Ampcontrol OCS User Manual
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Ampcontrol OCS User Manual

Outlet cassette system
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OCS
OUTLET CASSETTE SYSTEM
User Manual
Version: 5, FEBRUARY/2020
Designed and manufactured in Australia by Ampcontrol Pty Ltd

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  • Page 1 OUTLET CASSETTE SYSTEM User Manual Version: 5, FEBRUARY/2020 Designed and manufactured in Australia by Ampcontrol Pty Ltd...
  • Page 2 The note symbol highlights key information. Please share these notes with other operators. ENVIRO The enviro (environmental) symbol highlights areas which may have an impact on the surrounding fauna and/or flora. Uncontrolled Copy - Refer to Ampcontrol Website for Latest Version Page 2 of 72...
  • Page 3 MAG-182 Version 5 – FEB/2020 Copyright Notice The Ampcontrol OCS 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.

  • Page 4: Table Of Contents

    6.4 Events Log ....................23 6.5 Protection Element Parameters ............... 26 6.6 Time and Date ..................28 6.7 Cassette Isolation & Earthing (OCS Only) ..........28 7 AS/NZS 2081:2011 PROTECTION FUNCTIONS ..........30 7.1 Earth Leakage ..................30 7.2 Residual Voltage ..................31...
  • Page 5 A1: Protection Element Full Load Current Table ..........53 A2: Protection Element TMS Table ..............55 APPENDIX B: DRAWINGS ................57 APPENDIX C: APPROVALS ................63 Uncontrolled Copy - Refer to Ampcontrol Website for Latest Version Page 5 of 72...
  • Page 6 Figure 3.1: Ampcontrol Outlet Cassette System (OCS) ................11 Figure 3.2: Ampcontrol Fixed Cassette System (FCS) ................12 Figure 4.1: 2-Way OCS Dimensions (Pictured with 2 Cassettes Installed) ..........16 Figure 4.2: 3-Way OCS Dimensions (Pictured with 3 Cassettes Installed) ..........16 Figure 4.3: FCS Dimensions (Pictured with 5 Cassettes Installed) ............

  • Page 7: Table 1: Definitions

    DEFINITIONS Table 1: Definitions Term Definition A Cassette is the unit that is installed within Outlet Cassette System (OCS) or Fixed Cassette System (FCS). There are two types: FCS Cassettes and OCS Cassettes. Cassette Each Cassette houses a Protection Element, phase current transformers and main contactor components.

  • Page 8: Safety And Other Warnings

    1.1.5 Operation As safety depends on the OCS functioning correctly it is highly recommended that all safety functions of the OCS be periodically tested to ensure correct operation.
  • Page 9  The latest certificate and its associated attachments outlining the special conditions of the certification are maintained and available on the IEC Ex Website: http://iecex.iec.ch. Uncontrolled Copy - Refer to Ampcontrol Website for Latest Version Page 9 of 72...

  • Page 10: Receiving And Storage

    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.

  • Page 11: Product Overview

    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 (HMI) screen.

  • Page 12: Figure 3.2: Ampcontrol Fixed Cassette System (Fcs)

    MAG-182 Version 5 – FEB/2020 The FCS (1.1kV 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.
  • Page 13 Individual outlet isolation and earthing system (OCS)  Operations via HMI interface  Ethernet communications  Cassette Protection Element All electrical protection functions are provided by the new generation OCS Protection Element and include:  Earth Leakage  Earth Fault Lockout ...

  • Page 14: Installation

    If modifications of any form are made to the OCS, the equipment may no longer be fit for purpose. If any modifications or damage to the OCS is evident, do not use the equipment and contact Ampcontrol for advice.

  • Page 15: Mandatory Installation Practices

     The OCS is to be installed in an electrical system having a fault level equal to or less than as marked on the name plate. ...

  • Page 16: Mechanical Arrangement

    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.

  • Page 17: Electrical Installation Information

    The FCS has a very high outlet density, allowing more outlets to be installed with a smaller footprint. 1160 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. Uncontrolled Copy - Refer to Ampcontrol Website for Latest Version Page 17 of 72...

  • Page 18: External Accessories

    4.5 External Accessories 4.5.1 Earth Leakage CT The Outlet Cassette Protection Element uses an Ampcontrol EL500 series current transformer for earth leakage measurements. For the purposes of outlet identification tests during operation, the earth leakage toroid is installed separately to the Cassette.

  • Page 19: Commissioning And Calibration

    If the Earth Fault Lockout and Earth Continuity tests are successful, check that an automatic HV insulation test is initiated by the Cassette Protection Element when the module is started. Uncontrolled Copy - Refer to Ampcontrol Website for Latest Version Page 19 of 72...

  • Page 20: Over Current/Motor Overload Current Injection

    NOTE A Main Contactor Fail (MCF) trip can be reset by pressing the MCF Reset Pushbutton on the front of the OCS Protection Element or through the communications protocol. While the Cassette Protection Element is stopped, close the MCI digital input. Ensure that a CBR trip is initiated by the Cassette Protection Element.

  • Page 21: Product Operation

    Protection Element and as such a reset push-button is accessible from the front of the Protection Element and can be operated with power off. Uncontrolled Copy - Refer to Ampcontrol Website for Latest Version Page 21 of 72...

  • Page 22: Internal Trips

    This trip will be set in the event that an internal fault has been detected. If this trip occurs the Cassette should be returned for repair. Uncontrolled Copy - Refer to Ampcontrol Website for Latest Version Page 22 of 72...

  • Page 23: Events Log

    Voltage was detected at the outlet while the Main Loss of Vacuum Contactor was open. The difference between the measured phase Current Balance Trip currents is greater that the selected trip level. Uncontrolled Copy - Refer to Ampcontrol Website for Latest Version Page 23 of 72...
  • Page 24 The system has powered up, but cannot work out if Unknown Restart the system powered down cleanly or if it had a Status restart. Short Circuit Trip Reset A short circuit trip was reset. Uncontrolled Copy - Refer to Ampcontrol Website for Latest Version Page 24 of 72...
  • Page 25 29, Dongle Load parameters are numbered 30-59 and RTX Load parameters are numbered 60-89. The value which was changed from is stored in Data1 and the new value is in Data2. Uncontrolled Copy - Refer to Ampcontrol Website for Latest Version Page 25 of 72...

  • Page 26: Protection Element Parameters

    Parameter Dongle of either the RTX (if present) or the Protection Element. NOTE Parameters cannot be changed while the Protection Element is running. Uncontrolled Copy - Refer to Ampcontrol Website for Latest Version Page 26 of 72...

  • Page 27: Table 4: Load Parameter Descriptions

    When remote start is enabled, the PLC will not be able to initiate a start. Insulation Test Trip Level Selects the trip level for or disables the automatic insulation test. Uncontrolled Copy - Refer to Ampcontrol Website for Latest Version Page 27 of 72...

  • Page 28: Time And Date

    The time and date are not used for any control functions. 6.7 Cassette Isolation & Earthing (OCS Only) Through the use of remotely controlled actuators, the OCS allows individual Outlet Cassettes to be moved between the service and 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.

  • Page 29: Figure 6.1: Actuator Position Within Chassis

    Position 1 Position 2 Red (p/no 164891) White (p/no 164892) Position 3 Position 4 Blue (p/no 164893) No Band (p/no 164894) Figure 6.1: Actuator position within chassis Uncontrolled Copy - Refer to Ampcontrol Website for Latest Version Page 29 of 72...

  • Page 30: As/Nzs 2081:2011 Protection Functions

    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 characteristic is provided with adjustable trip sensitivity and an adjustable time delay.

  • Page 31: Residual Voltage

    Open Main Contactor Trip Actions Prevent Main Contactor from closing Active Period Always active Logging Always logged Trip Level Parameters Trip Time Monitoring Residual Voltage displayed as voltage Uncontrolled Copy - Refer to Ampcontrol Website for Latest Version Page 31 of 72...

  • Page 32: Earth Continuity

    The Protection Element can be configured to operate in either diode or RTX mode. This determines what terminating device the relay is expecting on the pilot. NOTE The RTX will only be recognised by an OCS Protection Element and will not be seen as a diode by other earth continuity devices. CAUTION! Cable parameters are important to the correct operation of the Pilot E/C function.

  • Page 33: Table 8 Protection Element - Earth Continuity Series Trip Characteristics

    Prevent Main Contactor from closing Active Period Always active Logging Always logged Trip time Parameters Trip latch enable Monitoring Available as the raw ohms measurement, resolution of 100Ω. Uncontrolled Copy - Refer to Ampcontrol Website for Latest Version Page 33 of 72...

  • Page 34: Earth Fault Lockout

    The Protection Element can provide a two-step insulation test as part of the Earth Fault Lockout protection function. The initial test is the mandatory intrinsically safe test and can be followed by an automatic High Voltage ‘Insulation Test’. Uncontrolled Copy - Refer to Ampcontrol Website for Latest Version Page 34 of 72...

  • Page 35: Table 11: Protection Element - Earth Fault Lockout (Eflo) Trip Characteristics

    The insulation test takes 4 seconds. The results of the insulation test should only be used as a guide to confirm that insulation remains above Uncontrolled Copy - Refer to Ampcontrol Website for Latest Version Page 35 of 72...

  • Page 36: Main Contactor Protection

    Frozen Contactor devices where large inertial loads are connected. The trip level can be selected at 25VAC or 50VAC. The trip time is less than 1sec. Uncontrolled Copy - Refer to Ampcontrol Website for Latest Version Page 36 of 72...

  • Page 37: Table 14: Protection Element - Frozen Contactor Trip Characteristics

    Close fail detects the event when the Protection Element attempts to close the output by closing its MCR output, but receives no confirmation of the close output contactor via the MCI digital input. Close fail protection activates in approximately 1sec. Uncontrolled Copy - Refer to Ampcontrol Website for Latest Version Page 37 of 72...

  • Page 38: Table 16: Protection Element - External Open Trip Characteristics

    Protection Element or alternatively over comms. All trip bits that feed into the Main Contactor Failure Flag are individually logged in the Protection Element for event analysis in the instance of a Circuit Breaker Trip. Uncontrolled Copy - Refer to Ampcontrol Website for Latest Version Page 38 of 72...

  • Page 39: Current Related Protection Functions

    When Over Current curve is set to Very Inverse or Extremely Inverse. Logging Always Time Multiplier Parameters Full Load Current Phase currents displayed as a percentage of selected full load current Monitoring Thermal Accumulator (TAC) Uncontrolled Copy - Refer to Ampcontrol Website for Latest Version Page 39 of 72...
  • Page 40 (trip) will occur. This will automatically clear once the thermal accumulator drops to, or is below the selected level. Note however that generally this will happen quickly when the inverse overcurrent modes are selected. Uncontrolled Copy - Refer to Ampcontrol Website for Latest Version Page 40 of 72...

  • Page 41: Table 19: Protection Element - Motor Overload Trip Characteristics

    TMS = the Over Current Time Multiplier Setting, Ip = the load current that was flowing (long enough to reach thermal stability) prior to the overload occurrence. ln = the natural logarithm. Uncontrolled Copy - Refer to Ampcontrol Website for Latest Version Page 41 of 72...
  • Page 42 While the main contactor is closed, the cooling output from the thermal model is calculated to achieve the necessary behaviour to match the characteristic above. The Over Load Cooling Multiplier modifies the cooling output of the thermal model when the motor is Uncontrolled Copy - Refer to Ampcontrol Website for Latest Version Page 42 of 72...
  • Page 43 CAUTION! Incorrect motor protection setup, or thermal memory resets may cause or lead to motor failure or permanent motor damage. Uncontrolled Copy - Refer to Ampcontrol Website for Latest Version Page 43 of 72...

  • Page 44: Short Circuit

    The circuit interrupting device tripped by the selected output relay for the Short Circuit function MUST be rated to interrupt the full prospective system short circuit current. Uncontrolled Copy - Refer to Ampcontrol Website for Latest Version Page 44 of 72...

  • Page 45: Current Balance

    If the trip level is exceeded, a timer is triggered. If the imbalance remains above the set level for more than two seconds the relay trips. Uncontrolled Copy - Refer to Ampcontrol Website for Latest Version Page 45 of 72...

  • Page 46: Under Current

    MCI input). If any of the phase voltages drop below the selected trip setting of the nominal line voltage for 800ms then the outlet is stopped. Uncontrolled Copy - Refer to Ampcontrol Website for Latest Version Page 46 of 72...

  • Page 47: Service, Maintenance & Disposal

    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 OCS and the systems into which it is fitted. Routine inspections may take the form of either visual-only checks, or visual and ‘hands-on’...

  • Page 48: Equipment Maintenance

    Cassette can seriously compromise the safety of the unit and voids product warranty. It is recommended that the electrical protection 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: ...

  • Page 49: Specifications

    100mA, 150mA, 200mA, 250mA, 300mA, 350mA, 400mA, 450mA, Trip Settings +/-10% 500mA Inst., 50ms, 75ms, 100ms, 150ms, 200ms, 250ms, 300ms, 350ms, Trip Time +0% -20% 400ms, 450ms, 500ms CT Failure 4.5s Uncontrolled Copy - Refer to Ampcontrol Website for Latest Version Page 49 of 72...
  • Page 50 Frozen Contactor < 100ms Loss of Contactor < 1s Control Back EMF Time 2s, 5s, 10s, 15s, 20s Loss of Control < 1s LOV Level 25VAC, 50VAC Uncontrolled Copy - Refer to Ampcontrol Website for Latest Version Page 50 of 72...
  • Page 51 5%, 10%, 20%, 50%, OFF Other Protection Functions Under Voltage Protection Trip Settings Off, 40%, 50%, 60%, 70%, 75%, 80%, 85%, 90%, 95% Trip Time 850ms Uncontrolled Copy - Refer to Ampcontrol Website for Latest Version Page 51 of 72...

  • Page 52: Equipment List

    OCS USER MANUAL MAG-182 Version 5 – FEB/2020 12 EQUIPMENT LIST Part Number Description 173694 Fixed OCS Cassette c/w Standard OCS Protection Element (EtherNet/IP) Withdrawable OCS Cassette c/w Standard OCS Protection Element 159689 (EtherNet/IP) 159325 Standard OCS Protection Element (Spare Part) (EtherNet/IP)

  • Page 53: Appendix A: Protection Element Load Current Tables

    119 64 151 128 183 256 23.4x 215 512 11.7x 24 8.250 56 16.50 88 33.0 120 66 152 132 184 264 22.7x 216 528 11.4x Uncontrolled Copy - Refer to Ampcontrol Website for Latest Version Page 53 of 72...
  • Page 54 126 78 158 156 190 312 19.2x 222 624 9.6x 31 10.00 63 20.00 95 40.0 127 80 159 160 191 320 18.8x 223 640 9.4x Uncontrolled Copy - Refer to Ampcontrol Website for Latest Version Page 54 of 72...

  • Page 55: A2: Protection Element Tms Table

    19.39 36.0 0.26 0.210 0.390 2.10 3.90 26.0 21.01 39.0 0.28 0.226 0.420 2.26 4.20 28.0 22.63 42.0 0.30 0.242 0.450 2.42 4.50 30.0 24.24 45.0 Uncontrolled Copy - Refer to Ampcontrol Website for Latest Version Page 55 of 72...
  • Page 56 Inv. 0.32 0.259 0.480 2.59 4.80 0.35 0.283 0.525 2.83 5.25 0.38 0.307 0.570 3.07 5.70 0.42 0.339 0.630 3.39 6.30 0.46 0.372 0.690 3.72 6.90 Uncontrolled Copy - Refer to Ampcontrol Website for Latest Version Page 56 of 72...

  • Page 57: Appendix B: Drawings

    OCSE002 Typical Connection Diagram OCSE001 I.S. System Diagram OCSA001 Protection Element Mechanical Details OCSB001 Overcurrent and Short Circuit Curves OCSB002 Motor Overload and Short Circuit Curves Uncontrolled Copy - Refer to Ampcontrol Website for Latest Version Page 57 of 72...
  • Page 58 Ampcontrol Pty Ltd – ABN 28 000 915 542 OCS USER MANUAL MAG-182 Version 5 – FEB/2020 Uncontrolled Copy - Refer to Ampcontrol Website for Latest Version Page 58 of 72...
  • Page 59 Ampcontrol Pty Ltd – ABN 28 000 915 542 OCS USER MANUAL MAG-182 Version 5 – FEB/2020 Uncontrolled Copy - Refer to Ampcontrol Website for Latest Version Page 59 of 72...
  • Page 60 Ampcontrol Pty Ltd – ABN 28 000 915 542 OCS USER MANUAL MAG-182 Version 5 – FEB/2020 Uncontrolled Copy - Refer to Ampcontrol Website for Latest Version Page 60 of 72...
  • Page 61 Ampcontrol Pty Ltd – ABN 28 000 915 542 OCS USER MANUAL MAG-182 Version 5 – FEB/2020 Uncontrolled Copy - Refer to Ampcontrol Website for Latest Version Page 61 of 72...
  • Page 62 Ampcontrol Pty Ltd – ABN 28 000 915 542 OCS USER MANUAL MAG-182 Version 5 – FEB/2020 Uncontrolled Copy - Refer to Ampcontrol Website for Latest Version Page 62 of 72...

  • Page 63: 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. Uncontrolled Copy - Refer to Ampcontrol Website for Latest Version Page 63 of 72...
  • Page 64 Ampcontrol Pty Ltd – ABN 28 000 915 542 OCS USER MANUAL MAG-182 Version 5 – FEB/2020 Uncontrolled Copy - Refer to Ampcontrol Website for Latest Version Page 64 of 72...
  • Page 65 Ampcontrol Pty Ltd – ABN 28 000 915 542 OCS USER MANUAL MAG-182 Version 5 – FEB/2020 Uncontrolled Copy - Refer to Ampcontrol Website for Latest Version Page 65 of 72...
  • Page 66 Ampcontrol Pty Ltd – ABN 28 000 915 542 OCS USER MANUAL MAG-182 Version 5 – FEB/2020 Uncontrolled Copy - Refer to Ampcontrol Website for Latest Version Page 66 of 72...
  • Page 67 Ampcontrol Pty Ltd – ABN 28 000 915 542 OCS USER MANUAL MAG-182 Version 5 – FEB/2020 Uncontrolled Copy - Refer to Ampcontrol Website for Latest Version Page 67 of 72...
  • Page 68 Ampcontrol Pty Ltd – ABN 28 000 915 542 OCS USER MANUAL MAG-182 Version 5 – FEB/2020 Uncontrolled Copy - Refer to Ampcontrol Website for Latest Version Page 68 of 72...
  • Page 69 Ampcontrol Pty Ltd – ABN 28 000 915 542 OCS USER MANUAL MAG-182 Version 5 – FEB/2020 Uncontrolled Copy - Refer to Ampcontrol Website for Latest Version Page 69 of 72...
  • Page 70 Ampcontrol Pty Ltd – ABN 28 000 915 542 OCS USER MANUAL MAG-182 Version 5 – FEB/2020 Uncontrolled Copy - Refer to Ampcontrol Website for Latest Version Page 70 of 72...
  • Page 71 Ampcontrol Pty Ltd – ABN 28 000 915 542 OCS USER MANUAL MAG-182 Version 5 – FEB/2020 Uncontrolled Copy - Refer to Ampcontrol Website for Latest Version Page 71 of 72...
  • Page 72 Ampcontrol Pty Ltd – ABN 28 000 915 542 OCS USER MANUAL MAG-182 Version 5 – FEB/2020 Uncontrolled Copy - Refer to Ampcontrol Website for Latest Version Page 72 of 72...

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