SA380-IT User Guide
- Mark Beeson (Deactivated)
- George Davies
- Janos Vaczi (Unlicensed)
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.
Contents
1) Product Overview
2) Safety Information
2.1) Explanation of Symbols
2.2) Intended Use
2.3) Warranty & Liability
2.4) Personnel
2.5) Handling Hazards
2.6) Safe Installation
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 |
|---|---|---|
| 1 | Yes | Connection of supply to "circuit 1" input using "Hi Z" supply output |
| 2 | Yes | Correct fitment of resistive cables. Connection to circuit bus-bar is via an independent fuse. |
| 3 | Yes | Correct fitment of resistive cables. No independent fuse is required for safe operation |
| 4 | No | No resistive cable fitted. Circuit vulnerable to short-circuit faults. |
| 5 | No | Incorrect fitment of resistive cable. Circuit vulnerable to through-crimp failure. |
| No. | Safe? | Notes |
|---|---|---|
| 1 | No | Do not "common" circuits. N50(E) and N50(I) isolation compromised. |
| 2 | No | 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
3.1) Parts and Tools Required
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 |
| 1 |
M5 A2 Stainless Steel Washers for device fitment |
| |
| NA |
| 2 |
M5 A2 Stainless Steel Nuts for device fitment |
| |
| NA |
| 2 |
GSM Antenna For cellular network communication |
| |
| Mpec Part No: MIS-PAN-PUK/LPAB |
| 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 |
| 4 - 16 |
Uninsulated Ferrule Crimps 10 mm crimps for 1.5 mm2 wire terminations |
| |
| WEIDMULLER H1,5/10 UNINSULATED FERULE. P/N: 0186500000 |
| 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 |
| 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 |
| 0 - 3m |
Resistive Cable For safe connection to monitored circuits |
| |
| Mpec Part No: COM-IT-RESCAB |
| 0 - 10 |
Cable Markers For termination identification. | No Image | |
| Quantity, type and requirement customer dependent |
| ?? |
"Live End" Circuit Termination Crimps For terminating power supply, monitored circuits and earth connections | No Image | |
| Quantity, type and requirement customer dependent |
| 4 - 14 |
Main Fuse T2A Fuse Main fuse for device power connection. | No Image | |
| Type and requirement customer dependent |
| 1 |
Additional Monitored Circuit Fuses Optional fuses fitted in the positive leg of monitored circuits | No Image | |
| Type and requirement customer dependent |
| 0-5 |
Screened Ethernet Cable For fixed IP network communication. |
| |
| RS Blue Cat6 Cable S/FTP PVC Male RJ45/Male RJ45, 10m - 411-306 |
| 0 - 1 |
0.5 mm2 Twisted Pair Cable For RS485 serial data connection. |
| |
| RS Belden 1 Pair Industrial Cable 0.5 mm² - 382-7189 |
| 0 - 1 |
Shrouded Ferrule crimps 0.5 mm2 For RS485 serial data connection. |
| |
| WEIDMULLER H0,5/14D W INSULATED FERRULE. PN. 9019010000 |
| 0 - 2 |
Tools
| 8 mm Nut driver or 8 mm spanner | For securing fixing nuts |
| WERA 190 i VDE Insulated Nut-driver - 05005315001 |
|
| Square Wire End Ferrule Crimper | For 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 Screwdriver | For removing wires from the SA380-IT spring-cage connectors |
| WERA 160 i VDE Screwdriver - 05006105001 |
|
| Wire Stripper / Cutter | For preparing wires for termination |
| WEIDMULLER STRIPAX 16 ZERT |
|
| Red Crimping Tool | For crimping the 0.75 mm2 stranded single core cable to the resistive-cable modules |
| TE - Premium Crimp Tooling - PIDG - 409775-1 |
|
| iPhone | For local set-up and diagnostics |
| Mpec Part No: COM-IT-CD |
|
| Laptop + Ethernet Cable | For local set-up and diagnostics if an iPhone is not available |
System Requirements:
|
|
| 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 dependent | No Image |
| Drill + 12 mm Drill bit | Maybe required to route the antenna to the exterior of the installation point. |
| Type and requirement customer dependent | No Image |
3.2) SA380-IT Layout
| Front Panel | ||
|---|---|---|
| No. | Name | Description |
| 1 | Power | Lit if the SA380-IT has main power |
| 2 | Network | Lit if the SA380-IT is connected to the GSM network |
| 3 | Server | Lit if the SA380-IT is connected to an Asset Management Server System |
| 4 | Test | Illuminates during self-test. |
| 5 | Run | Pulsates if the software is running. |
| 6 | HW Fault | Indicates a hardware or earth loop integrity problem |
| 7 | Earth Fault | Indicates the presence of an insulation fault |
| 8 | Bluetooth | Combined Indicator and touch-sensitive button. Touch to enable bluetooth functionality. Extinguished: Bluetooth disabled. Blinking: Awaiting pairing. Lit: Paired and active |
| 9 | Serial Number | Easy-read serial number of the device. |
| 10 | SIM Serial | Serial number of the built-in SIM |
| 11 | MFG Serial | Full serial number of the device. |
| Rear Panel | ||
|---|---|---|
| No. | Name | Description |
| 1 | Supply | Power supply to the SA380-IT |
| 2 | Functional Earth | Common Earth point for all device measurement |
| 3 | Loop Earth | Secondary Earth point for earth continuity measurement |
| 4 | Monitored Circuits | Connections for the IT circuits that require insulation monitoring |
| 5 | HiZ Outputs | A simple means of safely monitoring the insulation of the supply circuit. |
| 6 | Auxiliary Outputs | I/O to other devices and alarm circuits |
| 7 | GSM Antenna | Facilitates GSM connection to an Enterprise Asset Management System |
| 8 | Ethernet Jack | Allows local configuration and diagnostics, or Ethernet connection to an Enterprise Asset Management System |
| 9 | Fixing Stud | M5 mounting studs to fit BR930 / Q Style relay mountings. Brackets are available to allow alternate mounting arrangements |
| 10 | Quality Control | Device had undergone voltage withstand, calibration and inspection processes. |
| 11 | Supply Voltage | 110 V AC or 12 V DC supply indication. |
3.3) Typical Circuit
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
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
| Parts | |
|---|---|
| SA380-IT |
|
| M5 A2 Stainless Steel Washers |
|
| M5 A2 Stainless Steel Nuts |
|
| Tools | |
| 8 mm Nut driver or 8 mm spanner |
|
- 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.
- 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
| Parts | |
|---|---|
| 0.75 mm2 Shrouded Ferrule crimps |
|
| Uninsulated Ferrule Crimps |
|
| 0.75 mm2 stranded single core cable |
|
| 1.5 mm2 stranded single core "earth" cable |
|
| Cable Markers | No Image |
| Tools | |
| Square Wire End Ferrule Crimper |
|
| Wire Stripper / Cutter |
|
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.
Affix cable marker beads if required.
Strip 12 mm of outer insulation from the end of the cable
Select the correct crimp:
- 0.75 mm2 cable: WEIDMULLER H0,75/16 W SV INSULATED FERULE. P/N: 9025860000
- 1.5 mm2 cable: WEIDMULLER H1,5/10 UNINSULATED FERULE. P/N: 0186500000
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
| Parts | |
|---|---|
| 0.75 mm2 stranded single core cable |
|
| 0.75 mm2 Shrouded Ferrule crimps |
|
| Cable Markers | No Image |
| "Live End" Circuit Termination Crimps | No Image |
| Main Fuse T2A Fuse | No Image |
| Tools | |
| Square Wire End Ferrule Crimper |
|
| Wire Stripper / Cutter |
|
| Additional Crimping / Fixing Tool(s) | No Image |
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.
Wire the "+" and "-" supply terminals as shown:
Do not use resistive cables
Supply Voltage Ranges:
Labelled Voltage | Min. V | Max. V |
|---|---|---|
| 110 V AC | 40 AC/DC | 160 AC/DC |
| 12 V DC | 10 DC | 16 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
| Parts | |
|---|---|
| 1.5 mm2 stranded single core "earth" cable |
|
| Uninsulated Ferrule Crimps |
|
| Cable Markers | No Image |
| "Live End" Circuit Termination Crimps | No Image |
| Tools | |
| Square Wire End Ferrule Crimper |
|
| Wire Stripper / Cutter |
|
| Additional Crimping / Fixing Tool(s) | No Image |
"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.
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
| Parts | |
|---|---|
| 0.75 mm2 Shrouded Ferrule crimps |
|
| 0.75 mm2 stranded single core cable |
|
| Cable markers | No Image |
| Resistive cable modules |
|
| "Live End" circuit termination crimps | No Image |
| Optional circuit fuses | No Image |
| Tools | |
| Square Wire End Ferrule Crimper | |
