Ampcontrol MEC-1 User manual

MEC-1 – Earth Continuity Protection Relay
User Manual
Part Number: 167261
Revision: 1 – March 2020
Designed and manufactured in Australia by Ampcontrol CSM Pty Ltd

Ampcontrol CSM Pty Ltd - ABN 35 000 770 141
ECDB006 MEC-1 User Manual
Rev 1 – MARCH/2020
MEC-1 USER MANUAL R0 13/03/2020 13:16 Page 2 of 18
WARNING!
This safety alert symbol identifies important safety messages in this manual and
indicates a potential risk of injury or even death to personnel. When you see this
symbol, be alert, your safety is involved, carefully read the message that follows, and
inform other operators.
CAUTION!
This safety alert symbol identifies important information to be read in order to ensure
the correct sequence of work and to avoid damage or even destruction of the
equipment, and reduce any potential risk of injury or death to personnel.
Supplementary information not directly affecting safety or damage to equipment.
Carefully read the message that follows, and inform other relevant personnel.
Information concerning possible impact on the environment and actions required for
prevention and proper response.

Ampcontrol CSM Pty Ltd - ABN 35 000 770 141
ECDB006 MEC-1 User Manual
Rev 1 – MARCH/2020
MEC-1 USER MANUAL R0 13/03/2020 13:16 Page 3 of 18
Copyright Notice
The Ampcontrol MEC-1 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 MEC-1 Earth Continuity Relay.
WARNING!
To become completely familiar with this equipment and to ensure correct
operation, we strongly recommend that you take the time to read and
thoroughly understand this user manual.
Ampcontrol CSM Contact Details
7 Billbrooke Close, Cameron Park, NSW, 2285
P [phone] | F [phone]
EMAIL: [e-mail]
WEB: www.ampcontrolgroup.com

Ampcontrol CSM Pty Ltd - ABN 35 000 770 141
ECDB006 MEC-1 User Manual
Rev 1 – MARCH/2020
MEC-1 USER MANUAL R0 13/03/2020 13:16 Page 4 of 18
TABLE OF CONTENTS
1 SAFETY AND OTHER WARNINGS.............................................................................5
1.1 Safe Use of Equipment......................................................................................5
2 RECEIVING AND STORAGE.....................................................................................6
2.1 Receiving.......................................................................................................6
2.2 Inspection ......................................................................................................6
2.3 Storage after Delivery .......................................................................................6
2.4 Unpacking of Equipment....................................................................................6
3INSTALLATION .....................................................................................................7
3.1 General Warnings ............................................................................................7
3.2 Mandatory Installation Practices ..........................................................................7
4 MEC-1 RELAY OVERVIEW.......................................................................................8
4.1 Mechanical Arrangement ...................................................................................9
4.2 Electrical Connections.....................................................................................10
5 COMMISSIONING AND CALIBRATION .....................................................................12
5.1 Earth Continuity Test – Series Resistance............................................................12
5.2 Earth Continuity Test – Shunt Resistance ............................................................12
5.3 Remote Start Function ....................................................................................12
6 AS/NZS 2081 PROTECTION FUNCTION: EARTH CONTINUITY .....................................13
6.1 Series Resistance..........................................................................................13
6.2 Shunt Resistance...........................................................................................13
6.3 Remote Start ................................................................................................14
6.4 Latching mode ..............................................................................................14
6.5 Manual reset procedure...................................................................................14
7 OPERATION SUMMARY........................................................................................15
7.1 DIP Switches Configuration ..............................................................................15
7.2 Rotary Switches Configuration ..........................................................................15
7.3 Indication LEDs .............................................................................................15
7.4 Fault Indication..............................................................................................16
7.5 Starting the MEC-1.........................................................................................16
8 SERVICE, MAINTENANCE & DISPOSAL ...................................................................17
8.1 Equipment Service .........................................................................................17
8.2 Equipment Maintenance ..................................................................................17
8.3 Disposal ......................................................................................................17
9 SPECIFICATIONS ................................................................................................18
10 EQUIPMENT LIST...............................................................................................18
APPENDIX ...............................................................Error! Bookmark not defined.

Ampcontrol CSM Pty Ltd - ABN 35 000 770 141
ECDB006 MEC-1 User Manual
Rev 1 – MARCH/2020
MEC-1 USER MANUAL R0 13/03/2020 13:16 Page 5 of 18
1SAFETY AND OTHER WARNINGS
For safety reasons, the MEC-1 must be installed, operated and serviced only by competent 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 manufactured according to the state of the art, and designed 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 maximum safety during operation.
The owner/user is responsible for observing 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, in case of a question on how to safely proceed, contact Ampcontrol immediately.
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 MEC-1 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 MEC-1 functioning correctly it is highly recommended that all safety functions of the MEC-1 be
periodically tested to ensure correct operation.

Ampcontrol CSM Pty Ltd - ABN 35 000 770 141
ECDB006 MEC-1 User Manual
Rev 1 – MARCH/2020
MEC-1 USER MANUAL R0 13/03/2020 13:16 Page 6 of 18
2RECEIVING 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 are shortages or evidence of physical
damage, notify Ampcontrol immediately.
Notify Ampcontrol within 7 days (maximum) in case of shortages or discrepancies, according to the packing list. This action will
help ensure a speedy resolution to any perceived problems. Keep a record of all 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, especially
if the wrappings are to be 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, preferably on shelves and protected from the elements.
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.
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 CSM Pty Ltd - ABN 35 000 770 141
ECDB006 MEC-1 User Manual
Rev 1 – MARCH/2020
MEC-1 USER MANUAL R0 13/03/2020 13:16 Page 7 of 18
3 INSTALLATION
3.1 General Warnings
These instructions have been designed to assist users of the MEC-1 relay with installation.
Before the MEC-1 can be installed, there are a number of things that need to be considered and understood to prevent incorrect
or unsafe operation of the MEC-1 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:
3.1.1 Ensure that the information provided in this user manual is fully understood.
It is extremely important that the limitations and functionality of the MEC-1 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.
3.1.2 Ensure that the application into which the MEC-1 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.
3.1.3 Ensure that the MEC-1 relay will properly perform the required functions within the system design.
It is important to understand how the MEC-1 is intended to interact with other equipment within a system. For safe and reliable
use, it is crucial that neither the MEC-1’s logical operation nor its signalling be compromised by incompatibilities with connected
equipment.
3.1.4 Modifications of any form to the MEC-1 relay are prohibited.
The MEC-1 as supplied has been designed and manufactured to comply with the requirements of protection standards. If
modifications of any form are made to the MEC-1, the equipment may no longer be fit for use. If any modifications or damage to
the MEC-1 is evident, do not use the equipment and contact Ampcontrol for advice.
3.2 Mandatory Installation Practices
The following information must be adhered to when installing the MEC-1. Failure to adhere to this information may give rise to
unsafe operation.
Using the MEC-1 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 MEC-1 must be powered within the specified voltage range.
•The installation of the MEC-1 must be carried out by suitably trained and qualified personnel.
•Identification labels fixed to the MEC-1 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 MEC-1. As supplied, the unit is built to, and complies with the
relevant standards. Modification 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.

Ampcontrol CSM Pty Ltd - ABN 35 000 770 141
ECDB006 MEC-1 User Manual
Rev 1 – MARCH/2020
MEC-1 USER MANUAL R0 13/03/2020 13:16 Page 8 of 18
4MEC-1 RELAY OVERVIEW
The MEC-1 is an electrical protection relay designed for operation in metalliferous mining applications. It provides earth
continuity protection in accordance with AS/NZS 2081:2011 ensuring the integrity of the earth connection through a trailing or
reeling cable is maintained. Earth Continuity protection is another layer of protection that, along with earth leakage protection,
can help keep step and touch voltage potentials at a safe level by ensuring the earth resistance is below a determined safe
level.
The MEC-1 relay is based on microprocessor digital logic, and features a user friendly LED and switch interface. It is installed
within a compact, DIN rail mounted unit with pluggable connectors that can easily be changed out in the event of a problem with
the relay.
Key Features
•Compact size
•DIN rail mounted
•Simple wiring and installation
•Six (6) settings for trip time
•Six (6) settings for trip level
•AS/NZS 2081:2011 Compliant
Typically the MEC-1 relay will be connected to the pilot conductor of a trailing or reeling cable. With the pilot conductor
terminated to earth through a diode, the relay measures the resistance of the pilot-earth loop (series resistance), to ensure the
integrity of the earth conductors, and the pilot to earth resistance (shunt resistance), to ensure the integrity of the pilot-earth
loop. If these tests fail the MEC-1 will trip, de-energising its output relay which can be used to switch a contactor, circuit breaker
or for signalling.
The MEC-1 can be configured for latching or non-latching operation and has a remote start option.
CAUTION!
A safe resistance level for the pilot-earth loop should be determined by risk assessment
and analysis of the system.

Ampcontrol CSM Pty Ltd - ABN 35 000 770 141
ECDB006 MEC-1 User Manual
Rev 1 – MARCH/2020
MEC-1 USER MANUAL R0 13/03/2020 13:16 Page 9 of 18
4.1 Mechanical Arrangement
4.1.1 Enclosure
The MEC-1 is housed in a plastic enclosure and is rated IP20.
The dimensions are shown in Figure 1 below (117x45x114mm):
Figure 1: MEC-1 enclosure dimensions
4.1.2 Mounting arrangement
The MEC-1 enclosure is designed to be mounted on a standard 35mm DIN rail.
The pilot and earth connections are located at the top of the enclosure and the power and user inputs and outputs are located
at the bottom of the enclosure.
The fascia of the relay includes two (2) adjustable DIP switches and two (2) rotary switches for configuration of relay settings
and five (5) indication LEDs to assist in fault finding.
45
117
114

Ampcontrol CSM Pty Ltd - ABN 35 000 770 141
ECDB006 MEC-1 User Manual
Rev 1 – MARCH/2020
MEC-1 USER MANUAL R0 13/03/2020 13:16 Page 10 of 18
4.2 Electrical Connections
Once the MEC-1 relay has been mounted at a suitable location, it is necessary to wire it correctly.
Figure 2 shows a typical wiring diagram for the application of the MEC-1 relay.
N.O. USER
PUSHBUTTON
RST
PILOT
EARTH
+
-
D.C. SUPPLY
USER
DEFINED
OPTIONAL
STOP
DIODE
1000V, 1A
OPTIONAL
REMOTE
START
RESISTOR
100Ω
MAIN
EARTH BAR
TERMINATION
EARTH BAR
Figure 2: MEC-1 Typical Electrical Application
The table below lists the terminal connections into the MEC-1 relay.
Terminal
Label
Description
1
RST
Reset
2
+
Power Supply Positive
3
-
Power Supply Negative
4
NC1
Relay Output Normally Closed Contact 1
5
NO1
Relay Output Normally Open Contact 1
6
COM1
Relay Output Common Contact 1
7
NO2
Relay Output Normally Open Contact 2
8
COM2
Relay Output Common Contact 2
9
NC
Not connected
10
NC
Not connected
11
NC
Not connected
12
NC
Not connected
13 Pilot
Pilot connection (Single core screened, screen connected to earth at MEC-1
end)
14
NC
Not connected
15
NC
Not connected
16
Earth
Earth
Using a screened cable helps in reducing the induced / coupled voltages. This noise
can cause spurious trips.