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Ampcontrol PF1 User Manual

Pump & fan relay
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PF1
PUMP & FAN RELAY
User Manual
Version: 6, March 2020
Created in Australia by Ampcontrol Pty Ltd

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Summary of Contents for Ampcontrol PF1

  • Page 1 PUMP & FAN RELAY User Manual Version: 6, March 2020 Created 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 71...
  • Page 3 MAG-165 Version 6 – March/2020 Copyright Notice The Ampcontrol PF1 and all associated parts and accessories that are described in this document are the property of AMPCONTROL PTY LTD. They are furnished under a license agreement and are to be used only in accordance with the terms of the agreement.

  • Page 4: Table Of Contents

    7.2 Fan Remote Start and Stop ..............37 8 EARTH LEAKAGE: AS/NZS 2081 PROTECTION FUNCTION ......38 8.1 Earth Leakage Bandwidth Mode .............. 38 8.2 EL Toroid Monitoring................39 Uncontrolled Copy - Refer to Ampcontrol Website for Latest Version Page 4 of 71...
  • Page 5 10 SMART TOOLS SOFTWARE ................ 44 10.1 Operating System Requirements ............44 10.2 Software Version Naming Conventions ..........44 10.3 Connecting the PF1 to Your PC ............. 45 10.4 Navigating the User Interface ..............45 10.5 Issue Reporting ..................52 11 OPERATIONAL INTERFACE ................
  • Page 6 Figure 3.2: Typical Application - Fan Protection (Only) ................13 Figure 3.3: Typical Application - Pump Protection (EL, EC, Remote Start & Remote Stop) ....14 Figure 4.1: PF1 Enclosure Dimensions (Terminal Plugs Removed) ............17 Figure 4.2: PF1 Enclosure Dimensions (Terminal Plugs Inserted) ............18 Figure 4.3: PF1 Terminal Layout ......................
  • Page 7 Table 1: PF1 Configuration for a Typical Application of Pump Protection (Only) ........12 Table 2: PF1 Configuration for a Typical Application of Fan Protection (Only) ........13 Table 3: PF1 Configuration for a Typical Application of Pump Protection (EL, EC, R.Start & R.Stop) ..15 Table 4: Recommended Surge Protection ....................19 Table 5: Pump Protection - Configuration - via Smart Tools PC Software ..........

  • Page 8: Safety And Other Warnings

    Operation As safety depends on the PF1 functioning correctly it is highly recommended that all safety functions of the PF1 be periodically tested to ensure correct operation.

  • Page 9: Summary Of Essential Cautions And Warnings

    NOTE The Facia Stop button will only open the K1 output relay if the PF1 is set to Pump Mode or Fan Mode. If the PF1 is not set to Section either Pump Mode or Fan Mode, the Fascia Stop button will not 11.2...

  • Page 10: Receiving And Storage

    If there is evidence of physical damage, notify Ampcontrol immediately. Notify Ampcontrol immediately in the case of any discrepancies to the packing list. Keep a record of any claims and correspondence. Photographs are recommended.

  • Page 11: Product Overview

    (known as snoring), the speed of the pump motor will rise to its maximum, which can burn out the pump motor in as little as 30 seconds. The under-current condition is detected by the PF1 which can apply a configurable sleep/run cycle to help prevent pump burnout due to a lack of water.

  • Page 12: Figure 3.1: Typical Application - Pump Protection (Only)

    ~ The EC Earth terminal must be connected to earth, even if EC is disabled Figure 3.1: Typical Application - Pump Protection (Only) Table 1: PF1 Configuration for a Typical Application of Pump Protection (Only) PF1 Typical Configuration – Pump Mode (Only) Setting Category...

  • Page 13: Figure 3.2: Typical Application - Fan Protection (Only)

    ~ The EC Earth terminal must be connected to earth, even if EC is disabled Figure 3.2: Typical Application - Fan Protection (Only) Table 2: PF1 Configuration for a Typical Application of Fan Protection (Only) PF1 Typical Configuration – Fan Mode (Only) Setting Category...

  • Page 14: Figure 3.3: Typical Application - Pump Protection (El, Ec, Remote Start & Remote Stop)

    Ampcontrol Pty Ltd – ABN 28 000 915 542 PF1 USER MANUAL MAG-165 Version 6 – March/2020 PF1 Pump (EL, EC, Remote Start & Remote Stop) Application To Contactor 24Vdc or 24Vac Control Supply Power Supply Circuit Breaker Vs (+)

  • Page 15: Table 3: Pf1 Configuration For A Typical Application Of Pump Protection (El, Ec, R.start & R.stop)

    Ampcontrol Pty Ltd – ABN 28 000 915 542 PF1 USER MANUAL MAG-165 Version 6 – March/2020 Table 3: PF1 Configuration for a Typical Application of Pump Protection (EL, EC, R.Start & R.Stop) PF1 Typical Configuration – Pump Mode with EL, EC, R.Start & R.Stop Setting Category...

  • Page 16: Installation

    It is important to understand how the PF1 is intended to interact with other equipment within a system. For safe and reliable use, it is crucial that neither the PF1 relay’s logical operation nor its signalling be compromised by incompatibilities with connected equipment.

  • Page 17: Mandatory Installation Practices

    The installation is to be in accordance with the relevant installation Standards/Codes of Practice. Modifications must not be made to any part of the PF1. As supplied, the unit is built to, and complies with the relevant standards. Any modifications will render the unit non-compliant.

  • Page 18: Figure 4.2: Pf1 Enclosure Dimensions (Terminal Plugs Inserted)

    PF1 Mounting Arrangements The PF1 is DIN Rail mounted and can be mounted in any orientation; however, it should ideally be oriented as shown. The DIN rail release tab is located on the bottom of the relay at the rear of the unit.

  • Page 19: Electrical Installation

    Vs Supply (Terminals 1 & 2) The acceptable regulated supply voltage range for the PF1 is from 18 to 28.8Vac (50 to 60Hz), or 18 to 28.8Vdc. It is recommended that a suitable form of surge protection is included, for installations, where the supply input can be subjected to surges outside of the limits defined by AS/NZS2081.
  • Page 20 When the contact closes, the VDC voltage will be applied to the input terminal, thereby “closing” the input. The PF1 relay’s digital inputs are intended to be wired to the output contacts of a PLC and/or to external pushbuttons.
  • Page 21 Earth Leakage Toroid Test (Terminals 25 & 26) The EL Test terminals (25 & 26) are used to output a test signal that is monitored by the PF1 via the outlet’s earth leakage toroid. This signal is used to prove that the wiring between the PF1 and the earth leakage toroid is undamaged, and that the toroid itself is still functioning.
  • Page 22 Front Panel STOP Button (PF1 Fascia) The Front Panel STOP button is located on the fascia of the PF1 relay. This button can be used to stop the PF1 relay, provided that the PF1 relay is operating in either its Pump or Fan protection function. If the PF1 does not have either of these functions enabled then the STOP button will not perform a function.
  • Page 23 MAG-165 Version 6 – March/2020 Remote Stop Button (Motor Enclosure) A remote stop button can be implemented in the motor enclosure provided that the PF1 relay’s earth continuity protection is enabled. In order to install a remote stop push button, wire a normally closed contact in series with the pilot conductor.

  • Page 24: Commissioning

    This is not intended to provide an exhaustive commissioning checklist, but should be considered to be a minimum set of tests. Each test need only be completed if that particular function of the PF1 is being utilised in the installation. 5.1 Pump Protection Test Required if: Pump Protection is enabled.

  • Page 25: Earth Continuity Test

    3Ω above the selected trip level to account for the tripping hysteresis level. Confirm that the PF1 initiates an earth continuity trip and that the main contactor is opened. The red “Trip” LED on the fascia of the PF1 should be illuminated.

  • Page 26: Remote Stop Test

    If the PF1 is being used as a standalone earth continuity relay, the remote start function must be enabled or the earth continuity trip must be set to latching.

  • Page 27: Pump Protection

    MAG-165 Version 6 – March/2020 6 PUMP PROTECTION Pump Protection is a selectable operating function of the PF1 that provides additional protection and control functionality for outlets that are supplying pump motors. Enabling Pump Protection provides two additional control functions that are individually configurable from within the Smart Tools software: Pump Sleep (Anti-Snore Mode) and Pump Resume after Power Failure.

  • Page 28: Pump Sleep Mode (Anti-Snore Mode)

    (iSet value). After a user defined time period (determined by the sleep cycle settings), the PF1 will ‘wake’ the outlet to check if the intake pipe has been fully submerged again. If the pump is still under-loaded, another sleep cycle will begin.

  • Page 29: Figure 6.1: Sleep Mode: Incremental Time Multiples For Consecutive Sleeps

    ���������������������� ���������� �������� = �������������� ���������� × 1.5 Where �� is the number of times the PF1 has consecutively entered a sleep state. The �� count is capped at 4 which represents a time period of roughly 5 times the initial delay. After the PF1 has entered sleep mode four consecutive times, the sleep time will no longer increase and will remain constant at that duration.

  • Page 30: Table 7: Sleep Cycle Setting Definitions

    Ampcontrol Pty Ltd – ABN 28 000 915 542 PF1 USER MANUAL MAG-165 Version 6 – March/2020 Sleep Cycle Settings The sleep cycle settings affect the operation of the PF1 relay’s sleep function. Table 7: Sleep Cycle Setting Definitions Pump Mode Set by...

  • Page 31: Figure 6.2: Sleep Mode Iset Procedure

    �������� �������������� + (�������� ������������ ( �������������������� ) �������������������� × �������� ��������������) In order to set the iSet Current (aka iSet level) in the PF1, the PF1 relay must be powered and power must be available at the outlet that is to be energised. Follow the procedure below to set the iSet level:...

  • Page 32: Figure 6.3: Pump Sleep Mode Operating Logic Diagram (See Table 8)

    3. Place the intake pipe back into the water. 4. It is possible to bring the PF1 out of the sleep state (caused by setting the iSet level) by pressing the start button again. This is shown in Zone 3.3 of the above example.
  • Page 33 PF1 will re-enter the sleep state. The PF1 re-enters a sleep state. In this instance the PF1 can be seen to be in Fixed Sleep Mode as the length of the sleep cycle is the same as in Zone 5. If the PF1 was in Incremental Mode, this subsequent sleep cycle would have been longer.

  • Page 34: Auto/Manual Mode

    The float system is simply a high and low water level float switch, which is interfaced with the local Start and Stop inputs of the PF1. An external stop button, on the face of the starter panel, would be included.

  • Page 35: Pump Resume After Power Failure

    PF1 enabled tripping functions are healthy (e.g. EL and EC). In order to enable this feature of the PF1, ensure that the relay is in Pump Control Mode and use the Smart Tools software to toggle the “Pump Resume after Power Failure” setting to “Yes”.

  • Page 36: Fan Protection

    MAG-165 Version 6 – March/2020 7 FAN PROTECTION Fan Protection is a selectable operating function of the PF1 that provides additional protection and control functionality for outlets that are supplying fan motors. Enabling Fan Protection provides a burp mode that allows ventilation tubes to be gradually inflated, preventing tearing due to sudden pressure increases.

  • Page 37: Fan Burp Mode

    Burp Mode can be set from 0 to 4 cycles. If “None” is selected, then the Burp Mode will be disabled and the PF1 will not perform any pulsing of the fan motor during start up. If a number of Burp cycles are selected, then it is possible to individually alter the duration of each burp.

  • Page 38: Earth Leakage: As/Nzs 2081 Protection Function

    When an earth leakage trip occurs, the PF1 will de-energise the K1 output relay to trip the outlet’s main contactor. All earth leakage trips are latching and are required to be reset before the outlet can be restarted again.

  • Page 39: El Toroid Monitoring

    AS/NZS 2081:2011. If the PF1 fails to detect the CT detection signal via the earth leakage toroid, an earth leakage trip will be initiated, opening the main contactor. This fault must be present for at least 5 seconds to cause a trip.

  • Page 40: Earth Continuity: As/Nzs 2081 Protection Function

    In a typical installation the PF1 relay’s EC Pilot terminal (20) will be connected to the pilot conductor of a trailing or reeling cable. The load end of the pilot conductor is terminated with a diode to earth, creating a return path through the earth conductors of the cable to the main earth point of the outlet and then to the PF1 relay’s EC Earth terminal (21).

  • Page 41: Ec Series Resistance Monitoring

    If the measured series resistance is above the trip setting for a period of time that exceeds the set trip time, the PF1 de-energises the K1 output relay to trip the outlet’s main contactor.

  • Page 42: Ec Latching Mode (Selectable)

    PF1 USER MANUAL MAG-165 Version 6 – March/2020 In latching mode, the PF1 must be reset after the fault has been cleared, before the outlet can be started. The EC shunt resistance monitoring function has a built in hysteresis function that prevents an earth continuity trip from being reset if the measured resistance is hovering around the trip level.
  • Page 43 The PF1 can be set as a standalone earth continuity relay (pump and fan protection both set to off). If set as a standalone earth continuity relay, the remote start button should be used, or the earth continuity trip should be set to latching.

  • Page 44: Smart Tools Software

    PF1, along with providing a number of diagnostic tools. This software is provided on a USB drive that is supplied with each PF1. The latest version of the Smart Tools software can be found by visiting the Ampcontrol website and navigating to the Software folder in the Technical Resources Library.

  • Page 45: Connecting The Pf1 To Your Pc

    MAG-165 Version 6 – March/2020 10.3 Connecting the PF1 to Your PC In order to communicate with the PF1 it is first necessary to install the Smart Tools software package. For information on this process, please refer to the Installation Guide in APPENDIX A: To connect (USB communications) to the PF1: 1.

  • Page 46: Figure 10.2: Smart Tools Software - Relay Status Page

    MAG-165 Version 6 – March/2020 Relay Status Page The Relay Status page allows the user view the status of the connected PF1 in real time. This can be used as a diagnostic tool if the user is experiencing faults on the system.

  • Page 47: Figure 10.3: Smart Tools Software - Relay Event Logs Page

    MAG-165 Version 6 – March/2020 Relay Event Logs Page The PF1 is provided with an event logging system that allows the user to diagnose system faults and review operational data. Each event is given a relative time stamp. Using the “Calculate Time”...
  • Page 48 Thus the password is different for each PF1 relay. New settings can be loaded into the PF1 whilst the outlet is in service. However, upon loading the new settings the PF1 will perform an automatic re-boot. At this point, all output relays (K1, K2, K3 and K4) will open, resulting in the outlet de-energising.

  • Page 49: Figure 10.4: Smart Tools Software - Relay Configuration Page

    Ampcontrol Pty Ltd – ABN 28 000 915 542 PF1 USER MANUAL MAG-165 Version 6 – March/2020 Figure 10.4: Smart Tools Software - Relay Configuration Page Uncontrolled Copy - Refer to Ampcontrol Website for Latest Version Page 49 of 71...

  • Page 50: Figure 10.5: Smart Tools Software - Smart Tools Settings Page

    The Smart tools Settings page allows the user to alter the USB connection settings for Smart Tools. In the majority of cases, the “Auto Detect” feature should automatically find the USB port that the PF1 has been plugged into. In rare cases, it may be necessary to force the software to communicate through a user selected USB port.

  • Page 51: Figure 10.6: Smart Tools Software - About Page

    The About page provides information about the software. It is also possible to access the “Report an Issue” feature, from the About Page. This feature is explained in detail in Section 10.5. Figure 10.6: Smart Tools Software - About Page Uncontrolled Copy - Refer to Ampcontrol Website for Latest Version Page 51 of 71...

  • Page 52: Issue Reporting

    10.5 Issue Reporting The Smart Tools PC software allows the user to compile an Issue Report that they can then send to the Ampcontrol Customer Service team for assistance with any PF1 / Smart Tools related issues that they may be experiencing.

  • Page 53: Operational Interface

    Figure 11.1: PF1 Operational Interface 11.1 Fascia LEDs The PF1 relay’s fascia has seven (7) LEDs. These LEDs give feedback on the current operating state of the PF1 and can provide diagnostic assistance in the case of system faults. The Pump LED, Fan LED, EL LED, and EC LED employ a flash rate system to provide indication on some of their operating states.

  • Page 54: Table 16: Status Led Operating Logic

    Fan Running Green Fan Burping Green Fan Stopped EL trip EL toroid trip EC open circuit trip (series) EC short circuit trip (shunt) EC start button trip Uncontrolled Copy - Refer to Ampcontrol Website for Latest Version Page 54 of 71...

  • Page 55: Fascia Stop Pushbutton (Item 8)

    Earth continuity trip 11.2 Fascia Stop Pushbutton (Item 8) The PF1 has a Stop pushbutton mounted on its fascia. Pressing the Stop pushbutton will open the K1 output relay, hence opening the outlet’s contactor. The fascia Stop pushbutton can be used as an alternative to the “Stop” digital input.

  • Page 56: Programmable Digital Input (Pi) (Item 10)

    11.4 Programmable Digital Input (PI) (Item 10) The PF1 relay has been implemented with an input that can be configured in the Smart Tools software to perform different functions. In the initial release of the PF1, this input can be configured as:...

  • Page 57: Table 24: Pi Filtered Stop - Configuration - Via Smart Tools Pc Software

    VDC supply is removed (opened). The Filter Period is the length of time that the input must be activated before the PF1 will issue a STOP command. For example, if the Filter Period is set to 5 seconds and the PI input is only active for 4 seconds, the PF1 will not issue a STOP command.

  • Page 58: Programmable Relay Outputs (K2, K3 & K4) (Item 11)

    MAG-165 Version 6 – March/2020 11.5 Programmable Relay Outputs (K2, K3 & K4) (Item 11) The PF1 has three output relays (K2, K3 & K4) with functionality that can be customised using the Smart Tools software. The relays can be programmed to have a default state of open (de-energised) or closed (energised).

  • Page 59: 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 PF1 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 60: Equipment Maintenance

    PF1 can seriously compromise the safety of the unit and will thus void product warranty and compliance. It is recommended that the electrical protection system incorporating the PF1 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 61: Specifications

    Toroid Window Size 50mm Inner Diameter S1/2 cable loop 0.1 Ω resistance (max) S1/2 length (max) S1/2 cable type Twisted pair + shield to Earth (on PF1 end only) Earth Leakage Trip Times 50 to 500ms Trip Levels 30 to 1000mA Toroid...
  • Page 62 USB Mini Current Consumption 75mA (when supply voltage is not energised) Find Out More 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 Uncontrolled Copy - Refer to Ampcontrol Website for Latest Version...

  • Page 63: Equipment List

    Earth Leakage Toroid - 60mm Inner Diameter (Included in Kit) ACCESSORIES Part Number Description 117023 EC Terminating Diode - 1N5404 3A (Included in Kit) 169732 EC Start Resistor - 100R 1% 5W (Included in Kit) Uncontrolled Copy - Refer to Ampcontrol Website for Latest Version Page 63 of 71...

  • Page 64: Appendix A: Smart Tools Installation Guide

    1024 x 768 Available USB Ports (minimum) Downloading The latest version of the Smart Tools software can be found by visiting the Ampcontrol website and navigating to the Software folder in the Technical Resources Library. http://www.ampcontrolgroup.com/technical-resources/ The installation file will depend upon the Windows system architecture and the software version or patch.
  • Page 65 Ampcontrol Pty Ltd – ABN 28 000 915 542 PF1 USER MANUAL MAG-165 Version 6 – March/2020 2) Select Troubleshoot 3) Select Advanced options 4) Select Start-up Settings Uncontrolled Copy - Refer to Ampcontrol Website for Latest Version Page 65 of 71...
  • Page 66 You can now install the software / drivers which were previously blocked. NOTE Disabling the signature verification is not permanent. It is only valid until you reboot the PC again. Uncontrolled Copy - Refer to Ampcontrol Website for Latest Version Page 66 of 71...
  • Page 67 (Note, this example is for the 64bit version, but the 32bit / x86 version will install in the same manner) 1. Open the Smart Tools setup file. 2. This will bring up the installation window: 3. Click Next. Uncontrolled Copy - Refer to Ampcontrol Website for Latest Version Page 67 of 71...
  • Page 68 PF1 USER MANUAL MAG-165 Version 6 – March/2020 4. This will bring up the installation window: 5. Click Install. 6. This will begin the installation process: Uncontrolled Copy - Refer to Ampcontrol Website for Latest Version Page 68 of 71...
  • Page 69 8. Click finish to complete the installation. 9. Navigate to the Smart Tools application, located in the Windows Start Menu. 10. Click on the Smart Tools icon to start the application. Uncontrolled Copy - Refer to Ampcontrol Website for Latest Version Page 69 of 71...

  • Page 70: Appendix B: Toroid & Current Txf Dimensions

    Mounting = Bracket and Screw Figure B.1: Earth Leakage Toroid - EL500/60 - P/N 115439 - Dimensions & Mounting Details (This is included in the PF1 Kit) Uncontrolled Copy - Refer to Ampcontrol Website for Latest Version Page 70 of 71...
  • Page 71 50mm Inner Diameter Figure B.2: Current TXF 1000:1 – PFCT SRS27 - P/N 175616 - Dimensions & Mounting Details (This is included in the PF1 Kit) Uncontrolled Copy - Refer to Ampcontrol Website for Latest Version Page 71 of 71...

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