Ground Detector

Created 05.03.200 Revision B, 21.11.
2011, Fabi
Ground-Detector Type 05 BA 30.24-211E

Blatt 1/13
GES9 332 030 P0001
1 Product Description ............................................................................................. 2

1.1 Front panel of the Ground-Detector Type 05 ............................................... 2
2 Function............................................................................................................... 3
3 Initial Commissioning .......................................................................................... 5
3.1 Commisioning after installation .................................................................... 5
3.1.1 Automatic tuning ................................................................................... 5
3.1.2 Tuning codes ........................................................................................ 6
3.1.3 Tuning errors......................................................................................... 6
3.1.4 Setting the value for „Error – furnace measurement circuit“.................. 7
3.1.5 Setting the value for „Warning level – Low Resistance“........................ 7
3.1.6 Setting the value for „Error – Ground connection“ ................................ 7
4 Operation............................................................................................................. 7
4.1 7-Segment Display ....................................................................................... 7
4.2 LEDs ............................................................................................................ 8
4.3 Analog Outputs ............................................................................................ 9
4.4 Digital Outputs.............................................................................................. 9
5 Serial interface .................................................................................................. 10
6 Hardware Information........................................................................................ 10
6.1 Supply voltages .......................................................................................... 10
6.2 Measurement range ................................................................................... 10
6.3 Analog outputs ........................................................................................... 10
6.4 Output contacts .......................................................................................... 10
6.5 Dimensions ................................................................................................ 10
6.6 Front panel ................................................................................................. 11
6.7 Frequency range, 2 units in one system .................................................... 11
6.8 Coupling circuit, Choke and Capacitor ....................................................... 11
7 Appendix ........................................................................................................... 12
7.1 Installation of the Philips Flash Utility ......................................................... 12
7.2 Software Upload......................................................................................... 12
7.3 Calibration of the analog outputs ............................................................... 13
ABP Induction Systems GmbH

Operating Instructions
44147 Dortmund, Kanalstr. 25
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Created 05.03.200 Revision B, 21.11.2011, Fabi

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GES9 332 030 P0001
1 Product Description
The Ground Detector Type 05 provides insulation supervision for induction furnaces
and induction heaters. The unit is connected though a series resonant circuit
between the furnace or heater coil and ground. As a result of the DC-blocking effect
of the series capacitor, the measurement circuit is immune to DC bias that may be
present on the load circuit. This DC voltage can be caused by unsymmetrical
operation of an inverter, through operation in a TwinPower circuit, and through
galvanic effects in the furnace refractory materials. With ground detectors that use
DC as a measurement signal, these external sources of DC signals can cause
nuisance tripping or destruction of the measurement unit.
An automatic tuning function has been provided to simplify the replacement of
components in the measurement circuit by automatically compensating for
component tolerances.
In addition there is a fail safe component supervision built into the unit which creates
an alarm in the event of a defective component in the measurement circuit.
1.1 Front panel of the Ground-Detector Type 05
Figure 1: Ground Detector Type 05


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GES9 332 030 P0001
2 Function
Figure 2 shows the external of this unit. The capacitor C1 is a film capacitor rated at
3200V. This capacitor blocks DC from entering the ground detector measurement
circuit. The choke has an inductance of about 100 Henries and is provided with high
voltage insulation rated at 7 kV from coil to core. The choke blocks the high AC
furnace voltage from entering the ground detector.
The microprocessor (µP) controlled unit is connected through this series resonant
L/C circuit to the load coil of the furnace. The measuring frequency is automatically
determined in the unit and from the actual values of components L1 and C1 in the
resonant measurement circuit.
The ground resistance of the load circuit is selectively measured in this unit and is
displayed on a 2-digit LED display. The measurement circuit is also continuously
supervised for faulty components.
Even with a high DC component, there is no disturbance to the measurement. The
measurement and signal circuit are isolated by means of a high voltage optical
coupler. So in case of a problem in the coupling circuit hazardous voltages cannot
appear on the low voltage terminals of the unit.
Additional protection is provided by means of a 75V varistor connected across the
measurement circuit terminals.
The unit is capable of automatically determining the resonance frequency of the
series resonant measurement circuit and self-calibrating to that frequency. This
should be done whenever any components in the measurement circuit are changed
or when the unit is first installed.


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GES9 332 030 P0001
M2
20mA
- + M1
10V
- +
8 7 6 5 4 3 2 1
Fres C1
Out 20mA
Out 10V
0-20mA
Closed:
+24V
GND
GND
GND
ca. 7Hz 4µF

X4
ca. 4Hz 2*4µF
Ground Detector
1
+24V
Type 05
parallel
2
GND
IN1
GES9 332 030 P1 ca. 9Hz 2*4µF
3
X1
GND series
4
IN2
5
Ground
2
GND
6
F2
X5
L1 C1 F1
1
+24V
RLC
1
GND
2
IN3
3
X2
GND
4
IN4
5
GND
6
X3
Rwarn
Rhigh
Rmin
Rmin
1 2 3 4 5 6 7 8
Figure 2: Connection Diagram
The unit is designed to be operated together with the following components:
• M1 Display unit 0 to 10V R>1kΩ

with scaling resistor GES9 430 111 P1
• M2 Optional, current display output 20mA, R<500 Ω
• L1 Choke ca. 100 H / 0.2A / 430Ω GES9 542 015 P3
• C1 Capacitor 4µF/3200V GES9 507 012 P11
• F1 Fuse 0.2A / 3000V GES9 302 019 P2
• Fuse holder GES9 302 019 P1
• F2 Varistor 75V GES9 182 008 P1


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GES9 332 030 P0001
3 Initial Commissioning
Figure 3: Front panel of the Ground Detector
3.1 Commisioning after installation

The unit must be calibrated together with the actual components of the measurement
circuit with which it will be operated. If any components are changed, the unit will
have to be recalibrated.
3.1.1 Automatic tuning

The system (meaning the furnace or heater coil) must first be grounded. In order to
activate the automatic tuning of the system-parameters and the testing of the
coupling circuit frequency, after reboot the unit, press the “Reset” button. On the LED
display you should see an “A-”. After this the automatic tuning routine is started by
pressing the „ “- key.
The tuning begins to automatically seek the natural series resonant frequency, by
looking for an in phase condition of the voltage and current signals. The frequency is
indicated on the LED display. After the frequency analysis is completed, the unit
begins to measure ground resistance.


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GES9 332 030 P0001
If no valid measurement result is determined during the frequency analysis, then the
display will indicate „EP“ (Error Phase measurement). After pressing the „ “-key the
frequency analysis routing will start again. In the case that no valid tuning condition is
found, the last valid tuning frequency will be used in the measurement mode.
If the automatic tuning results in a valid measurement, the display will automatically switch to
the measurement mode, and the measured parameters will be saved in the unit’s memory.
3.1.2 Tuning codes

The following codes are indicated on the display for each tuning step:
„A-“: The unit is waiting for the grounding of the load circuit, followed with
pressing the „ “ key
Number: The unit is seeking the resonance of the coupling circuit in the range
from 3…12Hz
„A1“: The short circuit current signal current is being measured
„A2“: The current signal is measured with a low resistance reference
resistance
„A3“: The current signal is checked with reference to a medium resistance
„A4“: The current signal is checked with a high reference resistance
3.1.3 Tuning errors

During the automatic tuning it is possible that error codes are displayed indicating
that the unit cannot find the resonant frequency or that the current signal is not within
its normal range. These errors generally mean that the test ground connection is not
properly installed or that there is a problem in the measurement components.
The error codes are:
„EP“: The phase measurement routine didn’t find a resonance, the test ground
connection is not secure, or there is a defective component in the coupling
circuit.
„E1“: The inductor resistance is outside the tolerance limits
„E2“: The test current signal for low resistances is outside the normal tolerance
limits
„E3“: The test current signal for medium resistances is outside the normal tolerance
limits
„E4“: The test current signal for high resistances is outside the normal tolerance
limits


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GES9 332 030 P0001
3.1.4 Setting the value for „Error – furnace measurement circuit“

The „R“-key is pressed and held for five seconds. The desired value is entered
using the „R“- und „R“-keys. The value is then confirmed with the „ “-key and the
display changes back to the measurement mode.
Operating range: 50 kΩ, but not higher than 80 kΩ.
3.1.5 Setting the value for „Warning level – Low Resistance“

The „R “- and the „R “-keys are pressed simultaneously and held for 5 seconds.
The desired value is then entered using the „R “- und „R “-keys. The value is then
confirmed using the “ “-key, and the display changes back to the measurement
mode.
3.1.6 Setting the value for „Error – Ground connection“

The „R“-key is pressed and held for 5 seconds. The desired value is then entered
using the „R“- und „R“-keys. The value is confirmed with the „ “-key, and the
display changes back to the measurement mode.
4 Operation
4.1 7-Segment Display

The unit has a 2-digit 7-segment display with a decimal point. The values displayed
are to be interpreted according to the following instructions.
If there is no decimal point indicated, the multiplier for the reading is 10Ω
(„78“ means 780Ω).
If a decimal point is indicated, then the multiplier for the reading is kΩ („1.2“ or „31.“
means 1.2kΩ or 31kΩ).
Note: The display has an active analog smoothing filter. The purpose of this is to
make the display more stable. As a result, for a particular change in the measured
ground resistance, the correct measured value will be reached a little bit after the
digital switching (alarm) output.
In the measurement mode the display can be toggled to the phase measurement
mode using the „ “-key. The display remains in the phase measurement mode as
long as the „ “-key is held.
If the decimal point is behind the second digit it indicates a negative phase angle
between current and voltage signals (leading phase angle). If the decimal point is
behind the first digit, it means the phase angle is over 90 degrees. In this case add
90 degrees to the indicated value to get the actual angle.


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GES9 332 030 P0001
4.2 LEDs
The condition of the unit and the measurements in normal operation are displayed
on the LEDs in the following way:
■ „24 V“: The internal isolated 24V voltage is OK
■ „3.3 V“: The internal isolated 3.3 V voltage is OK
■ „Sys Fault“: There is a fault in the unit
■ „Sys OK“: The unit is working OK
■ „Adj OK“: The automatic tuning procedure worked OK
■ „Adj Fault“: Too big phase difference between measurement voltage and
current, (coupling circuit fault)
■ „R Low“: The alarm value for ground fault was reached
■ „R Warn“: The warning value for ground resistance was reached, but it is not
yet a ground fault
■ „R OK“: The ground resistance is in the normal range
■ „R High“: Die maximum resistance of the furnace measurement circuit was
reached


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GES9 332 030 P0001
4.3 Analog Outputs

The analog outputs give the values of the measurement signals according to the
transfer function. For current and voltage there is only one signal and the signal
musts be scaled according to the desired display. (See GES9 430 111).
The range is 0.5V up to 10V ∞ to 0Ω and
1.0mA or 4.8mA up to 20mA ∞ to 0Ω.
The current output can be provided with a 0 mA (with jumper) or 4 mA (without

jumper) baseline by putting the jumper on plug X4 from position 7 to position 8. A 5%
offset applies to both the current and voltage signal.
The maximum load resistance for the 20 mA output is 100Ω.
Note: The analog outputs have an active smoothing filter. As a result of this, the
analog values are somewhat delayed with respect to the associated digital switching
(alarm) outputs.
Riso /
kΩ U/V I / mA I / mA
0 - 10V 0 - 20mA 4 - 20mA
0,0 10,00 20,00 20,00
0,1 9,41 18,82 19,00
0,7 7,01 14,02 15,20
1,5 5,31 10,62 12,50
5,0 2,75 5,50 8,40
10,0 1,77 3,54 6,80
∞ 0,50 1,00 4,80
0,00 0,00 4,00
4.4 Digital Outputs
„Rmin“: The alarm value for ground fault was reached. If the measured value is
smaller than Rmin = Contact open
„Rwarn“: The warning value of ground resistance was reached, but it is not yet a
ground fault. If the measured value is in “warning” range than Rwarn =
Contact open


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GES9 332 030 P0001
„Rhigh“: The maximum resistance for the measurement circuit was reached. If the
measured resistance is higher than Rhigh = Contact open.
„Rmin“: Rmin with reversed logic (compatible with old units). If the measured value
is smaller than Rmin = Contact closed.
5 Serial interface
The serial interface transmission rate is 115200 Baud, 8 Bit without Parity to debug
internal values of the resistance calculation. (This is only used by the equipment
manufacturer)
6 Hardware Information
6.1 Supply voltages

The supply voltage for this unit is 18 to 32V DC/ 250mA
Caution: Reversing the polarity to the 24 V supply will destroy the unit!
All 24V and 0V connections are internally connected together.
6.2 Measurement range

Measurement range: 0 Ω to 50 kΩ (functional range), max. 80 kΩ.
6.3 Analog outputs

Voltage 10V DC RLoad > 1kΩ
Current 0 – 20mA DC RLoad < 500Ω (with jumper X4/7-X4/8) or
Current 4 – 20mA DC RLoad < 500Ω (without jumper X4/7-X4/8)
6.4 Output contacts

Isolated contacts.
Voltage (DC or AC): max 100V
Current: max 100mA
Isolation voltage: 1000V
6.5 Dimensions
Without mounting hardware LxBxH: 125X85X55mm3
Weight: 400g


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GES9 332 030 P0001
The unit is designed to be mounted with standard top hat rail.
6.6 Front panel
6.7 Frequency range, 2 units in one system

The measurement technique is designed to work over a range of 3Hz to 12Hz.
Values outside this range will cause a measurement error. The frequency is
determined automatically according to the resonant frequency of the coupling circuit.
In operation with a single unit a higher frequency should be chosen because the
reaction time to resistance change is generally faster at the higher end of the
frequency range.
In operation with two units in one system, frequencies that are near the opposite
ends of the range should be chosen in order to minimize the interaction between
measurements. Both frequencies must be separated by at least a factor of 2.
6.8 Coupling circuit, Choke and Capacitor

The coupling choke has a nominal value of about 100 Henry and 450Ω. The
tolerance for inductance is 30% and for resistance 20%.
The coupling capacitor value typically has a range of 2.2µF ... 10µF und 20%
tolerance.
The voltage withstand rating of these components must be high enough to work
reliably in this application.


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GES9 332 030 P0001
7 Appendix
This information is only for equipment manufacturers and ABP in Dortmund.
7.1 Installation of the Philips Flash Utility

To perform a software update using a PC, the Philips Flash Utility must be installed.
This works like a normal Windows installation, and in general all the programmable
values can be loaded.
After installation this programming tool must be started and configured. The serial
port can be specified. Under Windows-XP, a USB Adapter und simulated ports can
also be selected. Use settings 115kBaud, w/o DTR/RTS.
Further, select the Processor „LPC2292“ and the clock -Frequency 14745kHz.
7.2 Software Upload

The unit can be opened by removing the four corner screws and removing the front
plate. The jumpers BR202 are monitored and these should always be installed. The
jumper BR101 is then installed and the PC is connected through a RJ-45 -> Dsub-9
serial cable.
Now switch on the unit and start the Philips Flash Tool program. In the software
activate the button „Read Device ID“. After this the Flash Tool transmits a reset
command to the unit. This reset is the power on reset and has nothing to do with the
reset key on the front panel! Now press the reset switch S600 and press the “OK”
button, then the Flash Tool displays on the screen.
The software now shows, that is trying to read the Device ID from the unit. In the
case of a fault there will be a little longer Time-Out, at the end of which a fault
message will be displayed. If that should occur, the serial cable, connectors,
adapters, port selection, software installation, and jumpers in the unit should be
checked again.
If the unit is recognized by the software, you must load the data set into the Flash
Tool for the software upload to proceed. This upload at the same time verifies the
existing contents of the flash memory in the processor. The separate “Compare”
Menu function is optional and can be ignored.
After the uploading is completed close the Philips Program und switch off the 24V


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GES9 332 030 P0001
DC power from the unit. The jumper BR101 is again removed and the front panel re-
attached. When the unit is powered up again, the unit will run with the new software.
(In general the unit will start with the updated software as in the initial commissioning.
However, if you want to run the tuning procedure, you must select it as described.)
7.3 Calibration of the analog outputs

(All units are precalibrated by the manufacturer)
If it appears that the analog outputs are not calibrated, then you can calibrate them.
To do this you will need a meter that can measure up to 10V and 20 mA. The
calibration is performed automatically during booting up if the internal reset button
pressed and held. While this is happening, the LEDs „System Fault“ and „System
OK“ are lit. During initial commissioning it is not necessary to press the internal or
external reset button. This is only required during a subsequent calibration.
The calibration is performed by pressing the „“- and „“-keys. When you first press
the „“-key, you can see the reaction on the display. The output current is set to 20
mA and the voltage to 10V. The tuning is set by pressing the „ “-key.
This tuning will in most cases not have to be performed again. To restore the default
calibration, switch the unit on with the reset key pressed and held. The unit will then
run in its default condition.


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Created 05.03.200 Revision B, 21.11.

Ground-Detector Type 05 BA 30.24-211E

1 Product Description ............................................................................................. 2

ABP Induction Systems GmbH

Ground-Detector Type 05 BA 30.24-211E

1.1 Front panel of the Ground-Detector Type 05

Figure 1: Ground Detector Type 05

ABP Induction Systems GmbH

Ground-Detector Type 05 BA 30.24-211E

ABP Induction Systems GmbH

Ground-Detector Type 05 BA 30.24-211E

ca. 7Hz 4µF

Figure 2: Connection Diagram

The unit is designed to be operated together with the following components:

• M1 Display unit 0 to 10V R>1kΩ

ABP Induction Systems GmbH

Ground-Detector Type 05 BA 30.24-211E

Figure 3: Front panel of the Ground Detector

3.1 Commisioning after installation

3.1.1 Automatic tuning

ABP Induction Systems GmbH

Ground-Detector Type 05 BA 30.24-211E

3.1.2 Tuning codes

3.1.3 Tuning errors

ABP Induction Systems GmbH

Ground-Detector Type 05 BA 30.24-211E

3.1.4 Setting the value for „Error – furnace measurement circuit“

3.1.5 Setting the value for „Warning level – Low Resistance“

3.1.6 Setting the value for „Error – Ground connection“

4.1 7-Segment Display

ABP Induction Systems GmbH

Ground-Detector Type 05 BA 30.24-211E

ABP Induction Systems GmbH

Ground-Detector Type 05 BA 30.24-211E

4.3 Analog Outputs

The current output can be provided with a 0 mA (with jumper) or 4 mA (without

4.4 Digital Outputs

ABP Induction Systems GmbH

Ground-Detector Type 05 BA 30.24-211E

6.1 Supply voltages

6.2 Measurement range

6.3 Analog outputs

6.4 Output contacts

ABP Induction Systems GmbH

Ground-Detector Type 05 BA 30.24-211E

The unit is designed to be mounted with standard top hat rail.

6.6 Front panel

6.7 Frequency range, 2 units in one system

6.8 Coupling circuit, Choke and Capacitor

ABP Induction Systems GmbH

Ground-Detector Type 05 BA 30.24-211E

This information is only for equipment manufacturers and ABP in Dortmund.

7.1 Installation of the Philips Flash Utility

7.2 Software Upload

ABP Induction Systems GmbH

Ground-Detector Type 05 BA 30.24-211E

7.3 Calibration of the analog outputs