Littelfuse AF0100 Instruction Manual
AF0100
ARC-FLASH RELAY
Instruction Manual
REVISION 0-B-013118
E-mail: techline@littelfuse.com
Tel: +1-800-832-3873
www.littelfuse.com/AF0100
Document Number: PM-1430-EN
Copyright © 2018 Littelfuse
All rights reserved.
AF0100 Arc-Flash Relay
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AF0100 Arc-Flash Relay
TABLE OF CONTENTS
1 KEY FEATURES ......................................................1
1.1 Easy Installation ......................................1
1.2 Fail-Safe Operation .................................. 1
1.3 Fast Error and Fault Location ................... 1
1.4 USB Interface ........................................... 1
2 ARC-FLASH PROTECTION SYSTEM DESIGN
3 SENSOR PLACEMENT
........................................... 5
3.1 General Guidelines ..................................5
3.2 Switchgear Protection .............................5
3.3 Transformer Protection ............................5
3.4 Generator Protection ...............................5
4 OPTICAL SENSORS
...............................................6
4.1 PGA-LS10 Photoelectric Point Sensor
with Sensor Check ................................... 7
4.1.1 PGA-LS10 Connection .............................8
4.1.2 PGA-LS10 Installation .............................9
4.2 PGA-LS20 and PGA-LS30
Fiber-Optic Sensors with
Sensor Check ......................................... 10
4.2.1 Fiber Connection ....................................10
4.2.2 Receiver Wiring Connections ................10
4.2.3 Transmitter Wiring Connections ...........10
4.2.4 PGA-LS20 and PGA-LS30 Connection ....
4.2.5 Fiber-Optic Sensor Adjustment .............12
4.2.6 Sensor Adjustment For a Fiber Length
Other Than 60 cm (24 in) ....................... 12
...... 3
11
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7 USER INTERFACE
................................................ 18
7.1 Reset Button .......................................18
7.2 LED Indication and
Relay Operation ..................................18
7.3 USB Conguration Software ...............20
7.3.1 USB Conguration Software –
Screen Examples .................................21
7.4 Firmware Upgrade ..............................24
8 COMMISSIONING
............................................... 25
8.1 Conguration of Installed Sensors .....25
8.2 Testing the Sensors ............................ 25
8.3 Testing the TRIP 1 and TRIP 2 Outputs
and Associated Circuit Breakers ........26
8.4 Full Operation Test..............................26
9 SUPPORT RESOURCES
.......................................27
9.1 Sending Information for Support ................27
10 SPECIFICATIONS
................................................. 28
10.1 AF0100 ...............................................28
10.2 EMC Tests ..........................................29
10.3 Environmental Tests ........................... 29
10.4 Safety ................................................. 30
10.5 Certication ........................................ 30
10.6 Sensors ...............................................31
10.7 Ordering Information ..........................32
10.8 Related Products ................................32
10.9 Warranty ............................................32
5 APPLICATION EXAMPLES
................................... 13
5.1 Basic Scenario: One Sensor –
One Circuit Breaker ...............................13
5.2 Total Clearing Time ...............................14
5.2.1 Arc-Detection Delay ..............................14
5.2.2 Circuit Breaker Operating Time .............14
5.2.3 Total Clearing Time Examples ...............14
6 INSTALLATION AND TERMINALS
6.1 Power Supply.......................................16
6.1.1 Line AC Supply (optional) .................... 16
6.1.2 Station Battery DC Supply (optional) ..16
6.1.3 Auxiliary DC Supply ............................. 16
6.1.4 Supply Surveillance ............................. 16
6.2 Inputs and Outputs .............................. 17
6.2.1 ERROR Signal Relay ............................17
6.3 Sensors ................................................17
6.3.1 Light Immunity Adjustment ................. 17
6.3.2
Extending or Shortening Cable Length ....
..................... 15
17
AF0100 Arc-Flash Relay
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APPENDIX A: INSTALLATION LOG SHEET
.............34
APPENDIX B: REDUNDANT TRIP
CIRCUIT DESCRIPTION
APPENDIX C: AF0100 REVISION HISTORY
.............................................35
.............36
LIST OF FIGURES
1 AF0100 Top View (ordering option
AF0100-00 shown) ....................................... 2
2 AF0100 with Sensor and USB View
(ordering option AF0100-00 shown) ............ 2
3 AF0100 Typical Wiring Diagram ..................4
4
PGA-LS10 Detection Range for a
3 kA Fault .........................................................
5 PGA-LS10 Connection Diagram ...................8
6 PGA-LS10 Mounting Detail .........................9
7 PGA-LS20 and PGA-LS30
Connection Diagram .................................. 11
8 Basic AF0100 Conguration ......................13
9 AF0100 Outline And
Mounting Details ....................................... 15
10 TRIP and ERROR Relays
Maximum Switching Capacity ....................33
7
LIST OF TABLES
1 Circuit Breaker Operating Time .................14
2 AF0100 Firmware Upgrade Sequence ......24
3
Sample Table for Testing a System
............26
AF0100 Arc-Flash Relay
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1 KEY FEATURES
The AF0100 Arc-Flash Relay is a high-speed, arc-detection
device for electrical power-distribution systems. The AF0100
has two Form-C Trip relays, and has inputs for up to two
optical sensors for optimal arc detection. The inputs support
both point sensors and fiber-optic line sensors, which cover
a larger area.
Using optical sensors rather than relying strictly on current
measurement allows a much faster detection time than
overcurrent relays or a circuit breaker alone can typically
provide, as the light from the arc is unique to arc faults,
whereas current pulses above the nominal level are part of
normal operation for many systems.
On the occurrence of an arc fault, the AF0100 detects the
fault and activates the trip relays, which trips the circuit
breaker(s) supplying the fault. In a typical system, a trip occurs
within 5ms. The total arcing time is effectively reduced to
the mechanical opening time of the circuit breaker, typically
between 30 and 75 milliseconds. This reduces the energy of
the arc fault significantly, increasing worker safety, reducing
fault damage, and improving uptime.
The AF0100 can be used on ac or dc electrical systems and
can be powered from either an ac or dc supply, or both. For
all available ordering options, see section 10.7.
1.1 Easy Installation
The relay will automatically learn which sensors and
power supplies are connected, and will indicate an alarm
if a previously connected wire breaks or is unplugged. If a
configuration change is needed, the redetection process
can be triggered by pressing the Reset button for 20 s, see
section 7.1.
1.2 Fail-Safe Operation
The AF0100 continuously monitors its internal circuitry as
well as the connected optical sensors. Any system faults,
including a sensor-cable fault, are indicated by an Error relay
and the Error LED on the front panel.
A redundant trip circuit ensures that the AF0100 will trip
the circuit breaker on an arc flash even if a primary tripcircuit component fails (shunt trip mode only). The design
of the redundant trip circuit also provides a significantly
faster response to an arc on power-up (for example, after
maintenance during a shutdown) than is possible with
microprocessor-only relays, which is an advantage in smaller
self-powered systems.
1.3 Fast Error and Fault Location
The optical sensors used with the AF0100 have built-in LED’s
for indication of health and for easy location of arc faults.
The AF0100 also has one LED per optical sensor on the front
panel to indicate which sensor(s) have caused a trip and for
indicating problems in the installation.
The AF0100 includes two sensor inputs, two trip relays,
one error relay, and a digital input and output interface
which makes it possible to connect additional AF0100 or
AF0500 units. See Fig. 1. The complete configuration and
“programming” of the system can be done by simply wiring
the inputs and outputs marked with green arrows – no
external software is needed.
A system with multiple zones and upstream circuit breakers
can be implemented such that in many applications, the
switchboard wiring diagram can completely describe how
the arc-flash system works.
1.4 USB Interface
A USB interface on the lower panel of the AF0100 provides
easy PC access to configuration settings. No PC driver or
software installation is required.
AF0100 Arc-Flash Relay
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FIGURE 1. AF0100 Top View (ordering option AF0100-00 shown).
FIGURE 2. AF0100 with Sensor and USB View (ordering option AF0100-00 shown).
AF0100 Arc-Flash Relay
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2 ARC-FLASH PROTECTION SYSTEM DESIGN
In order to find the necessary components and configuration
for protecting a system, a single line diagram and knowledge
of the physical configuration of the system is needed.
1. Start by identifying the number and type of sensors
that are needed to have coverage of the complete
system. In order to have complete coverage, all
bus bar sections, circuit breaker connection points,
and bolted connections must have a sensor nearby.
Typically, a single point sensor per enclosed
switchgear compartment is sufficient, but if a large
internal component is blocking the line-of-sight, an
additional sensor may be necessary. A fiber sensor
can be threaded along a bus bar to protect many
compartments, but only if they are interrupted by
the same circuit breaker. The fiber sensor can also
be used to improve coverage of compartments with
many bulky components.
2. Identify which circuit breakers to open in order to
completely interrupt all current to each sensor. If
more sensors are isolated by the same set of circuit
breakers, these are said to be in the same zone – an
arc-flash event on any of these sensors will open the
same set of circuit breakers.
4. Based on the number of sensors and zones, the
necessary number of outputs and sensors can be
found. Each AF0100 provides one zone (one or two
circuit breaker outputs) and two sensor inputs, which
can be bundled into larger zones by a single wire, and
which can combine fiber and point sensors completely
as needed.
5. Now, place one AF0100 trip output for each circuit
breaker in the system. If there are more than two
sensors per zone, connect additional AF0100 or
AF0500 zones together by connecting the “TRIP” and
“TRIPPED” terminals in all zones. Zones can also be
made larger by using a sensor covering a larger area,
i.e. by changing point sensors to fiber sensors. Place
the sensors in the cabinets, and connect them to the
zone inputs. The sensor cables, which use copper
wire, can be shortened or extended as needed.
3. Identify if the system needs coordinated tripping – if
upstream circuit breakers, which trips the incoming
feeder for several downstream circuit breakers, are
present in the system, a decision must be made to
either merge all the smaller zones and trip all circuit
breakers at once (fast and inexpensive, but may trip
more outgoing feeders than necessary), or to only
trip the upstream circuit breaker if the downstream
circuit breaker fails to interrupt the current (slower
and costlier, but trips only what is necessary).
AF0100 Arc-Flash Relay
N
L1 L1
N N
Protection
Active
G
Tri p
R
L1
A B C
x x x
Tri p
Coil
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A B C
Reset
L1 L1
Protection
G
Active
N
Tri p
R
N N
L1
Tri p
Coil
N
x x x
PGA-LS10
Point Sensor
NOTES:
1. RELAY OUTPUTS SHOWN DE-ENERGIZED.
2. A TOTAL OF TWO POINT OR FIBER-OPTIC SENSORS
CAN BE CONNECTED.
3. USB ‘B’ CONNECTOR. FOR CONFIGURATION, SEE
SECTION 7.3.
FIGURE 3. AF0100 Typical Wiring Diagram.
PGA-LS20/PGA-LS30
Fiber Optic Sensor
Sensor 1 Sensor 2
L1
USB
Note 3
AF0100 Arc-Flash Relay
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3 SENSOR PLACEMENT
3.1 General Guidelines
Optical sensors should have line-of-sight to points being
monitored. Ensure that the point sensors and fiber are not
blocked by fixed or moveable objects. Areas that will be
accessed for maintenance or with moveable parts (such
as draw-out circuit breakers) should be considered a high
priority for installation. Do not place sensors or cables on
bare components that will be energized and avoid sharp
bends in the cable, particularly when using the PGA-LS20
and PGA-LS30 fiber-optic sensors. The electrical cables and
sensors should be considered to be at ground potential when
determining electrical clearances.
Sensors should be mounted in a location that will minimize
the chance of debris or dust build-up and with easy access
for maintenance if needed. A point sensor mounted at the
top of an enclosure and facing down is optimal for reducing
dust build-up. It should be noted that most enclosures are
metallic and the reflectivity combined with the high intensity
of an arc mean that even a moderately dusty sensor will
collect adequate light.
In dusty environments, sensor cleaning should be part of a
regular maintenance schedule and can be performed using
compressed air or a dry cloth.
3.3 Transformer Protection
The AF0100 can also be used for the protection of transformers.
Two or more point sensors should be used per transformer to
monitor the primary and secondary connection terminals. For
the placement of the sensors, the same considerations apply
as for switchgear protection.
3.4 Generator Protection
The main area of concern for protecting the generator is the
conductors between the generator and the generator breaker.
A fault in this area is not protected by the generator breaker
from overcurrent or arc flash. Often, one or two sensors are
enough to monitor the breaker and bus connection back to
the generator. If other electrical equipment is installed on
the generator, it should also be considered in an arc-flash
risk assessment. When protecting the generator to a breaker
connection, it is important to disconnect all sources of energy
for the arc flash. Open the generator breaker to disconnect
from the utility or other parallel generators, and connect
to the automatic voltage regulator (AVR), emergency stop
or other control circuit to turn off the generator. The two
trip relays on the AF0100 are isolated so that the breaker
and control circuit can both be tripped using independent
voltages if necessary.
3.2 Switchgear Protection
The sensors used for arc-flash detection are optical sensors.
Line-of-sight between the points where an arc could occur
and the sensor is optimal, but the reflectivity of metallic
compartments will help in distributing the light from an arc
fault in the entire cabinet.
Often one point sensor is sufficient to monitor a complete
switchgear compartment. However, if there are large
components such as circuit breakers that cast shadows over
wider areas, more than one point sensor is required.
AF0100 Arc-Flash Relay
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4 OPTICAL SENSORS
The AF0100 has two inputs for optical arc-fault sensors.
Two sensor types are supported:
• PGA-LS10 Photoelectric Point Sensors with sensor check
• PGA-LS20 and PGA-LS30 Fiber-Optic Sensors with
sensor check
The sensors can be used together, in any combination.
Both sensor types have LED indication of sensor health and
fault location. A sensor-check circuit tests the sensor to verify
that the sensor assembly is functioning correctly. A healthy
sensor will flash its internal red LED every few seconds. A
sensor that has detected an arc will indicate solid red until
the trip is reset.
The sensors connect to the AF0100 with shielded three-wire
20 AWG (0.5 mm2) electrical cable. Each sensor includes 10 m
(33 ft) of cable which can be shortened or extended up to 50 m
(164 ft). These cables should be considered to be at ground
potential when determining electrical clearances in the
cabinet.
NOTE: Inserting and removing a sensor cable can
cause a trip, depending on which terminals make
contact first. To guard against nuisance tripping,
remove the trip coil terminal blocks before
connecting and disconnecting sensors, or perform
the maintenance while the system is de-energized.
PGA-LS10
PGA-LS20 / PGA-LS30
Any connected optical sensor with circuit check will be
automatically detected and cause the AF0100 to report an
error if it is subsequently disconnected.
AF0100 Arc-Flash Relay
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4.1 PGA-LS10 Photoelectric Point Sensor with
Sensor Check
This sensor has a detection area of a 2-m (7-ft) half-sphere
for arcs of 3 kA or more.
A built-in LED enables the AF0100 to verify the function of
the light sensor, wiring, and electronics. If the sensor does
not detect the sensor-check LED, a sensor-fail alarm will
occur – the ERROR relay will change state and the sensor
indication LED will begin to flash. See Section 7.
The sensor includes 10 m (33 ft) of shielded three-wire
electrical cable which can easily be shortened or extended to
a maximum of 50 m (164 ft). For more information on sensor
cabling, see Section 6.3.2.
FIGURE 4. PGA-LS10 Detection Range for a 3 kA Fault.
4.1.1 PGA-LS10 Connection
9.6
(0.38)
14.2
(0.56)
8.3
(0.33)
2.4
(0.09)
23.8
(0.94)
AF0100 Arc-Flash Relay
SENSOR 1 SENSOR 2
5V TX RX 0V
5V TX RX 0V
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52.0
(0.16)
10 m
4.0
(32.8 ft)
44.0
(2.05)
RED
WHITE
SHIELD / BLACK
YELLOW
(1.73)
24.0
(0.94)
32.0
(1.26)
Ø4.25(0.167)
MOUNTING HOLES
Ø8.3(0.33)
SENSOR LENS
RED LED FOR
CIRCUIT CHECK AND
VISUAL DIAGNOSTICS
RED
WHITE
SHIELD / BLACK
YELLOW
NOTE 2
NOTES
1. DIMENSIONS IN MILLIMETERS (INCHES) UNLESS OTHERWISE STATED.
2. UP TO 2 PGA-LS10 PHOTOELECTRIC POINT SENSORS WITH BUILT-IN
CIRCUIT CHECK CAN BE CONNECTED.
3. THE PGA-LS10 SENSOR SHIPS ASSEMBLED WITH A PLUG-IN CONNECTOR.
IT MAY BE NECESSARY TO DISCONNECT THE PLUG-IN CONNECTOR
DURING INSTALLATION.
TERMINAL FUNCTION COLOR
5V
TX
RX
0V
SUPPLY
CIRCUIT CHECK TRANSMIT
RECEIVE
SHIELD
RED
WHITE
YELLOW
BLACK/COPPER
FIGURE 5. PGA-LS10 Connection Diagram.
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