Ampcontrol ELV-PRO User manual

Version: 5, November 2020
Designed and manufactured in Australia by Ampcontrol Pty Ltd
ELV-PRO
EARTHLEAKAGERELAY
UserManual

Ampcontrol Pty Ltd –ABN 28 000 915 542
ELV-PRO USER MANUAL
MAG-219 Version 5 –NOVEMBER/2020
Uncontrolled Copy - Refer to Ampcontrol Website for Latest Version
Page 2 of 59
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
ELV-PRO USER MANUAL
MAG-219 Version 5 –NOVEMBER/2020
Uncontrolled Copy - Refer to Ampcontrol Website for Latest Version
Page 3 of 59
APPROVED FOR EXTERNAL DISTRIBUTION –PROPERTY OF AMPCONTROL PTY LTD –NOT TO BE REPRODUCED IN PART
Copyright Notice
The Ampcontrol Earth Leakage Relay ELV-PRO 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
Thank you for purchasing the Ampcontrol ELV-PRO 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
ELV-PRO USER MANUAL
MAG-219 Version 5 –NOVEMBER/2020
Uncontrolled Copy - Refer to Ampcontrol Website for Latest Version
Page 4 of 59
APPROVED FOR EXTERNAL DISTRIBUTION –PROPERTY OF AMPCONTROL PTY LTD –NOT TO BE REPRODUCED IN PART
TABLE OF CONTENTS
1 SAFETY AND OTHER WARNINGS..................................................................9
Safe Use of Equipment..............................................................................9
2 RECEIVING AND STORAGE..........................................................................10
Receiving.................................................................................................10
Inspection................................................................................................10
Storage after Delivery..............................................................................10
Unpacking of Equipment..........................................................................10
3 PRODUCT OVERVIEW ..................................................................................11
Description...............................................................................................11
Key Features...........................................................................................11
Application...............................................................................................11
4 INSTALLATION...............................................................................................12
General Warnings....................................................................................12
Mandatory Installation Practices..............................................................12
Mechanical Installation Information..........................................................13
Electrical Installation Information .............................................................15
5 PRODUCT OPERATION.................................................................................22
Earth Leakage Protection ........................................................................22
Earth Leakage Analysis Tool ...................................................................22
Data Logging ...........................................................................................23
Real Time Clock (RTC)............................................................................23
IP Configuration.......................................................................................24
Protection Settings...................................................................................26
ELV-PRO CIP over EtherNet/IP Interface................................................28
ELV-PRO Modbus TCP Interface.............................................................28
6 OPERATIONAL INTERFACE..........................................................................29
ELV-PRO Facia Interface ........................................................................29
ELV-PRO Web Interface..........................................................................30
7 SERVICE, MAINTENANCE & DISPOSAL.......................................................42
Equipment Service...................................................................................42
Equipment Maintenance..........................................................................43
Disposal...................................................................................................43
8 SPECIFICATIONS ..........................................................................................44
9 EQUIPMENT LIST ..........................................................................................44
APPENDIX A: MINING EARTH LEAKAGE PROTECTION WITH VARIABLE SPEED
DRIVES..............................................................................................................45

Ampcontrol Pty Ltd –ABN 28 000 915 542
ELV-PRO USER MANUAL
MAG-219 Version 5 –NOVEMBER/2020
Uncontrolled Copy - Refer to Ampcontrol Website for Latest Version
Page 5 of 59
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A1 Variable Speed Drives..............................................................................45
A2 Improving Protection.................................................................................47
APPENDIX B: ELV-PRO CURRENT TRANSFORMERS ...................................48
B1 Earth Leakage Toroids.............................................................................48
B2 Toroid selection........................................................................................48
B3 Toroid installation guidelines ....................................................................48
APPENDIX C: ELV-PRO CIP OVER ETHERNET/IP..........................................49
C1 ELEMENTARY DATA TYPES..................................................................49
C2 LIVE DATA SEGMENT DEFINITION.......................................................50
C3 CONTROLS.............................................................................................51
C4 EXPLICIT MESSAGES............................................................................52
C5 EVENT LOGS..........................................................................................54
APPENDIX D: ELV-PRO Modbus TCP ..............................................................56
D1 Modbus Commands.................................................................................56
D2 Modbus Status.........................................................................................56
D3 Read Modbus Address Table...................................................................57
D4 Uint16 Encoded String .............................................................................58
D5 Write Modbus Address Table...................................................................58
APPENDIX E: ELV-PRO Default Settings..........................................................59

Ampcontrol Pty Ltd –ABN 28 000 915 542
ELV-PRO USER MANUAL
MAG-219 Version 5 –NOVEMBER/2020
Uncontrolled Copy - Refer to Ampcontrol Website for Latest Version
Page 6 of 59
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TABLE OF FIGURES
Figure 4-1: ELV-PRO Dimensions..........................................................................................................13
Figure 4-2: ELV-PRO Terminal Layout...................................................................................................13
Figure 4-3: Electrical Connections –ELV-PRO Circuit Diagram .............................................................15
Figure 4-4: Electrical Connections –ELV-PRO Power Supply (Plug 3)...................................................16
Figure 4-5: Electrical Connections –Trip Resent and Digital Inputs (Plugs 2 & 4)..................................16
Figure 4-6: Electrical Connections –EL CT, CT Test and Zero Crossing Connections (Plug 6)..............17
Figure 4-7: Electrical Connections –Phase CT Input (Plug 5)................................................................18
Figure 4-8: Electrical Connections –Control Contact Outputs Connections (Plug 1) ..............................19
Figure 4-9: ELF-PRO Parameter Dongle................................................................................................19
Figure 4-10: Ethernet and Dongle Connections......................................................................................19
Figure 4-11: ELV-PRO Toroid Installation Examples..............................................................................20
Figure 5-1: Taskbar Icon: Wired Connection Available...........................................................................24
Figure 5-2: Network and Sharing Center ................................................................................................25
Figure 5-3: Local Area Connection Status (left) and Properties (right)....................................................25
Figure 5-4: Internet Protocol Versions 4 (TCP/IPv4) Properties..............................................................26
Figure 6-1: ELV-PRO Relay Fascia Interface.........................................................................................29
Figure 6-2: ELV-PRO Web Interface –Overview....................................................................................30
Figure 6-3: ELV-PRO Web Interface - Live Graphs (RMS).....................................................................32
Figure 6-4: ELV-PRO Web Interface - Live Graphs (OSC) .....................................................................33
Figure 6-5: ELV-PRO Web Interface - Live Graphs (FFT).......................................................................33
Figure 6-6: ELV-PRO Web Interface - Data Logs...................................................................................34
Figure 6-7: ELV-PRO Web Interface - Data Logs (OSC)........................................................................35
Figure 6-8: ELV-PRO Web Interface - Data Logs (RMS)........................................................................35
Figure 6-9: ELV-PRO Web Interface - Data Logs (FFT) .........................................................................36
Figure 6-10: ELV-PRO Web Interface - Event Logs................................................................................36
Figure 6-11: ELV-PRO Web Interface - Device Info................................................................................38
Figure 6-12: ELV-PRO Web Interface –Settings....................................................................................39
Figure 6-13: ELV-PRO Web Interface - About........................................................................................40
Figure 6-14: ELV-PRO Web Interface - Interactive Graph Navigation.....................................................41
Figure 6-15: ELV-PRO - Web Interface - Protection Function Trip..........................................................41

Ampcontrol Pty Ltd –ABN 28 000 915 542
ELV-PRO USER MANUAL
MAG-219 Version 5 –NOVEMBER/2020
Uncontrolled Copy - Refer to Ampcontrol Website for Latest Version
Page 7 of 59
APPROVED FOR EXTERNAL DISTRIBUTION –PROPERTY OF AMPCONTROL PTY LTD –NOT TO BE REPRODUCED IN PART
TABLE OF TABLES
Table 1: Definitions...................................................................................................................................8
Table 2: ELV-PRO Terminal Designators...............................................................................................14
Table 3: Earth Leakage Trip level...........................................................................................................27
Table 4: Earth Leakage Trip Time ..........................................................................................................27
Table 5: Digital Input Settings.................................................................................................................28
Table 6: ELV-PRO Relay Fascia LED Operation....................................................................................29
Table 7: Web Interface Status Indicators................................................................................................31
Table 8: Event ID Descriptions...............................................................................................................37
Table 9: Login Details.............................................................................................................................39
Table 10: Modbus Commands................................................................................................................56
Table 11: Modbus Exception..................................................................................................................56
Table 12: Modbus Status........................................................................................................................56

Ampcontrol Pty Ltd –ABN 28 000 915 542
ELV-PRO USER MANUAL
MAG-219 Version 5 –NOVEMBER/2020
Uncontrolled Copy - Refer to Ampcontrol Website for Latest Version
Page 8 of 59
APPROVED FOR EXTERNAL DISTRIBUTION –PROPERTY OF AMPCONTROL PTY LTD –NOT TO BE REPRODUCED IN PART
Table 1: Definitions
Term
Definition
BUEL
Back Up Earth Leakage
CB
Circuit Breaker; Main circuit breaker that controls power to all outlets
CCM
Cable Connection Module
CIP
Common Industrial Protocol
CT
Current Transformer
EC
Earth Continuity (Pilot to earth loop resistance)
DHCP
Dynamic Host Configuration Protocol
EFLO
Earth Fault Lock Out
FFT
Fast Fourier Transform
FLC
Full Load Current
GUI
Graphical User Interface
HMI
Human/Machine Interface
HTTP
Hypertext Transfer Protocol
IP
Internet Protocol
MC
Main Contactor; the main power circuit opening device. The main
contactor is opened and closed in order to turn the outlet on and off
MCR
Main Contactor Relay; A relay installed within the protection module to
control the supply to the main contactor coil. All trip times specified are to
the opening of the MCR
NER
Neutral Earthing Resistor
NTP
Network Time Protocol
RMS
Root Means Square
RTC
Real Time Clock
TCP
Transmission Control Protocol
UTP
Unshielded Twisted Pair

Ampcontrol Pty Ltd –ABN 28 000 915 542
ELV-PRO USER MANUAL
MAG-219 Version 5 –NOVEMBER/2020
Uncontrolled Copy - Refer to Ampcontrol Website for Latest Version
Page 9 of 59
APPROVED FOR EXTERNAL DISTRIBUTION –PROPERTY OF AMPCONTROL PTY LTD –NOT TO BE REPRODUCED IN PART
1 SAFETY AND OTHER WARNINGS
For safety reasons, the ELV-PRO must be installed, operated and serviced only by competent
personnel. Please 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.
Safe Use of Equipment
The equipment supplied has been designed and manufactured to ensure safe operation. The equipment
must 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 relay 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 relay functioning correctly, it is highly recommended that all safety functions
of the relay be periodically tested to ensure correct operation.

Ampcontrol Pty Ltd –ABN 28 000 915 542
ELV-PRO USER MANUAL
MAG-219 Version 5 –NOVEMBER/2020
Uncontrolled Copy - Refer to Ampcontrol Website for Latest Version
Page 10 of 59
APPROVED FOR EXTERNAL DISTRIBUTION –PROPERTY OF AMPCONTROL PTY LTD –NOT TO BE REPRODUCED IN PART
2 RECEIVING AND STORAGE
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 the 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 wrapping being discarded.
Inspection
Equipment that is found to be damaged or has been modified away from its published specifications
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.
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.
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.