EFL Relay User Manual
Contents
1. LED Indication LED ON OF FLASHING Status IntemalFaut gt gt Trip FC FCHealthy FC Trip Logical FC Le NE Undervoltage UV Trip S n Fygle UV EFLO Status EFLO Trip EFLO Healthy EFLO Test Underway Find Out More Elec FC Electrical FC Trip A For more information on this product contact Ampcontrol Customer Service on 61 1300 267 373 or customerservice ampcontrolgroup com or visit the Ampcontrol website ampcontrolgroup com 9 EQUIPMENT LIST Part Number 173151 EFL Protection Relay 173175 EFL Protection Relay with Internal 415V 1100V Barrier 173176 External 415V 1100V Barrier suit EFL Protection Relay2. YN IN EARTH FAULT LOCKOUT PROTECTION RELAY User Manual Version 1 JUL 2015 Designed and manufactured in Australia by Ampcontrol Pty Ltd AMPCONTROL 1 7 a hs Ampcontrol Pty Ltd ABN 28 000 915 542 NTR EFL PROTECTION RELAY USER MANUAL cs an MAG 178 Version 1 JUL 15 WARNING This safety alert symbol identifies important safety messages in this manual and indicates a potential risk of injury or even death to personnel When you see this symbol be alert your safety is involved carefully read the message that follows and inform other operators CASTON This safety alert symbol identifies important information to be read in order to ensure the correct sequence of work and to avoid damage or even destruction of the equipment and reduce any potential risk of injury or death to personnel Supplementary information not directly affecting safety or damage to equipment Carefully read the message that follows and inform other relevant personnel Information concerning possible impact on the environment and actions required for prevention and proper response PP hs Ampcontrol Pty Ltd ABN 28 000 915 542 NTR EFL PROTECTION RELAY USER MANUAL Qu sn MAG 178 Version 1 JUL 15 Copyright Notice The Ampcontrol EFL Relay described in this document is the property of AMPCONTROL PTY LTD It is furnished under a license agreement and is to be used only in accordance with the terms of the agreement No par
3. A oiai M 6 PRODUCT OPERATION Ampcontrol Pty Ltd ABN 28 000 915 542 EFL PROTECTION RELAY USER MANUAL MAG 178 Version 1 JUL 15 6 1 Logical Operation of the EFL Relay The following flow chart provides an insight into the logical operation of the EFL Relay Individual test functions are presented as sub processes and the functionality of these tests can be seen in the Individual test flow charts C EFL Relay Energised p Tripped State Await reset Open CBR FC Logical Trip MC closed prior initial EFLO test Are there any latched trips Is the main contactor already closed Perform EFLO Test refer to EFLO Test Process flow chart Open MCR EFLO Trip Outlet failed EFLO test MCR Closed EFLO healthy EFLO test passed Perform FC Test refer to FC Test Process flow chart Open CBR FC Trip Outlet failed FC test Trip type as per FC Test Process FC test passed CBR Closed FC healthy Is the MCI input closed No Yes Outlet Running Perform UV Test refer to UV Test Process flow chart Open MCR UV Trip Outlet failed UV test No UV test passed Yes Figure 6 1 Logical Operation of the EFL Relay General Overview PP hs Ampcontrol Pt
4. amp UV Trip Reset S4 N O Pushbutton Typical Control Schematic se p 13 26 CB SSI Q RUN NO RESET COM O Pee From MCA 20 e a al o 9 NS EFL CBR CB STOP Pic Contact lt So RUN COM MCA A 5 29 21 ae A als Py EARTH Q EARTH FC TRIP RESET EARTH o START EFL MCR MC STOP L 6 30 PUSHBUTTON S va External vema 00 vema RUN INPUT f MCA Barrier 7 31 ERRE Ed cs ME ee En Et fe Sad AR eas J ae e O Vb If Used VcmB C i 5 VemB I i 0 Vc VemC Oo VemC r Enclosure C T gt Trailing Reeling Cable NOTE TERMINALS 3 4 12 16 22 23 24 27 amp 28 Load Figure 4 6 Typical Electrical Application 4 4 1 Power Supply Terminals 1 amp 2 The EFL relay is supplied by either 24Vdc 20 or 24Vac 20 The power consumption of the relay is less than 5W 4 4 2 Earth Fault Lockout EFLO Trip Indication Terminals 5 amp 6 The EFLO Trip Indication Contact is a normally closed NC contact that is used to provide external indication that an EFLO trip has occurred The contact is energised when the system is healthy and will de energise close when an EFLO trip is active PP hs Ampcontrol Pty Ltd ABN 28 000 915 542 EFL PROTECTION RELAY USER MANUAL MPCONTRO a MS MAG 178 Version 1 JUL 15 4 4 3 Frozen Contactor FC Trip Indication Terminals 7 amp 8 The FC Trip Indication Contact is a normally closed NC contact that is used to provide external indication that
5. 1 Enclosure Dimensions Stand Alone EFL Relay eeeeee 10 Figure 4 2 Enclosure Dimensions External Barrier rrrnrrvnnrrnnrrvnnvrnnnrennvrennr 11 Figure 4 3 Enclosure Dimensions EFL Relay with Internal Barrier 11 Figure 4 4 Terminal Numbering Arrangements for EFL Relay with Extemal DAIVICE EEE 11 Figure 4 5 Terminal Numbering Arrangement for EFL Relay with Tee AE Barle EEE 12 Figure 4 6 Typical Electrical Application anonnnrnnnrnnnennnrnnnennnrnnnevnnrnnnennnennnnnnee 12 Figure 6 1 Logical Operation of the EFL Relay General Overview 15 Figure 6 2 Logical Operation of the EFL Relay EFLO Test 9 0 O oepa E AEE EE EE 16 Figure 6 3 Logical Operation of the EFL Relay FC Test Process 0 17 Figure 6 4 Logical Operation of the EFL Relay UV Test Process 18 Figure 6 5 EFL Relay User Interface Functionality of Operators 0006 19 Figure 6 6 EFL Relay User Interface Functionality of LEDS rrrrrnnrnnnnrnnnrrnnre 19 a hs Ampcontrol Pty Ltd ABN 28 000 915 542 NTR EFL PROTECTION RELAY USER MANUAL cs an MAG 178 Version 1 JUL 15 1 SAFETY AND OTHER WARNINGS For safety reasons the EFL Relay must be installed operated and serviced only by competent electrical personnel Read and understand this instruction manual completely before installing operating or servicing this equipment Fail
6. Lockout TeSt cccccceccceccceeecececeeeceeeceecseeseeeceeeseeeseeeseeenes 14 2 TNT 14 5 3 Undervoltage Test rarrnnnnnnnnnnnanernnnnvnrnranrnnnnnnnnennanennnnnnnnennanennnsnnanennnsennn 14 PRODUC TPM 15 6 1 Logical Operation of the EFL Relay rrrrnnrrnnnnrnnnnrrnnnrrnnnnrennnrrnrnnrennnrennn 15 6 2 Earth Fault Lockout EFLO Protection FUNCTION cccccecseeeeeeeeeeees 16 6 3 Frozen Contactor FC Protection Function rrarrrrnrerarrnnarennnneranennanennn 17 6 4 Undervoltage UV Protection Function rrrnrrvnnvrnnnrennvrennrrnnnrernernnneennn 18 ES VET qi cl ene ene eee ene er eee cee eee eee ee ese cere 19 6 6 First Time Use Use after Extended Storage cccscceseeeeseeeseeeeneeeeaes 20 7 SERVICE MAINTENANCE amp DISPOSAL ruernrnnvrvvnrnnervennnnrrrennnnrerennrnnerernnnne 21 7 1 Equipment INSPECTIONS ccccceccceeeceeeceeese esse eeseeeseeesaeeseeseeeneeeneeeneeenes 21 7 2 Equipment Maintenance ccccccecccecccececeeeceeeceeeseeeceeeseeeceeeseeeseeeneeenes 22 7 3 Equipment Service rrarrrranrrrrarrrrnnnrnrnnrrnnnnennnnrnnnnsennnnennnnnennnnennnnsennanennnn 22 TARE Ned 22 SPENN 23 9 EQUIPMENT LIS T secasscmewnecetcaudassnneensadeutde suanedaanadannseseesevanettaxesienaidneastanccasmenes 23 PP he Ampcontrol Pty Ltd ABN 28 000 915 542 AMPCONTROL EFL PROTECTION RELAY USER MANUAL al yr MAG 178 Version 1 JUL 15 TABLE OF FIGURES Figure 4
7. an FC trip has occurred The contact is energised when the system is healthy and will de energise close when an FC trip Is active 4 4 4 Main Contactor Relay MCR Terminals 9 10 amp 11 The MCR relay is the EFL s control relay for the main contactor The relay is a change over allowing the control circuit to be implemented with either normally open or normally closed MCR The MCR relay is intended to be wired into the control circuit for the main contactor s auxiliary relay MCA The MCR will energise when the system is deemed healthy allowing power to be applied to the interposing relay when required When the system cannot be deemed healthy either when the EFL is Starting in a tripped state or immediately after the contactor has opened prior to EFLO test being performed the MCR relay will be de energised preventing the interposing relay from energising and hence preventing the main contactor from closing 4 4 5 Circuit Breaker Relay CBR Terminals 13 14 amp 15 The CBR relay is the EFL s control relay for the upstream circuit breaker The relay is a change over allowing the control circuit to be implemented with either normally open or normally closed CBR The CBR relay is intended to be wired into the control circuit for the upstream circuit breaker The CBR will energise when the FC is in a healthy state If an FC trip occurs the CBR will be de energised tripping the upstream circuit breaker and removing power from th
8. housings wall boxes and other mechanical fixtures are secured in place This includes terminal box lids tightness of cable glands integrity of wall box mountings security of equipment fixing to walls DIN rails etc e Verify all electrical connections are secure with no loose screw terminals or DIN rail terminals not fitted to rails etc PP i N Ampcontrol Pty Ltd ABN 28 000 915 542 AMPCONTROL EFL PROTECTION RELAY USER MANUAL p MAG 178 Version 1 JUL 15 7 2 Equipment Maintenance The EFL Relay has no user serviceable parts All repairs must be WARNING carried out by Ampcontrol only If a fault develops return the EFL Relay to Ampcontrol for repair It is essential that no attempt be made to repair the EFL Relay as any attempt to dismantle or repair the EFL Relay can seriously compromise the safety performance of the unit and voids any product warranty It is recommended that the electrical protection system incorporating the EFL Relay be subject to regular functional tests at intervals determined by risk assessment or FMEA These intervals typically coincide with periodic maintenance checks and will cover but not limited to tests such as e Functional testing of the Earth Fault Lockout EFLO protection function e Functional testing of the Frozen Contactor FC protection function e Functional testing of the Undervoltage UV protection function 7 3 Equipment Service To ensure the continuing safe operation of the
9. inside a separate enclosure allowing this barrier to be installed closer to the phase conductors if required This external barrier is supplied with flying leads for connection to the phase conductors The external barrier is then required to be wired to a stand alone EFL Relay no internal barrier Key Features AS NZS 2081 2011 compliant Earth Fault Lock out EFLO protection Frozen Contactor FC protection Selectable Undervoltage UV protection Compatible with a wide range of system voltages Internal or external barriers available 3 2 Applications The Ampcontrol EFL is compliant to AS NZS 2081 2011 sections 7 amp 9 and has been designed for installation on mining outlets that require earth fault lockout and frozen contactor protection The EFL is capable of being installed on a wide range of system voltages from 110V up to 3 3kV barrier dependent In addition to EFLO and FC protection the EFL also offers a selectable undervoltage protection function The EFL Relay is not for use in hazardous areas Customers should select the EFL IS available in 2016 or OMA products for applications requiring intrinsic safety For a typical electrical installation diagram refer to Figure 4 6 a hs Ampcontrol Pty Ltd ABN 28 000 915 542 NTR EFL PROTECTION RELAY USER MANUAL cs an MAG 178 Version 1 JUL 15 4 INSTALLATION 4 1 General Warnings These instructions have been designed to assist users of the EFL Relay wit
10. 3 4 25 26 27 28 29 30 31 32 5 6 7 8 Stand Alone EFL Barrier Figure 4 4 Terminal Numbering Arrangements for EFL Relay with External Barrier a hs Ampcontrol Pty Ltd ABN 28 000 915 542 AMPCONTROL EFL PROTECTION RELAY USER MANUAL al por MAG 178 Version 1 JUL 15 13 14 15 16 Va Vb Vc 9 10 11 12 Flying Leads 1 2 3 4 5 6 7 8 17 18 19 20 21 22 23 24 25 26 27 28 EFL with Internal Barrier Figure 4 5 Terminal Numbering Arrangement for EFL Relay with Internal Barrier 4 4 Electrical Installation Information A B C To CB UV Coil Supply 13 c 1 al BRNO POWER is 24Vdc or 24Vac CBR COM POWER2 0 Supply Upstream NNN a9 15 g Circuit Breaker O CBR NC Internal Barrier Connections 5 E bo gs ae ee rn Se EFLO TRIP NC To Indication Circuit S 9 INDICATION 6 NC Energised When a O MCR NO COM O Healthy AN AN To MCA Relay Input 10 l To MCA Energised When Healthy 4 MCR COM aN O flying Leads Contact 11 7 I Q MCR NC ectrip NEO To Indication Circuit 17 INDICATION 8 NC Energised When GA Ne J MCI NO Q Q e d O COM O Healthy ee a Outlet NN Fro E Outlet Contactor F F L EE ae TT Contactor i Auxiliary Contact Ge 18 25 om O MCI COM RESET NO _ s EFLO
11. EFL Relay Ampcontrol recommends that the EFL Relay and associated barriers be returned to an Ampcontrol registered repair facility for service and inspection every 5 years 7 4 Disposal The electronic equipment discussed in this manual must not be treated as general waste By ensuring that this product is disposed of correctly you will be helping to prevent potentially negative breil consequences for the environment and human health which could acai otherwise be caused by incorrect waste handling of this product PP hs Ampcontrol Pty Ltd ABN 28 000 915 542 NT EFL PROTECTION RELAY USER MANUAL ED an MAG 178 Version 1 JUL 15 gt a 8 SPECIFICATIONS Supply Voltage Voltage 24Vd c 20 or 24Va c 20 50Hz Relay Contacts roug MCR Trip Contacts 1 x CO NO COM NC 23901 2 0 G SOON AGT GOVA ACTS CBR Trip Contacts 1 x CO NO COM NC 250V a c 6A 300VA AC1 60VA AC15 30V d c 1 2A DC1 250V a c 6A 300VA AC1 60VA AC15 EFLO Indication Contacts 1xNC 30V d c 1 2A DC1 250V a c 6A 300VA AC1 60VA AC15 FC Indication Contacts 1xNC 30V d c 1 2A DC1 Mechanical amp Environment Dimensions HxWxD 111 x 45 x 114mm EFL 111 x 22 x 114mm Barrier 111 x 75 x 114mm EFL with Internal Barrier Terminal Max Wire Gauge IP Rating Operating Temperature Humidit Air Flow The EFL is to be mounted in a position that allows unrestriced air flow through the upper and lower air vents
12. Logical Operation of the EFL Relay FC Test Process PP hs Ampcontrol Pty Ltd ABN 28 000 915 542 NTR EFL PROTECTION RELAY USER MANUAL Qu sn MAG 178 Version 1 JUL 15 6 4 Undervoltage UV Protection Function In addition to the EFLO and FC protection functions provided by the EFL Relay the EFL Relay also offers a selectable Undervoltage Protection Function This function will monitor the voltage on the outlet via the relay s HV Barrier and initiate an UV trip if the measured voltage falls below 50 of the selected system voltage The UV Protection Function can be activated and deactivated via the Voltage Selector Switch on the fascia of the EFL Relay If a UV trip occurs this trip will be latched in the memory of the EFL Relay In order to clear a UV trip the External Reset terminals must be shorted together This is typically achieved through the use of an externally wired normally open push button To reset a UV trip the External Reset terminals of the EFL Relay must be shorted together using an externally wired pushbutton or relay A UV trip cannot be cleared whilst the EFL Relay is de energised Begin UV Test Is UV Protection Activated Return UV Healthy Outlet Running RUN amp MCI are Closed Return UV Healthy Measured Voltage gt 50 of Setting Return UV Trip Figure 6 4 Logical Operation of the EFL Relay UV Test Process Return UV H
13. STATUS mn EFL Relay Charging the Undervoltage Trip Phase Cables during EFLO Test Undervoltage Healthy or Disabled OFF EFLO Healthy Figure 6 6 EFL Relay User Interface Functionality of LEDs PP he Ampcontrol Pty Ltd ABN 28 000 915 542 NTR EFL PROTECTION RELAY USER MANUAL cs ane MAG 178 Version 1 JUL 15 6 6 First Time Use Use after Extended Storage The EFL Relay uses an internal super capacitor to provide long term energy storage however after long periods of storage time the energy stored in the super capacitor will dissipate The consequence of the EFL Relay having a discharged super capacitor is that latched FC trips will not be able to be reset until the super capacitor has been recharged Recharging the super capacitor requires the unit to be connected to an external power source for a period of Smin This charging can occur when the unit is installed in its service enclosure by energising the control supply to the relay or when the relay is not installed by connecting the EFL relay to a standard car battery a hs Ampcontrol Pty Ltd ABN 28 000 915 542 NTR EFL PROTECTION RELAY USER MANUAL cs an MAG 178 Version 1 JUL 15 7 SERVICE MAINTENANCE amp DISPOSAL 7 1 Equipment Inspections A number of external system based checks should be completed on a regular basis These routine inspections must be carried out by suitably trained people with knowledge of the EFL Rela
14. d 2 2 Inspection Equipment that is found to be damaged or has been modified away from its published specification must not be used Please contact Ampcontrol if the equipment is suspected to be different than that ordered or if it does not match the published specifications 2 3 Storage after Delivery When the equipment is not to be installed immediately proper storage is important to ensure protection of equipment and validity of warranty All equipment should be stored indoors between 0 40 C preferably on shelves and protected from moisture and sunlight 2 4 Unpacking of Equipment The method of packing used will depend on the size and quantity of the equipment The following cautions should be interpreted as appropriate CAUTION Take care when unpacking crates as the contents may have shifted AN during transport The disposal of packaging materials replaced parts or components must comply with environmental restrictions without polluting the soil air or water Ensure that any timber and cardboard used as packaging is disposed of in a safe and environmentally responsible manner CRORE NTL ALERT Where possible dispose of all waste products i e oils metals plastic and rubber products by using an approved recycling service centre a hs Ampcontrol Pty Ltd ABN 28 000 915 542 NTR EFL PROTECTION RELAY USER MANUAL cs an MAG 178 Version 1 JUL 15 3 PRODUCT OVERVIEW 3 1 Product Description The Ampcon
15. e during or after installation e The installation is to be in accordance with the relevant installation Standards Codes of Practice e Modifications must not be made to any part of the EFL Relay As supplied the unit is built to and complies with the relevant standards Modifications to its construction will render the unit non compliant e Complete and accurate records of the installation must be kept as part of the site installation 4 3 Mechanical Installation Information The EFL Relay is available in two configurations the EFL Relay with Internal Barrier version or the Stand Alone EFL Relay with External Barrier 4 3 1 Mounting Arrangements The EFL Relay with Internal Barrier the Stand Alone EFL Relay and the External Barrier are all DIN Rail mounted CAUTION The EFL Relay and Barrier MUST be mounted in such a manner that allows unrestricted air flow through the upper and lower air vents 4 3 2 Enclosure Dimensions 118 114 Figure 4 1 Enclosure Dimensions Stand Alone EFL Relay pa i W Ampcontrol Pty Ltd ABN 28 000 915 542 AMPCONTROL EFL PROTECTION RELAY USER MANUAL hol DP MAG 178 Version 1 JUL 15 110 23 114 Figure 4 2 Enclosure Dimensions External Barrier 118 114 Figure 4 3 Enclosure Dimensions EFL Relay with Internal Barrier 4 3 3 Terminal Layouts 13 14 15 16 oe iy eads 9 10 11 12 5 6 7 8 ying 1 2 3 4 17 18 19 20 21 22 23 24 1 2
16. e frozen contactor 4 4 6 Main Contactor Input MCI Terminals 17 amp 18 The main contactor indication terminals should be wired to one of the main contactors normally open NO auxiliary contacts This provides indication on whether the main contactor is open or closed 4 4 7 Run Input RUN Terminals 19 amp 20 The run indication terminals should be wired to the contacts of the interposing relay that drives the main contactor This provides indication on whether the interposing relay is open or closed and hence whether the main contactor should be open or closed The RUN input tells the EFL what the main contactor should be doing and the MCI input tells the EFL what the main contactor is doing 4 4 8 Earth Connection Terminals 21 22 23 amp 24 The EFL Relay is to be earthed to the main earth using at least one 1 5mm earth cable 4 4 9 Reset Terminals 25 amp 26 The EFL Relay s Reset terminals allow a normally open pushbutton or contact to be wired to the EFL Relay to provide a reset function Provided that a fault condition is not still present shorting these two terminals will reset any EFLO or UV trips on the relay all FC trips must be reset using the push button on the fascia of the relay 4 4 10 Phase Conductor Connections Flying Leads The EFL Relay interfaces with the phase conductors of the protected outlet via a high voltage barrier The EFL can be purchased with an internal barrier or the EFL Relay and bar
17. ealthy r pb Ampcontrol Pty Ltd ABN 28 000 915 542 PCONTR EFL PROTECTION RELAY USER MANUAL v or MAG 178 Version 1 JUL 15 6 5 User Interface Rotate the Voltage Selector to select to system voltage of the outlet The Undervoltage Protection Function is also activated with this selector To turn UV Protection on select a system voltage within the white portion of the circle To turn off UV protection select a system voltage from the red side of the circle All FC Trips must be reset by pressing the RST pushbutton Provided that the EFL Relay s super capacitor is charged an FC Trip reset can be performed when power is not applied to the relay Rotate the Time Selector to select to time setting for the back emf timer This setting will determine the length of time that the EFL Relay will wait for back emf voltages to subside after the contactor has opened before applying the trip conditions to the UNDER VOLTAGE measurements EFLO STATUS Figure 6 5 EFL Relay User Interface Functionality of Operators Internal Fault EFL Relay Operating System Healthy FC Logical Trip Active FC Healthy FC Logical Healthy FC Trip Logical or Electrical Active Will continue to flash when power is not applied FC Electrical Trip Active FC Electrical Healthy UNDER VOLTAGE EFLO Trip EFLO
18. h installation Before the EFL Relay can be installed there are a number of things that need to be considered and understood to prevent incorrect or unsafe operation of the EFL Relay or the system into which it is installed Along with relevant competence and an understanding of the target application the following points should be considered 4 1 1 Ensure that the information provided in this user manual is fully understood It is extremely important that the limitations and functionality of the EFL Relay are understood to prevent incorrect installation and use from creating a potentially dangerous risk If in doubt as to the nature of the limitations or their implication consult a competent authority such as a Supervisor or Ampcontrol technical representative 4 1 2 Ensure that the application into which the EFL Relay is being installed has been properly defined designed and approved Any system intended to mitigate the risk of injury needs to be properly designed and implemented Such a system must be the result of structured risk analysis with the outcomes used to define the system requirements These requirements in turn will guide the choice of instrumentation logic solvers and actuators needed to implement the system Understanding the needs of the system will ensure proper selection of equipment 4 1 3 Ensure that the EFL Relay will properly perform the required functions within the system design It is important to understa
19. nd how the EFL Relay is intended to interact with other equipment within a system For safe and reliable use it is crucial that neither the EFL Relay logical operation nor its signalling be compromised by incompatibilities with connected equipment 4 1 4 Modifications of any form to the EFL Relay are prohibited The EFL Relay as supplied has been designed and manufactured to comply with the requirements of protection standards If modifications of any form are made to the EFL Relay the equipment may no longer be fit for use If any modifications or damage to the EFL Relay is evident do not use the equipment and contact Ampcontrol for advice gt Ampcontrol Pty Ltd ABN 28 000 915 542 POCOONTHR EFL PROTECTION RELAY USER MANUAL ess _ MAG 178 Version 1 JUL 15 4 2 Mandatory Installation Practices The following information must be adhered to when installing the EFL Relay Failure to adhere to this information may give rise to unsafe operation Using the EFL Relay in a manner that exceeds its electrical functional or physical specifications or ina way that is contrary to its operating restrictions may create risks to personnel and or equipment resulting in injury or death e The EFL Relay must be powered within the specified voltage range e The installation of the EFL Relay must be carried out by suitably trained and qualified personnel e Identification labels fixed to the EFL Relay must not be damaged removed or covered befor
20. r When the contactor is opened the EFL Relay will wait a period of time for the back emf of the supplied motor to subside determined by the back emf time setting before applying the test conditions to the voltage measured on the outlet After the back emf timer has expired if the measured voltage exceeds the test conditions of 25Vac or 60Vdc then the EFL Relay will initiate an FC Electrical trip Both the FC Logical trip and FC Electrical trip will result in the EFL Relay opening its CBR output relay which should be wired into the tripping circuit of the upstream device e g circuit breaker An FC trip will be latched in the memory of the EFL Relay and can be reset by pressing the FC Trip Reset Button on the fascia of the EFL Relay after the fault condition has been investigated and rectified FC trios cannot be reset via the externally wired remote reset To reset an FC trip the button on the fascia of the EFL Relay must be pressed A FC trip is not able to be reset unless the EFL Relay s super capacitor is charged refer to Section 6 6 Begin FC Test MCI input matches the RUN input Return No FC Trip Logical Return No FC Healthy Is the MCI input closed Yes exceeds permissible No FC Healthy Yes Has the Back emf timer expired Return No FC Healthy Yes Return FC Trip Electrical Figure 6 3
21. rgised Begin EFLO Test Outlet Running RUN amp MCI are Closed Return EFLO Healthy Phase to earth impedance gt IMQ Return EFLO Trip Figure 6 2 Logical Operation of the EFL Relay EFLO Test Process Return EFLO Healthy PP hs Ampcontrol Pty Ltd ABN 28 000 915 542 NTR EFL PROTECTION RELAY USER MANUAL Qu sn MAG 178 Version 1 JUL 15 6 3 Frozen Contactor FC Protection Function The EFL s FC Protection Function provides frozen contactor and contactor loss of vacuum protection for the connected outlet as per AS NZS 2081 2011 requirements The EFL Relay provides this protection in two forms logical protection and electrical protection The FC Logical Protection Function is initiated when a discrepancy is observed between the positon of the main contactor and the position of the main contactor s interposing relay A discrepancy between the positon of these two devices will indicate that the main contactor is either welded shut or frozen open The position of the main contactor is monitored by the EFL Relay by wiring an auxiliary contact of the main contactor to the MCI input of the EFL Relay The position of the main contactor s interposing relay is monitored by the EFL Relay by wiring an auxiliary contact to the RUN input of the relay The FC Electrical Protection Function monitors the voltage on the load side of the main contactor via the HV barrie
22. rier can be purchased as separate stand alone units The connection to the phase conductors is made using the three flying leads A B amp C phase that extend from the EFL Relay Barrier These leads are each 1 2m long If the EFL Relay is purchased with the external barrier configuration the EFL Relay and the external barrier will need to be wired together as per Figure 4 6 a hs Ampcontrol Pty Ltd ABN 28 000 915 542 NTR EFL PROTECTION RELAY USER MANUAL cs an MAG 178 Version 1 JUL 15 5 COMMISSIONING AND CALIBRATION Prior to being put into service the electrical protection system must be correctly commissioned This manual does not cover system commissioning the full scope of commissioning tests should be determined during the risk assessment or FMEA covering the design of the electrical protection system The following tests can provide guidance on checking the correct operation of the EFL Relay during commissioning This is not intended to provide an exhaustive commissioning checklist but should be considered to be a minimum set of tests 5 1 Earth Fault Lockout Test In order to ensure that the EFL Relay s earth fault lockout protection is operating correctly performing the following test 1 Open the main contactor that the EFL Relay is protecting 2 Connect a 0 9MO resistor between each phase conductor on the load side of the main contactor WARNING if the outlet is attempted to be started while these resisto
23. rs are connected and the EFL Relay fails during EFLO test the full system voltage will be applied to the resistors 3 Ensure that the EFL initiates an EFLO trip when each the resistors are placed on the phase conductors 4 Confirm that an EFLO trip prevents the main contactor from being closed 5 2 Frozen Contactor Test In order to ensure that the EFL Relay s frozen contactor protection is operating correctly perform the following test 1 Open the main contactor that the EFL Relay is protecting 2 Apply a 25Vac or 60Vdc voltage to the load side of the contactor and wait until the EFL Relay s back emf timer has expired 3 Ensure that the EFL Relay s CBR output de energises tripping the upstream circuit breaker 5 3 Undervoltage Test In order to ensure that the EFL Relay s under voltage protection is operating correctly perform the following test 1 Open the main contactor that the EFL Relay is protecting 2 Using a double poled switch close the RUN and MCI inputs to the EFL Relay at the same time This will indicate to the EFL Relay that the main contactor is closed As the main contactor remains open the relay should see no voltage on the load side of the contactor 3 Confirm that the EFL Relay initiates an undervoltage trip 4 After an undervoltage trip occurs which should result in the main contactor opening if the MCI input to the EFL does not open within 1 second a Frozen Contactor FC trip will occur
24. s 7 Billbrooke Close Cameron Park NSW 2285 P 61 1300 267 373 F 61 2 4903 4888 EMAIL customerservice ampcontrolqroup com WEB ampcontrolgroup com PP he Ampcontrol Pty Ltd ABN 28 000 915 542 AMPCONTROL EFL PROTECTION RELAY USER MANUAL al yr MAG 178 Version 1 JUL 15 TABLE OF CONTENTS 1 SAFETY AND OTHER WARNINGS ccccccceeecceeeeeeeeeeceeeeceeseeeeeeeseeeeeeeeeas 6 1 1 Safe Use of Equipment rrrrarnrrnnnorranrrrnnnerranrrvnnnnnnnnennnnrnnnnnennanennnnnennnssnnnn 6 2 RECEIVING AND TOP 7 Zl 10 Gh zyiinsauinanianiiaeabinahaniaenaLinaaNnae Linea NRA LinenaunmmaEinaunets 7 2 2 INSpection RR 7 NTN 7 2 4 Unpacking of Equipment rrranennnnnnnrrnnrvnnrnnnrvnnrvnnennnennnnnnnnnnnennnennnennnennnee 7 SPRUTE TIEN de 8 3 1 Product Description ranrnnnnennnrnnnnennnnennnrnnnnennnnnnanennnnennsnnnanennnsennennnsennnene 8 de AEA 8 AIN TALLA TON Pee eee eee eee ee ee eee ee ee eee ee eee 9 4 1 General Warnings rarrnnnnnrnnnnrnvannnnnnnrnrnnrnnnnnennansnnnnnennnnennnnsennanennnssennnnene 9 4 2 Mandatory Installation Practices rarrnrnrrnnnrrvnnrnrnnennnnnvanrnnnnennnrnnanennnnennn 10 4 3 Mechanical Installation Information rrarrnnnrnnrrnnnrvnrrvnnrnnnrnnnrnnnrnnnrnnnnnnn 10 4 4 Electrical Installation Information ernnrrnnrnnnrnnnrnnnrrnnrnnnrnnnrnnnrnnrrnsrnnnnnn 12 5 COMMISSIONING AND CALIBRATION rrnurnnnnnnnennrnnnrennrnnerennrnnsnrennnnnsrennnnnn 14 5 1 Earth Fault
25. t of the hardware or documentation may be reproduced transmitted transcribed stored in a retrieval system or translated into any language or computer language in any form or by any means without prior written permission of AMPCONTROL PTY LTD Disclaimer While every effort has been made to assure the accuracy and clarity of this document AMPCONTROL PTY LTD assumes no liability resulting from any omissions in this document or from misuse of the information obtained herein The information in this document has been carefully checked and is believed to be entirely reliable with all of the necessary information included AMPCONTROL PTY LTD reserves the right to make changes to any products described herein to improve reliability function or design and reserves the right to revise this document and make changes from time to time in content hereof with no obligation to notify any persons of revisions or changes AMPCONTROL PTY LTD does not assume any liability arising out of the application or any use of any product or circuit described herein neither does it convey license under its patent rights or the rights of others Before You Begin We would like to take a moment to thank you for purchasing the Ampcontrol EFL Relay WARNING To become completely familiar with this equipment and to ensure correct operation we strongly recommend that you take the time to read and thoroughly understand this user manual Ampcontrol Contact Detail
26. talled correctly Mechanical and or electrical installation and maintenance of plant and equipment must only be carried out by appropriately qualified personnel and must be tested thoroughly prior to operation 1 1 5 Operation As safety depends on the EFL Relay functioning correctly it is highly recommended that all safety functions of the EFL Relay be periodically tested to ensure correct operation a hs Ampcontrol Pty Ltd ABN 28 000 915 542 NTR EFL PROTECTION RELAY USER MANUAL cs an MAG 178 Version 1 JUL 15 2 RECEIVING AND STORAGE 2 1 Receiving All possible precautions are taken to protect the equipment against damage or losses during shipment however before accepting delivery check all items against the packing list or bill of loading If there is evidence of physical damage notify Ampcontrol immediately Notify Ampcontrol immediately in case of any discrepancies to the packing list Keep a record of any claims and correspondence Photographs are recommended Where practicable do not remove protective covers prior to installation unless there are indications of damage Boxes opened for inspection and inventory should be carefully repacked to ensure protection of the contents or else the parts should be packaged and stored in a safe place Examine all packing boxes wrappings and covers for items attached to them Retain and store any approval documentation for your safety file as applicable prior to wrappings being discarde
27. trol EFL Protection Relay provides earth fault lockout EFLO and frozen contactor FC protection that is compliant to AS NZS 2081 2011 sections 7 amp 9 While the outlets main contactor is open the EFL will continually monitor the resistance of the phase conductors to earth on the load side of the contactor If this resistance falls below an acceptable level then the EFL will initiate an EFLO trip preventing the outlet from being started The EFL will also monitor the state of the outlets main contactor If voltage appears on the line when the contactor is open a Frozen Contactor electrical trip will occur opening the circuit breaker If the main contacior is either open when it should be closed or closed when it should be open a Frozen Contactor logical trip will occur opening the circuit breaker A back EMF timer is also provided to inhibit the frozen contactor electrical trip function for a short period after the main contactor is open The EFL also has an undervoltage protection function which if activated will open the main contactor if the voltage on the load side of the contactor falls below 50 of the selected system voltage The EFL is available in two configurations an internal barrier configuration and an external barrier configuration If using the internal barrier unit the high voltage connection leads will extend directly from the EFL Relay If using the external barrier version the high voltage connection circuitry is stored
28. ure to install or operate this instrument in accordance with the instructions contained in this manual may create hazardous operating conditions 1 1 Safe Use of Equipment The equipment supplied has been manufactured according to the state of the art and designed to ensure a Safe operation The equipment may only be used within the design parameters The instructions within this manual must be observed as an aid towards achieving maximum safety during operation The owner user is responsible for observing the following instructions 1 1 1 Changes to Equipment Changes in the design and modifications to the equipment are not permitted Unauthorised changes made to the hardware or operating firmware will void the manufacturer s warranty and may compromise the integrity of the system into which it is installed and other connected equipment 1 1 2 Equipment Knowledge Experience with or understanding of this equipment is essential for the safe installation and removal of the equipment Therefore please read and understand this manual prior to use Competency based training courses are recommended and are available on request 1 1 3 Manual Handling Precautions have been taken to ensure all equipment is safe to handle and free from sharp edges However care should always be taken when handling enclosures and gloves should be worn 1 1 4 Installation Correct operation and safety depend on the EFL Relay and associated equipment being ins
29. y Ltd ABN 28 000 915 542 NTR EFL PROTECTION RELAY USER MANUAL Qu sn MAG 178 Version 1 JUL 15 6 2 Earth Fault Lockout EFLO Protection Function The EFL s EFLO Protection Function provides earth fault lockout protection for the connected outlet as per AS NZS 2081 2011 requirements Whilst the outlet s main contactor is open the EFL Relay will continually monitor the impedance of each of the phase conductors to earth When the impedance of any of the phase conductors falls below the tripping threshold of 1MQ then the EFL Relay with initiate an EFLO trip by opening the MCR output relay When the EFL Relay first energises an EFLO test will be performed before the MCR output relay can close The initial EFLO test can take up to 10 seconds to complete as the EFL Relay must first charge the cable before the measurements can be taken If the EFLO test is successful the EFL Relay will then energise the MCR output relay provided that there are no latched FC EFLO or UV trips lf an EFLO trip occurs this trip will be latched in the memory of the EFL Relay In order to clear an EFLO trip the External Reset terminals must be shorted together This is typically achieved through the use of an externally wired normally open push button To reset an EFLO trip the External Reset terminals of the EFL Relay must be shorted together using an externally wired pushbutton or relay An EFLO trip cannot be cleared whilst the EFL Relay is de ene
30. y and the systems into which it is fitted Routine inspections may take the form of either visual only checks or visual and hands on checks 7 1 1 Visual Only Inspections A basic visual inspection focuses on looking at the installation for signs of physical damage water or dust ingress and the condition of cables and labels This type of inspection may involve opening cabinets to gain access to the EFL Relay and other equipment This level of inspection may also include cleaning display windows that have become obscured by dirt Observations would typically be e Check that equipment enclosures cable trays conduits etc are in good order with no physical damage e Check that sealed wall boxes are free from water and dust ingress internally Door seals are in good condition e Check that connected cables are free from cuts abrasions and obvious signs of damage Cable restraints are in good order and correcily fitted e Check that labels on equipment wall boxes and cables are present and in good condition especially certification labels e Check that no modifications have been carried out to installed equipment 7 1 2 Hands On Detailed Inspections A more detailed inspection would include all of the elements of a visual inspection plus some checks that cover the integrity of connections fixtures and fittings In addition to basic visual observations more detailed integrity checks would involve e Verify that equipment
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