Ampcontrol OCS Page 1 User Manual Download

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Version: 5, FEBRUARY/2020

Designed and manufactured in Australia by Ampcontrol Pty Ltd

OCS

OUTLET CASSETTE SYSTEM

User Manual

Summary of Contents for OCS

Page 1: ...Version 5 FEBRUARY 2020 Designed and manufactured in Australia by Ampcontrol Pty Ltd OCS OUTLET CASSETTE SYSTEM User Manual ...

Page 2: ...NING The warning symbol highlights a potential risk of injury or death Please share these warnings with other operators CAUTION The caution symbol highlights a potential risk of damage to equipment Please share these cautions with other operators NOTE The note symbol highlights key information Please share these notes with other operators ENVIRO The enviro environmental symbol highlights areas whi...

Page 3: ...ent 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 t...

Page 4: ...on Practices 15 4 3 Mechanical Arrangement 16 4 4 Electrical Installation Information 17 4 5 External Accessories 18 5 COMMISSIONING AND CALIBRATION 19 5 1 Earth Leakage 19 5 2 Residual Voltage 19 5 3 Earth Fault Lockout 19 5 4 Earth Continuity 19 5 5 Insulation Test High Voltage 19 5 6 Over Current Motor Overload Current Injection 20 5 7 Short Circuit Current Injection 20 5 8 Main Contactor Fail ...

Page 5: ...FUNCTIONS 39 8 1 Inverse Time Protection 39 8 2 Short Circuit 44 8 3 Current Balance 45 8 4 Under Current 46 9 OTHER PROTECTION FUNCTIONS 46 9 1 Under Voltage 46 10 SERVICE MAINTENANCE DISPOSAL 47 10 1 Equipment Service 47 10 2 Equipment Maintenance 48 10 3 Disposal 48 11 SPECIFICATIONS 49 11 1 Cassette Specifications 49 11 2 Protection Element Specifications 49 12 EQUIPMENT LIST 52 APPENDIX A PRO...

Page 6: ...esidual Voltage Trip Characteristics 31 Table 8 Protection Element Earth Continuity Series Trip Characteristics 33 Table 9 Protection Element Earth Continuity Shunt Trip Characteristics 33 Table 10 Protection Element Earth Continuity Pilot Interlock Trip Characteristics 34 Table 11 Protection Element Earth Fault Lockout EFLO Trip Characteristics 35 Table 12 Protection Element High Voltage Insulati...

Page 7: ...t s CBR output is designed for use with under voltage tripping coils FCS FCS is the acronym for the Ampcontrol Fixed Cassette System MC Main Contactor the main power circuit opening device Installed within the Cassette the main contactor is opened and closed in order to turn the outlet on and off MCR Main Contactor Relay power relay installed within the Cassette Protection Element to control the s...

Page 8: ...hanges 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 ...

Page 9: ...nts Failure to comply with the Conditions of Certification may seriously compromise the integrity of the system and or its components and the consequence could be fatal The user must ensure that the Special Conditions outlined in the certificate and associated attachment is met or the certificate and the I S rating will not be valid Refer to the relevant section of the safety file for copies of ce...

Page 10: ...umentation for your safety file as applicable prior to wrapping being discarded 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...

Page 11: ...s and outlet test circuitry into a single replaceable unit This has the advantage of resulting in minimal down time in the event of a fault The Ampcontrol OCS is available in two types the standard OCS and the Fixed Cassette System FCS The OCS provides isolation and earthing of individual outlets via integrated actuators that are controlled at the touch of a button via a Human Machine Interface HM...

Page 12: ... systems only sacrifices the remote isolation and earthing functionality of the OCS to provide a higher outlet density Due to the compact nature of the FCS 10 outlets are able to be installed in the same area used by a conventional 8 outlet system The FCS is designed as a fully bolted non withdrawable installation whilst still minimising downtime by providing fast and easy removal of the cassette ...

Page 13: ...e Earth Leakage Earth Fault Lockout Earth Continuity including remote start mode Contactor Failure protection Motor thermal overload protection Short circuit protection Under current protection Current balance protection Under voltage protection Automatic HV insulation test prior to outlet closing Machine identification The following Control and Monitoring functions are accessed via the Ethernet I...

Page 14: ...or Ampcontrol technical representative 4 1 2 Ensure that the application into which the OCS 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...

Page 15: ...on the name plate The OCS s control supply must remain within the specified voltage range The installation of the OCS must be carried out by suitably trained and qualified personnel Identification labels fixed to the OCS must not be damaged removed or covered The installation is to be in accordance with the relevant installation Standards Codes of Practice Modifications must not be made to any par...

Page 16: ...LTD NOT TO BE REPRODUCED IN PART 4 3 Mechanical Arrangement 4 3 1 OCS Dimensions The OCS is available in two sizes the 2 Way OCS and the 3 Way OCS These modules are designed to be stacked on top of each other allowing the best utilisation of the installation area Figure 4 1 2 Way OCS Dimensions Pictured with 2 Cassettes Installed Figure 4 2 3 Way OCS Dimensions Pictured with 3 Cassettes Installed ...

Page 17: ...UTION PROPERTY OF AMPCONTROL PTY LTD NOT TO BE REPRODUCED IN PART 4 3 2 FCS Dimensions The FCS has a very high outlet density allowing more outlets to be installed with a smaller footprint Figure 4 3 FCS Dimensions Pictured with 5 Cassettes Installed 4 4 Electrical Installation Information Refer to drawing OCSE002in APPENDIX B DRAWINGS for electrical installation information 450 665 1160 ...

Page 18: ...the chance of the outlet operating when not required to do so due to wiring faults It should be noted that these functions are operational only and that any emergency stops should be wired directly into the pilot circuit PTC terminals are provided for a semiconductor switching thermistor These terminals are protected in a similar manner to the stop and start circuits If the remote start stop and P...

Page 19: ...ion only Test the correct operation of residual voltage detection circuitry by injecting a residual voltage onto the phases Ensure that all relevant tripping circuits operate successfully and that latched trips may be reset in the appropriate manner These tests can be facilitated using residual voltage test relays built into the Cassette Protection Element These relays are controlled using the Cas...

Page 20: ...ment Inject a current value relevant to the settings employed into one of the CT terminals and ensure that all relevant tripping circuits operate successfully in the time expected and that latched trips may be reset in the appropriate manner Repeat on the other CT terminals 5 8 Main Contactor Fail While the Cassette Protection Element is stopped that is the MCR output is open apply a voltage on th...

Page 21: ... the Protection Element will report an insulation test trip The insulation test can also be disabled via parameter settings If the insulation test passes the start sequence moves to the closing state and the MCR output will be closed The Protection Element now waits for the MCI digital input to close This auxiliary feedback from the signal confirms that the main contactor has closed If the MCI doe...

Page 22: ...identity fails to match with that which is expected the Protection Element will set this trip There is currently one CCM version which is used for both 1 1kV and 3 3kV outlets If this trip occurs the Cassette should be returned for repair 6 3 2 MCF Battery Trip The Protection Element has an internal battery This is used to power the real time clock used to timestamp log messages as well has power ...

Page 23: ...he series resistance of the pilot was measured to be above the selected trip level 5 Over current Overload Trip The currents exceeded the bounds of the selected trip characteristic 6 Short Circuit INST Trip An Instantaneous Short Circuit trip occurred 7 Close Failed After being requested to close the Main Contactor has not closed within 5 seconds As detected via the MCI 8 Main Contactor Relay Clos...

Page 24: ... 24 Insulation Trip The pre start high voltage insulation test failed 25 RTX Comms Timeout RTX is online but there was repeated data corruption 26 Power Up The system has powered up after a clean power down 27 Under Voltage Trip The phase voltage dropped below the trip level causing the outlet to drop out of run mode 28 Stopped General log denoting when the system completed the request to drop out...

Page 25: ...ithin the Protection Element The log is used to denote that the stack has grown too big or that the system has run out of RAM In normal operation neither of these things should occur 43 PTC Trip The outlet was stopped due to the RTX s PTC input exceeding its trip resistance level 44 RTX RTD Group 1 Trip The outlet was stopped due to one of the RTD inputs within group 1 going above the set trip lev...

Page 26: ...Address Byte 4 Subnet mask Byte 1 Subnet mask for Ethernet communications with the PLC Subnet mask Byte 2 Subnet mask Byte 3 Subnet mask Byte 4 Gateway Address Byte 1 Gateway address for Ethernet communications with the PLC Gateway Address Byte 2 Gateway Address Byte 3 Gateway Address Byte 4 Pilot mode Selects the pilot termination method diode or RTX Loss Of Vacuum Level Trip level for loss of va...

Page 27: ...ier Defines the cooling output of the thermal model when thermal motor protection is selected Over Load Start Block Level The thermal accumulator must be below this value to allow an outlet start Current Balance Trip Level Selects the trip level for or disables current balance protection Under Current Trip Level Selects the trip level for or disables under current protection Earth Leakage Trip Lev...

Page 28: ...d earth positions This provides both a break between the outlet phase conductors and the incoming supply as well as visual earthing of the outlet cable without the requirement of a separate earthing outlet Each Cassette houses the line and load contacts vacuum contactor three current transformers Earth Leakage CT and the Protection Element The cassette is driven between the service and earth posit...

Page 29: ...o Ampcontrol Website for Latest Version Page 29 of 72 APPROVED FOR EXTERNAL DISTRIBUTION PROPERTY OF AMPCONTROL PTY LTD NOT TO BE REPRODUCED IN PART Figure 6 1 Actuator position within chassis Position 2 White p no 164892 Position 3 Blue p no 164893 Position 1 Red p no 164891 Position 4 No Band p no 164894 ...

Page 30: ...n Contactor from closing Active Period Always active Logging Always logged Parameters Trip Level Trip Time Monitoring Earth Leakage current displayed as 0 150 of selected trip level 7 1 2 Operation Summary The earth leakage protection function uses an Ampcontrol EL500 series toroid to measure the earth fault current This function is tested to AS NZS 2081 2011 A definite time operating characterist...

Page 31: ... test the integrity of earth leakage circuit The CT Detection signal continually tests the earth leakage current transformer the wiring loop to the transformer and the input to the protection relay as required by AS NZS 2081 2011 The signal is fed from Pin 6 of the Protection Element Pass one loop through the earth leakage current transformer then back to Pin 7 The Earth Leakage CT Failure trip ti...

Page 32: ...ables the EL CT detection trip NOTE The Residual Voltage Protection Element and the Standard Protection Element can be interchanged however the outlet will not be able to energise 7 3 Earth Continuity The earth continuity function tests for the continuity of the earth between the outlet and the machine via the pilot in the trailing cable This is in accordance with AS NZS 2081 2011 The pilot is als...

Page 33: ...lot Series Table 8 Protection Element Earth Continuity Series Trip Characteristics Parameter Action Power Cycle Trip status maintained Reset Requires a general reset after the trip condition has cleared Alternatively the trip can be automatically reset depending on the status of the EC Latch parameter Trip Actions Open Main Contactor Relay Prevent Main Contactor from closing Active Period Always a...

Page 34: ...s enable bit must be enabled for a remote start condition to be possible and accepted 3 The pilot resistance must be detected above 90Ω to ensure a start resistor is in place 4 As soon as the resistance calculation drops below the EC series threshold a start is triggered Note that the EC series protection function will still be operating and the start will not be triggered if the EC measurement is...

Page 35: ... a trip occurs 7 4 2 High Voltage Insulation Test Table 12 Protection Element High Voltage Insulation Test Characteristics Parameter Action Power Cycle Trip status maintained Reset Requires a general reset after a failed test Trip Actions Prevent Main Contactor from closing Active Period Single test performed during the start sequence Optionally can be disabled Logging Always logs the measured tes...

Page 36: ...hysical reset button is found on the front cover of the Protection Element Trip Actions Open Circuit Breaker Prevent Main Contactor from closing Active Period When outlet is not running and the Back EMF timer has finished counting down Logging Logged when a trip occurs Parameters Trip Level Back EMF Timer Monitoring Phase voltages are continuously updated Loss of Vacuum provides a mechanism for ch...

Page 37: ...he Protection Element detects that the main contactor has closed or remains closed after the MCR is opened for any reason it will result in a frozen contactor trip The frozen contactor protection activates in approximately 100ms 7 5 3 Close Fail Table 15 Protection Element Contactor Close Fail Trip Characteristics Parameter Action Power Cycle Trip status maintained Reset Communication reset or phy...

Page 38: ...e Reset Automatic Trip Actions Open Circuit Breaker Prevent Main Contactor from closing Active Period Always Logging Only logged if it results in the Protection Element stopping a running outlet Parameters No parameters Monitoring Coil voltage status bit The coil voltage is internally detected by sensing the voltage across terminals 12 13 COIL SUPPLY 1 COIL SUPPLY 2 This additional functionality i...

Page 39: ...urrent Motor Overload NOTE When the Motor Overload parameter is set the Short Circuit functionality is also modified to better suit motor starting transients See the Short Circuit section Section 8 2 for further information The Over Current Time Multiplier setting TMS scales the basic trip time for the basic over current characteristics to the desired response time Values are provided from 0 05 to...

Page 40: ...follows the characteristic defined by 𝑡 𝐼 𝑇𝑀𝑆 80 𝐼2 1 𝑡𝑅 𝐼 𝑇𝑀𝑆 1 28 1 𝐼2 Where t I the idealised trip time I the input current ratio relative to the full load current set point ie per unit current TMS the Over Current Time Multiplier Setting tR I the idealised reset time NOTE 1 The per unit current is clipped to a maximum of 1250 Therefore the trip time for input currents above this level will not...

Page 41: ...the effects of that heating persist in the model where as in the Over Currents functions the trip accumulator resets relatively quickly if the current falls below the selected full load current level The three measured phase currents are squared and added together to provide the heating input into the thermal model The cooling is assumed to be proportional to the model s temperature at any given t...

Page 42: ... drawing OCSB002in APPENDIX B DRAWINGS The TAC provides information about how much thermal capacity is left and therefore how long it will take to trip from a given starting point and overload current If the motor current I is constant and below 1 05PU the TAC will eventually settle to a value as follows 𝑇𝐴𝐶 𝐼 1 05 2 100 For example if the long term average load current was 0 7PU the TAC would set...

Page 43: ... 0 Cold 100 Trip When a trip occurs it cannot be reset until the current is below the pick up level When the Protection Element is not in the running state if the thermal accumulator is not below the selected start block level a start block trip will occur This will automatically clear once the thermal accumulator drops to or is below the selected level This functionality is used to ensure adequat...

Page 44: ...ected the short circuit will trip at 9 4PU 940 even if the short circuit level is set to 9 5x or above The per unit current at which the 6kA limit takes effect is listed as SC max along with the full range current values in APPENDIX A PROTECTION ELEMENT LOAD CURRENT TABLES The trip time is selectable from 40 to 200ms If the Over Current function is set to Motor Overload the short circuit functiona...

Page 45: ...ement Current Balance Trip Characteristics Parameter Action Power Cycle Trip Status maintained Reset General reset Trip Actions Open Main Contactor Prevent Main Contactor from closing Active Period Always Logging Always Parameters Trip Level Monitoring Phase currents displayed in Amps The current balance measurement is available and is calculated as 𝑖𝑏𝑎𝑙 𝑀𝐴𝑋 𝑖 100 𝑖𝑎𝑣 Where iav the average of the ...

Page 46: ...n Amps Under current protection monitors all three phase currents If any phase drop below the selected threshold the trip timer start counting The under current protection will trip after any phase current is below the threshold for 4 second 9 OTHER PROTECTION FUNCTIONS 9 1 Under Voltage Table 23 Protection Element Under Voltage Trip Characteristics Parameter Action Power Cycle Reset Automatic Act...

Page 47: ...der with no physical damage Check that connected cables are free from cuts abrasions and obvious signs of damage Cable restraints are in good order and correctly fitted Check that labels on equipment and cables are present and in good condition especially certification labels Check that no modifications have been carried out to installed equipment 10 1 2 Hands On Detailed Inspections A more detail...

Page 48: ...tion system incorporating the OCS 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 Earth Leakage injection tests Earth Continuity tests Earth Fault Lockout tests Overcurrent injection tests CAUTION When conducting insulation tests on the outgo...

Page 49: ...s 11 2 Protection Element Specifications I S Parameters Combined Phase and Pilot RDX Port RTX Uo 28 0V Uo 17 3V Ui 28 0V Io 322mA Io 756mA Ci 18 8nF Po 2 25W Po 3 09W Li nil Co 3 72μF Co 9 05μF Ci 18 8nF Lo 816μH Lo 4 5mH L R 134μH Ohm General Temperature Range 0 C Ta 60 C Auxiliary Supply Voltage 24 VDC 20 30 W Sys Phase Phase Voltage 1100V 20 3 3kV 20 Contact Ratings 110VAC 20A 1000VA Power Fact...

Page 50: ... 4s 5s Earth Continuity Series Trip 3Ω 10Ω 15Ω 20Ω 25Ω 30Ω 35Ω 40Ω 45Ω Shunt Trip 1 5kΩ Pilot Interlock Trip Residual Voltage Version Only 100Ω Trip Time 100ms 150ms 200ms 250ms 300ms 350ms 400ms 450ms 500ms Additional Trip Times for Residual Voltage Version only 600ms 800ms 1s 1 5s 2s 2 5s 3s 3 5s 4s 4 5s 5s OFF Pilot Interlock Trip Shunt Trip Time Residual Voltage Version Only 100ms 150ms 200ms ...

Page 51: ...ent Full Load Current Selection Table Appendix A Time Multiplier 0 05 30 See Protection Element TMS Table Cooling Multiplier 1 0 1 5 2 0 2 5 3 0 4 0 5 0 Start Block Level 20 30 40 50 60 70 80 90 Short Circuit Protection Trip Settings 1 5x to 12 5x in 0 25x increments in OC mode 3 0x to 25x when in MOL mode with addition slower trip element at 1 5x to 12 5x Multiples of Full Load Current Trip occur...

Page 52: ...andard OCS Protection Element EtherNet IP 159689 Withdrawable OCS Cassette c w Standard OCS Protection Element EtherNet IP 159325 Standard OCS Protection Element Spare Part EtherNet IP 178819 Standard OCS Protection Element Spare Part Modbus TCP 179798 Residual Voltage OCS Protection Element Spare Part Modbus TCP 160292 Outlet Cassette Remote Termination Unit RTX 101649 Earth Leakage Toroid EL500 ...

Page 53: ... 71 24 0 103 48 135 96 167 192 25 0x 199 384 15 6x 8 6 125 40 12 25 72 24 5 104 49 136 98 168 196 25 0x 200 392 15 3x 9 6 250 41 12 50 73 25 0 105 50 137 100 169 200 25 0x 201 400 15 0x 10 6 375 42 12 75 74 25 5 106 51 138 102 170 204 25 0x 202 408 14 7x 11 6 500 43 13 00 75 26 0 107 52 139 104 171 208 25 0x 203 416 14 4x 12 6 625 44 13 25 76 26 5 108 53 140 106 172 212 25 0x 204 424 14 2x 13 6 75...

Page 54: ...s Value Amps Value Amps Value Amps Value Amps Value Amps SC max Value Amps SC max 25 8 500 57 17 00 89 34 0 121 68 153 136 185 272 22 1x 217 544 11 0x 26 8 750 58 17 50 90 35 0 122 70 154 140 186 280 21 4x 218 560 10 7x 27 9 000 59 18 00 91 36 0 123 72 155 144 187 288 20 8x 219 576 10 4x 28 9 250 60 18 50 92 37 0 124 74 156 148 188 296 20 3x 220 592 10 1x 29 9 500 61 19 00 93 38 0 125 76 157 152 1...

Page 55: ... 06 11 25 6 0 080 0 065 0 120 36 0 80 0 646 1 200 66 8 0 6 46 12 00 7 0 085 0 069 0 128 37 0 85 0 687 1 275 67 8 5 6 87 12 75 8 0 090 0 073 0 135 38 0 90 0 727 1 350 68 9 0 7 27 13 50 9 0 10 0 081 0 150 39 1 0 0 808 1 50 69 10 0 8 08 15 0 10 0 11 0 089 0 165 40 1 1 0 889 1 65 70 11 0 8 89 16 5 11 0 12 0 097 0 180 41 1 2 0 970 1 80 71 12 0 9 70 18 0 12 0 13 0 105 0 195 42 1 3 1 05 1 95 72 13 0 10 5...

Page 56: ... IN PART Protection Element Over Current Time Multiplier Settings TMS including nominal trip time in seconds at 10 PU Current Value TMS 10 x trip time Value TMS 10 x trip time Value TMS 10 x trip time Ext Inv MOL Very Inv Ext Inv MOL Very Inv Ext Inv MOL Very Inv 25 0 32 0 259 0 480 55 3 2 2 59 4 80 26 0 35 0 283 0 525 56 3 5 2 83 5 25 27 0 38 0 307 0 570 57 3 8 3 07 5 70 28 0 42 0 339 0 630 58 4 ...

Page 57: ...N PROPERTY OF AMPCONTROL PTY LTD NOT TO BE REPRODUCED IN PART APPENDIX B DRAWINGS The drawings in this appendix are as per the below table Drawing Number Drawing Title Page Number OCSE002 Typical Connection Diagram 58 OCSE001 I S System Diagram 59 OCSA001 Protection Element Mechanical Details 60 OCSB001 Overcurrent and Short Circuit Curves 61 OCSB002 Motor Overload and Short Circuit Curves 62 ...

Page 58: ...000 915 542 OCS USER MANUAL MAG 182 Version 5 FEB 2020 Uncontrolled Copy Refer to Ampcontrol Website for Latest Version Page 58 of 72 APPROVED FOR EXTERNAL DISTRIBUTION PROPERTY OF AMPCONTROL PTY LTD NOT TO BE REPRODUCED IN PART ...

Page 59: ...000 915 542 OCS USER MANUAL MAG 182 Version 5 FEB 2020 Uncontrolled Copy Refer to Ampcontrol Website for Latest Version Page 59 of 72 APPROVED FOR EXTERNAL DISTRIBUTION PROPERTY OF AMPCONTROL PTY LTD NOT TO BE REPRODUCED IN PART ...

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Page 61: ...000 915 542 OCS USER MANUAL MAG 182 Version 5 FEB 2020 Uncontrolled Copy Refer to Ampcontrol Website for Latest Version Page 61 of 72 APPROVED FOR EXTERNAL DISTRIBUTION PROPERTY OF AMPCONTROL PTY LTD NOT TO BE REPRODUCED IN PART ...

Page 62: ...000 915 542 OCS USER MANUAL MAG 182 Version 5 FEB 2020 Uncontrolled Copy Refer to Ampcontrol Website for Latest Version Page 62 of 72 APPROVED FOR EXTERNAL DISTRIBUTION PROPERTY OF AMPCONTROL PTY LTD NOT TO BE REPRODUCED IN PART ...

Page 63: ...ion Page 63 of 72 APPROVED FOR EXTERNAL DISTRIBUTION PROPERTY OF AMPCONTROL PTY LTD NOT TO BE REPRODUCED IN PART APPENDIX C APPROVALS This appendix contains a copy of Issue No 1 of the IECEx ITA 12 0032X certificate of conformity and relevant attachments For the most up to date copy of this certification refer to the http iecex iec ch website ...

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