E3 and E3 Plus Solid-State Overload Relay User Manual

1 User ManualE3 & E3 Plus Solid-State Overload RelayCatalog Numbers 193/592-EC1, -EC2, -EC3, -EC5 Important User InformationSolid-state equipment has operational characteristics differing from those of electromechanical equipment. Safety Guidelines for the Application, Installation and Maintenance of Solid State Controls (publication available from your local Rockwell Automation sales office or online at ) describes some important differences between Solid-State equipment and hard-wired electromechanical devices. Because of this difference, and also because of the wide variety of uses for Solid-State equipment, all persons responsible for applying this equipment must satisfy themselves that each intended application of this equipment is no event will Rockwell Automation, Inc. be responsible or liable for indirect or consequential damages resulting from the use or application of this examples and diagrams in this Manual are included solely for illustrative purposes.

2 Because of the many variables and requirements associated with any particular installation, Rockwell Automation, Inc. cannot assume responsibility or liability for actual use based on the examples and patent liability is assumed by Rockwell Automation, Inc. with respect to use of information, circuits, equipment, or software described in this of the contents of this Manual , in whole or in part, without written permission of Rockwell Automation, Inc., is this Manual , when necessary, we use notes to make you aware of safety , Rockwell Software, Rockwell Automation, and TechConnect are trademarks of Rockwell Automation, not belonging to Rockwell Automation are property of their respective : Identifies information about practices or circumstances that can cause an explosion in a hazardous environment, which may lead to personal injury or death, property damage, or economic : Identifies information about practices or circumstances that can lead to personal injury or death, property damage, or economic loss.

3 Attentions help you identify a hazard, avoid a hazard, and recognize the consequenceSHOCK HAZARD: Labels may be on or inside the equipment, for example, a drive or motor, to alert people that dangerous voltage may be HAZARD: Labels may be on or inside the equipment, for example, a drive or motor, to alert people that surfaces may reach dangerous information that is critical for successful application and understanding of the Automation Publication 193-UM002I-EN-P - December 20113 Table of ContentsManual Objectives .. 9 Who Should Use This Manual .. 9 Vocabulary.. 9 Conventions .. 9 Reference Manuals .. 9 Product OverviewIntroduction .. 11 Description .. 11 Catalog Number Explanation .. 12 Single-/Three-Phase Operation.. 12 Protection & Warning Functions .. 12 Parameter Monitoring .. 13 Current-Based Operational Data .. 13 Diagnostic Parameters .. 13 Voltage Parameters .. 13 Power Parameters.. 13 Overload Relay Features.

4 14 Trip Relay .. 14 Inputs & Outputs .. 14 User Interface .. 15 DeviceNet Compatibility .. 16 Flash Memory .. 16 Installation & WiringIntroduction .. 17 Receiving .. 17 Unpacking/Inspecting .. 17 Storing .. 17 General Precautions .. 18 Starter Assembly .. 18 Installation .. 18 Approximate Dimensions .. 21 Separate Panel Adapter .. 24 Approximate Dimensions .. 24 Voltage Input Module .. 26 Specifications .. 26 Power Terminals .. 26 Three-Pole Terminal Blocks .. 27 Terminal Lug Kits .. 27 Control, DeviceNet, & Voltage Input Module Terminals .. 27 Terminal Designations.. 29 Control Terminals.. 29 DeviceNet Terminals .. 29 Grounding.. 29 Short-Circuit Ratings .. 30 Short-Circuit Ratings .. 30 High-Fault Short-Circuit Ratings .. 31 Fuse Coordination .. 324 Rockwell Automation Publication 193-UM002I-EN-P - December 2011 Typical Motor Connections .. 34 Three-Phase Direct On-Line (DOL) & Single-Phase Full Voltage 34 External Line Current Transformer Application.

5 34 Specifications .. 34 Installation Requirements .. 35 External Potential Transformer (PT) Connection .. 36 Core Balanced Ground Fault Sensor Application .. 37 Typical Control Circuit.. 41 Wiring Diagrams .. 41 External/Remote Reset (FRN & Later) .. 44 Protective Trip & Warning FunctionsIntroduction .. 45 Trip Enable .. 45 Warning Enable .. 45 Overload Protection .. 45 Overload Trip .. 45 FLA Setting .. 46CT Ratio .. 47 Trip Class .. 47 Trip Curves .. 47 Auto/ Manual Reset .. 49 Overload Warning.. 50 Overload Diagnostics .. 51 Non-Volatile Thermal Memory.. 51 Phase Loss Protection.. 51 Phase Loss Trip.. 51 Ground Fault Protection (E3 Plus) .. 52 Ground Fault Setting Range .. 53 Ground Fault Trip.. 53 Ground Fault Trip Inhibit .. 54 Ground Fault Warning .. 55 Ground Fault Filter .. 55 Stall Protection .. 56 Stall Time .. 56 Jam Protection (High Overload ).. 57 Jam Trip .. 57 Jam Warning.

6 58 Underload Protection .. 58 Underload Trip .. 58 Underload Warning .. 59 PTC Trip .. 61 PTC Warning .. 62 Current Imbalance Protection .. 62 Current Imbalance Trip.. 62 Current Imbalance Warning .. 63 Communication Fault Protection .. 64 Rockwell Automation Publication 193-UM002I-EN-P - December 20115 Comm Fault Trip .. 64 Comm Fault Warning .. 65 Communication Idle Protection .. 65 Comm Idle Trip .. 65 Comm Idle Warning.. 66 Remote Trip .. 66 Voltage Protection .. 67 Under Voltage (UV) Trip .. 67 Under Voltage (UV) Warning .. 68 Over Voltage (OV) Trip .. 68 Over Voltage (OV) Warning .. 69 Voltage Unbalance Protection.. 69 Voltage Unbalance Trip .. 69 Voltage Unbalance Warning.. 70 Voltage Rotation Protection.. 71 Voltage Rotation Trip .. 71 Voltage Rotation Warning .. 71 Frequency Protection .. 72 Under Frequency (UF) Trip .. 72 Under Frequency Warning .. 72 Over Frequency (OF) Trip.

7 73 Over Frequency (OF) Warning .. 73 Voltage Input Module Detection .. 74 Voltage Hardware Trip .. 74 Voltage Hardware Warning .. 74 Real Power (kW) Protection .. 75 Under Real Power Trip .. 75 Under Real Power Warning .. 75 Over Real Power Trip .. 76 Over Real Power Warning.. 76 Reactive Power (kVAR) Protection .. 77 Under Reactive Power Consumed Trip.. 77 Under Reactive Power Consumed Warning .. 78 Over Reactive Power Consumed Trip .. 78 Over Reactive Power Consumed Warning .. 79 Under Reactive Power Generated Trip .. 79 Under Reactive Power Generated Warning .. 80 Over Reactive Power Generated Trip.. 80 Over Reactive Power Generated Warning .. 81 Apparent Power (kVA) Protection.. 81 Under Apparent Power Trip .. 82 Under Apparent Power Warning .. 82 Over Apparent Power Trip .. 83 Over Apparent Power Warning .. 83 Power Factor Protection .. 84 Under Power Factor Lagging Trip .. 846 Rockwell Automation Publication 193-UM002I-EN-P - December 2011 Under Power Factor Lagging Warning.

8 85 Over Power Factor Lagging Trip .. 85 Over Power Factor Lagging Warning .. 86 Under Power Factor Leading Trip .. 86 Under Power Factor Leading Warning .. 87 Over Power Factor Leading Trip .. 87 Over Power Factor Leading Warning.. 88 Protective Trip & Warning Summary .. 88 Preventive Maintenance Diagnostics (E3 Overload Relays Series C & Later) .. 91 Monitoring .. 91 Start Inhibit .. 91 Start Inhibit Trip .. 91 Preventive Maintenance Flags .. 92 Queue Clearing.. 93 DeviceNet Node CommissioningIntroduction .. 95 Setting the Hardware Switches (Series B & Later) .. 95 Using RSNetWorx for DeviceNet.. 96 Commissioning the Protection Functions .. 103 Programmable ParametersIntroduction .. 105 Programming .. 105 Program Lock .. 105 Reset to Default Factory Settings.. 105 Parameter Group Listing .. 105 Overload Setup Group .. 111 Advanced Setup Group .. 114 Reset/Lock Group.. 123 DeviceNet Setup Group .. 125 Output Setup Group.

9 127 DeviceLogix Group E3 Plus.. 131 Monitoring ParametersIntroduction .. 135 Phase Current Reporting.. 135 Current Range .. 135 Reporting Accuracy .. 136 Ground Fault Current Reporting .. 137 Current Range .. 137 Frequency Range .. 137 Diagnostic Parameters .. 137 Monitor Group .. 138 Voltage ParametersIntroduction .. 147 Phase Voltage Reporting .. 147 Rockwell Automation Publication 193-UM002I-EN-P - December 20117 Voltage Range .. 147 Voltage Accuracy .. 148 Voltage Monitor Group.. 148 Voltage Setup Group .. 151 Power ParametersIntroduction .. 159 Phase Power Reporting .. 159 Power Range .. 159 Power Accuracy .. 161 Power Monitor Group .. 161 Power Setup Group.. 171 Trip History and SnapshotTrip and Warning History .. 183 TripWarn History Group .. 183 Trip Snapshot.. 189 Trip Snapshot Group .. 190 Logic Controller Communication ExamplesIntroduction .. 193I/O Messaging .. 193 Explicit Messaging .. 195 Reading Device Status using the Parameter Object Class (0x0F).

10 195 Reading Device Status using the Control Supervisor Object Class (0x29) .. 197 Reading the Trip Class using the Overload Object Class (0x2C) . 199 Reading a Group of Parameters using the E3 Status Object Class (0x0375) .. 201 Using DeviceLogix Introduction .. 205 DeviceLogix Programming .. 206 DeviceLogix Programming Example.. 206 TroubleshootingIntroduction .. 213 Advisory LEDs .. 213 Trip/Warn LED .. 213 Network Status LED.. 215 OUT A & OUT B LEDs.. 215IN 1,2,3 & 4 LEDs.. 215 Power-Up Sequence .. 215 DeviceNet Modes of Operation .. 216 Power-Up Reset Mode .. 216 Run Mode .. 216 Recoverable Error Mode .. 217 Unrecoverable Error Mode .. 217 Resetting a Trip .. 217 Trip/Warn LED Troubleshooting Procedures .. 2188 Rockwell Automation Publication 193-UM002I-EN-P - December 2011 DeviceNet Troubleshooting Procedures .. 222 Loss of Node Address .. 222 Input and Output Troubleshooting Procedures .. 222 SpecificationsElectrical Specifications.