY LTD – NOT TO BE REPRODUCED IN PART 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. 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. NOTE Similar graphs can be obtained for 50mA, 100mA, 200mA and 500mA trip levels. 0 50 100 150 200 250 300 100 1000 Trip Time (ms) Fault Current (mA) 25mA 50mA 100mA 200mA 500mA 0 20 40 60 80 100 120 140 160 180 200 100 1000 Trip Time (ms) Fault Current (mA) INST 50ms 100ms 150ms

IPM V2 USER MANUAL IPM2B003 Revision 15 – MAY/18 Uncontrolled Copy - Refer to Ampcontrol Website for Latest Version Page 66 of 83 APPROVED FOR EXTERNAL DISTRIBUTION – PROPERTY OF AMPCONTROL PTY LTD – NOT TO BE REPRODUCED IN PART 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 IPM2B003 Revision 15 – MAY/18 Uncontrolled Copy - Refer to Ampcontrol Website for Latest Version Page 67 of 83 APPROVED FOR EXTERNAL DISTRIBUTION – PROPERTY OF AMPCONTROL PTY LTD – NOT TO BE REPRODUCED IN PART APPENDIX 3: IPM Full Load Current Selection Table (1000:1 CT) 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 IPM2B003 Revision 15 – MAY/18 Uncontrolled Copy - Refer to Ampcontrol Website for Latest Version Page 68 of 83 APPROVED FOR EXTERNAL DISTRIBUTION – PROPERTY OF AMPCONTROL PTY LTD – NOT TO BE REPRODUCED IN PART APPENDIX 4: IPM Menu Structure Level Menu Level - Screen Menu Message / Function Sub Menu Display Default 1 Need IPM Start 1.1 Start / Status / See Trip / Status Messages; Error Messages Type 1 – Latched for Display Type 2 – Enabled & Cleared Automatically Type 3 – Triggered by Trip Function 1.2- 1.50 Event Log : (last 50 events) L2: Event, L3: Time - Event, L4 :Present Time Pwr Up, Pwr Down, MCR Close, Stopped, Ext. Stop, MC Fail, Close Fail, ECW Trip, EC Leak Trip, EL trip, Burp Done, Burp Fail, SC Trip, OC Trip,I bal-Trp, RESET, Set up Mod, 2 Earth Leakage 2.1 Current / Voltage / Overload 2.2 All Currents; E/L, E/L, IB % Trip Level to 100% Trip, Current Balance 3 Earth Continuity 3.1 Earth Continuity When either EC Res or Earth Loop Leakage reaches 100% a trip occurs 3.2 Insulation Test Level 1MW, 2MW, 5MW, 10MW, 20MW (Alarm - 1.5 x Set Value) Display shows last measured value 3.3 Status Indicator Remote Input 4 IPM Relays & Keys 4.1 IPM Relay & Keys CBR, MCR, ALM, MCI, Str, Rst, Stp 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: Grp1-IPM 5.1 EC Pilot Mode [Diode, RTM] –Earth Loop Resist. < 45W 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 /P [12000,E,N, 24000,E,N, 48000,E,N, 96000,E,N, 192000,E,N] 96000 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: Grp2-RTM 6.1 RTM Machine Type [J-bo, Fan, Dril, Pump, Hpmp, Wpmp, DCB, Bolt, HRMr, Belt, Winc, Crsh, Dplg, Spare] 6.2 RTM Mach. Num. [ 1 to 40 ] 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 IPM2B003 Revision 15 – MAY/18 Uncontrolled Copy - Refer to Ampcontrol Website for Latest Version Page 69 of 83 APPROVED FOR EXTERNAL DISTRIBUTION – PROPERTY OF AMPCONTROL PTY LTD – NOT TO BE REPRODUCED IN PART Level Menu Level - Screen Menu Message / Function Sub Menu Display Default 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 (Delay – 1s) [100 – 600% FLC & Off] 100% 6.22 O/L Alarm Lev (Delay – 2s) 50%, 60%, 70%, 75%, 80%, 85%, 90%, 95%, Alarm Off 50% 6.23 Under I Alarm (Delay – 2s) 32%, 40%, 48%, 56%, 64%, 72%,80%, 88%, 96%, Off 32% 6.24 E/L Alarm Lev (Delay – 1s) 10%, 20%, 30%, 40%, 50%,60%, 80%, Off 10% 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 Opened Need IPM Start High Current Alarm Earth Cont. Trip IPM Memory Error 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 IPM2B003 Revision 15 – MAY/18 Uncontrolled Copy - Refer to Ampcontrol Website for Latest Version Page 70 of 83 APPROVED FOR EXTERNAL DISTRIBUTION – PROPERTY OF AMPCONTROL PTY LTD – NOT TO BE REPRODUCED IN PART APPENDIX 5: IPM Modbus Address Table Modbus Address Byte Name Bit Identification 0-3 Reserved 4 Note: Bit set when tripped trips_1 trips_2 Trip Status 1 0 = Earth Leakage 1 = Earth Continuity Trip 2 = Insulat. test trip 3 = Overload Trip 4 = Short Circuit Trip 5 = Current Balance Trip 6 = Residual Current Trip 7 = Main Contactor Fail Trip Status 2 0 = External Stop 1 = RTM Offline Trip 2 = IPM Memory Error 3 = RTM Memory Error 4 = Stopped - IPM 5 = Modbus Timeout 6 = Modbus Stop 7 = RTM CT Ratio Error 5 Note: Bit set when tripped soft_trips alarms Soft Trip Status 0 = Tripped No Volts 1 = MC Close Fail 2 = External MC Open 3 = Burp MCI Fail 4 = Under Current 5 = OTS Test Mode Exited 6 = Spare 7 = Last T: Alarms 0 = High Current Alarm 1 = Thermal Acc Alarm 2 = Current Balance 3 = Under Cur. Alarm 4 = Earth Leakage Alarm 5 = Under Voltage Alarm 6 = Insulation Test Alarm 7 = Spare 6 Note: Bit set when active ipm_stat2_byte ipm_stat_byte Relay Status 0 = Outlet Paused 1 = Need IPM Start 2 = Testing Insulation 3 = Closing Main Cont. 4 = Burp: MC Closed 5 = Burp: MC Open 6 = Running 7 = Manual Insulation Test Relay Status 2 0 = Snore 1 = Snore – Close Aux 2 = RTM Version Error 3 = RTM Stop 4 = Wait on RTM Start 5 = Config Error 6 = OTS Test Mode 7 = Spare Modbus Address Byte Name Bit Identification 7 Note: Key Bits 0-7 clear when key pressed keys_control digital_inputs Digital Inputs 0 = Spare 1 = Spare 2 = Lock 3 = Reset 4 = Aux 5 = External Stop 6 = External Start 7 = MCI Keys 0 = Stop 1 = Start 2 = Reset 3 = Test 4 = Spare 5 = Spare 6 = Spare 7 = Spare 8 Reserved 9 pilot_fwd Pilot Forward Resistance as a Percentage (%) of the trip level. Note: The IPM aims to trip at 36Ω (100%). 10 pilot_rev Pilot Forward Resistance as a Percentage (%) of the trip level (nominally 2k). 11 meg_result Insulat. Test Result (MOhms) 12 cur_gain_Leds keys_menu_ra w (in high byte) Control Keys 0 = Up Key 1 = Down Key 2 = Left key 3 = Right key 4 = Enter key 5 = ESC Key 14 = Red LED 15 = Green LED 13 el_cur Earth Leakage Current (0…250%) 14 cur_a A Phase Current (0…1000%) 15 cur_b B Phase Current (0…1000%) 16 cur_c C Phase Current (0…1000%) 17 current_bal Current Balance (0…100%) 18 ir_cur_high Residual Current (0…1000%) 19 OC Thermal Accum (0…120%) 20 volts_a A Phase Voltage (0…120%) 21 volts_b B Phase Voltage (0…120%) 22 volts_c C Phase Voltage (0…120%)

IPM V2 USER MANUAL IPM2B003 Revision 15 – MAY/18 Uncontrolled Copy - Refer to Ampcontrol Website for Latest Version Page 71 of 83 APPROVED FOR EXTERNAL DISTRIBUTION – PROPERTY OF AMPCONTROL PTY LTD – NOT TO BE REPRODUCED IN PART Modbus Address Byte Name Bit Identification 23 volts_average Phase Voltage Average (BCD format) 24 current_ave Current Average (0…250%) 25-29 Reserved 30 serial_high Serial Number High Top 16 bit of serial number 31 Serial_low Serial Number Low Lower 16 bit of serial number 32 mia_sw_ver IPM Software Version – where x = Top 3 bits (Hardware Ver.) y = Bot 5 bits (Software Ver.) 33 sub_second Time Sub – Second 34 second Time – Second 35 minute Time – Minute 36 hour Time – Hour 37 date Date eg. 1 = 1st, 15 = 15th 38 month Month eg. 1 = Jan, 6 = Jun 39 year Year (two digits only) 40 day Day eg. 0 = Sunday, 1 = Monday 41 pilot_mode EC Pilot Mode 0 = Invalid Data 1 = RTM 2 = Diode 42 param_itm ITM Module 0 = Invalid Data 1 = 415V 2 = 1000V 3 = None 43 param_mb_adr Modbus Address 0 = Invalid Data 1……31 44 param_mb_bau d Modbus Baud Rate 0 = Invalid Data 1 = 1200 Even Parity 2 = 1200 Odd Parity 3 = 1200 No Parity 4 = 2400 Even Parity 5 = 2400 Odd Parity 6 = 2400 No Parity 7 = 4800 Even Parity 8 = 4800 Odd Parity 9 = 4800 No Parity 10 = 9600 Even Parity 11 = 9600 Odd Parity 12 = 9600 No Parity 13 = 19200 Even Parity 14 = 19200 Odd Parity 15 = 19200 No Parity Modbus Address Byte Name Bit Identification 45 machine_type Machine Type 0 = - - - - 1 = J-bo - Jumbo 2 = Fan 3 = Drill 4 = Pump 5 = Hpmp - Hydraulic Pump 6 = Wpmp - Water Pump 7 = DCB 8 = Bolt - Bolter 9 = HRMr - Hard Rock Miner 10 = Belt 11 = Winc - Winch 12 = Crush - Crusher 13 = DPlug – Dummy Plug 14 = Spare 46 machine_num Machine Number 0 = Invalid Data 1 …. 40 47 cur_range_para m FLC Setting (See OC section) 1..32 = 5.125..10.000A 33..64 = 10.25..20.00A 65..96 = 20.5..40.0A 97..128 = 41..80A 129..160 = 82..160A 161..192 = 164..320A 193..224 = 328..640A 48 short_cct_para m SC Trip Level (xFLC) 0 = Invalid Data 1 = 3x 2 = 3.5x 3 = 4x 4 = 4.5x 5 = 5x 6 = 5.5x 7 = 6x 8 = 6.5x 9 = 7x 10 = 7.5x 11 = 8x 12 = 8.5x 13 = 9x 14 = 9.5x 15 = 10x 49 sc_trp_tm_para m SC Trip Time 0 = Invalid Data 1 = 20 ms 2 = 40 ms 3 = 60 ms 4 = 80 ms 5 = 100 ms 6 = 120 ms 7 = 160 ms

IPM V2 USER MANUAL IPM2B003 Revision 15 – MAY/18 Uncontrolled Copy - Refer to Ampcontrol Website for Latest Version Page 72 of 83 APPROVED FOR EXTERNAL DISTRIBUTION – PROPERTY OF AMPCONTROL PTY LTD – NOT TO BE REPRODUCED IN PART Modbus Address Byte Name Bit Identification 50 time_mul_para m O/L Trip Time @ 6x FLC 0 = Invalid Data 1 = 3s 2 = 4s 3 = 5s 4 = 6s 5 = 7s 6 = 8s 7 = 10s 8 = 12s 9 = 14s 10 = 16s 11 = 20s 12 = 24s 13 = 28s 14 = 32s 15 = 40s 51 cool_mul_para m S-Cool Ratio 0 = Invalid Data 1 = 1.0 2 = 1.5 3 = 2.0 4 = 2.5 5 = 3.0 6 = 4.0 7 = 5.0 52 ol_rst_param O/L Reset Level 0 = Invalid Data 1 = 30% 2 = 40% 3 = 50% 4 = 60% 5 = 70% 6 = 80% 7 = 90% 8 = A-30% 9 = A-40% 10 = A-50% 11 = A-60% 12 = A-70% 13 = A-80% 14 = A-90% 53 cur_bal_param Current Balance Trip 0 = Invalid Data 1 = 5% 2 = 10% 3 = 20% 4 = 50% 5 = OFF 54 p_und_cur Under I Trip 0 = Invalid Data 1 = 32% 2 = 40% 3 = 48% 4 = 56% 5 = 64% 6 = 72% 7 = 80% 8 = 88% 9 = 96% 10 = OFF Modbus Address Byte Name Bit Identification 55 rc_lev_param Ires Trip Level (%FLC) 0 = Invalid Data 1 = 10% 2 = 20% 3 = 30% 4 = 40% 5 = 50% 6 = 60% 7 = 80% 8 = 100% 9 = 120% 10 = 150% 11 = 200% 12 = 250% 13 = OFF 56 rc_tim_param Ires Trip Time 0 = Invalid Data 1 = 100ms 2 = 200ms 3 = 500ms 4 = 1 Sec 5 = 2 Sec 6 = 3 Sec 7 = 5 Sec 57 el_sens RCD Trip Level 0 = Invalid Data 1 = 25mA 2 = 50mA 3 = 100mA 4 = 200mA 5 = 500mA 6= OFF 58 el_time RCD Trip Time 0 = Invalid Data 1 = Ins. (Instantaneous) 2 = 50ms 3 = 100ms 4 = 150ms 59 ectime_adj Pilot Trip Time 0 = Invalid Data 1 = 80ms 2 = 120ms 3 = 160ms 4 = 200ms 5 = 300ms 6 = 400ms 7 = 500ms 60 remote_control Remote Start 0 = Invalid Data 1 = No 2 = Yes 3 = Aux 61 pilot_latch Pilot Latch 0 = Invalid Data 1 = On 2 = OFF 62 meg_level Meg Level 0 = Invalid Data 1 = 1.0M 2 = 2.0M 3 = 5.0M 4 = 10M 5 = 20M 6 = None

IPM V2 USER MANUAL IPM2B003 Revision 15 – MAY/18 Uncontrolled Copy - Refer to Ampcontrol Website for Latest Version Page 73 of 83 APPROVED FOR EXTERNAL DISTRIBUTION – PROPERTY OF AMPCONTROL PTY LTD – NOT TO BE REPRODUCED IN PART Modbus Address Byte Name Bit Identification 63 uv_lev_param Under Voltage Trip Level 0 = Invalid Data 1 = 40% 2 = 50% 3 = 60% 4 = 70% 5 = 75% 6 = 80% 7 = 85% 8 = 90% 9 = 95% 10 = OFF 64 b_emf_time Back EMF Time 0 = Invalid Data 1 = 2 Sec 2 = 5 Sec 3 = 10 Sec 4 = 15 Sec 5 = 20 Sec 65 hc_alm_param High Current Alarm 0 = Invalid Data 1 = 100% 2 = 108% 3 = 120% 4 = 140% 5 = 160% 6 = 200% 7 = 240% 8 = 280% 9 = 320% 10 = 360% 11 = 400% 12 = 500% 13 = 600% 14 = OFF 66 ta_alm_param O/L Alarm Level 0 = Invalid Data 1 = 50% 2 = 60% 3 = 70% 4 = 75% 5 = 80% 6 = 85% 7 = 90% 8 = 95% 9 = OFF 67 uc_alm_param Under Current Alarm 0 = Invalid Data 1 = 32% 2 = 40% 3 = 48% 4 = 56% 5 = 64% 6 = 72% 7 = 80% 8 = 88% 9 = 96% 10 = Off Modbus Address Byte Name Bit Identification 68 ec_alm_param Earth Leakage Alarm 0 = Invalid Data 1 = 10% 2 = 20% 3 = 30% 4 = 40% 5 = 50% 6 = 60% 7 = 80% 8 = OFF 69 p_burp_num Number of Burp Pulses 0 = Invalid Data 1 = None 2 = 1 3 = 2 4 = 3 5 = 4 6 = 5 7 = 6 70 p_burp_on Burp On Time 0 = Invalid Data 1 = 0.6 S 2 = 0.8 S 3 = 1.0 S 4 = 1.2 S 5 = 1.5 S 6 = 2.0 S 7 = 2.5 S 8 = 3.0 S 71 p_burp_off Burp Off Time 0 = Invalid Data 1 = 0.6 S 2 = 0.8 S 3 = 1.0 S 4 = 1.2 S 5 = 1.5 S 6 = 2.0 S 7 = 2.5 S 8 = 3.0 S 72 p_4_20_op 4-20mA Output 0 = Invalid Data 1 = O/L 2 = Iave 3 = lel 4 = MΩ 73-74 Reserved 75 _snoreIndex Snore Delay 0 = Invalid Data 1 = OFF 2 = 5 3 = 10 4 = 15 5 = 20 6 = 8F 7 = 15F 8 = 20F 9 = 30F 10 = 60F 76 RCD_rst_lock RCD Reset Lock 0 = Invalid Data 1 = OFF 2 = ON 77-78 Reserved

IPM V2 USER MANUAL IPM2B003 Revision 15 – MAY/18 Uncontrolled Copy - Refer to Ampcontrol Website for Latest Version Page 74 of 83 APPROVED FOR EXTERNAL DISTRIBUTION – PROPERTY OF AMPCONTROL PTY LTD – NOT TO BE REPRODUCED IN PART 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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