Ampcontrol EFL User manual

Version: 5, March 2020
Designed and manufactured in Australia by Ampcontrol Pty Ltd
EFL
EARTHFAULTLOCKOUTPROTECTIONRELAY
UserManual

Ampcontrol Pty Ltd –ABN 28 000 915 542
EFL PROTECTION RELAY USER MANUAL
MAG-178 Version 5 –MARCH/2020
Uncontrolled Copy - Refer to Ampcontrol Website for Latest Version
Page 2 of 23
APPROVED FOR EXTERNAL DISTRIBUTION –PROPERTY OF AMPCONTROL PTY LTD –NOT TO BE REPRODUCED IN PART
WARNING!
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 which may have an
impact on the surrounding fauna and/or flora.

Ampcontrol Pty Ltd –ABN 28 000 915 542
EFL PROTECTION RELAY USER MANUAL
MAG-178 Version 5 –MARCH/2020
Uncontrolled Copy - Refer to Ampcontrol Website for Latest Version
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APPROVED FOR EXTERNAL DISTRIBUTION –PROPERTY OF AMPCONTROL PTY LTD –NOT TO BE REPRODUCED IN PART
Copyright Notice
The Ampcontrol EFL Relay described in this document is the property of AMPCONTROL PTY LTD. It is
furnished under a license agreement and is to be used only in accordance with the terms of the
agreement.
No part of the hardware or documentation may be reproduced, transmitted, transcribed, stored in a
retrieval system, or translated into any language or computer language, in any form or by any means,
without prior written permission of AMPCONTROL PTY LTD.
Disclaimer
While every effort has been made to assure the accuracy and clarity of this document, AMPCONTROL
PTY LTD assumes no liability resulting from any omissions in this document, or from misuse of the
information obtained herein. The information in this document has been carefully checked and is
believed to be entirely reliable with all of the necessary information included. AMPCONTROL PTY LTD
reserves the right to make changes to any products described herein to improve reliability, function, or
design, and reserves the right to revise this document and make changes from time to time in content
hereof with no obligation to notify any persons of revisions or changes. AMPCONTROL PTY LTD does
not assume any liability arising out of the application or any use of any product or circuit described
herein; neither does it convey license under its patent rights or the rights of others.
Before You Begin
We would like to take a moment to thank you for purchasing the Ampcontrol EFL Relay.
WARNING!
In the interests of safety and correct equipment operation, please
take the time to read and understand the content in this manual.
Ampcontrol Contact Details
7 Billbrooke Close, Cameron Park, NSW, 2285
P [phone] | F [phone]
EMAIL: [e-mail]
WEB: ampcontrolgroup.com

Ampcontrol Pty Ltd –ABN 28 000 915 542
EFL PROTECTION RELAY USER MANUAL
MAG-178 Version 5 –MARCH/2020
Uncontrolled Copy - Refer to Ampcontrol Website for Latest Version
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APPROVED FOR EXTERNAL DISTRIBUTION –PROPERTY OF AMPCONTROL PTY LTD –NOT TO BE REPRODUCED IN PART
TABLE OF CONTENTS
1 SAFETY AND OTHER WARNINGS..................................................................6
1.1 Safe Use of Equipment..............................................................................6
2 RECEIVING AND STORAGE............................................................................7
2.1 Receiving...................................................................................................7
2.2 Inspection..................................................................................................7
2.3 Storage after Delivery................................................................................7
2.4 Unpacking of Equipment............................................................................7
3 PRODUCT OVERVIEW ....................................................................................8
3.1 Product Description ...................................................................................8
3.2 Applications...............................................................................................8
4 INSTALLATION.................................................................................................9
4.1 General Warnings......................................................................................9
4.2 Mandatory Installation Practices ..............................................................10
4.3 Mechanical Installation Information..........................................................10
4.4 Electrical Installation Information .............................................................13
5 COMMISSIONING AND CALIBRATION .........................................................15
5.1 Earth Fault Lockout Test..........................................................................15
5.2 Frozen Contactor Test.............................................................................15
5.3 Undervoltage Test ...................................................................................15
6 PRODUCT OPERATION.................................................................................16
6.1 Logical Operation of the EFL Relay .........................................................16
6.2 Earth Fault Lockout (EFLO) Protection Function......................................17
6.3 Frozen Contactor (FC) Protection Function..............................................18
6.4 Undervoltage (UV) Protection Function....................................................19
6.5 User Interface..........................................................................................19
6.6 First Time Use / Use after Extended Storage...........................................20
7 SERVICE, MAINTENANCE & DISPOSAL.......................................................21
7.1 Equipment Inspections.............................................................................21
7.2 Equipment Maintenance..........................................................................21
7.3 Equipment Service...................................................................................22
7.4 Disposal...................................................................................................22
8 SPECIFICATIONS ..........................................................................................23
9 EQUIPMENT LIST ..........................................................................................23

Ampcontrol Pty Ltd –ABN 28 000 915 542
EFL PROTECTION RELAY USER MANUAL
MAG-178 Version 5 –MARCH/2020
Uncontrolled Copy - Refer to Ampcontrol Website for Latest Version
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TABLE OF FIGURES
Figure 4.1: Enclosure Dimensions –Stand Alone EFL Relay....................................10
Figure 4.2: Enclosure Dimensions –External Barrier................................................11
Figure 4.3: Enclosure Dimensions –EFL Relay with Internal Barrier ........................11
Figure 4.4: Terminal Numbering Arrangements for EFL Relay with External Barrier.12
Figure 4.5: Terminal Numbering Arrangement for EFL Relay with Internal Barrier....12
Figure 4.6: Typical Electrical Application...................................................................13
Figure 6.1: Logical Operation of the EFL Relay –General Overview ........................16
Figure 6.2: EFL Relay User Interface: Functionality of Operators..............................19
Figure 6.6: EFL Relay User Interface: Functionality of LEDs.....................................20

Ampcontrol Pty Ltd –ABN 28 000 915 542
EFL PROTECTION RELAY USER MANUAL
MAG-178 Version 5 –MARCH/2020
Uncontrolled Copy - Refer to Ampcontrol Website for Latest Version
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1 SAFETY AND OTHER WARNINGS
For safety reasons, the EFL Relay must be installed, operated and serviced only by competent electrical
personnel. Read and understand this instruction manual completely before installing, operating or
servicing this equipment. Failure to install or operate this instrument in accordance with the instructions
contained in this manual may create hazardous operating conditions.
1.1 Safe Use of Equipment
The equipment supplied has been designed and manufactured to ensure a safe operation. The
equipment may only be used within the design parameters.
The instructions within this manual must be observed as an aid towards achieving the safest possible
installation.
Persons responsible for installation, maintenance, or operation, must observe the following
instructions:
1.1.1 Changes to Equipment
Changes in the design and modifications to the equipment are not permitted. Unauthorised changes
made to the hardware or operating firmware will void the manufacturer's warranty, and may
compromise the integrity of the system into which it is installed and other connected equipment.
1.1.2 Equipment Knowledge
Experience with, or understanding of, this equipment is essential for the safe installation and removal of
the equipment. Therefore, please read and understand this manual prior to use. Competency based
training courses are recommended and are available on request.
1.1.3 Manual Handling
Precautions have been taken to ensure all equipment is safe to handle and free from sharp edges.
However care should always be taken when handling enclosures and gloves should be worn.
1.1.4 Installation
Correct operation and safety depend on the EFL Relay and associated equipment being installed
correctly. Mechanical and or electrical installation and maintenance of plant and equipment must only
be carried out by appropriately qualified personnel and must be tested thoroughly prior to operation.
1.1.5 Operation
As safety depends on the EFL Relay functioning correctly it is highly recommended that all safety
functions of the EFL Relay be periodically tested to ensure correct operation.

Ampcontrol Pty Ltd –ABN 28 000 915 542
EFL PROTECTION RELAY USER MANUAL
MAG-178 Version 5 –MARCH/2020
Uncontrolled Copy - Refer to Ampcontrol Website for Latest Version
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APPROVED FOR EXTERNAL DISTRIBUTION –PROPERTY OF AMPCONTROL PTY LTD –NOT TO BE REPRODUCED IN PART
2 RECEIVING AND STORAGE
2.1 Receiving
All possible precautions are taken to protect the equipment against damage or losses during shipment,
however before accepting delivery, check all items against the packing list or bill of loading. If there is
evidence of physical damage, notify Ampcontrol immediately.
Notify Ampcontrol immediately in case of any discrepancies to the packing list. Keep a record of any
claims and correspondence. Photographs are recommended.
Where practicable do not remove protective covers prior to installation unless there are indications of
damage. Boxes opened for inspection and inventory should be carefully repacked to ensure protection of
the contents or else the parts should be packaged and stored in a safe place. Examine all packing
boxes, wrappings and covers for items attached to them. Retain and store any approval documentation
for your safety file as applicable, prior to wrappings being 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 not to be installed immediately, proper storage is important to ensure protection
of equipment and validity of warranty.
All equipment should be stored indoors between 0-40˚C, preferably on shelves and protected from
moisture and sunlight.
2.4 Unpacking of Equipment
The method of packing used will depend on the size and quantity of the equipment. The following
cautions should be interpreted as appropriate.
CAUTION!
Take care when unpacking crates as the
contents may have shifted during transport.
ENVIRO
The disposal of packaging materials, replaced parts, or components
must comply with environmental restrictions without polluting the soil,
air or water.
Ensure that any timber and cardboard used as packaging is disposed
of in a safe and environmentally responsible manner.
Where possible, dispose of all waste products i.e. oils, metals, plastic
and rubber products by using an approved recycling service centre.

Ampcontrol Pty Ltd –ABN 28 000 915 542
EFL PROTECTION RELAY USER MANUAL
MAG-178 Version 5 –MARCH/2020
Uncontrolled Copy - Refer to Ampcontrol Website for Latest Version
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APPROVED FOR EXTERNAL DISTRIBUTION –PROPERTY OF AMPCONTROL PTY LTD –NOT TO BE REPRODUCED IN PART
3 PRODUCT OVERVIEW
3.1 Product Description
The Ampcontrol EFL Protection Relay provides earth fault lockout (EFLO) and frozen contactor (FC)
protection that is compliant to AS/NZS 2081:2011 sections 7 & 9.
While the outlet’s main contactor is open, the EFL will continually monitor the resistance of the phase
conductors to earth, on the load side of the contactor. If this resistance falls below an acceptable level,
then the EFL will initiate an EFLO trip, preventing the outlet from being started.
The EFL will also monitor the state of the outlet’s main contactor. If voltage appears on the line when the
contactor is open, a Frozen Contactor electrical trip will occur, opening the CBR output. If the main
contactor is either open when it should be closed or closed when it should be open a Frozen Contactor
logical trip will occur, opening the CBR relay. The CBR relay is intended to be used to open the
upstream circuit breaker. A back EMF timer is also provided to inhibit the frozen contactor electrical trip
function for a short period after the main contactor is open.
The EFL also has an undervoltage protection function which, if activated, will open the main contactor if
the voltage on the load side of the contactor falls below 50% of the selected system voltage.
The EFL is available in two configurations, an internal barrier configuration and an external barrier
configuration. If using the internal barrier unit, the high voltage connection leads will extend directly from
the EFL Relay. If using the external barrier version, the high voltage connection barrier is stored inside a
separate enclosure, allowing the barrier to be installed closer to the phase conductors if required. This
external barrier is supplied with ‘flying leads’ for connection to the phase conductors. The external barrier
is then required to be wired to a stand-alone EFL Relay (no internal barrier).
Key Features
AS/NZS 2081:2011 compliant
Earth Fault Lock-out (EFLO) protection
Frozen Contactor (FC) protection
Selectable Undervoltage (UV) protection
Compatible with a wide range of system voltages
Internal or external barriers available
3.2 Applications
The Ampcontrol EFL is compliant to AS/NZS 2081:2011 sections 7 & 9, and has been designed for
installation on mining outlets that require earth fault lockout and frozen contactor protection. The EFL is
capable of being installed on a wide range of system voltages from 110V up to 1.1kV (barrier
dependent). In addition to EFLO and FC protection, the EFL also offers a selectable undervoltage
protection function.
NOTE
The EFL Relay is not for use in hazardous areas. Customers should
select the EFL-IS (available in 2016) or OMA products for applications
requiring intrinsic safety.
For a typical electrical installation diagram, refer to Figure 4.6.

Ampcontrol Pty Ltd –ABN 28 000 915 542
EFL PROTECTION RELAY USER MANUAL
MAG-178 Version 5 –MARCH/2020
Uncontrolled Copy - Refer to Ampcontrol Website for Latest Version
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APPROVED FOR EXTERNAL DISTRIBUTION –PROPERTY OF AMPCONTROL PTY LTD –NOT TO BE REPRODUCED IN PART
4 INSTALLATION
4.1 General Warnings
These instructions have been designed to assist users of the EFL Relay with installation.
Before the EFL Relay can be installed, there are a number of things that need to be considered and
understood to prevent incorrect or unsafe operation of the EFL Relay or the system into which it is
installed.
Along with relevant competence, and an understanding of the target application, the following points
should be considered:
4.1.1 Ensure that the information provided in this user manual is fully understood.
It is extremely important that the limitations and functionality of the EFL Relay are understood to
prevent incorrect installation and use from creating a potentially dangerous risk. If in doubt as to the
nature of the limitations or their implication, consult a competent authority such as a supervisor or
Ampcontrol technical representative.
4.1.2 Ensure that the application into which the EFL Relay is being installed has been
properly defined, designed and approved.
Any system intended to mitigate the risk of injury needs to be properly designed and implemented.
Such a system must be the result of structured risk analysis with the outcomes used to define the
system requirements. These requirements, in turn, will guide the choice of instrumentation, logic
solvers and actuators needed to implement the system. Understanding the needs of the system will
ensure proper selection of equipment.
4.1.3 Ensure that the EFL Relay will properly perform the required functions within the
system design.
It is important to understand how the EFL Relay is intended to interact with other equipment within a
system. For safe and reliable use, it is crucial that neither the EFL Relay logical operation nor its
signalling be compromised by incompatibilities with connected equipment.
4.1.4 Modifications of any form to the EFL Relay are prohibited.
The EFL Relay, as supplied, has been designed and manufactured to comply with the requirements of
protection standards. If modifications of any form are made to the EFL Relay, the equipment may no
longer be fit for use. If any modifications or damage to the EFL Relay is evident, do not use the
equipment and contact Ampcontrol for advice.

Ampcontrol Pty Ltd –ABN 28 000 915 542
EFL PROTECTION RELAY USER MANUAL
MAG-178 Version 5 –MARCH/2020
Uncontrolled Copy - Refer to Ampcontrol Website for Latest Version
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APPROVED FOR EXTERNAL DISTRIBUTION –PROPERTY OF AMPCONTROL PTY LTD –NOT TO BE REPRODUCED IN PART
4.2 Mandatory Installation Practices
The following information must be adhered to when installing the EFL Relay. Failure to adhere to this
information may give rise to unsafe operation.
Using the EFL Relay in a manner that exceeds its electrical, functional or physical specifications, or in a
way that is contrary to its operating restrictions, may create risks to personnel and/or equipment resulting
in injury or death.
The EFL Relay must be powered within the specified voltage range.
The installation of the EFL Relay must be carried out by suitably trained and qualified personnel.
Identification labels fixed to the EFL Relay must not be damaged, removed or covered before,
during or after installation.
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 EFL Relay. As supplied, the unit is built to, and
complies with the relevant standards. Modifications to its construction will render the unit non-
compliant.
Complete and accurate records of the installation must be kept as part of the site installation.
4.3 Mechanical Installation Information
The EFL Relay is available in two configurations –the EFL Relay with Internal Barrier version, or the
Stand-Alone EFL Relay with External Barrier.
4.3.1 Mounting Arrangements
The EFL Relay with Internal Barrier, the Stand-Alone EFL Relay and the External Barrier are all DIN
Rail mounted.
CAUTION!
The EFL Relay and Barrier must be mounted in such a manner that
allows unrestricted air flow through the upper and lower air vents.
4.3.2 Enclosure Dimensions
Figure 4.1: Enclosure Dimensions –Stand Alone EFL Relay
118
45 114