Ampcontrol HPB - User Manual

Questions and Answers

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Michelle AlvarezAug 18, 2025
Why does my Ampcontrol Relay cycle while the start input is held closed?
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  Kimberly BradleyAug 18, 2025
  If the Ampcontrol relay cycles while the start input is held closed, it could be due to several reasons: * The relay's MCI input is not closing. Ensure that the main contactor is closing and check the circuit, auxiliary contacts, and wiring. * The relay isn't receiving voltage feedback on all three outlet phases within 800ms of contactor closing. Check the system voltage display as the contactor closes and compare it with the undervoltage threshold. * There may be a continuity issue from the relay through the CCMB – 6.6kV to power conductors. Check continuity from the relay, through the CCMB – 6.6kV to power conductors.
D
David HamiltonAug 20, 2025
What to do if Ampcontrol HPB Relays trips on MCF on power up?
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  Anthony HillAug 20, 2025
  If the Ampcontrol relay trips on MCF (Main Contactor Fail) upon power up, it could be due to: * A main contactor fail condition. Check the main contactor for leakage across terminals or a frozen contactor condition. * A flat or faulty battery. The AA cell installed under the top cover may require replacement. It is recommended that the relay be returned to Ampcontrol for battery replacement and full testing.
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Mariah DavisAug 23, 2025
Why Ampcontrol Relay will not close with EC fault?
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  christycharlesAug 23, 2025
  If the Ampcontrol relay will not close and indicates an EC fault, it is likely due to a faulty pilot circuit (open or high resistance or shorted to earth). Check the pilot circuit. If the issue persists, consider replacing the relay.
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Amber WadeAug 26, 2025
How to fix a blank screen on Ampcontrol HPB remote display?
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  William BishopAug 26, 2025
  If the Ampcontrol Remote Display shows a blank screen and the HDM LED indicator is off, it could be due to: * Loss of power to the display. Check that there is power to the relay and it is correctly plugged in. The relay supplies 15VDC to the HDM. Also, check the cable between the HDM and the relay. * A faulty display module. Consider replacing the module.
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Lori RussellAug 28, 2025
Why Ampcontrol HPB time and date incorrect?
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  Philip WilsonAug 28, 2025
  If the time and date on your Ampcontrol relay are incorrect and reset to 1/01/9? on power-up, it is likely due to a low battery. The AA cell installed under the top cover requires replacement. It is recommended that the relay be returned to Ampcontrol for battery replacement and full testing.
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Dawn SmithAug 31, 2025
What does error #2 mean on Ampcontrol HPB Relays in HTU pilot mode?
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  Michele ChangAug 31, 2025
  If Error Indication #2 (level 0, position 1) appears when the Ampcontrol relay is in HTU pilot mode, it indicates that either the HTU-1 Module is not online or the HTU-1 Module’s non-volatile memory has been corrupted. Check that the HTU-1 Module is online (level 3, position 1), indicating a healthy pilot loop. If the HTU-1 Module is online, examine the Group 2 Settings stored in the HTU Settings (level 9). If some settings show ‘???’, reprogram lost settings into the HTU-1 memory.
S
Shannon WhiteSep 2, 2025
What to do if Ampcontrol Relays remote display is blank and the HDM LED flashes?
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  Daniel TylerSep 2, 2025
  If the Ampcontrol Remote Display shows a blank screen and the HDM LED flashes at 1Hz, it indicates that power to the HDM is healthy, but there is no data. Check the data cable between the relay and the HDM.
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Leah JonesSep 4, 2025
What does 'MC Opened' mean on Ampcontrol HPB Relays?
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  Corey RiceSep 4, 2025
  If the outlet is off and the log records “MC Opened” on your Ampcontrol relay, it means the outlet was turned off but not by the relay. Check the main contactor coil or control circuit.
A
Anthony RogersSep 7, 2025
What does error #1 mean on Ampcontrol Relays?
- K
  Kyle ColemanSep 7, 2025
  Error indication #1 (level 0, position 1) on your Ampcontrol relay indicates corruption in the Group 1 Settings stored in the relay. Examine the Group 1 Settings (level 8) to check the stored parameters in the non-volatile memory. If one or several settings show ‘???’, reprogram list settings into the memory.
B
Brian PerezSep 10, 2025
What does [HTU Stop] mean on Ampcontrol HPB?
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  lynchbriannaSep 10, 2025
  If the HPB Status page displays [HTU Stop] on your Ampcontrol relay, it means the relay is waiting for the HTU-1 Module’s Stop input to be closed. Ensure the HTU-1 Module’s stop input is closed (through a diode to earth).

Summary

SAFETY AND OTHER WARNINGS

Safe Use of Equipment

Details how to safely operate the HPB unit, covering modifications, knowledge requirements, handling, installation, and operation.

RECEIVING AND STORAGE

Receiving

Procedures for checking equipment upon delivery, including damage assessment and notification.

Inspection

Guidelines for inspecting equipment to ensure it matches specifications and is free from damage.

Storage after Delivery

Recommendations for proper storage conditions to maintain equipment integrity and warranty validity.

Unpacking of Equipment

Cautions and environmental considerations for safely unpacking the equipment and its components.

PRODUCT OVERVIEW

Introduction

Overview of the HPB Integrated Protection Relay, its technology, and applications in mining operations.

Remote Display Module (HDM)

Details the functionality and features of the HDM for local display, monitoring, and configuration of the HPB Relay.

INSTALLATION

General Warnings

Critical safety and operational warnings regarding HPB installation, including understanding the manual and system design.

Mandatory Installation Practices

Essential installation requirements and safety practices to ensure correct and safe operation of the HPB unit.

Installation and Wiring Instructions

Guidance on mounting, wiring, and connecting the HPB relay and associated modules for proper installation.

Integrated Protection Relay

Instructions for mounting the HPB relay enclosure, including considerations for ventilation and space.

Remote Display Module (HDM)

Information on the housing and mounting of the HDM for external switchgear integration.

Cable Connection Module

Description of the CCMB for 6.6kV and 22kV systems, detailing its function in interfacing with power circuits.

Overload & Earth Leakage Toroids

Explanation of toroid function and potential issues like nuisance tripping due to installation errors.

Toroid Installation Guide Lines

Best practices for installing toroids to ensure accurate measurements and prevent operational problems.

Wiring Installation

Guidelines for managing high and low voltage wiring to reduce induction and ensure system integrity.

Low Voltage Signals

Precautions for routing low voltage circuits to prevent contact with higher voltages and minimize interference.

High Voltage Circuits

Details on high voltage circuits within the HPB, including supply and relay contacts, and their separation from other wiring.

Earthing

Information on the HPB's earth connections and recommendations for proper earthing practices for safety.

MACHINE COMMUNICATION

HPB Termination Unit (HTU)

Describes the HTU-1 for machine communication, its connection, power, and function in parameter configuration.

Machine Type Codes

Explains the selectable codes used to identify different machine types connected to the HPB system.

Machine Number

Details on assigning unique numbers to machines for identification and management within the HPB system.

Receiver Sensitivity

Guidance on adjusting HTU receiver sensitivity for optimal performance in various installation environments.

EARTH PROTECTION FUNCTIONS

Earth Leakage

Details the Earth Leakage protection function, its measurement via toroid, and adjustable trip sensitivity/time delay.

Earth Fault Lockout

Explains the Earth Fault Lockout test, including 'megger test' procedures for 6.6kV and 22kV systems.

Earth Continuity

Describes the Earth Continuity function, testing pilot core continuity, and configuration modes (Resistor/HTU).

CURRENT RELATED FUNCTIONS

Basic Over-Current Protection

Details the over-current protection, including CT usage, range/multiplier settings, and trip accumulator functionality.

Over-Current Characteristic

Explains the selectable inverse time over-current characteristics and their trip curves.

Short Circuit

Describes the short circuit protection, its definite time characteristic, and selectable trip levels/times.

Phase Current Balance

Explains phase current balance protection, its calculation, trip level settings, and trigger conditions.

VOLTAGE RELATED FUNCTIONS

Main Contactor Fail Protection

Details the Main Contactor Fail protection, covering failure to open and failure to maintain insulation.

Under Voltage Trip

Describes the under voltage protection, including trip level selection and delay for outlet shutdown.

Voltage Metering

Explains how the CCMB provides line voltage metering, displayed as a percentage on the HDM.

USER ADJUSTABLE SETTINGS

Group 1 Settings

Covers settings related to the power system, stored in the HPB relay's non-volatile memory.

Group 2 Settings

Covers settings related to the load, stored in HPB or HTU memory based on Pilot Mode.

Changing Settings

Step-by-step procedure for viewing and modifying HPB relay settings via the HDM Remote Display Module.

SYSTEM CONTROL

Digital Inputs

Describes the five digital inputs (MCI, start, stop, lock, reset) and their function activation.

Output Relays

Information on HPB output relays for main contactor and circuit breaker control, including RL3 for lockout testing.

Open Collector Outputs

Details the eight open collector outputs for driving LEDs or external relays, used for additional indication.

Outlet Control

Explains how to energize and de-energize the outlet using Start and Stop inputs, including remote stop requirements.

Operational Sequence

Outlines the sequence of operations required to energize an outlet, including fault checks and the lockout test.

TROUBLESHOOTING

Pilot Fault Finding Information

Guides on diagnosing and resolving faults related to the pilot circuit, including open circuit and continuity issues.

Ampcontrol HPB Specifications

General

Mechanical Life	10, 000, 000 operations
Electrical Life	100, 000 operations
Category	Relays
Contact Rating	10A at 250V AC, 10A at 30V DC
Operating Temperature Range	-40°C to +70°C