SIGMA 3

GROUND FAULT RELAY

C-EG44EM, February 2021

ABOUT I-GARD
I-Gard’s commitment to electrical safety provides both industrial and commercial
customers with the products needed to protect their electrical equipment and the
people that operate them.
As the only electrical-safety focused company whose product portfolio includes
neutral grounding resistors, high-resistance grounding systems and optical arc
mitigation, we take pride in our technologies that reduce the frequency and
impact of electrical hazards, such as arc flash and ground faults.
For those customers who have purchased from us over the last 30 years, you
know us for the quality and robustness of our products, our focus on customer
service and technical leadership. We build on this foundation by investing
in developing new products in electrical safety education - including EFC
scholarship program - by actively participating in the IEEE community programs
on technical and electrical safety standard, and working with local universities
at discovering new technologies. We remain unrelenting in our goal of improving
electrical safety in the workplace.
Our commitment to excellence is validated by long-standing relationships with
industry leaders in fields as diverse as petroleum and gas, hospitals, automotive,
data centers, food processing, aerospace, water and waste water plants, and
telecommunications. We provide our customers with the product and application
support required to ensure that their electrical distribution system is safe and reliable.

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TABLE OF CONTENTS
SUBJECT
1. Introduction .................................................................................................................................2
2. Description ..................................................................................................................................2
3. Operation ....................................................................................................................................2
4. Trip Relay and Auxiliary Fault Relays .......................................................................................6
5. LED Indicators and Diagnostics ................................................................................................6
6. Settings .......................................................................................................................................8
7. Use with Sigma3-TDM Touchscreen Display Module ...........................................................14
8. MODBUS Communication ........................................................................................................18
9. Installation .................................................................................................................................22
10. Commissioning ..........................................................................................................................25
11. Technical Specifications ............................................................................................................32
12. Catalogue Numbers ...................................................................................................................33
Appendix A: Excerpt from CAN / CSA M421-00: Use of Electricity in Mines .............................33

TABLES
Table 6.1: Trip Relay Operating Mode Setting Dip switch #1 (left hand array)
Table 6.2 Trip Memory Selection Dip switch #2 (left hand array)
Table 6.3 Ground Fault Trip Time Delay Settings Dip switches #3 - #4 - #5 - #6 - #7 (left hand
array)
Table 6.4 Ground Fault Trip Current Level Settings Dip switches #8 - #9 - #10 (left hand array)
Table 6.5 System Frequency Selection Dip Switch #11 (right hand array)
Table 6.6 NGR Let-through Current Settings Dip Switches #12 - #13 - #14 - #15 - #16 (Right
Hand Array )
Table 8.1: MODBUS ID Address Map
Table 8.2: MODBUS RTU Standard 8 Byte Holding Register Read Function (03)
Table 8.3: Returned Information Structure for Holding Register Request
Table 8.4: Sigma Relay Register Definitions
Table 8.5: Relay Status Registers
Table 8.6: MODBUS Register Format Conventions
Table 10.1 NGR Test Values

FIGURES
Figure 3.1: Sigma 3 Typical System Diagram (HRG System)
Figure 3.2: Sigma 3 Typical System Diagram (LRG System)
Figure 3.3: The Creation of a Pulse Signature by Cycling the Let-Through Current Under Various
Arrangements
Figure 6.1: Sigma 3 Dip Switch Array
Figure 7.1: Sigma 3 to Sigma3-TDM Connection Diagram
Figure 7.2: Home Screen
Figure 7.3: Status Screen
Figure 7.4: Event Log
Figure 7.5: Settings Page
Figure 7.6: Sigma and Alarm Settings Page
Figure 7.7: Pulse Contactor Settings Page
Figure 7.8: Communications Settings Page
Figure 8.1(a): Preferred 4-wire MODBUS Communication Connection
Figure 8.1(b): Alternate 2-wire MODBUS Communication Connection
Figure 9.1: Sigma 3 Terminal Connections
Figure 10.1: Potentiometer to be used to Adjust HF1 Current
Figure 10.2(a): Setup for Offline Calibration Showing the Ammeter Connected
Figure 10.2(b): Example of DC Ammeter used in Calibration Procedure
Figure 10.3: Partial Short NGR when Performing Offline Calibration
Figure 10.4: Sigma3-TDM to Sigma3 Connection
Figure 10.5: Sigma3 Settings Page
Figure 10.6: Sigma3 Calibration Page
Figure 11.1: Dimensional Drawings

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1. INTRODUCTION
The I-Gard Sigma 3 monitor relay is a combination ground fault relay and Neutral Grounding Resistor (NGR)
monitoring relay. The Sigma 3 monitor relay protects against ground faults and abnormal resistance values of the
NGR.

The Sigma 3 monitor relay is specifically designed for a variety of system voltages and an NGR limiting the
maximum NGR current to the relay’s set let-through current.

The Sigma 3 monitor relay is designed to operate with a TxA or Rx-yA zero sequence current sensor, an NGRS#
sensing resistor with NGRX filter, and an NGR sized to limit ground fault current.

The let-through current measured by the zero sequence current sensor will be the vector sum of any leakage
currents or charging currents normally in the system and any ground fault currents that may be present.

2. DESCRIPTION

The Sigma 3 monitor relay measures the current through the NGR, the transformer neutral-to-ground voltage, and
the NGR resistance. The relay compares the measured values with the field settings of the relay and provides relay
outputs and LED indications when an abnormal condition is detected.

Ground fault current is measured using the zero sequence current sensor. The ground fault trip level is DIP switch
selectable as a percentage of the NGR let-through current setting at 5%, 10%, 15%, 20%, 25%, 30%, 40%, and
50%. Trip time is DIP switch selectable from 60 milliseconds to 3.15 seconds.

Neutral-to-ground voltage is measured by means of the NGRS-. The NGRS- sensing resistor is used by the Sigma
3 monitor relay in combination with the zero sequence current sensor as part of a comparator to monitor the NGR
resistance. This NGR resistance monitoring complies with the requirements of CSA C22.1 section 10-302.

The Sigma 3 monitor relay provides a current source output for connection to a 1mA full scale ammeter. The output
signal is proportional to the measured current and is expressed as a percentage of the NGR let-through current
setting.

A watchdog failsafe normally open contact is also provided.

Pulsing signal terminals are provided to facilitate pulsing of the NGR as a ground fault locating technique where the
NGR is outfitted with a solid state relay pulsing contactor.

The Sigma 3 can be used with the Sigma3-TDM touchscreen display module to provide an advanced HMI.

3. OPERATION
3.1 System Components

The Sigma 3 is used with voltage and current sensors to monitor the system. The NGRS-## sensing resistor is
used to sense the voltage over the NGR. The zero sequence current sensor, which is used to sense the current
through the NGR, is an i-Gard type T2A, T3A, TxA or any Rx-yA zero sequence current sensor. In addition, the
Sigma 3 operates in injection mode when the current through the NGR is low, whereby a high frequency signal
is injected into the system to measure the zero sequence impedance. A filter is used in conjunction with the high
frequency injection signal called the NGRX. Combination NGRS / NGRX are also available, called NGRXS-##.

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For High Resistance Grounded Systems (HRG) a single high frequency injection channel (HF1) is employed. See
Figure 3.1 below for the typical system with the Sigma 3 connections. For Low Resistance Grounded Systems
(LRG) two high frequency injection channels (HF1 and HF2) are employed. See Figure 3.2 below for the typical
system with the Sigma 3 connections.

Figure 3.1: Sigma 3 Typical System Diagram (HRG System)

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 DANGER

Figure 3.2: Sigma 3 Typical System Diagram (LRG System)

3.2 Ground Fault Detection

The Sigma 3 monitor detects ground faults by measuring the current through the NGR using the zero sequence
current sensor (TxA or Rx-yA sensors). When the measured value exceeds the set-point the GND FLT LED
illuminates, the GND FLT form-C contact energizes, and the trip relays energize.

The Sigma 3’s NGR let-through current setting is set by DIP switch to match the rating of the NGR. The trip level
is DIP switch selectable as a percentage of the NGR let-through current setting and can be set as: 5%, 10%, 15%,
20%, 25%, 30%, 40%, and 50%.

The ground fault trip delay setting defines the length of time that a ground fault must persist before the fault is
qualified as such. This setting is DIP switch selectable from its minimum setting of 60 milliseconds to 3.15 seconds.

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3.3 NGR Monitoring

The Sigma 3 monitor relay also monitors the health of the NGR to ensure that it does not become open or short
circuit. If the Sigma 3 determines that the NGR is not healthy the NGR FLT LED illuminates, the NGR FLT form-C
contact energizes, and the trip relays energize.

The Sigma 3 monitor relay monitors the NGR using one of two methods: measurement mode and injection mode.
If the leakage current through the NGR is over 5% of the rated let-through current, the Sigma 3 operates in
measurement mode. In measurement mode, the leakage current through the NGR is measured by the ZSCS and
the voltage across the NGR is measured by the NGRS. The Sigma 3 uses these values to calculate the apparent
resistance of the NGR. If this calculated value is determined to be over 150% of the nominal value or less than 66%
of the nominal value, the Sigma 3 annunciates an NGR fault.

If the leakage current through the NGR is below 5% of the rated let-through current, the Sigma 3 operates in
injection mode. In injection mode, a high frequency signal is injected into the system through a band-pass
filter (NGRX). The Sigma 3 uses the current and voltage of the high frequency signal to calculate the apparent
resistance of the NGR. If this calculated value is determined to be over 150% of the nominal value or less than 66%
of the nominal value, the Sigma 3 annunciates an NGR fault.

3.4 Pulsing

Pulsing is a technique that is employed in high resistance grounded systems to locate a ground fault. The NGR
is divided into a non-pulsing section and a pulsing section that includes a contactor. The pulsing section can be
inserted into the system by the operation the contactor. This cycles the let-through current of the NGR between
different values (usually from 50% to 100% of the rated let-through current) and this signature can be used to trace
the location of the ground fault. Various pulse arrangements are shown in Figure 3.3 below.

Pulse signals are available from the Sigma 3 that can be used to create the signature by driving an NO solid state
relay that is used as the pulsing contactor. These are available at terminals 19, 20, and 21. If using pulse down
signals use terminals 19 and 21. If using pulse up signals use terminals 20 and 21. Terminals 19-21 are normally
energized with +12VDC and terminals 20-21 are normally de-energized. When pulsing is enabled by closing
terminals 25-26 or by enabling at the Sigma3-TDM touchscreen HMI, the pulse signals cycle at a frequency of 1Hz.
The cycle frequency can be changed using the Sigma3-TDM touchscreen HMI.

Figure 3.3: The creation of a pulse signature by cycling the let-through current under various arrangements

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4. TRIP RELAY AND AUXILIARY FAULT RELAYS
The Sigma 3 has four output relays:

- A TRIP relay
- An NGR FAULT auxiliary relay
- A GROUND FAULT auxiliary relay
- A WATCHDOG auxiliary relay

All relays are electrically held, i.e. when control power is off the relays are always in the de-energized state. The de-
energized states are shown on the front of the Sigma 3. Note that this is irrespective of the trip relay operating mode.
All relays can be in one of two states: idle or tripped. For the trip relay, its status (energized or de-energized) when in
each of these states depends on its operating mode, which is set by DIP switch 1.

4.1 Trip Relay (15-16, 17-18)

A trip relay consisting of an NO and NC pair is provided. Terminal 15-16 is normally closed and terminal 17-18 is nor-
mally open. This relay energizes on occurrence of a ground fault or NGR fault. The trip relay can be programmed for
shunt trip or failsafe operation.

When the Sigma 3 is operating in shunt trip mode, when there is no fault condition present the trip relay remains idle
(de-energized). If a fault condition is detected and qualified, the trip relays becomes tripped (energized).

When the Sigma 3 is operating in failsafe mode, when there is no fault condition present the trip relay is normally idle
or energized. The trip relay is tripped of de-energized if a fault condition is detected on the system. The trip relay is
also de-energized when control power is off.

4.2 NGR Fault (AUXILIARY RELAY)

A Form-C auxiliary contact for NGR faults is provided. This is located at terminals 39, 40, and 41. The NGR FAULT
auxiliary relay operates exclusively in shunt trip mode regardless of the setting of DIP switch.

4.3 Ground Fault (AUXILIARY RELAY)

A Form-C auxiliary contact for ground faults is provided. This is located at terminals 42, 43, and 44. The GROUND
FAULT auxiliary relay operates exclusively in shunt trip mode regardless of the setting of DIP switch.

4.4 Watchdog (51-52)

Terminals 51-52 is a system normal watchdog. When the Sigma 3 is de-energized it is open. When the Sigma 3 is
energized but not in alarm it is closed. If the Sigma 3 goes into alarm mode, the watchdog changes state and opens
back.

5. LED INDICATORS AND DIAGNOSTICS

The Sigma 3 has 4 indication LEDs located on its front panel: the Green PWR (Power) LED; the Red GND (Ground)
FAULT LED; the Red NGR FAULT LED; and the ZONE GR. (Zone Grading) LED.

5.1 Start-up and Reset Indications

The Sigma 3 has a start-up sequence where the Red GND FAULT, NGR FAULT and ZONE GR. LEDs flash twice
before being turned OFF. The Green PWR LED may also flash before it is turned ON.

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During a manual reset the Red GND FAULT, NGR FAULT and ZONE GR. LEDs turn ON for two seconds as indication that the
reset sequence is taking place. During this time the Green PWR LED will intermittently flash. After this sequence the LEDs
give the start-up sequence described above.

After the Sigma 3 has gone through the start-up sequence and is operating normally the Green PWR LED will turn ON and
the Red GND FAULT, NGR FAULT and ZONE GR. LEDs will turn off.

5.2 Power On LED (Green)

The Green PWR LED will turn ON when control power is applied to the Sigma 3 and the relay is operating normally.

The Green PWR LED will intermittently flash if control power is applied to the Sigma 3 but the relay is not operating correctly
due to a malfunction in the microprocessor circuit. Control power must be cycled in order to reset the Sigma 3.

The Greed PWR LED will intermittently flash during a manual reset or a power-up reset.

5.3 GND Fault LED (Red)

The Red GND FAULT LED will turn OFF when the Sigma 3 is operating normally and no ground fault has been detected or
qualified.

The Red GND FAULT LED will turn ON when the Sigma 3 has detected and qualified a ground fault. The Red GND FAULT
LED will remain ON until the Sigma 3 is manually reset even if the ground fault condition has been rectified.

The Red GND FAULT LED will intermittently flash when the Sigma 3 is powered up after having been powered down while
indicating a ground fault. The Sigma 3 must be manually reset to clear this condition.

The Red GND FAULT LED will turn on during manual reset as described above.

5.4 NGR Fault LED (Red)

The Red NGR FAULT LED will turn OFF when the Sigma 3 is operating normally and no NGR Fault has been detected and
qualified.

The Red NGR FAULT LED will turn ON when the Sigma 3 has detected and qualified an NGR Fault. The RED NGR FAULT
LED will remain ON until the Sigma 3 is manually reset even if the NGR fault condition has been corrected.

The Red NGR FAULT LED will intermittently flash when the relay is powered up after having been powered down while indi-
cating an NGR Fault. The Sigma 3 must be manually reset to clear this condition.

The Red NGR FAULT LED will turn ON during a manual reset as described above.

5.5 Func. (Red)

The FUNCTION LED will turn ON when the ZONE I/L input circuit is active, i.e. Normally Open (NO) contacts connected to
these inputs are closed.

The FUNCTION LED will intermittently flash when the relay’s self-test circuit is enabled through the operation of the TEST
pushbutton on the front panel.

The FUNCTION LED will turn ON while the installer is adjusting the operational settings on the Sigma 3 by way of the DIP
switches. When the relay detects that the installer has stopped making adjustments to these settings the Red ZONE GR. LED
will turn OFF.

The FUNCTION LED will turn ON during a manual reset as described above. 7
6. SETTINGS

Settings are defined using selectable DIP switches. A diagram of the DIP switch array is shown in Figure 6.1 below.

Figure 6.1: Sigma 3 Dip Switch Array

6.1 Trip Relay Operating Modes

The trip relay operating settings can be set with DIP switch 1. The Sigma 3 can be set for a shunt trip operating mode
(not failsafe) or an undervoltage trip operating mode (failsafe) operation with the trip relay operating mode dip switch.
See Table 6.1 for configuration details.

6.1.1 Shunt Trip Mode

In the shunt trip mode (not failsafe), the trip relay remains de-energized (no trip) when control voltage is applied to the
Sigma monitor relay and the system is operating normally. The trip relay is energized (trip) when the measured values
of the ground fault current or NGR Resistance exceed the threshold settings for the time specified.

The trip relay will energize (trip) after a fault is qualified and will remain energized (tripped) until the Sigma monitor relay
is reset whether or not the fault that caused the trip remains present on the system. The trip relay will be de-energized
(no-trip) if the control voltage is removed.

When control voltage is applied the trip relay will at first be de-energized (no-trip) and the Sigma monitor relay will start
operating normally. If the trip memory option is OFF the trip relay will remain de-energized (no-trip). However, if the trip
memory option is ON and a trip state is stored in the non-volatile memory, the trip relay will energize (trip) approximate-
ly 1 second after control voltage is applied and will remain energized (tripped), regardless of whether a fault is present
on the system.

The trip relay will de-energize (no-trip) if the Sigma monitor relay is reset through a local or remote reset. When reset,
the Sigma monitor relay will resume monitoring of the system and, if a fault remains on the system, will detect the fault
and will re-trip, energizing the trip relay.

6.1.2 Failsafe (Undervoltage Trip) Mode

When programmed for the FAILSAFE (UNDERVOLTAGE TRIP) MODE and the Sigma 3 is operating normally, the trip
relay energizes approximately 1 second after control voltage is applied. The trip relay de-energizes (trips) under any of
the following conditions:

- The measured values of the ground fault current or NGR resistance exceed the threshold settings for the
time specified
- The Sigma 3 is reset
- Control voltage is removed

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The trip relay remains energized after a trip, providing control voltage is present, until the Sigma 3 is reset whether or
not the fault that caused the trip remains present on the system.

When control voltage is applied the trip relay will at first be energized (no-trip) and the Sigma 3 will start operating
normally. If the trip memory option is OFF the trip relay will remain energized (no-trip). However, if the trip memory
option is ON and a trip state is stored in the non-volatile memory, the trip relay will de-energize (trip) approximately
1 second after control voltage is applied to the relay and will remain de-energized (tripped), regardless of whether a
fault is present on the system.

The trip relay will energize (no-trip) if the Sigma 3 is reset through a local or remote reset. When reset, the Sigma 3
will resume monitoring of the system and, if a fault remains on the system, will detect the fault and will re-trip, de-
energizing the trip relay.

6.2 Trip Memory Setting

The trip memory settings can be set with DIP switch 2. The Sigma 3 stores the states of the trip relay and auxiliary
fault relays in non-volatile memory and can, if programmed to do so by means of the TRIP MEMORY Setting, restore
the state of the trip relay when control power is applied.

The Sigma 3 can be set for trip memory ON (DIP switch #2 UP) or trip memory OFF (DIP switch #2 DOWN). See
Table 6.2 for configuration details.

When the trip memory option is OFF the trip relay and auxiliary fault relays are returned to their idle operating states
when control power is applied.

When the trip memory is ON the trip relay and auxiliary fault relays are restored to the state these relays had prior to
the loss of control power. If the Sigma 3 was indicating a fault condition when control power was lost, the states of the
trip relay and auxiliary fault relays will be maintained until the relay is manually reset.

The Sigma 3 retains the states of the trip relay and auxiliary fault relays stored in non-volatile memory indefinitely.

6.3 Ground Fault Trip Time Delay

The ground fault time delay settings can be set with DIP switches 3-7. The Sigma 3 can be programmed for ground
fault trip delays ranging from 60 milliseconds to 3.15 seconds.

Refer to TABLE 6.3 GROUND FAULT TRIP TIME DELAY SETTINGS to determine the DIP switch settings for the ap-
plication.

6.4 Ground Fault Trip Current Level

The ground fault trip current level setting can be set with DIP switches 8-10. The Sigma 3 can be programmed for a
number of ground fault trip levels expressed as a percentage of the NGR let-through current setting. Eight ground
fault trip level settings are available and are: 5%; 10%; 15%; 20%; 25%; 30%; 40%; 50%.

I-Gard recommends that the ground fault trip level setting be set as low as possible to provide maximum operating
personnel and equipment protection without having the Sigma 3 report ground faults falsely.

Refer to TABLE 6.4 GROUND FAULT TRIP CURRENT LEVEL SETTINGS to determine the DIP switch settings for
the application.
Caution: CAN/CSA-M421-00 Use of Electricity in Mines Paragraph 3.5.5 states, in part, that “Where ground-fault
protection is used, the supply shall be … de-energized in less than 1s if ground-fault current exceeds 20% of the pro-
spective ground-fault current”. Therefore, I-Gard recommends that the ground fault trip level be set as low as possible
and not higher than 20% when complying with this CSA Mine Safety Standard.

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6.5 System Frequency

The system frequency setting can be set with DIP switches 11. A system frequency of 50Hz or 60Hz can be chosen.
Refer to TABLE 6.5 SYSTEM FREQUENCY SETTINGS to determine the DIP switch settings for the application.

6.6 NGR Let-Through Current

The NGR let-through current setting can be set with DIP switches 12-16. The Sigma monitor relay has thirty two
settings for the NGR let-through current. Refer to TABLE 6.6 FOR DIP SWITCH SETTINGS for the NGR let-through
current.

The NGR let-through current settings in Table 9.6 show that the Sigma monitor relay can be configured for let-through
currents ranging from 5 Amperes through 400 Amperes using a standard I-Gard TxA ZSCS.

The NGR let-through current settings in Table 6.6 are intended to show that the Sigma monitor relay can be config-
ured for let-through currents ranging from 1 Ampere through 4 Amperes using a standard I-Gard TxA ZSCS with the
conductor carrying the NGR current wrapped through the CT’s primary window 10 times to create a primary winding
of 10 turns.

The Sigma monitor relay can be configured for let-through currents over 400 Amperes using an I-Gard ZSCS sized for
the intended application.

Contact the factory if settings other than those are required in the intended application.

6.7 DIP Switch Configurations

Mode Dip Switch Setting

Failsafe (Undervoltage Trip)

Sigma Relay is Idle/Not-Tripped:

Trip Relay is energized
Aux Fault Relays are not energized UP
Sigma Relay is Tripped:
Trip Relay is energized
Aux Fault Relays are energized

Non-Failsafe (Shunt Trip)

Sigma Relay is Idle/Not-Tripped

Trip Relay is not Energized
Aux Fault Relays are not energized DOWN

Sigma Relay is Tripped

Trip Relay is Energized
Aux Fault Relays are energized

(U = Up, D = Down)

Table 6.1: Trip Relay Operating Mode Setting Dip Switch #1 (left hand array)

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 Trip Memory On/Off Dip Switch Setting
TRIP MEMORY ON

Control voltage off after trip:

When control voltage restored
Trip and Aux relays idle* then immediately UP
re-trip (within 2 seconds).

TRIP MEMORY OFF

Control voltage off after trip:

When control voltage restored
Trip and Aux relays idle* but do not DOWN
immediately re-trip
Trip and Aux relays will re-trip if a fault is
detected after monitoring starts.

(U = Up, D = Down)
Table 6.2: Trip Memory Selection Dip Switch #2 (Left hand array)

Ground Fault Trip Time Dip Switch Settings

Delay (in milliseconds) 3 4 5 6 7
60 D D D D D
150 D D D D U
250 D D D U D
350 D D D U U
450 D D U D D
550 D D U D U
650 D D U U D
750 D D U U U
850 D U D D D
950 D U D D U
1050 D U D U D
1150 D U D U U
1250 D U U D D
1350 D U U D U
1450 D U U U D
1550 D U U U U
1650 U D D D D

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 1750 U D D D U
1850 U D D U D
1950 U D D U U
2050 U D U D D
2150 U D U D U
2250 U D U U D
2350 U D U U U
2450 U U D D D
2550 U U D D U
2650 U U D U D
2750 U U D U U
2850 U U U D D
2950 U U U D U
3050 U U U U D
3150 U U U U U
(U = Up, D = Down)
Table 6.3: Ground Fault Trip Time Delay Settings Dip Switches #3-#4-#5-#6-#7 (left hand array)

Ground Fault Trip Level (% of NGR Dip Switch Settings

Let-Through Current) 8 9 10
5% D D D
10% D D U
15% D U D
20% D U U
25% U D D
30% U D U
40% U U D
50% U U U
(U = Up, D = Down)
Table 6.4: Ground Fault Trip Current Level Settings Dip Switches #8 - #9 - #10 (left hand array)

System Frequency 60/50 Hz Dip Switch Setting

System Frequency 50 Hz U

System Frequency 60 Hz D
(U = Up, D = Down)
Table 6.5: System Frequency Selection Dip Switch #11 (right hand array)
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NGR Let-Through Dip Switch Settings ZSCS Employed
Current (Amps)
12 13 14 15 16
1 D D D D U TxA or Rx-yA w/10 Turns
Through Primary
2 D D D U U TxA or Rx-yA w/10 Turns
Through Primary
3 D D U D U TxA or Rx-yA w/10 Turns
Through Primary
4 D D U U U TxA or Rx-yA w/10 Turns
Through Primary
5 D D D D D TxA or Rx-yA
10 D D D D U TxA or Rx-yA
15 D D D U D TxA or Rx-yA
20 D D D U U TxA or Rx-yA
25 D D U D D TxA or Rx-yA
30 D D U D U TxA or Rx-yA
35 D D U U D TxA or Rx-yA
40 D D U U U TxA or Rx-yA
45 D U D D D TxA or Rx-yA
50 D U D D U TxA or Rx-yA
55 D U D U D TxA or Rx-yA
60 D U D U U TxA or Rx-yA
65 D U U D D TxA or Rx-yA
70 D U U D U TxA or Rx-yA
75 D U U U D TxA or Rx-yA
80 D U U U U TxA or Rx-yA
90 U D D D U TxA or Rx-yA
95 U D D U D TxA or Rx-yA
100 U D D U U TxA or Rx-yA
125 U D U D D TxA or Rx-yA
150 U D U D U TxA or Rx-yA
175 U D U U D TxA or Rx-yA

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 200 U D U U U TxA or Rx-yA
225 U U D D D TxA or Rx-yA
250 U U D D U TxA or Rx-yA
275 U U D U D TxA or Rx-yA
300 U U D U U TxA or Rx-yA
325 U U U D D TxA or Rx-yA
350 U U U D U TxA or Rx-yA
375 U U U U D TxA or Rx-yA
400 U U U U U TxA or Rx-yA
500 D U D D U 10,000:1
600 D U D U U 10,000:1
800 D U U U U 10,000:1
1000 U D D U U 10,000:1
1250 U D U D D 10,000:1
1500 U D U D U 10,000:1
2000 U D U U U 10,000:1
2250 U U D D D 10,000:1
2500 U U D D U 10,000:1
(U = Up, D = Down)

Table 6.6: NGR Let-Through Current Settings Dip Switches #12-#13-#14-#15-#16 (Right Hand Array)

7. USE WITH TOUCHSCREEN DISPLAY MODULE

The Sigma 3 can be used with a touchscreen HMI called the Sigma3-TDM. The Sigma 3 is connected to the Sigma3-
TDM using its MODBUS communication. The connection of the Sigma 3 to the Sigma3-TDM is shown in Figure 7.1.

The Sigma3-TDM touchscreen HMI provides for: display of the status and readings of the Sigma 3; configuration and
operation of pulse contactor settings; viewing of logging and trending data; remote reset of the Sigma 3; as well as
providing TCP/IP communication.

When the Sigma 3 is connected to the Sigma3-TDM the home screen shown in Figure 7.2 below appears on the
Sigma3-TDM. Navigate to the System Status page using the associated button. The screen as shown in Figure 7.3
appears. Here the fault current and NGR voltage can be observed as well as the System Ground Fault and NGR Fault
statuses. TEST and RESET can be activated here, as well as pulsing.

Navigate to the Logging and Trending page using the associated button on the home screen. The Logging and Trend-
ing page is shown in Figure 7.4 below.

14
 Figure 7.1: Sigma 3 to Sigma3-TDM Connection Diagram

Navigate to the Settings page using the associated button on the home screen. The Settings page is shown in Figure
7.5 below. From here, the Sigma Settings page can be accessed. Select the system voltage (i.e. L-L voltage). Pulse
frequency can be selected. Settings for the alarm annunciation can be selected here as well.

Figure 7.2: Home Screen

15
 Figure 7.3: Status Screen

Figure 7.4: Event Log Page

16 Figure 7.5: Settings Page

Figure 7.6: Sigma and Alarm Settings Page

Figure 7.7: Pulse Contactor Settings Page

Figure 7.8: Communications Settings Page 17

8. MODBUS COMMUNICATION

The Sigma 3 has 4-wire RS-485 communications port to allow communications to a remote terminal or network, a
4-wire RS-485 communications port is provided at the bottom left of the Sigma 3. The 6-slot terminal block supplied
has screw terminals. Terminal # 1 must not be used. Only terminals 2, 3, 4, 5 and 6 are to be used as shown in Figure
8.1 below, with the preferred 4-wire connection in Figure 8.1(a) and the 2-wire connection in Figure 8.1(b). Note that
when the Sigma3-TDM is being used, communication connections to the system should be made through the
Sigma3-TDM. This is through the Sigma3-TDM TCP/IP communication port.

The protocol supported is MODBUS RTU. The MODBUS I/D number for the Sigma 3 is not programmable and is set
according to the serial number (see Table 8.1 below). The baud rate is not programmable and is set to 9600 BPS. The
frame set-up is 8 bit, no parity and 1 stop bit.

The communications cable should ideally be standard 4-wire with two twisted-pairs, and a grounding shield to prevent
electromagnetic interference. The shield of the cable between nodes should not be continuously grounded but should
be grounded at one end. The cable may be grounded at the Sigma 3 using the ground connection provided on termi-
nal # 6.

Figure 8.1 (a): Preferred 4-wire MODBUS Communication Connection

18
 Figure 8.1 (b): Alternate 2-wire MODBUS Communication Connection

8.1 MODBUS Functions

One MODBUS function is supported, read holding register (03). The Sigma 3 provides access to 32 MODBUS regis-
ters available. This document summarizes the format and function of these registers. The request from the master is
always 8 bytes long and are as shown in the table below. In the MODBUS RTU system the Sigma 3 operates in a cli-
ent/server communications model or master/slave communications model. In the client/server communications model
the Sigma 3 is the MODBUS server and will respond to requests sent to it by a MODBUS client. In the master/slave
communications model the Sigma relay is the MODBUS slave and will respond to requests sent to it by a MODBUS
master.

Last Digit of Sigma 3 MODBUS Slave ID (Hex)

Serial Number
XXX0 0A
XXX1 0B
XXX2 02
XXX3 03
XXX4 04
XXX5 05
XXX6 06
XXX7 07
XXX8 08
XXX9 09
Table 8.1: MODBUS ID Address Map
19
The MODBUS requests sent to the MODBUS master or client are 8 bytes long as shown in Table 8.2 below.

Starting Address No. of Registers CRC

Unit I/D Function Requested
High Low High Low High Low

02 03 nn nn nn nn cc cc

Table 8.2: MODBUS RTU Standard 8 Byte Holding Register Read Function (03)

The data format of the MODBUS registers is nnnnH for four hexadecimal digits, ddddB for four binary digits and
ddddddddB for eight binary digits. Numbers above are, for example, a request for 2 registers only, starting from ad-
dress 02. CRC checksum is a 16 bit CRC as described in MODBUS information.

If successful, the Sigma 3 will return the message shown in Table 8.3 below.

Unit I/D Function No. of Bytes Data 1 Data N CRC

High Low High Low High Low High Low
02 03 nn nn nn nn nn nn cc cc

Table 8.3: Returned Information Structure for Holding Register Request

Register contents are shown in Tables 8.4 to 8.6 as below.

NOTE: Register number is shown in decimal but must be sent in hexadecimal form in the request.

The MODBUS register number is translated in the request such that register number 40001 is sent as hexadecimal
address 0000H, register number 40002 is sent as hexadecimal address 0001H, register number 40003 is sent as
hexadecimal address 0002H and so on.

The MODBUS registers can be read using the starting address in a block and the number of registers required up to
the number of registers available in a given block.

There are times when the Sigma 3 relay processor will not be able to respond to a request since it is busy with other
tasks and no response will be returned. For this reason it is recommended to request the maximum number of regis-
ters used by the system in a single request.

Register # Contents Format Register # Contents Format

400012 ASCII nnnnH 40021 nnnnH
characters
40002 nnnnH 40022 nnnnH
40003 nnnnH 40023 nnnnH
40004 nnnnH 40024 nnnnH
40005 nnnnH
40006 nnnnH
40007 nnnnH
20
 40008 nnnnH
40009 nnnnH
40010 nnnnH
40011 nnnnH
40012 nnnnH 40030 Relay status nnnnH 40012
40013 nnnnH 40031 NGR Status nnnnH 40013
40014 nnnnH
40015 nnnnH 40040 Internal measurement of the GF cur- nnnnH 40015
rent as measured by the CT
40016 nnnnH 40041 Reserved (always 0000h) nnnnH 40016
40017 nnnnH 40042 Internal measurement of the NGR + nnnnH 40017
NGRS Resistance
40018 nnnnH 40043 Internal measurement of the NGR + nnnnH 40018
NGRS Resistance
40019 nnnnH 40044 The measurement of the let-through nnnnH 40019
current expressed as a percentage,
0-100 decimal, of the set let-through
current

40020 nnnnH 40045 The measurement of the let-through nnnnH 40020

current expressed as a percentage,
scaled to 0-1ffH of the set let-through
current

Table 8.4: Sigma Relay Register Definitions

Registers 040040 to 040045:

Register CTavg Nresv NGR1 NGR2 Pct1 Pct2

40040: 0000H 0000H 0000H 0000H 0000H 0000H

40040: Ctavg 0 to 0ffH
Internal measurement of the GF current measured by the CT
40041: Resv Reserved (always 0000h)
40042: NGR1 0 to 0ffH Internal measurement of the NGR + NGRS resistance
40043: NGR2 0 to 0ffH Internal measurement of the NGR + NGRS resistance
40044: Pct1 0 to 064H The measurement of the let-through current expressed as a
percentage, 0-100 decimal, of the set let-through current
40045: Pct2 0 to 1ffH The measurement of the let-through current expressed as a
percentage, scaled to 0-1ffH of the set let-through current

21
 Register 40030
The status of the Sigma relay’s output relay are bit mapped register 40030. The main trip relay
is mapped to Bit 0 which is 1 when the relay is tripped otherwise this bit is 0. The GND fault
relay is mapped to Bit 1 which is 1 when the relay is operated otherwise this bit is 0. The NGR
fault relay is mapped to Bit 2 which is 1 when the relay is operated otherwise this bit is 0

40030: 0000H or xxxx-xxxx-xxxx-0bbbB

X - don’t care
b - bit mapped relay status: 0 = all relays off
3 = main & gnd fault relays ON
5 = main & ngr fault relays ON
6 = main gnd fault & ngr fault relays ON

Register 40031
The status of each of the Sigma relay’s three red LEDs is mapped to individual hexadecimal digits in
MODBUS register 400031 as shown below.
40031: 0000H
0zng
hex. digit 0: g - gnd fault led status: 0 = OFF, 1 = ON, 2 = FLASHING
hex. digit 1: n - ngr fault led status: 0 = OFF, 1 = ON, 2 = FLASHING
hex. digit 2: z - zone led status: 0 = OFF, 1 = ON, 2 = FLASHING
hex. digit 3: always zero

Table 8.5: Relay Status Registers

nnnnH four decimal digits where n can b 0-9 or A-F

ddddB four binary digits where d can be 0 or 1
ddddddddB eight binary digits where d can be 0 or 1
Table 8.6: MODBUS Register Format Conventions

9. INSTALLATION
9.1 Sigma 3

9.9.1 Location

The Sigma monitor relay should be located as close as possible to the system’s isolating device, circuit breaker or
contactor.

9.1.2 Mounting

Mount the Sigma monitor relay horizontally using 35 mm DIN rail bolted or firmly fixed to flat surface. Allow at least 20
mm of rail to extend beyond each end of the relay.

22
Secure the relay to the DIN rail ensuring the release latches at the bottom of the relay engage the rail. If the relay is to
be mounted in any other position take appropriate steps to prevent the relay from disengaging from the DIN rail.

9.1.3 Connections

Refer to Figure 9.1 for electrical connections to the Sigma monitor relay. Terminals on the relay will accept up to #14
AWG wire.

Connect the G terminal on the Sigma monitor relay to a suitable grounding point. Connect control power to terminals L
and N. An isolation transformer is recommended as the source of supply to prevent excessive voltage being applied to
the relay’s internal power supply.

This grounding point should be electrically common to the grounding point of the NGR.

The Sigma monitor relay must be grounded as described above. As the relay’s housing is non-metallic, no chassis
bond is required.

Connect the sensing resistor input terminals on the Sigma monitor relay to the R terminal of the NGRS-XX sensing
resistor as shown in the connection diagram below.

Connect terminals 47 & 48 on the Sigma monitor relay to the X1 and X2 terminals of the zero sequence current sensor
as shown in the connection diagram below.

Refer to the description of the trip relay operating mode settings for an explanation of the shunt (not failsafe) and un-
dervoltage (failsafe) operating modes and the relay contact states for each of these operating modes. The connection
of field devices to the terminals of the Sigma monitor relay must be as specified in the installation specifications. These
include the trip relay terminals, the auxiliary fault relay terminals, the external reset, test and the G/F meter terminals.
If door/panel mounted or remote test and/or reset controls are required, connect momentary single pole single throw
(SPST) normally open contact pushbuttons to the appropriate terminals on the Sigma monitor relay. Refer to the con-
nection diagram below. These contacts are to be voltage free.

If a panel/door mounted or remote ground fault meter is required, an I-Gard GM-AM1 type meter or a meter conform-
ing to specifications given in this document can be connected to the appropriate terminals on the Sigma monitor relay.
Refer to Figure 9.1. The I-Gard percentage ammeter is designed for use in this application. If a meter other than the
I-Gard GM-AM1 is used, observe the polarity shown on the front panel and in Figure 9.1.

9.2 Zero Sequence Current Sensor

9.2.1 Location

The ZSCS should be mounted near the system transformer neutral (whether a transformer or a generator) along with
the NGRS-XX sensing resistor and NGR.

9.2.2 Mounting

The overall dimensions of the T2A ZSCS are 104 mm x 104 mm x 44 mm. If another size zero sequence current sen-
sor is used please refer to document C-700EM sensors.

9.2.3 Connections

The neutral point of the system is to be connected to the ungrounded end of the neutral grounding resistor such that
this conductor passes through the window of the ZSCS.
The secondary terminals, X1 and X2, must be connected to the appropriate terminals on the Sigma monitor relay as
shown in the connection diagram below.
23
9.3. NGRXS-## Sensing Resistor

The NGRS-XX sensing resistor must be selected from those available from I-Gard and must be one that is designed
for use in a system with a system voltage in which it will be installed.

9.3.1 Location

The NGRS-XX sensing resistor should be mounted near the system transformer, along with the ZSCS and the NGR.

9.3.2 Mounting

The overall dimensions of NGRS-1 to NGRS-7 (from 140 to 700 volts) sensing resistor are 89 mm x 65 mm x 71
mm. A metal mounting bracket extends from one side of the housing. The bracket has two 6 mm mounting holes in it
through which bolts or self threading screws can be used to mount the 1 to NGRS-7 sensing resistor to a flat surface.
Refer to Figure 11.1.

9.3.3 Connections

The neutral terminal of the NGRS-XX sensing resistor must be connected to the ungrounded end of the NGR. This is
the same connection point as it is connected to the system neutral. Refer to Figure 3.1 or 3.2. The R terminal of the
NGRS-XX sensing resistor must be connected to the appropriate terminal of the Sigma monitor relay as shown in
Figure 3.1 or 3.2. The G terminal of the NGRS-XX sensing resistor should be connected to a suitable ground point.
This grounding point should be separate from the ground path from the NGR so that the ground path from the NGR is
monitored as well as the NGR itself.

Figure 9.1: Sigma 3 Terminal Connections

24
10. COMMISSIONING
A general breakdown of commissioning of the Sigma 3 would involve the following:

- Review of installation and condition of unit

- Verification of connections
- Verification of settings
- Energization of Sigma 3
- Functional Verifications:
o Test and Reset
o Pulsing
o Communication with the Sigma3-TDM
- Current injection (primary or secondary) to verify GND Fault functionality
- NGR short circuit test
- NGR open circuit test
- Offline Calibration (may be initially omitted if NGR > 20Ω)
- Energization of system
- Online Calibration (if system zero sequence impedance noticeably changes while online)

10.1 Calibration Procedure

1. Introduction

1.1 Calibration of the Sigma3 may or may not need to be performed.

1.2 Calibration of the Sigma3 may need to be done if it is experiencing nuisance NGR faults or if it is failing to
produce an NGR fault on the short circuit test or open circuit test.

2. Description of General Procedure

2.1 Perform Pre-calibration: Measure HF1 current and adjust if needed (see 4 below)

2.2 De-energize the system.

2.3 Perform Offline Calibration: Calibrate the sensitivity of the Sigma3 NGR fault lower threshold

Alternately:

Perform Online calibration using the Sigma3-TDM touchscreen display module. Skip to section 6 below.

3. Required Equipment

3.1 DC micro ammeter; scaled 0-1mA: 0-100%

3.2 Wire to partially short the NGR

4. Pre-Calibration Procedure

4.1 Measure the HF1 current to verify if it is between 10mA and 25mA. If it is not, adjust as follows:

4.2 Remove the cover from the Sigma3.

25
4.3 Locate potentiometer R84 as shown in the Figure 10.1 below.

4.4 With control power still provided to the Sigma3, adjust the potentiometer until the HF1 current is 19mA.

Figure 10.1: Potentiometer to be used to Adjust HF1 Current

5. Offline Calibration Procedure

1. Make note of the present Sigma3 DIP switch settings.

2. De-energize the system (i.e. ensure the NGR associated with this Sigma3 is not live).

3. Install (if not present already) a DC micro ammeter (scaled 0-1mA : 0-100%) to terminals 49 and 50 of the
Sigma3 as shown in Figure 10.2 below.

4. Set DIP switch 14 and 15 to ON with the rest of the DIP switches set to OFF.

5. Wait for the FUNC LED to clear.

6. Press RESET.

7. Enter calibration mode by pressing TEST and RESET at the same time. Ensure that the LEDs are not on at the
moment that calibration mode is initiated.

8. Short part of the NGR out so that it has an impedance of 10% of the NGR ohmic value (e.g. if the NGR has a rating
of 55Ω, short out enough elements of the NGR to give an impedance of approximately 5Ω. See Figure 10.3 below.
If the NGR has a pulsing section, ensure that the short includes the pulsing section.

26
9. In this calibration mode, the DIP switches #1 to #10 represent the value of the NGR fault short-circuit tripping value
as a binary number. Adjust DIP switches #1 to #10 by sequentially increasing the setting in the following manner:

9.1. Observe that the DC meter goes to 100% full scale upon entering calibration mode.

9.2. Start with an initial value of 0000 0000 01 and systematically find the value of the most significant bit.

9.3. Increase to 0000 0000 10. Observe if the needle of the DC meter decreases in value.

9.4. Continue to increase the most significant bit (MSB) until the meter goes to a little higher than 40% of full scale.

9.5. Find the value at which the meter goes lower than 40% and produces an NGR fault (for example 0001 0000 00).

9.6. Then return the MSB to the value one less than the value found in 9.5 above (for example 0000 1000 00) and
continue in the same manner to find the next significant bit, until the NGR fault short-circuit tripping value has
been found to its least significant bit.

10. Press RESET.

11. Return DIP switches back to the normal settings recorded in step 1.

12. Press RESET.

13. Remove the short from the NGR.

Figure 10.2 (a): Setup for Offline Calibration Showing the Ammeter Connected
27
 Figure 10.2 (b): Example of DC Ammeter used in Calibration Procedure

Figure 10.3: Partial Short on NGR when Performing Offline Calibration

28
6. Online Calibration Procedure Using Sigma3-TDM

1. Ensure the Sigma3-TDM is connected to the Sigma3 as shown in Figure 10.4 below, or refer to the installation section
of C-EG44-EM.

Figure 10.4: Sigma3 -TDM to Sigma3 connection

2. From the home page, navigate to SETTINGS -> SIGMA & ALARM SETTINGS and ensure that the system settings
are correct for the application (see Figure 10.5 below).

Figure 10.5: Sigma3 Settings Page

29
3. From the home page, navigate to SETTINGS -> SYSTEM CALIBRATION as shown below.

Figure 10.6: Sigma3 Calibration Page

4. With the system in its stable normal operating conditions observe the value of “Conductance Measurement”.
Note this value as CM (normal).

5. Turn “Calibration Mode” to ON.

6. Calculate and set the new “Open Circuit Sensitivity Threshold” as = 70% * CM(normal).

7. Calculate and set the new “Short Circuit Sensitivity Threshold” as = 2 * CM(normal).

8. Turn “Calibration Mode” to OFF.

9. Return to home screen.

30
10.3 Warning Concerning Hi-Pot and Dielectric Testing of the System

As the Sigma monitor relay, NGRS-XX sensing resistor and ZSCS have undergone and passed high-pot testing at
the factory, field testing of the relay is unnecessary and may damage these components. For any high-pot tests or
dielectric withstand tests on the system conducted in the field, the Sigma monitor relay, NGRS-XX sensing resistor
and ZSCS must be prepared as described below to avoid damaging this equipment.

1) Ensure all control circuits are disconnected and insulated.

2) Disconnect the conductor on terminal R of the NGRS-XX sensing resistor from the Sigma monitor relay
and ensure the conductor is insulated.

3) Disconnect the conductor on terminal G of the NGRS-XX sensing resistor from ground and ensure the con-
ductor is insulated.

4) Disconnect the conductors between the X1 and X2 terminals of the ZSCS and the Sigma monitor relay and
ensure these conductors are insulated.

5) Disconnect the control power leads from the Sigma monitor relay and ensure these conductors are insulated

6) Connect short conductors between the L, N and G terminals of the Sigma monitor relay ensuring that the G
terminal remains connected to ground.

7) Perform the high-pot or dielectric withstand tests required.

8) Reconnect the conductors between the X1 and X2 terminals of the CT and the Sigma monitor relay.

9) Reconnect the conductor between terminal G of the NGRS-XX sensing resistor and the appropriate
terminal on the Sigma monitor relay. Refer to Figure 3.1.

10) Reconnect the conductor from the G terminal on the NGRS-XX sensing resistor to ground.

11) Remove the conductors added between the L, N and G terminals of the Sigma monitor relay ensuring that
the G terminal remains connected to ground.

12) Reconnect the conductor from the R terminal of the NGRS-XX sensing resistor to the appropriate terminal of
the Sigma monitor relay. Refer to Figure 3.1.

13) Reconnect all control circuits which were disconnected in step 1.

14) Reconnect the control power to the L and N terminals of the Sigma monitor relay.

31
11. TECHNICAL SPECIFICATIONS
Electrical Ratings:

Control: 110-240VAC
5VA AC or 5W DC
Range: -45% to + 10%
(60-264V AC/DC)

Output Relay Contacts:

Main Trip Relay:

Type: Form Z (NO and NC Pair)
Rating: 10A @ 240VAC
10A @ 30VDC
1/2 HP @ 240VAC All relays are electrically held and are de-energized
when control power if OFF.
Auxiliary Ground Fault Relay:

Type: 1 Form C (NO/NC) Failsafe: When the failsafe option is ON, the trip relay is
Rating: 10A @ 240VAC normally energized when control power is ON and is
8A @ 24VDC de-energized in a trip state. When in shunt trip mode,
1/2 HP @ 240VAC the trip relay is normally de-energized when control
Auxiliary NGR Fault Relay: power is ON and is energized in a trip state.

Type: 1 Form C (NO/NC)

Rating: 10A @ 240VAC
8A @ 24VDC
1/2 HP @ 240VAC

Figure 11.1: Dimensional Drawings

32
 12. CATOLOGUE NUMBERS

Sigma3: Ground fault relay & neutral grounding resistor monitor

GM-AM1: Analog meter, 3 ½ in. 0-1 mA with scale 0-100%
NGRS-XX: Sensing Resistor
TxA ZSCS: T2A, T3A, T6A or T9A zero sequence current sensors.
Rx-yA ZSCS: R4-17A, R7-13A or R8-26A zero sequence current sensors.

APPENDIX A: EXCERPT FROM CAN / CSA M421-00: USE OF

ELECTRICITY IN MINES

3.5.5 Ground-Fault Protection

Where ground-fault protection is used, the supply shall be:

a) Grounded through a neutral-grounding device that limits ground-fault voltage to 100V or less; and
b) De-energized in less than 1s if ground-fault current exceeds 20% of the prospective ground-fault current.

3.6.2 Neutral-Grounding Devices

A neutral-grounding device shall be:

a) Continuously rated, except when ground-fault tripping is provided;

b) Monitored so as to de-energize the supply in less than 60s if the neutral-grounding device opens; and
c) Connected as close as practical to the supply neutral.

C-EG44EM SIGMA3

Phone: 905-673-1553 Fax: 905-673-8472

Toll Free: 1-888-737-4787 [email protected]
www.i-gard.com