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SA380-IT User Guide

SA380-IT User Guide


IMPORTANT!

The SA380-IT user guide is presently undergoing an extensive update to reflect the latest advancements in features and operation. Please check this page regularly for updates.

6 Pinnacle Way, Pride Park, Derby, UK, DE24 8ZS

Sales:sales@mpec.co.uk
General Enquiries:enquiries@mpec.co.uk

© Mpec Ltd. 2020 All rights reserved.

No part of this publication may be copied without the prior consent of Mpec.

www.mpec.co.uk


Contents

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1) Product Overview

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The SA380-IT is designed to facilitate the continuous monitoring of circuit voltage and resistance to earth of up to 5 independent circuits.

Maintenance Reduction and Failure prevention of Earth Faults are best realised through continuous monitoring. It facilitates:

  • Detection of transient safety and operational risks that may be missed by infrequent periodic inspection.
  • The removal of the requirement for time-consuming and dangerous physical inspection and measurement.
  • The ability to predict, schedule and fix developing earth faults before they become an operational or safety risk.

Key Features

  • Independent monitoring of up to 5 circuits, each circuit can be one of the following systems:

    • Single phase IT AC system up to 160 V RMS.
    • Single phase IT AC system up to 160 V RMS with galvanically connected rectifiers.
    • IT DC system up to 160 V RMS. 

  • Equivalent resistance to earth measurement of AC circuits.
  • Resistance to earth measurement of each circuit leg of DC circuits.
  • Automatic adaptation to system leakage capacitance.
  • 1.5 seconds-per-circuit rapid response time.
  • Adjustable response values.
  • Detection of measurement interference due to core-to-core insulation degradation.
  • Monitored circuits supply voltage measurement.
  • Earth-loop continuity measurement.
  • Continual self-test for accuracy and safety.
  • Volt-free contact alarm output.
  • Auxiliary power supply output.
  • In-built GSM communication.
  • In-built Ethernet communication.
  • In-built RS485 communication.
  • In-built Bluetooth LE communication
  • 90 days data storage
  • Compatible with leading enterprise asset management systems.



2) Safety Information

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2.1) Explanation of Symbols

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The following designations are used to bring important hazards and information to the attention of the user:

A real threat to human life. It must be adhered to at all times.

A possible dangerous situation. There could be a risk to human life is correct procedure is not followed.

Information that should be followed to assure accurate and reliable operation.

A particularly useful application tip.



2.2) Intended Use

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The intended use of the SA380-IT insulation monitor is to remotely monitor pole-to-pole voltage and pole-to-earth resistance to earth (insulation resistance) of IT (earth-free) power supply circuits. Any other use, or use beyond the product specification is deemed improper. Mpec Technology Ltd shall not be liable for any loss or damage to life or property arising from improper use.

Correct use includes compliance with all instructions from the operation and maintenance manual with regard to transportation, installation, operation and maintenance.



2.3) Warranty & Liability

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Warranty and Liability claims due to injury to persons or damage to property are excluded if they can be attributed to any of the following causes:

  • Improper use of the SA380-IT as defined in section 1.2.
  • Unauthorized modification to the SA380-IT, structural or electrical.
  • Unauthorized repair of the SA380-IT.
  • Disasters caused by foreign bodies, fire, or force majeure.



2.4) Personnel

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Only personnel familiar with the installation, commissioning and operation of the SA380-IT may work with the SA380-IT. Such personnel must:

  • Read and understand the safety chapter of this document. 
  • Undertake appropriate training in the installation of electrical equipment.
  • Comply with all rules and regulations regarding safety for the given place of work.

Members of the public must never be permitted access to the SA380-IT.



2.5) Handling Hazards

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The following precautions must be taken during storage and transportation:

  • Protection from prolonged rainfall.
  • Protection from immersion in water.
  • Ensure that the storage temperature is not exceeded.
  • Protection against crushing.

Damaged enclosures can expose hazardous voltages and nullifies the SA380-IT Ingress-Protection.

Prolonged exposure to, or immersion in water exceeds the SA380-IT Ingress-Protection rating. Under such conditions dielectric withstand voltages cannot be guaranteed.

Never install or energise an SA380-IT that appears to be either physically damaged or suffering from water ingress.



2.6) Safe Installation

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Detailed wiring instructions can be found in section 3. The purpose of this section is to reinforce critical safety information.

Please note the following important wiring information:

No.Safe?Notes
1YesConnection of supply to "circuit 1" input using "Hi Z" supply output
2YesCorrect fitment of resistive cables. Connection to circuit bus-bar is via an independent fuse.
3YesCorrect fitment of resistive cables. No independent fuse is required for safe operation
4NoNo resistive cable fitted. Circuit vulnerable to short-circuit faults.
5NoIncorrect fitment of resistive cable. Circuit vulnerable to through-crimp failure.


No.Safe?Notes
1No

Do not "common" circuits.

N50(E) and N50(I) isolation compromised.

2No

Ensure correct connector position alignment.

N120 and B24 isolation compromised.

Not following this advice risks:

  • Circumvention if the inter-isolation of monitored circuits.
  • Short circuit of individual monitored circuits.
  • Electric shock.

The Functional Earth and Loop Earth must be connected to suitable earthing points using separate wires.

  • It is preferable to use independent earthing points for loop earth and functional earth connections.
  • It is tolerable to use a common earthing point if provision of a secondary earthing point is prohibitive.
  • It is not acceptable to simply strap Functional Earth to Loop Earth.

An ineffective Earth Loop circuit is unable to verify correct connection of the SA380-IT, hence insulation readings may be incorrect.

Only one insulation monitoring device may be used on a single interconnected circuit. Installation of additional monitoring devices will cause each device to "fight" the other, resulting in incorrect readings on both devices.

Check that the factory set earth loop and insulation resistance alarm levels are correct for your application. (See section 4.4.10)

Nominal voltage is used to drive important safety features of the SA380-IT

It is important that this is set correctly.

The Ethernet port is sensitive to electrical surges:

  • Additional surge protection must be fitted if the port is to be used continuously for data transmission using:
    • A dedicated Ethernet surge protection device, or
    • Use of screened Ethernet cable

  • Surge protection is not required for temporary configuration and diagnostics activities.

Power Supply

The SA380-IT can be purchased with two alternate power supply options:

  • 110 V AC
  • 12 V DC

The device power supply voltage is clearly indicated on the rear of the device.

Connection of a 110 V AC supply to 12 V DC units will render the device inoperable!


Limitations of use in the United Kingdom

The following restrictions upon use must be observed when the SA380-IT is deployed on UK rail infrastructure:

Never attempt to power the SA380-IT from a DC power source

Never attempt to wire any conductors from differing monitored circuits into the same input channel.

Users in other countries may disregard these warnings.

No residual hazards have been identified if the above advice is not followed, but these practices are against UK railway policy.

Ensure that you have exhausted all fault finding tasks prior to manually resetting any device interlock (see section 5.2 and section 4.4.5).

It is wise to conduct a manual insulation test on monitored circuits prior to, and after installation. This will help verify correct installation of the measurement circuit wiring during commissioning.

A manual continuity test between Functional Earth and Loop Earth connections after installation will help verify correct installation of the earth-loop circuit wiring during commissioning.

When conducting manual insulation testing on monitored circuits after commissioning, the SA380-IT must be either:

  • Prevented from attempting measurement (see section 4.4.5).
  • Physically disconnected from the monitored circuit.
  • Powered-down.

Failure to do so will result in incorrect readings.



3) Installation

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3.1) Parts and Tools Required

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Ensure you have the following parts and tools to hand prior to installation. Tools are not supplied.

Please note that the cable terminations to the "live" system, and cable markers are not supplied. This is because of the wide variety of methods of termination to power supply busbars encountered. Please ensure you have an adequate supply of appropriate terminations and a suitable master fuse prior to installation.


Parts


SA380-IT

Insulation Monitoring Unit

NA
  • SA380-IT-NR
  • SA380-IT-SD
1

M5 A2 Stainless Steel Washers

for device fitment

NA
  • SA380-IT-NR
  • SA380-IT-SD
2

M5 A2 Stainless Steel Nuts

for device fitment

NA
  • SA380-IT-NR
  • SA380-IT-SD
2

GSM Antenna

For cellular network communication

Mpec Part No:
MIS-PAN-PUK/LPAB
  • SA380-IT-NR
  • SA380-IT-SD
0 - 1

Shrouded Ferrule crimps 0.75 mm2

10 mm crimps for 0.75 mm2 wire terminations

WEIDMULLER H0,75/16 W SV INSULATED FERULE. P/N: 9025860000 
  • SA380-IT-NR
  • SA380-IT-SD
4 - 16

Uninsulated Ferrule Crimps

10 mm crimps for 1.5 mm2 wire terminations

WEIDMULLER H1,5/10 UNINSULATED FERULE. P/N: 0186500000
  • SA380-IT-NR
  • SA380-IT-SD
2

0.75 mm2 stranded single core cable

For power supply and monitored circuit connections

ELAND Grey NR Approved A1 0.75mm 1 Core Cable - A5RA1010075GR
  • SA380-IT-NR
  • SA380-IT-SD
0 - 30m

1.5 mm2 stranded single core "earth" cable

For primary and "loop" earth connections

ELAND Single Core, Stranded, 1.5 mm sq. CSA, Yellow / Green - A2TGY0015
  • SA380-IT-NR
  • SA380-IT-SD
0 - 3m

Resistive Cable

For safe connection to monitored circuits

Mpec Part No:
COM-IT-RESCAB
  • SA380-IT-NR
  • SA380-IT-SD
0 - 10

Cable Markers

For termination identification.

No Image
Quantity, type and requirement customer dependent
  • SA380-IT-NR
  • SA380-IT-SD
??

"Live End" Circuit Termination Crimps

For terminating power supply, monitored circuits and earth connections

No Image
Quantity, type and requirement customer dependent  
  • SA380-IT-NR
  • SA380-IT-SD
4 - 14 

Main Fuse T2A Fuse

Main fuse for device power connection. 

No Image
Type and requirement customer dependent 
  • SA380-IT-NR
  • SA380-IT-SD
1 

Additional Monitored Circuit Fuses

Optional fuses fitted in the positive leg of monitored circuits

No Image
Type and requirement customer dependent  
  • SA380-IT-NR
  • SA380-IT-SD
0-5

Screened Ethernet Cable

For fixed IP network communication. 

RS Blue Cat6 Cable S/FTP PVC Male RJ45/Male RJ45, 10m - 411-306
  • SA380-IT-NR
  • SA380-IT-SD
0 - 1

0.5 mmTwisted Pair Cable

For RS485 serial data connection.

RS Belden 1 Pair Industrial Cable 0.5 mm² - 382-7189
  • SA380-IT-NR
  • SA380-IT-SD
0 - 1

Shrouded Ferrule crimps 0.5 mm2

For RS485 serial data connection.

WEIDMULLER H0,5/14D W INSULATED FERRULE. PN. 9019010000
  • SA380-IT-NR
  • SA380-IT-SD
0 - 2


Tools


8 mm Nut driver or 8 mm spannerFor securing fixing nuts
WERA 190 i VDE Insulated Nut-driver - 05005315001

190 i VDE Insulated nutdriver


Square Wire End Ferrule CrimperFor crimping wire ferrules for correct wire termination to the SA380-IT device
WEIDMULLER PZ 10 SQR WIRE END FERULE CRIMPER. P/N: 1445080000


Insulated 2.5 mm Flat-blade ScrewdriverFor removing wires from the SA380-IT spring-cage connectors
WERA 160 i VDE Screwdriver - 05006105001

160 i VDE Insulated screwdriver for slotted screws


Wire Stripper / CutterFor preparing wires for termination
WEIDMULLER STRIPAX 16 ZERT


Red Crimping ToolFor crimping the 0.75 mm2 stranded single core cable to the resistive-cable modules
TE - Premium Crimp Tooling - PIDG - 409775-1


iPhoneFor local set-up and diagnostics
Mpec Part No: COM-IT-CD


Laptop + Ethernet CableFor local set-up and diagnostics if an iPhone is not available

System Requirements:

  • No Operating System requirement
  • Must run a "modern" web-browser
  • User must have ability to change IP settings
  • Cat5 or better RJ45 Ethernet cable.


Additional Crimping / Fixing Tool(s)For crimping and connecting power supply, monitored circuits and earth connections to the "live" system to be monitored. 
Type and requirement customer dependentNo Image

Drill + 12 mm Drill bitMaybe required to route the antenna to the exterior of the installation point.
Type and requirement customer dependentNo Image



3.2) SA380-IT Layout

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Front Panel
No.NameDescription
1PowerLit if the SA380-IT has main power
2NetworkLit if the SA380-IT is connected to the GSM network
3ServerLit if the SA380-IT is connected to an Asset Management Server System
4TestIlluminates during self-test.
5RunPulsates if the software is running.
6HW FaultIndicates a hardware or earth loop integrity problem
7Earth FaultIndicates the presence of an insulation fault
8Bluetooth

Combined Indicator and touch-sensitive button.

Touch to enable bluetooth functionality.

Extinguished: Bluetooth disabled.

Blinking: Awaiting pairing.

Lit: Paired and active

9Serial NumberEasy-read serial number of the device.
10SIM SerialSerial number of the built-in SIM
11MFG SerialFull serial number of the device.


Rear Panel
No.NameDescription
1SupplyPower supply to the SA380-IT
2Functional EarthCommon Earth point for all device measurement
3Loop EarthSecondary Earth point for earth continuity measurement
4Monitored CircuitsConnections for the IT circuits that require insulation monitoring
5HiZ OutputsA simple means of safely monitoring the insulation of the supply circuit.
6Auxiliary OutputsI/O to other devices and alarm circuits
7GSM AntennaFacilitates GSM connection to an Enterprise Asset Management System
8Ethernet JackAllows local configuration and diagnostics, or Ethernet connection to an Enterprise Asset Management System
9Fixing StudM5 mounting studs to fit BR930 / Q Style relay mountings. Brackets are available to allow alternate mounting arrangements
10Quality ControlDevice had undergone voltage withstand, calibration and inspection processes.
11Supply Voltage110 V AC or 12 V DC supply indication.



3.3) Typical Circuit

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Use the typical circuit below to aid in the production of reference designs.

Please ensure that you do however read and observe the complete installation instructions.



3.4) Pre-Installation

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The following precautions must be taken during storage and transportation:

  • Protection from prolonged rainfall.
  • Protection from immersion in water.
  • Ensure that the storage temperature is not exceeded.
  • Protection against crushing

Damaged enclosures can expose hazardous voltages and nullifies the SA380-IT Ingress-Protection.

Prolonged exposure to, or immersion in water exceeds the SA380-IT Ingress-Protection rating. Under such conditions dielectric withstand voltages cannot be guaranteed.

Never install or energise an SA380-IT that appears to be either physically damaged or suffering from water ingress.

It is wise to conduct a manual insulation test on monitored circuits both prior to, and after installation, but before energising the SA380-IT. This will help verify correct installation of the measurement circuit wiring.

A manual continuity test between Functional Earth and Loop Earth connections after installation, but before energising SA380-IT will help verify correct installation of the earth-loop circuit wiring.



3.5) Fitting

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Parts
SA380-IT

M5 A2 Stainless Steel Washers

M5 A2 Stainless Steel Nuts

Tools
8 mm Nut driver or 8 mm spanner

190 i VDE Insulated nutdriver

Information
  • Mounting studs are arranged to fit relay racking spaced for BR930 or "Q Style" relays
  • Exact mounting stud spacings can be found in the specification section of the user guide
  • Hinged wall brackets and adaptor brackets are available to accommodate alternative mounting arrangements. Contact Mpec.
Method
  • Offer the SA380-IT device up to the relay racking
  • Slide the washers over the mounting studs
  • Fit the nuts and tighten using the nut-driver / spanner.

  • Inspect that the spring washers are not fully compressed (over-tightened). Optimum tightening torque is 1.0 Nm-1
  • The SA380-IT should feel secure and free of play or wobble.



3.6) Termination of SA380-IT Wiring

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Parts
0.75 mmShrouded Ferrule crimps 

Uninsulated Ferrule Crimps

0.75 mm2 stranded single core cable

1.5 mm2 stranded single core "earth" cable

Cable MarkersNo Image
Tools
Square Wire End Ferrule Crimper

Wire Stripper / Cutter

Information

All wire terminations into the SA380-IT use require wire insertion into spring-clamp connectors at the rear of the device.

  • All wire ends must be correctly terminated with a ferrule crimp of the appropriate size.
  • The ferrules must be compressed using a square-end ferrule crimping tool.
Method

Affix cable marker beads if required.

Strip 12 mm of outer insulation from the end of the cable

Select the correct crimp:

Fit the crimp over the wire end, ensuring the crimps fit flush against the cable insulation.

Compress the crimp using a square-ended ferrule crimping tool

Inspect the crimp

  • No loose strands
  • No excessive copper exposed at either crimp end.
  • Sufficient exposed wire held firm by the crimp
  • An even square profile.
  • Ferrule is secure

To insert a wire into the spring-cage connector

  • Simply press the ferrule fully-home into the spring cage plug
  • Pull at the wire, if secure the wire will not move.
  • No exposed metal should be visible if wire correctly crimped and pushed fully-home into the connector.

To remove a wire from the spring-cage connector

  • Press the blade of an insulated flat-bladed screwdriver into the release latch
  • Withdraw to wire



3.7) Wiring the Power Supply

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Parts
0.75 mm2 stranded single core cable

0.75 mmShrouded Ferrule crimps 

Cable Markers

No Image

"Live End" Circuit Termination CrimpsNo Image
Main Fuse T2A FuseNo Image
Tools
Square Wire End Ferrule Crimper

Wire Stripper / Cutter

Additional Crimping / Fixing Tool(s)No Image
Information

Power Supply

The SA380-IT can be purchased with two alternate power supply options:

  • 110 V AC
  • 12 V DC

The device power supply voltage is clearly indicated on the rear of the device.

Connection of a 110 V AC supply to 12 V DC units will render the device inoperable!

Limitations of use in the United Kingdom

The following restrictions upon use must be observed when the SA380-IT is deployed on UK rail infrastructure:

Never attempt to power the SA380-IT from a DC power source

Users in other countries may disregard these warnings.

No residual hazards have been identified if the above advice is not followed, but these practices are against UK railway policy.

"Live end" crimp types and fuse-holder sizes vary, therefore no specific crimps or fuses are recommended.

Method

Wire the "+" and "-" supply terminals as shown:

Do not use resistive cables

Supply Voltage Ranges:

Labelled Voltage

Min. VMax. V
110 V AC40 AC/DC160 AC/DC
12 V DC10 DC16 DC

Use appropriate cable markers, crimps & crimp tools for the live terminations.

Use appropriate tools to to affix the live cables their terminations.

The "positive" leg of the supply circuit must be fitted with a type "T2A" (2 Amp Slow-Blow fuse) of the appropriate size.

It is recommended to not apply power to the device until all installation steps are complete.



3.8) Wiring the Earth Loop

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Parts
1.5 mm2 stranded single core "earth" cable

Uninsulated Ferrule Crimps

Cable Markers

No Image

"Live End" Circuit Termination CrimpsNo Image
Tools
Square Wire End Ferrule Crimper

Wire Stripper / Cutter

Additional Crimping / Fixing Tool(s)No Image
Information

"Earth bus-bar" crimp types will vary, therefore no specific crimps are recommended.

The Functional Earth and Loop Earth must be connected to suitable earthing points using separate wires.

  • It is preferable to use independent earthing points for loop earth and functional earth connections.
  • It is tolerable to use a common earthing point if provision of a secondary earthing point is prohibitive.
  • It is not acceptable to simply strap Functional Earth to Loop Earth.

An ineffective Earth Loop circuit is unable to verify correct connection of the SA380-IT, hence insulation readings may be incorrect.

Method

Wire the FE and LOOP EARTH in one of the two ways shown below:

Use green / yellow sleeved cable to differentiate earth connections from monitored circuit and power connections

Use appropriate cable markers, crimps & crimp tools for the earth bus-bar terminations.

Use appropriate tools to to affix the earth cables to bus-bar terminals.

A manual continuity test between Functional Earth and Loop Earth connections after installation, but be aware that a standard digital multimeter may not obtain a true reading if stray voltages are present. If in doubt, use a earth-test device designed specifically for this purpose.

This measurement should therefore be considered a "sanity check" of the wiring, not the absolute resistance of the earth loop path.

  • Earth loop readings <= 40 Ω between FE and Loop Earth connections is considered acceptable.
  • Earth loop readings <= 500 Ω maybe considered tolerable by you organisation, but should be investigated,



3.9) Wiring of Input Circuits

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Parts
0.75 mmShrouded Ferrule crimps 

0.75 mm2 stranded single core cable

Cable markersNo Image
Resistive cable modules

"Live End" circuit termination crimpsNo Image
Optional circuit fusesNo Image
Tools
Square Wire End Ferrule Crimper