Page 1 User Manual Version No: 5 Doc No: / Name: MAG-222 - ROCKSTARTER USER MANUAL Author / SME Approval by Process March 2025 Zach Curran Tasman Dunn Prepared by: Owner: Refer to Ampcontrol Intranet for latest version Page 1 of 132...
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 132...
Page 3: Copyright Notice
Version: 5, Date 11 March 2025 Copyright Notice The Ampcontrol Rockstarter described in this document is the property of AMPCONTROL LIMITED. 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
5.11 Remote Start Test ........................42 5.12 Emergency Stop ........................42 6 PRODUCT OPERATION........................43 6.1 Interfacing Elements ........................43 6.2 Outlet Starting ..........................56 6.3 Outlet Resets ..........................57 Uncontrolled Copy - Refer to Ampcontrol Website for Latest Version Page 4 of 132...
Page 5 B1 Outlet Control Registers ......................109 B2 Outlet Live Data........................109 B3 UI Live Data – Fan Mode ......................113 B4 UI Live Data – Pump Mode ...................... 114 Uncontrolled Copy - Refer to Ampcontrol Website for Latest Version Page 5 of 132...
Page 6 B10 RKS Load Parameters – LCM Mode ..................126 B11 RKS General Parameters – LCM Mode .................. 127 APPENDIX C: HMI REPLACEMENT ....................128 APPENDIX D: DRAWINGS ........................ 129 Uncontrolled Copy - Refer to Ampcontrol Website for Latest Version Page 6 of 132...
Page 7 Figure 41: Rockstarter Mounting Frame C/W Bolts – PN: 177190 ............91 Figure 42: Rockstarter Mounting Bar Kit – PN: 177191................91 Figure 43: Rockstarter Adaptor Plates - 60A left (PN: 179292) & 150A right (PN: 181811) ..... 92 Figure 44: Feed Through Kit – 181441 ....................92 Figure 45: Junction Box Dual Gland .......................
Page 8 Figure 46: Dual Incomer: Option 1 Flexible Busbar................. 94 Figure 47: Dual Incomer: Option 2 Side Entry Box (192647) ..............95 Figure 48: Rockstarter Gland Plate & Feed Through Kits ............... 96 Figure 49: Rockstarter Terminal Cover Kit ....................97 Figure 50: Rockstarter Secondary Covers ....................
Page 9 Table 14: Fan Incremental Timing Mode ....................65 Table 15: Pump Protection – Configuration Settings................67 Table 16: Rockstarter Pump Sleep Timing Mode ..................67 Table 17: Pump Incremental Timing Mode ..................... 68 Table 18: Earth Leakage Trip Characteristics ..................70 Table 19: Earth Leakage CT Failure Trip Characteristics................
Page 10 (fault dependent) to clear the Trip fault, or prevents the closing of the main contactor or circuit breaker Transformer Undercurrent Undervoltage Uncontrolled Copy - Refer to Ampcontrol Website for Latest Version Page 10 of 132...
Page 11: Safety And Other Warnings
Operation As safety depends on the Rockstarter functioning correctly it is highly recommended that all safety functions of the Rockstarter be periodically tested to ensure correct operation. 1.2 Supplementary Documentation The Rockstarter’s User Manual is expected to be read in conjunction with the following documentation:...
Page 12: Requirements For Safe Operation
Upstream protection must be implemented in accordance with the user’s fault and touch potential control studies • The terminal compartment cover must not be removed unless the Rockstarter’s circuit breaker is open • Through Feed gland plates must not be removed unless the Rockstarter has been isolated upstream •...
Page 13: 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 14: Storage After Delivery
All equipment should be stored indoors between 0–40 ˚C, preferably on shelves and protected from moisture and sunlight. The Rockstarter must be stored lying flat on its back, alternatively it is recommended to use the Rockstarter’s optional Mounting Frame to provide additional protection whilst.
Page 15: Product Description
It is also suitable for use in tunnelling and other industrial applications. The Rockstarter controls a single power outlet, rated up to 250 A / 1000 V, incorporating an integrally designed circuit breaker, contactor and protection electronics, all into a single robust unit.
Page 16: Application
Ampcontrol’s integrated Outlet Test System (OTS) provides a fully automated and comprehensive outlet testing facility. The OTS enables the Rockstarter to undergo routine testing quickly and easily, with all test results uploaded to cloud storage. This satisfies statutory testing requirements while also providing a secure and comprehensive record management tool.
Page 17: Configuration Examples
MAG-222 - ROCKSTARTER USER MANUAL Version: 5, Date 11 March 2025 3.4 Configuration Examples Figure 3: Rockstarter Overview – Two Rockstarters with one incoming feed Wall mount (optional) RKS mounting frame to wall mount clamp RKS mounting frame (optional) Through feed connection (optional)
Page 18: Arc Fault Mitigation
Version: 5, Date 11 March 2025 3.5 Arc Fault Mitigation The Rockstarter implements high level engineering controls to eliminate the possibility or arcs and faults being generated. This development of the Rockstarters design provides compliance with the requirements of AS/NZS3000:2018 and AS/NZS4871.1:2012 in regard to arc fault protection. Arc Fault Mitigation should not be confused with Arc Fault Containment, containment is a lower level of control against are faults.
Page 19: Installation
If modifications of any form are made to the Rockstarter, the equipment may no longer be fit for use. If any modifications or damage to the Rockstarter is evident, do not use the equipment and contact Ampcontrol for advice.
Page 20: Mechanical Installation Information
1 or 2 Rockstarters mounted to wall mount 2055 x 1194 x 442 mm 3 or 4 Rockstarters mounted to wall mount 4055 x 1194 x 442 mm Uncontrolled Copy - Refer to Ampcontrol Website for Latest Version Page 20 of 132...
Page 21: Figure 7: Rockstarter Lifting Adaptor
Rockstarter. The lifting adaptor is rated for securing the Rockstarter with a sling or chain with an internal angle (α) of no more than 90°, refer to Figure 7. An internal sling angle of 60 or 90° will result in a sling height approximately 290 mm or 170 mm respectively.
Page 22: Figure 8: Rockstarter Wall Bracket Mount
4. Lift the Rockstarter over the wall mount, aligning the slot at the back of the mounting frame with the tab on the wall mount, refer to Figure 8. The mounting frame and wall mount are keyed and will self-align provided the Rockstarter is placed near the final position.
Page 23 The user replaceable fuses and control supply termination block is also located behind this cover. The terminal compartment cover can be seen in Figure 10. The terminal compartment cover is secured with 6 M8x60 mm bolts. The cover must not be removed unless the Rockstarter’s circuit breaker is isolated.
Page 24: Figure 10: Rockstarter Terminal Compartment Cover Overview
Through feed – L1 Earth busbar Through feed – L2 Incoming pilot termination block Through feed – L3 Outgoing pilot termination block Control supply termination block Uncontrolled Copy - Refer to Ampcontrol Website for Latest Version Page 24 of 132...
Page 25: Figure 11: Rockstarter Adaptor Plate (60A Pictured)
Version: 5, Date 11 March 2025 Incoming & Outgoing Cable Terminations The Rockstarter’s incoming and outgoing connections may be configured to suit either a glanded cable entry or a restrained receptacle. The incoming and outgoing feeds natively support a 300 A receptacle footprint while the blanking plate may be drilled to accommodate glanded cables up to 120 mm .
Page 26: Figure 12: Dual Gland J-Box
Figure 12: Dual Gland J-Box 4.3.4.2 Dual Incomer Termination There are two options for connecting dual incomers to the Rockstarter. The first option is the Flexible busbar, suited to installations using smaller diameter cables of 70 mm and lower. The second option is...
Page 27: Figure 13: Dual Incomer Termination
2. The flexible buses allow the second termination point to move out of the way while securing the incoming feed/first termination point to the original incomer termination point of the Rockstarter as per normal. 3. Thread the supplied insulation sleeve over the second incoming cable and away from termination point.
Page 28: Figure 14: Dual Connection Side Entry Box
2. Install one incomer as normal on the Rockstarter’s incomer / line connection point. 3. Remove the desired through feed internal cover and the external side entry gland plate. 4. Install the side entry box onto the Rockstarter using the supplied hex head screws and ensuring the seal is not damaged.
Page 29: Figure 15: Through Feed - With (Left) & Without (Right) Cover
9. Install terminal compartment cover. When the through supply functionality is not required, all cable entries and exits must be sealed using Ampcontrol supplied blanking plates. Ensure unused pilot entries are sealed using nylon blanking plugs. WARNING! The through supply kit must only be used with all connected Rockstarters mounted to the wall mount assembly.
Page 30: Figure 16: Ethernet & Terminal I/O Connector
Auxiliary I/O & Ethernet Connectors The Rockstarter is equipped with an Ethernet and auxiliary I/O connector at the top of the unit, refer to Figure 16 item 1 and 2. Ethernet connectivity is provided by way of an RJ45. The auxiliary I/O connector utilises a Bulgin PXP6012/16S/CR connector, refer to Table 2 for the auxiliary I/O connector pinout.
Page 31: Figure 17 The Fan Sequencing Cable (181876)
Version: 5, Date 11 March 2025 Sequencing Cables There are two specific cables provided for sequencing Rockstarters, Cable Fan Sequencing Rockstarter and Cable Rockstarter Sequencing Tee. The Fan Sequencing cable (Part Number 181876), this cable connects the “Run” output of one RKS to the “Delayed Start Input”...
Page 32: Figure 19: Load Connection Module (Lcm) (Mm)
The resistance threshold is as follows, trip when resistance exceeds 1960 Ω and reset when value drops back below 1847 Ω. Five RTD inputs are provided for PT100 RTDs. The Rockstarter can be programmed to trip on RTD over-temperature.
Page 33: Figure 20: Float Junction Box (196069)
The module is a IP66 plug and play extension and utilises 2x M25 glanded entries to the junction box for each of the start and stop (High and low float level) inputs. To use this with the Rockstarter, you cannot have the Rockstarter configured for Remote start.
Page 34: Figure 21: H3Ro Fibre Communications Junction Box Complete With Terminals (192139)
The H3RO fibre communications junction box provides an interface between local copper Ethernet/IP connections to Rockstarter panels and a site fibre network, significantly increasing the distance at which data can be exchanged with Rockstarters remotely. The equipment is powered from a connected RKS through the IO cable.
Page 35: Electrical Installation Information
OPT 3. LCM Termination Motor Enclosure RTD’s Digital Inputs START PILOT PILOT STOP 100Ω OPT 2. Diode Remote Start OPT 1. Diode Termination Figure 22: Electrical Connection Diagram Uncontrolled Copy - Refer to Ampcontrol Website for Latest Version Page 35 of 132...
Page 36: Figure 23: Incoming Pilot - Terminations
4.4.1.2 Through Terminations Pilot in Pilot in E-Stop E-Stop Pilot Out Pilot Out Pilot Pass Through Pilot Pass Through + E-Stop Figure 24: Incoming Pilot – Through Terminations Uncontrolled Copy - Refer to Ampcontrol Website for Latest Version Page 36 of 132...
Page 37: Figure 25: Outgoing Pilot - Terminations
(PN 115119), alternatively a 1N5404 diode can be utilised. 4.4.2.2 Diode Remote Start Termination A remote start button can be implemented in the motor enclosure provided that the Rockstarter’s earth continuity protection is enabled and the remote start function is enabled within the UI.
Page 38: Figure 27: Load Connection Module (Lcm) - Connection Diagram
Version: 5, Date 11 March 2025 4.4.2.4 Load Connection Module (LCM) A remote Start / Stop button can be implemented in the motor enclosure provided that the Rockstarter’s earth continuity protection is enabled. If the remote start, stop, and PTC functions are not required, each set of terminals must be bridged to prevent incorrect data and control inputs being detected.
Page 39: Figure 28: Control Supply Termination
1000 V AC terminal. A third auxiliary I/O fuse is also located in the termination compartment. This supply is fed through to the AUX connector at the top of the Rockstarter and is for Ampcontrol diagnostic use only. WARNING! The system voltage must be set in conjunction with the appropriate...
Page 40: Commissioning
All tests and trips can be monitored through the Log menu on the Rockstarter HMI. When testing is undertaken, the logs should be monitored to ensure all events are captured and logged correctly.
Page 41: Insulation Test (High Voltage)
5.5 Main Contactor Fail While the Rockstarter is stopped (MC open), apply a voltage on the load side of the contactor. The voltage must be greater than the selected trip level to initiate a Loss of Vacuum (LOV) trip. Ensure that a CB trip is initiated by the Rockstarter.
Page 42: Remote Start Test
5 seconds to initiate a Held/Stuck Start Input trip. Ensure that the contactor successfully trips and required a general reset. The indication LEDs on the fascia of the Rockstarter should illuminate yellow to indicate a trip (as detailed in Section 6.1.5) and the HMI should display the relevant trip messages.
Page 43: Product Operation
6 PRODUCT OPERATION 6.1 Interfacing Elements The Rockstarter is controlled via the HMI. The system is menu driven and navigated via the 7-inch capacitive-touch LCD display. The touchscreen provides an intuitive interface for viewing and modifying the outlet’s configuration. All outlet control and protection settings are made through this interface. The touchscreen can be operated while wearing gloves or using a stylus and will function (within reasonable limits) with dirt and other contaminants on the screen.
Page 44: Figure 30: Rockstarter Ui - Home Screen
Version: 5, Date 11 March 2025 Home Interface The HOME screen of the Rockstarter will appear similar to that of Figure 30 below. The interface has a number of features which are identified in this image by numbered circles. Items identified in this figure are detailed in the following sub-sections.
Page 45: Table 5: Outlet Control
MAG-222 - ROCKSTARTER USER MANUAL Version: 5, Date 11 March 2025 6.1.1.2 Item 2: Outlet Control The buttons displayed here are action buttons and allow for control of the Rockstarter. Refer to Table 5 for an overview of the buttons/icons. Table 5: Outlet Control...
Page 46: Table 6: Outlet Status Icons
Stop Input Circuit input detected as open circuit Remote Termination Remote Termination device PTC Input detected as open Remote Termination Circuit Remote Termination device communications fault Remote Termination Uncontrolled Copy - Refer to Ampcontrol Website for Latest Version Page 46 of 132...
Page 47 Circuit Breaker has opened Internal Electronics Fault TM32 Internal Electronics Fault TM33 Internal Electronics Fault TM34 Internal Electronics Fault TM35 Internal Electronics Fault TM36 Internal Electronics Fault TM37 Uncontrolled Copy - Refer to Ampcontrol Website for Latest Version Page 47 of 132...
Page 48: Figure 31: Rockstarter Ui - Testing Screen
Version: 5, Date 11 March 2025 Testing Interface The TESTING screen of the Rockstarter UI is shown in Figure 31 below. Authorised access is required to operate the Rockstarter’s testing functions, refer to Section 6.1.6 for details on gaining authorised access.
Page 49: Figure 32: Rockstarter Ui - Outlet Test System
Table 8: OTS Status Symbols below. When the Rockstarter’s Earth Continuity protection is disabled the EC test should be unchecked within the OTS application. Otherwise the Rockstarter will not trip on EC and the application will report a fault. NOTE If OTS test mode is disabled either due to user selection, time out or power cycle all parameters will revert to their previous settings.
Page 50: Figure 33: Rockstarter Ui - Status Screen
An OTS test sweep may be performed as detailed in the OTS documentation with the following exceptions: • OTS testing will not be allowed to proceed unless the Rockstarter’s OTS enable button has been selected • There is no ‘CONFIG’ option within the OTS application as it is automatically configured for use...
Page 51: Table 9: Status Page Overview
MC Closures Time Rockstarter Serial Number Protection Firmware Version Display Firmware Version Supervisor Firmware Version OTS Firmware Version Processor Image Version Rockstarter HMI IP Address Free Memory Uncontrolled Copy - Refer to Ampcontrol Website for Latest Version Page 51 of 132...
Page 52 Earth Leakage (EL) ▪ Trip Time ▪ Trip Level o Frozen Contact / Loss of Vacuum (FC) ▪ Back EMF Time ▪ Loss of Vacuum Level Uncontrolled Copy - Refer to Ampcontrol Website for Latest Version Page 52 of 132...
Page 53 Save Changes – changes must be saved before taking effect. Refer to Section 6.1.4.1. NOTE Parameters cannot be changed while the outlet is running. If the outlet is running, then only the current parameters may be viewed. Uncontrolled Copy - Refer to Ampcontrol Website for Latest Version Page 53 of 132...
Page 54: Figure 34: Rockstarter Ui - Setup Page
Certain parameters are linked and changing one will modify another. For instance, the UC trip point is used as the snore current level when the Rockstarter is operating in Pump Mode. When this occurs the modified parameters are indicated by “****” appearing in place of the red dot in the corresponding upper menu levels.
Page 55: Figure 35: Rockstarter Lighting
Lighting and Indication The Rockstarter incorporates LED lighting in the LCD surround to indicate the location and operating state. The LEDs are very bright but dim upon touchscreen interaction. After 15 minutes of UI inactivity, the lighting will revert to full brightness and the LCD will enter a sleep state.
Page 56: Outlet Starting
A successful RFID read will be indicated by a blue flash while a failed tag read will be indicated by a yellow flash. If there are trips present in the Rockstarter then the LEDs will be solid yellow. In this situation a failed tag read will be indicated by the yellow LEDs will dimming momentarily.
Page 57: Outlet Resets
Version: 5, Date 11 March 2025 6.3 Outlet Resets All resets in the Rockstarter are handled through the HMI. Most trips are reset with a general reset, not requiring authorised access. Some trips require an authorised reset to provide a level of competency associated with resetting faults.
Page 58: Internal Trips
Version: 5, Date 11 March 2025 6.4 Internal Trips The Rockstarter has a number of trip functions that are not directly associated with the protection of the outlet, but signal that an internal fault has been detected. If an internal trip is detected, contact Ampcontrol for assistance.
Page 59 "Circuit Breaker Trip" CB Has Tripped, See Section 8.4 / 9.2 HMI putting protection into bootloader mode, HMI has "Kill Switch Trip" stopped the protection electronics operation Uncontrolled Copy - Refer to Ampcontrol Website for Latest Version Page 59 of 132...
Page 60: Time And Date
The Rockstarter has implemented Virtual Network Computing (VNC), this can be used to monitor control and configure the Rockstarter remotely. The VNC will need to be used in conjunction with MODBUS TCP to provide the Authorisation input. Any VNC software can be used by accessing the unit directly through the configured IP address.
Page 61: Outlet Control
LCM, refer to Section 6.1.4 o LCM Name o RTD 1-2 Trip Level o RTD 3-5 Trip Level o RTD 1-2 Reset Level o RTD 3-5 Reset Level Uncontrolled Copy - Refer to Ampcontrol Website for Latest Version Page 61 of 132...
Page 62: Figure 36: Rockstarter Ui - Mode Control
If the outlet has already been auto restarted but is in the restart delay period, and another power cycle occurs The Rockstarter will not auto-restart if a power cycle occurs while in the “Delayed Fan Start” or “Post- Blast Start” delays.
Page 63: Fan Control Mode
When operating in LCM mode, it is possible to connect RTD input that can be monitored at the Rockstarter. The LCM can be programmed with a name to allow it to be identified easier by the user. This identifier can be up to 15 characters.
Page 64: Table 12: Fan Protection - Configuration Settings
Burp Timing Modes The Rockstarter can be configured to two burp timing modes, fixed and incremental. These modes refer to the length of time that the Rockstarter remains in the ON and OFF state each time that a burp event occurs.
Page 65: Figure 37: Starting Options - Post Blast Start Enabled, Remote Start Disabled
In the Incremental Timing Mode, the burp ON time increases as per the values shown in Table 14. Table 14: Fan Incremental Timing Mode Burp Cycle 1 Burp Cycle 2 Burp Cycle 3 Burp Cycle 4 x 1.5 x 2.25 x 3.375 Uncontrolled Copy - Refer to Ampcontrol Website for Latest Version Page 65 of 132...
Page 66: Figure 38: Starting Options - Post Blast Start And Delayed Start Enabled, Remote Start Disabled
Figure 38: Starting Options - Post Blast Start and Delayed Start Enabled, Remote Start Disabled Delayed Start Input In order to perform dual fan sequence starts with the Rockstarter, the ‘Run’ output of the first Fan stage Rockstarter (accessed through the Auxiliary I/O connector) must be connected to the ‘Delayed Start’...
Page 67: Pump Control Mode - (Anti Snore Mode)
(Snore Current). After a user defined time period (Sleep Time), the Rockstarter will ‘wake’ the outlet to check if the intake pipe has been fully submerged again. If the pump is still underloaded, another sleep cycle will begin.
Page 68: Table 17: Pump Incremental Timing Mode
The Rockstarter is considered to have entered sleep mode consecutively if, after waking up from a sleep state, the pump operates 5 seconds and does not exceed the specified Snore Current and therefore returns to sleep. The Rockstarter will then initiate another sleep cycle, and the consecutive sleep count will increase.
Page 69: Figure 39: Starting Options - Pump Mode
Or remote stop Or Aux Start Or Comms Start Auto Start Auto Start enabled, enabled, power cycles power cycles Figure 39: Starting Options – Pump Mode Uncontrolled Copy - Refer to Ampcontrol Website for Latest Version Page 69 of 132...
Page 70: Touch Potential Protection Functions
MAG-222 - ROCKSTARTER USER MANUAL Version: 5, Date 11 March 2025 8 TOUCH POTENTIAL PROTECTION FUNCTIONS The Rockstarter provides a number of protection functions that meet the requirements of the AS/NZS 2081 standard. These protection functions are: • Earth Leakage •...
Page 71: Earth Continuity
AS/NZS 2081:2011, by passing a 15 mA, 200 Hz test signal through the primary of the earth leakage CT. If the test signal is not detected by the Rockstarter a ‘CT Detection Error’ trip will occur. As the test signal is always present, the display will constantly indicate an earth leakage level of approximately 15 mA, even when no actual earth leakage current is present.
Page 72: Table 20: Earth Continuity Series Trip Characteristics
MAG-222 - ROCKSTARTER USER MANUAL Version: 5, Date 11 March 2025 NOTE The LCM will only be recognised by the Rockstarter and will not be seen as a suitable pilot termination by other earth continuity devices. NOTE If earth continuity protection was disabled prior to changing the...
Page 73 The remote start setting requires the following sequence for a start to be triggered: Diode Mode: 1. The Rockstarter must be healthy and ready to start, all trips must be clear. 2. The Rockstarter’s earth continuity protection and remote start function must be enabled.
Page 74: Figure 40: Starting Options - Normal Mode
If earth continuity is not set to latch, the Rockstarter can be started and stopped at the motor enclosure. If earth continuity is set to latch, a reset must be performed before the outlet can be started again.
Page 75: Earth Fault Lockout
Test Time 2 seconds The earth fault lockout function tests the resistance of the three phase lines to earth. The Rockstarter applies an extra low voltage signal prior to the closure of the main contactor in accordance with AS/NZS 2081:2011. The test is automatically initiated by a starting sequence once all starting conditions are met.
Page 76: Main Contactor Protection
Trip Time < 1 Second The Loss of Vacuum trip in the Rockstarter acts like a Main Contactor Fail Electrical trip. Loss of Vacuum detection provides protection against a faulty contactor that has failed due to ionisation between the contacts (or welded contacts) causing voltage to be detected on the output when the contactor is open.
Page 77: Table 25: Frozen Contactor Trip Characteristics
Trip Time 100 ms The Frozen Contactor trip in the Rockstarter acts like a main contactor fail logical trip. If the Rockstarter detects that the main contactor has closed when requested to be open, or remains closed after requested to open, it will result in a frozen contactor trip, tripping the circuit breaker.
Page 78: Table 27: External Open Trip Characteristic
Monitoring Coil voltage status bit The coil voltage is internally detected by the Rockstarter. This additional functionality is provided so in the event of the contactor coil voltage being lost while the outlet is running a nuisance main contactor Failure trip does not occur, as the changing of state for the main contactor can be explained by the loss of coil voltage.
Page 79: Load Related Protection Functions
MAG-222 - ROCKSTARTER USER MANUAL Version: 5, Date 11 March 2025 9 LOAD RELATED PROTECTION FUNCTIONS The Rockstarter individually measures all three of the outlets phase currents. The measured currents are used to implement the following protection functions: • Inverse time protection – Overcurrent or Motor Overload •...
Page 80: Table 29: Overcurrent Trip Characteristics
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Page 81 – i.e. per unit current, fault current full Load TMS = the Overcurrent Time Multiplier Setting, (I) = the idealised reset time. See Overcurrent Curves, drawing IPXB014 in Uncontrolled Copy - Refer to Ampcontrol Website for Latest Version Page 81 of 132...
Page 82 100% with the #Burp starts programmed into the Rockstarter. The individual starts of the sequence will be protected by a thermal start block of 90% regardless of this setting.
Page 83: Table 30: Motor Overload Trip Characteristics
The thermal accumulator (TAC) is the model’s ‘temperature’ (presented in a %) where 0% represents the motor being cold, and 100% meaning the motor has reached its maximum temperature limit (and will therefore trip). Uncontrolled Copy - Refer to Ampcontrol Website for Latest Version Page 83 of 132...
Page 84 The base thermal model provides a thermal time constant of 72.9 seconds. The TMS setting scales the basic thermal time constant, allowing a maximum time constant of over 36 minutes (TMS = 30). See Motor Overload Curves drawing IPXB013 in Uncontrolled Copy - Refer to Ampcontrol Website for Latest Version Page 84 of 132...
Page 85 MAG-222 - ROCKSTARTER USER MANUAL Version: 5, Date 11 March 2025 APPENDIX D: DRAWINGS. Uncontrolled Copy - Refer to Ampcontrol Website for Latest Version Page 85 of 132...
Page 86 When the Rockstarter 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.
Page 87: Short Circuit
Any other trips or control action to open the contactor during this time – except for earth leakage, will be blocked. Uncontrolled Copy - Refer to Ampcontrol Website for Latest Version Page 87 of 132...
Page 88: Undervoltage
If the trip level is exceeded, a timer is triggered. If the imbalance remains above the set level for more than 2 seconds, the Rockstarter trips. Uncontrolled Copy - Refer to Ampcontrol Website for Latest Version Page 88 of 132...
Page 89: Undercurrent
4 seconds. Undercurrent trips will latch only when the operating mode is Normal or Fan. In Pump Mode, the UC faults are used for the pump sleep detection. Uncontrolled Copy - Refer to Ampcontrol Website for Latest Version Page 89 of 132...
Page 90: 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 Rockstarter 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 91: Equipment Maintenance
The Rockstarter must be returned to Ampcontrol for all other repairs. If, during an inspection, it is determined that there is damage to the Rockstarter’s through connection, these should be replaced. Ensure through connections are only performed with Ampcontrol supplied accessories.
Page 92: Accessories & Spare Parts
MAG-222 - ROCKSTARTER USER MANUAL Version: 5, Date 11 March 2025 11 ACCESSORIES & SPARE PARTS 11.1 Accessories Figure 41: Rockstarter Mounting Frame C/W Bolts – PN: 177190 Figure 42: Rockstarter Mounting Bar Kit – PN: 177191 Accessories Part Number...
Page 93: Figure 43: Rockstarter Adaptor Plates - 60A Left (Pn: 179292) & 150A Right (Pn: 181811)
MAG-222 - ROCKSTARTER USER MANUAL Version: 5, Date 11 March 2025 Figure 43: Rockstarter Adaptor Plates - 60A left (PN: 179292) & 150A right (PN: 181811) Figure 44: Feed Through Kit – 181441 PN: 181441 - Kit Feed Through Complete with Guard Rockstarter...
Page 94: Figure 45: Junction Box Dual Gland
MAG-222 - ROCKSTARTER USER MANUAL Version: 5, Date 11 March 2025 Figure 45: Junction Box Dual Gland PN: 181903 - Kit Junction Box Dual Gland Rockstarter Part Number Description Item Number 181905 Junction Box Dual Gland Rockstarter Kit Plate Gland Extension Housing Rockstarter...
Page 95: Figure 46: Dual Incomer: Option 1 Flexible Busbar
Cover Plastic Line Caddy Dual Feed Rockstarter 138972 Cable Tie Nylon Black 300x4.8mm Accessories (Not Included in Kit) Part Number Description Item Number 181872 Kit Cover Internal Incomer Rockstarter Uncontrolled Copy - Refer to Ampcontrol Website for Latest Version Page 95 of 132...
Page 96 Version: 5, Date 11 March 2025 Figure 47: Dual Incomer: Option 2 Side Entry Box (192647) PN: 193292 - Kit Junction Box Side Entry Rockstarter Complete With 95mm Lugs PN: 193291 - Kit Junction Box Side Entry Rockstarter Complete With 120mm...
Page 97: Spare Parts
MAG-222 - ROCKSTARTER USER MANUAL Version: 5, Date 11 March 2025 11.2 Spare Parts Figure 48: Rockstarter Gland Plate & Feed Through Kits PN: 179169 - Kit Gland Plate Line/Load Rockstarter Part Number Description Item Number 179126 Plate Gland Main Rockstarter...
Page 98: Figure 49: Rockstarter Terminal Cover Kit
180513 Seal Termination Cover Rockstarter 181871 Kit Screw Washer Terminal Chamber Rockstarter Kit Label Main Rockstarter Terminal Cover 181870 (Requires Rockstarter serial number to be provided) Uncontrolled Copy - Refer to Ampcontrol Website for Latest Version Page 98 of 132...
Page 99: Figure 50: Rockstarter Secondary Covers
Secondary Covers Part Number Description Item Number 179173 Kit Cover Feed Through Internal Rockstarter 181872 Kit Cover Internal Incomer Rockstarter 190883 Kit Nut Washer Electrical Main Rockstarter Uncontrolled Copy - Refer to Ampcontrol Website for Latest Version Page 99 of 132...
Page 100: Figure 51: Rockstarter Capacitive Touch Panel Kit
Part Number Description Item Number 179300 O-ring Screen Rockstarter 179158 Panel Capacitive Touch Rockstarter 179299 Frame Screen Rockstarter Screen Frame Screws M5x16mm SS304 CSK Head 130680 Socket Page 100 of Uncontrolled Copy - Refer to Ampcontrol Website for Latest Version...
Page 101: Specifications
MAG-222 - ROCKSTARTER USER MANUAL Version: 5, Date 11 March 2025 12 SPECIFICATIONS NOTE The Rockstarter’s default settings are indicated below with bold font. Specifications General System Voltage 415 V / 690 V / 1000 V Fault Rating 20 kA, 0.5 s...
Page 102 Latching Trip ON / OFF Frozen Contactor/Loss of Vacuum Back EMF Timer (Sec) 2, 5, 10, 15, 20 Loss of Vacuum Level (VAC) OFF, 25, 50, 100, 150 Page 102 of Uncontrolled Copy - Refer to Ampcontrol Website for Latest Version...
Page 103 OFF, 30, 35, 40 , 45, 50, 55, 60 , 65, 70, 75, 80, 85, 90, 95 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: www.ampcontrolgroup.com...
Page 104: Equipment List
Rockstarter 1000V 250A Motor Starter 192614 Rockstarter 1000V 250A Motor Starter Complete with Frame 192615 Rockstarter 1000v 250A Complete with Frame & 60A Receptacle 192616 Rockstarter 1000v 250A Complete with Frame & 150A Receptacle 192617 Rockstarter 1000v 250A Complete with Frame & 300A Receptacle Accessories –...
Page 105 Outlet Testing System Part Number Description Tablet 8” LTE Complete with Case 176852 Tablet NON-LTE 8” Complete with Case 177451 197693 Tablet NON-LTE NFC 8” OTS with Case Page 105 of Uncontrolled Copy - Refer to Ampcontrol Website for Latest Version...
Page 106: Rockstarter Spares
Kit Cover Internal Incomer Rockstarter 179091 Cover Plastic Line Caddy Rockstarter 190501 Cover Plastic Line Caddy Dual Feed Rockstarter General Part Number Description 190491 Clamp 48mm Pipe Swivel Coupling Page 106 of Uncontrolled Copy - Refer to Ampcontrol Website for Latest Version...
Page 107 Cap Dust RJ45 Bulkhead 181438 Cap Dust Bulgin 6012 Series 181878 Kit Fuse 10x 4A 1.2kV Slow Blow HRC-15kA 190558 Kit Fuse 10x 3.15A 250V Slow Blow HRC Page 107 of Uncontrolled Copy - Refer to Ampcontrol Website for Latest Version...
Page 108: Appendix A: Protection Element Load Current Tables
157 59.3 189 119 19.7x 9.9x 3.80 7.61 15.2 126 30.4 158 60.9 190 122 19.3x 9.6x 3.90 7.80 15.6 127 31.2 159 62.4 191 125 18.8x 9.4x Page 108 of Uncontrolled Copy - Refer to Ampcontrol Website for Latest Version...
Page 109: A2: Protection Module Tms Table
24.24 45.0 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 Page 109 of Uncontrolled Copy - Refer to Ampcontrol Website for Latest Version...
Page 110: Appendix B: Rockstarter Modbus Tcp
Ohms x 100. Range of values is 0.9 kΩ Pilot Shunt Resistance Read Only to 10 kΩ. (9 to 100). Trip if below 1.5 kΩ (i.e. value <15). Page 110 of Uncontrolled Copy - Refer to Ampcontrol Website for Latest Version...
Page 111 0x0080 Frozen Contactor 0x0100 No Coil Supply 0x0200 HMI Comm’s Timeout 0x0400 Unused 0x0800 Unused 0x1000 CCM ID Trip 0x2000 MCF Battery Trip 0x4000 Unused 0x8000 Unused Page 111 of Uncontrolled Copy - Refer to Ampcontrol Website for Latest Version...
Page 112 32767 – Open Circuit LCM RTD Temp 4 Read Only 32766 – Short Circuit 32765 – Other Fault LCM RTD Temp 5 Read Only 32764 – LCM Offline Page 112 of Uncontrolled Copy - Refer to Ampcontrol Website for Latest Version...
Page 113 Temperature measured within the LCM. Value is LCM Internal Temp Read Only given to the nearest degree. Range of values is -20 ˚C to +100 ˚C. 53-103 <Reserved> Read Only Page 113 of Uncontrolled Copy - Refer to Ampcontrol Website for Latest Version...
Page 114: B3 Ui Live Data - Fan Mode
Fan Blast Detect Enabled Read Only 0 = No, 1 = Yes Fan Sequence Burping Read Only 0 = No, 1 = Yes 114 - 118 <Reserved> Read Only Page 114 of Uncontrolled Copy - Refer to Ampcontrol Website for Latest Version...
Page 115: B4 Ui Live Data - Pump Mode
To determine the Power Cycle Timer; remaining time you will need to subtract this value from your timer / delay setting. 131 - 133 <Reserved> Read Only Page 115 of Uncontrolled Copy - Refer to Ampcontrol Website for Latest Version...
Page 116: B6 Ui Live Data - Common
0 = Off, 1 = On Stop Pressed Read Only 0 = Off, 1 = On Reset Pressed Read Only 0 = Off, 1 = On 172-179 <Reserved> Read Only Page 116 of Uncontrolled Copy - Refer to Ampcontrol Website for Latest Version...
Page 117: B7 Outlet Parameters
Loss of Vacuum Level Read Only 50 V AC 100 V AC 150 V AC Value Trip Name Voltage Level Read Only 1000 211 – 225 <Reserved> Read Only Page 117 of Uncontrolled Copy - Refer to Ampcontrol Website for Latest Version...
Page 118: B8 Rks Load Parameters - Diode Mode
Short Circuit Trip Time Read Only 120 ms 140 ms 160 ms 180 ms 200 ms Value Description Very Inverse Overcurrent Curve Read Only Extremely Inverse Motor Overload Page 118 of Uncontrolled Copy - Refer to Ampcontrol Website for Latest Version...
Page 119 0.22 19.0 0.24 20.0 0.26 22.0 0.28 24.0 0.30 26.0 0.32 28.0 0.35 30.0 0.38 0.42 Value Cooling Multiplier Overload Cooling Multiplier Read Only <Reserved> Read Only Page 119 of Uncontrolled Copy - Refer to Ampcontrol Website for Latest Version...
Page 120 30 mA 50 mA 100 mA 150 mA 200 mA Earth Leakage Trip Level Read Only 250 mA 300 mA 350 mA 400 mA 450 mA 500 mA Page 120 of Uncontrolled Copy - Refer to Ampcontrol Website for Latest Version...
Page 121 Earth Continuity Trip Time Read Only 300 ms 400 ms 500 ms Value Meaning Earth Continuity Latch Read Only Value Meaning Remote Start Read Only Disabled Enabled <Reserved> Read Only Page 121 of Uncontrolled Copy - Refer to Ampcontrol Website for Latest Version...
Page 122: B9 Rks General Parameters - Diode Mode
251 – 256 <Reserved> Read Only B9 RKS General Parameters – Diode Mode Modbus Name Read/Write Bit Identification Register Value Meaning Normal Operation mode Read Only Pump Page 122 of Uncontrolled Copy - Refer to Ampcontrol Website for Latest Version...
Page 123 10 min Delayed Fan Start Read Only 15 min 20 min 25 min 30 min 45 min 60 min 75 min 90 min 105 min 120 min Page 123 of Uncontrolled Copy - Refer to Ampcontrol Website for Latest Version...
Page 124 Burp Cycles Read Only Value Meaning 1 sec 2 sec 3 sec Burp On Time Read Only 4 sec 5 sec 10 sec 15 sec 20 sec Page 124 of Uncontrolled Copy - Refer to Ampcontrol Website for Latest Version...
Page 125 Read Only Char 7 = High, Char 8 = Low 8 Bit ASCII Characters, Asset name char 9-10 Read Only Char 9 = High, Char 10 = Low Page 125 of Uncontrolled Copy - Refer to Ampcontrol Website for Latest Version...
Page 126 UI Gateway Address Byte 3 Read Only 0-255 UI Gateway Address Byte 4 Read Only 0-255 Value Meaning Fan Thermal Block Level Read Only 298 - 301 <Reserved> Read Only Page 126 of Uncontrolled Copy - Refer to Ampcontrol Website for Latest Version...
Page 127: B10 Rks Load Parameters - Lcm Mode
1-200 which will reset/clear the LCM RTD Temperature Trip. 0-4 (As Per RKS – Diode Mode) Back EMF Time Read Only 327 - 331 <Reserved> Read Only Page 127 of Uncontrolled Copy - Refer to Ampcontrol Website for Latest Version...
Page 128: B11 Rks General Parameters - Lcm Mode
Read Only Char 15 = High, Char 16 = Low 0-18 (As Per RKS – Diode Mode) Fan Thermal Block Level Read Only 361-368 <Reserved> Read Only Page 128 of Uncontrolled Copy - Refer to Ampcontrol Website for Latest Version...
Page 129: Appendix C: Hmi Replacement
Version: 5, Date 11 March 2025 APPENDIX C: HMI REPLACEMENT The Rockstarter’s display and digitiser is replaceable. To replace the display and digitiser: 1. Ensure the correct isolation procedures are followed. 2. Remove the 8 M5x16 mm hex head screws from the top and bottom screen holders.
Page 130: Appendix D: Drawings
The drawings in this appendix are as per the below table. Drawing Number Drawing Title IPXB014 Overcurrent and Short Circuit Curves IPXB013 Motor Overload and Short Circuit Curves Page 130 of Uncontrolled Copy - Refer to Ampcontrol Website for Latest Version...
Page 131 MAG-222 - ROCKSTARTER USER MANUAL Version: 5, Date 11 March 2025 Page 131 of Uncontrolled Copy - Refer to Ampcontrol Website for Latest Version...
Page 132 MAG-222 - ROCKSTARTER USER MANUAL Version: 5, Date 11 March 2025 Page 132 of Uncontrolled Copy - Refer to Ampcontrol Website for Latest Version...

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