Allen-bradley E3, E3 Plus User Manual
User Manual
E3 & E3 Plus Solid-State Overload Relay
Catalog Numbers
193/592-EC1, -EC2, -EC3, -EC5
Important User Information
IMPORTANT
Solid-state equipment has operational characteristics differing from those of electromechanical equipment. Safety
Guidelines for the Application, Installation and Maintenance of Solid State Controls (publication SGI-1.1
your local Rockwell Automation sales office or online at http://www.rockwellautomation.com/literature/
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 acceptable.
In no event will Rockwell Automation, Inc. be responsible or liable for indirect or consequential damages resulting from
the use or application of this equipment.
The examples and diagrams in this manual are included solely for illustrative purposes. 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 diagrams.
No patent liability is assumed by Rockwell Automation, Inc. with respect to use of information, circuits, equipment, or
software described in this manual.
Reproduction of the contents of this manual, in whole or in part, without written permission of Rockwell Automation,
Inc., is prohibited.
Throughout this manual, when necessary, we use notes to make you aware of safety considerations.
WARNING: 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 loss.
available from
) describes some
ATTENTION: Identifies information about practices or circumstances that can lead to personal injury or death,
property damage, or economic loss. Attentions help you identify a hazard, avoid a hazard, and recognize the
consequence
SHOCK HAZARD: Labels may be on or inside the equipment, for example, a drive or motor, to alert people that
dangerous voltage may be present.
BURN HAZARD: Labels may be on or inside the equipment, for example, a drive or motor, to alert people that
surfaces may reach dangerous temperatures.
Identifies information that is critical for successful application and understanding of the product.
Allen-Bradley, Rockwell Software, Rockwell Automation, and TechConnect are trademarks of Rockwell Automation, Inc.
Trademarks not belonging to Rockwell Automation are property of their respective companies.
Table of Contents
Manual Objectives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Who Should Use This Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Vocabulary. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Conventions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Reference Manuals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Product Overview
Installation & Wiring
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Trip Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Inputs & Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
User Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
DeviceNet Compatibility . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Flash Memory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Rockwell Automation Publication 193-UM002I-EN-P - December 2011 3
Typical Motor Connections. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Three-Phase Direct On-Line (DOL) & Single-Phase Full Voltage 34
External Line Current Transformer Application . . . . . . . . . . . . . . . . . . . . 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 3.001 & Later) . . . . . . . . . . . . . . . . . . . 44
Protective Trip & Warning
Functions
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Trip Enable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Warning Enable. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Overload Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Overload Trip. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
FLA Setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
CT 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. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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
4 Rockwell Automation Publication 193-UM002I-EN-P - December 2011
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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
Rockwell Automation Publication 193-UM002I-EN-P - December 2011 5
Under Power Factor Lagging Warning . . . . . . . . . . . . . . . . . . . . . . . . . 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
Commissioning
Programmable Parameters
Monitoring Parameters
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
Setting the Hardware Switches (Series B & Later) . . . . . . . . . . . . . . . 95
Using RSNetWorx for DeviceNet. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
Commissioning the Protection Functions . . . . . . . . . . . . . . . . . . . . . . . . . 103
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
DeviceLogix Group — E3 Plus. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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 Parameters
6 Rockwell Automation Publication 193-UM002I-EN-P - December 2011
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
Phase Voltage Reporting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
Voltage Range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
Voltage Accuracy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148
Voltage Monitor Group. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148
Voltage Setup Group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151
Power Parameters
Trip History and Snapshot
Logic Controller
Communication Examples
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159
Phase Power Reporting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159
Power Range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159
Power Accuracy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161
Power Monitor Group. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161
Power Setup Group. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171
Trip and Warning History . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 183
TripWarn History Group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 183
Trip Snapshot. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 189
Trip Snapshot Group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 190
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 193
I/O Messaging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 193
Explicit Messaging. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 195
Reading Device Status using the Parameter Object Class (0x0F) . 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™
Troubleshooting
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205
DeviceLogix Programming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206
DeviceLogix Programming Example. . . . . . . . . . . . . . . . . . . . . . . . . . . 206
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 213
Advisory LEDs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 213
Trip/Warn LED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 213
Network Status LED. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 215
OUT A & OUT B LEDs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 215
IN 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. . . . . . . . . . . . . . . . . . . . . 218
Rockwell Automation Publication 193-UM002I-EN-P - December 2011 7
DeviceNet Troubleshooting Procedures. . . . . . . . . . . . . . . . . . . . . . . . . . . 222
Loss of Node Address . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 222
Input and Output Troubleshooting Procedures. . . . . . . . . . . . . . . . . . . . 222
Specifications
DeviceNet™ Information
Electrical Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 225
Environmental Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 227
Electromagnetic Compatibility Specifications. . . . . . . . . . . . . . . . . . . . . . 227
Functionality Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 228
Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 229
Electronic Data Sheets (EDS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 231
Product Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 231
DeviceNet Objects . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 232
Identity Object – Class Code 0x01. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 233
Message Router – Class Code 0x02 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 234
DeviceNet Object – Class Code 0x03 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 234
Assembly Object – Class Code 0x04 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 235
Output Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 236
Input Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 237
Connection Object – Class Code 0x05. . . . . . . . . . . . . . . . . . . . . . . . . . . . 239
Discrete Input Point Object – Class Code 0x08. . . . . . . . . . . . . . . . . . . . 243
Discrete Output Point Object – Class Code 0x09. . . . . . . . . . . . . . . . . . 243
Parameter Object – Class Code 0x0F . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 244
Parameter Group Object – Class Code 0x10. . . . . . . . . . . . . . . . . . . . . . . 245
Discrete Output Group Object - CLASS CODE 0x001E . . . . . . . . . 246
Control Supervisor Object – Class Code 0x29 . . . . . . . . . . . . . . . . . . . . . 247
Control Supervisor ODVA Fault and Warning Codes . . . . . . . . . . 250
Acknowledge Handler Object – 0x2B. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 251
Overload Object – Class Code 0x2C. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 251
DPI Fault Object - CLASS CODE 0x0097 . . . . . . . . . . . . . . . . . . . . . . . . 254
DPI Warning Object - CLASS CODE 0x0098 . . . . . . . . . . . . . . . . . . . . 257
DeviceNet Interface Object – Class Code 0xB4 . . . . . . . . . . . . . . . . . . . . 260
MCC Object - CLASS CODE 0x00C2 . . . . . . . . . . . . . . . . . . . . . . . . . . . 261
Logic Supervisor Object - CLASS CODE 0x030E . . . . . . . . . . . . . . . . . 261
E3 Status Object - CLASS CODE 0x0375 . . . . . . . . . . . . . . . . . . . . . . . . 262
CE Compliance
Two-Speed Applications
Accessories
8 Rockwell Automation Publication 193-UM002I-EN-P - December 2011
EC Directive Compliance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 269
EMC Directive. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 269
Low Voltage Directive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 270
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 271
External Control Applications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 271
Output Control Applications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 271
Accessories. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 273
Preface
IMPORTANT
Manual Objectives
Who Should Use This Manual
Vocabulary
The purpose of this manual is to provide you with the necessary information to
apply the E3 Overload Relay with DeviceNet communications. Described in this
manual are methods for installing, configuring, and troubleshooting.
Read this manual in its entirety before installing, operating,
servicing, or initializing the E3 Overload Relay.
This manual is intended for qualified personnel responsible for setting up and
servicing these devices. You must have previous experience with and a basic
understanding of communications technology, configuration procedures,
required equipment, and safety precautions.
To make efficient use of the E3 Overload Relay, you must be able to program and
operate devices with communications and have a basic understanding of the E3
Overload Relay’s parameter settings and functions. You should also understand
DeviceNet network operations, including how slave devices operate on the
network and communicate with a DeviceNet master.
In this manual, we refer to the:
• E3 Overload Relay as it applies to both the E3 and E3 Plus Overload
Relays.
• E3 Plus Overload Relay when features and/or functions apply specifically
to it.
Conventions
Reference Manuals
Parameter names are shown in italic typeface.
E3 refers to the overload relays E3 and E3 Plus. “E3” is the standard version. “E3
Plus” is the enhanced version.
For SLC 500 and 1747-SDN information:
• DeviceNet Scanner Module Installation Instructions Publication
1747-IN058E-EN-P
• DeviceNet Scanner Module User Manual Publication
1747-UM655B-EN-P
For PLC5 and 1771-SDN information:
• DeviceNet Scanner Module Installation Instructions Publication 1771-5.14
• DeviceNet Scanner Module Configuration Manual Publication
1771-6.5.118
For MicroLogix/CompactLogic and 1769-ADN information:
Rockwell Automation Publication 193-UM002I-EN-P - December 2011 9
Preface
IMPORTANT
• DeviceNet Module Installation Instructions Publication
1769-IN001B-EN-P
• DeviceNet Module User Manual Publication 1769-UM001B-EN-P
For ControlLogic and 1756-DNB information:
• DeviceNet Module Installation Instructions Publication
1756-IN566C-EN-P
• DeviceNet Module User Manual Publication DNET-UM004A-EN-P
To install and implement a DeviceNet network:
• DeviceNet Media Design and Installation Guide Publication
DNET-UM072_-EN-P
Read the DeviceNet Media Design and Installation Guide,
Publication DNET-UM072_-EN-P, in its entirety before
planning and installing a DeviceNet system. If the network is
not installed according to this document, unexpected
operation and intermittent failures can occur.
If this manual is not available, please contact either the local
Rockwell Automation Distributor or Sales Office and request
a copy. Electronic copies may also be obtained via the
Internet or from the Allen-Bradley Home Page at
“www.ab.com.”.
10 Rockwell Automation Publication 193-UM002I-EN-P - December 2011
Product Overview
E3 PLUS
S1
S2
13 14 23 24 95 96 IT1 IT2
1 2 3 4 5 6
NETWORK
STATUS
OUT A
IN 1
IN 2
OUT B
IN 3
IN 4
MSD
LSD
TRIP
WARN
TEST/
RESET
DS/N
FRN
4.XXX
1AOXXXXX
XXX
SER
Test/Reset Button
Voltage Input Module
Connection
(193/592 EC5 only)
Ground Fault
Sensor Input
Output & PTC
Terminals
NOTE: On model EC5
devices, terminals IT1 and
IT2 are marked 7 and
8, respectively.
LED Status
Indicators
Node Address Switches
(series B and later)
DeviceNet Port
Input
Terminals
Chapter
1
Introduction
Description
This chapter provides a brief overview of the features and functionality of the E3
Overload Relay.
The E3 Overload Relay is a multi-function solid-state microprocessor-based
electronic overload relay for the protection of squirrel-cage induction motors
rated from 0.4…5,000 A. Four versions are available: the E3 model, EC1, and
E3Plus models EC2, EC3, and EC5.
Figure 1 - Front Panel Display (E3 Plus Overload Relay shown)
Rockwell Automation Publication 193-UM002I-EN-P - December 2011 11
Chapter 1 Product Overview
193 - EC1 B B
592
Bulletin
Number
Type
EC1 E3
EC2 E3 Plus➊
EC3 E3 Plus➋
EC5 E3 Plus➋
Current Rating
(Amps)
P0.4…2.0
A1…5
B 3…15
C 5…25
D 9…45
E18…90
F28…140
G42…210
H60…302
J84…420
K 125…630
L 172…860
Bulletin 500
Contactor Size
T Size 00
C Size 0…2
D Size 3
E Size 4
F Size 5
G Size 6
Bulletin 100 Contactor
Size
B C09…C23
D C30…C43
E C60…C85
F D95…D180
G D210…D420
H D630…D860
ZPanel Mount, CT fed
➊ (0.4…90 A) Provides 1…5 A internal core-balanced ground fault protection
➋ (0.4.…5000 A) Provides 20 mA…5 A external core balanced ground fault protection. External ground fault
sensor required (Cat. nos. 193-CBCT-1…4).
Catalog Number Explanation
The solid-state overload relay purchased has its own catalog number. The catalog
number is explained below.
Single-/Three-Phase Operation
The overload relay is factory programmed for three-phase operation. The
installer can easily be changed to single-phase operation by accessing and
changing Single/Three Phase, Parameter 27. Refer to page 34 for typical motor
connections.
Protection & Warning Functions
12 Rockwell Automation Publication 193-UM002I-EN-P - December 2011
The E3 Overload Relay provides the following protection and warning functions:
Function Model
• Overload
• Phase loss (trip only)
• Stall (trip only)
• Jam
• Underload
• Current imbalance
• Number of starts (warning only)
• Operating hours (warning only)
• Voltage
• Power
• Frequency
• Ground fault EC2, EC3, & EC5 Only
• Thermistor (PTC) input EC2 and EC3 Only
Refer to Chapter 3 on page 45 for further explanation of these protection and
warning functions.
All Models
EC5 Only
Product Overview Chapter 1
Parameter Monitoring
The E3 Overload Relay allows the user to monitor information on various
parameters over the DeviceNet™ network.
Current-Based Operational Data
Current-Based Operational Data Unit of Measure
Individual phase currents Amperes
Average current Amperes
Average current % of motor FLC
Percentage of thermal capacity utilized %
Current imbalance percentage %
Ground fault current (EC2, EC3, and EC5 only) Amperes
Refer to Chapter 6 for further information.
Diagnostic Parameters
• Device Status
• Trip S t atus
• Warning Status
• Time to an overload trip (in seconds)
• Time to reset after an overload trip (in
seconds)
• History of the past five trips and warnings
• Diagnostic data at the time of a trip
Refer to Chapter 6 for further information.
Voltage Parameters
• Voltage range
• Phase rotation
• Voltage warning status
Refer to Chapter 7 for further information.
• Voltage unbalance
• Voltage frequency
Power Parameters
• Power range
• Reactive power
• Apparent power
Refer to Chapter 8 for further information.
• Power factor
• Power consumed
Rockwell Automation Publication 193-UM002I-EN-P - December 2011 13
Chapter 1 Product Overview
Overload Relay Features
Trip Relay
When the E3 Overload Relay is in the unpowered state, the trip relay contact is
open. The trip relay contact closes approximately 2 to 35 seconds after power is
applied if no trip condition exists.
Inputs & Outputs
In addition to the trip relay, the E3 Overload Relay provides inputs and outputs as
shown below.
Table 1 - Inputs & Outputs
Model Inputs ➊ Outputs
EC1 2 1
EC2, EC3 4 2
EC5 6 2
➊ Inputs are rated at 24V only. For 120V AC inputs, add the AC Input Interface Module, Cat. No. 193-EIMD.
The status of each input and output can be monitored over the DeviceNet
network through Device Status, Parameter 21, or one of the input assemblies.
Additionally, the outputs can be controlled over the network using one of the
output assemblies. Refer to Appendix B for listings of the available input and
output assemblies.
Series B and later E3 Plus Overload Relays offer added flexibility by providing the
capability to perform control functions with the inputs and outputs through
DeviceLogix™.
Series B or later E3 Overload Relay inputs are independently configurable for trip
reset, remote trip, two-speed, and normal operation.
ATTENTION: If the outputs are being commanded via an explicit
message, ensure that there is no established I/O connection that is
actively controlling the outputs and that the explicit message connection
has a non-zero expected packet rate (EPR) setting.
ATTENTION: The state of the outputs during a protection fault,
DeviceNet communication fault, or a DeviceNet communication idle may
be dependent on the following OUT A or OUT B parameters: PrFltState, Pr
FltValue, Dn FltState, Dn FltValue, Dn IdlState, and Dn IdlValue. For
details, refer to the Output Setup Group section in Chapter 5.
14 Rockwell Automation Publication 193-UM002I-EN-P - December 2011
Product Overview Chapter 1
ATTENTION: The E3 Overload Relay’s output control firmware latches
OUT A and OUT B closed upon receipt of a network close command. The
outputs will maintain the commanded closed state until receipt of a
network open command. Parameters OutX Pr FltState and OutX Pr
FltValue, found in the E3 Overload Relay’s output setup group, allows
flexibility concerning the operation of the outputs in the event of a trip.
Factory default settings cause the outputs to open upon
occurrence of a trip. E3 outputs that were closed prior to a trip
will reclose upon trip reset, provided that a network open
command is not received first.
User Interface
Refer to Figure 1 on page 11 for the location of LED status indication, Test/Reset
button, and node address switches.
LED Status Indication
The following LED status indicators are provided on the E3 Overload Relay. See
Chapter 12 for detailed information on each status.
Network Status — Illuminated in green or red, this indicates the network
connection status.
Tr ip / Wa rn i ng — Under a warning condition, the LED status flashes a sequence
of red and/or amber. Under the trip condition, the LED status flashes a sequence
of red. In either condition, the flash pattern followed by a pause identifies the
specific trip or warning. The meaning of the flash pattern can be found on the E3
Overload Relay’s side label or Table XX on page XX.
OUT A and OUT B — When the output contacts are commanded closed, the
LED illuminates amber.
IN 1…IN 4 —When the user-connected device contact is closed, the LED status
illuminates in amber.
NOTE: IN 3, IN 4, and OUT B are available only on the E3 Plus Overload Relay.
Test/Reset ButtonT
Tes t — If Test Enable is activated, the trip relay contact will open if the E3
Overload Relay is in an untripped condition and the Test/Reset button is
pressed. For devices with firmware revision number (FRN) 2.000 and later, the
Test/Reset button must be pressed for a minimum of two seconds to activate the
test function.
Reset — If the E3 Overload Relay (a) is in a tripped condition, (b) the cause of
Rockwell Automation Publication 193-UM002I-EN-P - December 2011 15
Chapter 1 Product Overview
IMPORTANT
the trip is no longer present, and (c) the test/reset button is pressed, the trip relay
contact will close.
ATTENTION: The Test function associated with the Test/Reset button is
enabled by default. Activating the Test function while a motor is operating
will cause the starting contactor to drop out and stop motor operation.
Node Address Switches
The node address switches, located on the front of the Series B and later E3
Overload Relays, provide a physical means for setting the device node address
value. Switch settings greater than 63 allow the node address to be software
configured.
DeviceNet Compatibility
The E3 Overload Relay supports the following DeviceNet functionality:
Functionality Models
• Polled I/O messaging
• Change-of-state/cyclic messaging
• Explicit messaging
• Group 4 off-line node recovery messaging
• Full parameter object support
• Auto-baud rate identification
• Configuration consistency value
• UCMM (Unconnected Message Manager) Series B and later devices
• DeviceLogix component technology E3 Plus, Series B and later devices
All models
Flash Memory
Series B and later E3 Overload Relays incorporate flash memory. This facilitates
updating of the product firmware as new revisions are released.
It is not possible to flash upgrade from Series B firmware to Series C
firmware.
16 Rockwell Automation Publication 193-UM002I-EN-P - December 2011
Installation & Wiring
Chapter
2
Introduction
Receiving
Unpacking/Inspecting
Storing
This chapter provides instructions for receiving, unpacking, inspecting, and
storing the E3 Overload Relay. Installation and wiring instructions for common
applications are also included.
It is the responsibility of the user to thoroughly inspect the equipment before
accepting the shipment from the freight company. Check the item(s) received
against the purchase order. If any items are damaged, it is the responsibility of the
user not to accept delivery until the freight agent has noted the damage on the
freight bill. Should any concealed damage be found during unpacking, it is again
the responsibility of the user to notify the freight agent. The shipping container
must be left intact and the freight agent should be requested to make a visual
inspection of the equipment.
Remove all packing material from around the E3 Overload Relay. After
unpacking, check the item’s nameplate catalog number against the purchase
order.
The E3 Overload Relay should remain in its shipping container prior to
installation. If the equipment is not to be used for a period of time, it must be
stored according to the following instructions in order to maintain warranty
coverage:
• Store in a clean, dry location.
• Store within an ambient temperature range of -40 °C…+85 °C
(-40 °F…+185 °F).
• Store within a relative humidity range of 0…95%, non-condensing.
• Do not store where the device could be exposed to a corrosive atmosphere.
• Do not store in a construction area.
Rockwell Automation Publication 193-UM002I-EN-P - December 2011 17
Chapter 2 Installation & Wiring
General Precautions
In addition to the specific precautions listed throughout this manual, the
following general statements must be observed.
ATTENTION: The E3 Overload Relay contains electrostatic discharge
(ESD) sensitive parts and assemblies. Status control precautions are
required when installing, testing, servicing, or repairing this assembly.
Component damage may result if ESD control procedures are not
followed. If you are not familiar with static control procedures, refer to
Allen-Bradley publication 8000-sb001_-en-p, Guarding Against
Electrostatic Damage”, or any other applicable ESD protection handbook.
ATTENTION: An incorrectly applied or installed E3 Overload Relay can
result in damage to the components or reduction in product life. Wiring or
application errors (e.g., incorrectly figuring the FLA setting, supplying
incorrect or inadequate DeviceNet supply voltage, connecting an external
supply voltage to the input or thermistor terminals, or operating.storing in
excessive ambient temperatures) may result in malfunction of the E3
Overload Relay.
ATTENTION: Only personnel familiar with the E3 Overload Relay and
associated machinery should plan to install, start up, and maintain the
system. Failure to comply may result in personal injury or equipment
damage.
Starter Assembly
ATTENTION: The purpose of this user manual is to serve as a guide for
proper installation. The National Electrical Code (NEC) and any other
governing regional or local code will overrule this information. Rockwell
Automation cannot assume responsibility for the compliance or proper
installation of the E3 Overload Relay or associated equipment. A hazard of
personal injury and/or equipment damage exists if codes are ignored
during installation.
ATTENTION: The earth ground terminal of the E3 Overload Relay shall be
connected to a solid earth ground via a low-impedance connection.
The following figures and tables illustrate the starter assembly instructions and
approximate dimensions.
Installation
The 100-C09…C43 Starter Assembly installation instructions for use with
Catalog Numbers 193-EC_ _B and -EC_ _D are shown in Figure 2
.
18 Rockwell Automation Publication 193-UM002I-EN-P - December 2011
Installation & Wiring Chapter 2
3
1
2
2.5 N m
2 lb in
2
4 N·m
35 lb-in
1
Figure 2 - 100-C09…C43 Starter Assembly Installation
The 100-C60…C85 Starter Assembly installation instructions for use with
Catalog Numbers 193-EC_ _E are shown in Figure 3
.
Figure 3 - 100-C60…C85 Starter Assembly Installation
The 100-D95…D860 Starter Assembly installation instructions for use with
Catalog Numbers 193-EC_ _F, 193-EC_ _G, and -EC_ _H are shown below.
ATTENTION: The voltage ratings of the E3 Overload Relay’s output and
trip relays must not be exceeded. If the voltage ratings are exceeded, an
interposing relay must be used.
ATTENTION: Connect the internal metal shield to a solid earth ground
via a low impedance connection.
Rockwell Automation Publication 193-UM002I-EN-P - December 2011 19
Chapter 2 Installation & Wiring
IMPORTANT
IMPORTANT
1
100-D95 / D110
100-D95E / D110E / D115E
100-D115 / D140 / D180
100-D210 / D420
100-D630 / D860
Ground fault protection requires connection of an external core balance
current transformer (CBCT).
For identification of the proper CT ratio to be programmed, refer to the
product nameplate.
Figure 4 - 100-D95…D860 Starter Assembly Installation
4
Supplied
with Contactor
1
Supplied
11 N·m (100 lb-in)
22 N·m (195 lb-in)
43 N·m (380 lb-in)
68 N·m (600 lb-in)
with
Contactor
Accessory 193-EIMD shown.
2
193-EC _ _ F
193-EC _ _ G
193-EC _ _ H
(M5) 3.4 N·m (30 lb-in)
(M6) 7.3 N·m (65 lb-in)
(M12 Provided)
45 N·m (400 lb-in)
3
a
b
5
6
a
20 Rockwell Automation Publication 193-UM002I-EN-P - December 2011
Installation & Wiring Chapter 2
Approximate Dimensions
Approximate dimensions are shown in millimeters (inches). Dimensions are not
intended to be used for manufacturing purposes.
Figure 5 - Overload Relay 193-EC_ _ B, D, & E with Contactor 100-C*
A
D1
D2
ØD
E1
B
H
B1
11.4
(29/64)
F1
Height B
Cat. No.
Overload
Relay
193-EC_ _B C09, C-12,
193-EC_ _D C30, C37 104
193-EC_ _E C60, C72,
Contactor
100-
C16, C2345(1-25/32)
C43 54
C85
Width
A without with B1
(2-1/8)
72
(2-53/64)
193-EIMD
188.3
(7-13/32)
236.1
(9-19/64)
207.7
(8-11/64)
255.5
(10-1/16)
145.1
(5-23/32)
173.2
(6-13/16)
Depth
C E1F1D1D2H Ø D
107
(4-7/32)
124.6
(4-29/32)
67.9
(2-43/64)
89.8
(3-17/32)
53.2
2-3/32)60(2-23/64)35(1-3/8)
62.2
(2-7/16)
80.2
(3-9/64)
100
(3-15/16)55(2-11/64)
45
(1-25/32)
C
85.1
(3-23/64)
(4-3/32)
107
(4-7/32)
125.5
(4-15/16)
4.2
(11/64)
5.5
(7/32)
Rockwell Automation Publication 193-UM002I-EN-P - December 2011 21
Chapter 2 Installation & Wiring
Figure 6 - Overload Relay 193-E_ _F, G, & H with Contactor 100-D*
A
G
11.4
(0.45)
C
L
H
K
J
F
E1
B1
B
D
Cat. No.
Overload
Relay
193-EC_ _F D95, D110 120
193-EC_ _G D210, D250,
193-EC_ _H D630, D860 255
Contactor
100-
D140, D180 339.8
D300, D420
Width
A without with B1
(4.72)
155
(6.10)
(10.04)
Height B
193-EIMD
336.3
(13.24)
(13.38)
385.8
(15.19)
552
(21.73)
418
(16.46)
487.4
(19.19)
915
(36.02)
ØM
311.8
(12.27)
317.8
(12.51)
360.8
(14.2)
508
(20.0)
C
L
Depth
C D E1F GHJ KL ØM
175.1
(6.89)
198.9
(7.83)
291.7
(11.49)
156
(6.14)
180
(7.09)
270.7
(10.66)
216.1
12.5
(8.51)
(0.49)
16
(0.63)
255
(10.04)21(0.83)
373.9
(14.72)
52.5
(2.07)
100
(3.94)
130
(5.12)
226
(8.90)
145
(5.71)
180
(7.09)
230
(8.90)
135
(5.31)
140
(5.51)
108
(4.25)
22.3
(0.88)
23.5
(0.93)
109
(4.29)
180.9
5.6
(7.12)
(0.22)
204.7
(8.06)
297.5
(11.71)13(0.51)
22 Rockwell Automation Publication 193-UM002I-EN-P - December 2011
Installation & Wiring Chapter 2
Figure 7 - Overload Relay 592-EC_ _ T, C, & D with NEMA Contactor
Size 00
A
D
ØF
Size 0...2
A
ØF
H
E
(29/64)
11.4
B
Size 3
J
J
K
L
D
C
11.4
(29/64)
E
H
B
H
11.4
(29/64)
E
B
C
Cat. No.
Overload
Relay
592-EC_ _T 00 45
592-EC_ _C 0, 1 90.4
592-EC_ _D 3 155.5
NEMA
Contactor
Size
2100
Width
A without with
(1-25/32)
(3-9/16)
(3-15/16)
(6-1/8)
K
ØF
Height B
193-EIMD
Depth
CDEØFHJKL
188.3
(7-13/32)
236.1
(9-19/64)
Rockwell Automation Publication 193-UM002I-EN-P - December 2011 23
207.7
(8-11/64)
255
(10-1/16)
107
(4-7/32)35(1-3/8)60(2-23/64)
112.1
(4-13/32)
126.3
(4-31/32)
69.9
(2-3/4)
80
(3-5/32)
139.9
(5-33/64)
L
D
A
179.4
(7-1/16)
219.3
(8-5/8)
219.9
(8-43/64)
4.2
(11/64)
5.15
((13.64)
5.54
(7/32)
7.1
(9/32)
97.9
(3-27/32)
159.4
(7-15/32)
186
(7-21/64)
276.7
(10.9)
C
———
163
(6-7/16)
189.5
(7-15/32)
256.3
(10-3/32)
47.5
(1-7/8)
78.5
(3-3/32)
27.5
(1-5/64)
42.3
(1-21/32)
Chapter 2 Installation & Wiring
11.4
(29/64)
30
(1-3/16)
45
(1-25/32)
7.3
(9-32)
135
(5-5/16)
154.2
(6-5/64)
100.5
(3-31/32)
6.1
(1/4)
115
(4-17/32)
Ø 4.4
(11/64)
Separate Panel Adapter
Approximate Dimensions
Approximate dimensions are shown in millimeters (inches). Dimensions are not
intended to be used for manufacturing purposes.
Figure 8 - 193-ECPM1 Panel Adapter for use with Cat. No. 193-EC_ _B
45
(1-25/32)
7.3
(9/32)
159.3
(6-17/64)
Ø 4.4
(11/64)
11.4
(29/64)
30
(1-3/16)
135
(5-5/16)
6.1
(1/4)
100.5
(3-31/32)
115
(4-17/32)
Figure 9 - 193-ECPM2 Panel Adapter for use with Cat. No. 193-EC_ _D & Z
24 Rockwell Automation Publication 193-UM002I-EN-P - December 2011
Installation & Wiring Chapter 2
K
0
2
4
6
8
0
2
4
6
8
M
N
P
A
D
B
C
E
F
E
L
J
G
I
H
Figure 10 - 193-ECPM3 Panel Adapter for use with Cat. No. 193-EC_ _E
71.7
(2-53/64)
60
(2-23/64)
11.4
(29/64)
150.5
(5-15/16)
155.1
(6-7/64) w/
130
(5-1/8)
(19/32)
193-EIMD
77
(3-1/32)
131.2
15
5.0
(13/64)
Ø 5.5
(7/32)
(5-11/64)
Figure 11 - Separate Panel Adapter for use with Cat. No. 193-EC_ _ F, G, & H
Overload
Cat. No.ABCDEFGHI JKLMNP
193-EC_ _ F 4.72
(120.0)
193-EC_ _ G 6.09
(154.7)
193-EC_ _H 10.0
(255.0)
7.19
(182.6)
7.40
(188.1)
10.28
(261.0)
6.09
(154.6)
6.41
(162.8)
8.54
(217.0)
3.94
(100)
5.12
(130)
8.90
(226)
1.54
(39)
1.89
(48)
2.76
(70)
0.45
(11.4)
0.45
(11.4)
0.45
(11.4)
1.03
(26.3)
1.06
(26.8)
3.97
(100.8)
5.32
(135)
5.51
(140.0)
4.24
(107.7)
1.94
(49.4)
2.03
(51.5)
1.37
(134.9)
0.22
(5.6)
0.26
(6.5)
0.53
(13.5)
0.24
0.47
(6.0)
(12)
0.08
0.49
(2.0)
(12.5)
—0.87
(22.0)
5.95
(151.2)
6.89
(175)
10.54
(267.8)
6.89
(175)
7.83
(198.9)
11.49
(291.7)
7.12
(180.9)
8.06
(204.7)
11.72
(297.5)
Rockwell Automation Publication 193-UM002I-EN-P - December 2011 25
Chapter 2 Installation & Wiring
Voltage Input Module
The voltage input module, Cat. No. 193-NVEC5VIM, is an add-on accessory for
use with the E3 Plus. Approximate dimensions are shown in millimeters (inches).
Dimensions are not intended to be used for manufacturing purposes.
Figure 12 - 193-NVEC5VIM Voltage Input Module
0.886
(22.5)
L1
L2
L3
0.457
(11.6)
2.972
(75.5)
2.782
(70.65)
Ø 0.177
(4.5)
Specifications
3.216
(82.0)
Power Terminals
Table 2 - Wire Size & Torque Specification
193-EC_ _B & D,
Wire Type Conductor Torque
Stranded/Solid [AWG] Single #14…6 AWG
Multiple #10…6 AWG
Flexible-Stranded with Ferrule Metric Single 2.5…16 mm
Multiple 6…10 mm
Coarse-Stranded/Solid Metric Single 2.5…25 mm
Multiple 6…16 mm
592-EC_ _T, C
22 lb-in.
30 lb-in.
2.5 Nm
3.4 Nm
2.5 Nm
3.4 Nm
Cat. No.
2
2
2
2
193-EC_ _E,
592-EC_ _D
#12…1 AWG
35 lb-in.
#6…2 AWG
35 lb-in.
4…35 mm
4 Nm
4…25 mm
4 Nm
4…50 mm
4 Nm
4…35 mm
4 Nm
2
2
2
2
26 Rockwell Automation Publication 193-UM002I-EN-P - December 2011
Three-Pole Terminal Blocks
Table 3 - Three-Pole Terminal Blocks
Installation & Wiring Chapter 2
Cat. No. 100-DTB1890 (A) 6…1/0 AWG, 16…50 mm
(B) 6 AWG…250 MCM, 16…120 mm
90…110 lb.-in., 10…12 Nm
100-DTB420 (2) 4 AWG…600 MCM, 25…240 mm
180…220 lb.-in., 20…25 Nm
2
Terminal Lug Kits
Table 4 - Terminal Lug Kits
Cat. No. 100-DL 110 Lug 6…2/0 AWG, 16…70 mm
90…110 lb.-in., 10…12 Nm
Terminal 13/32 in, 10 mm
150 lb.-in., 17 Nm
180 Lug 6 AWG…250 MCM, 16…120 mm
90…110 lb.-in., 10…12 Nm
Terminal 1/2 in., 13 mm
275 lb.-in., 16 Nm
420 Lug 2 AWG…350 MCM
375 lb.-in., 42 Nm
Terminal 11/16 in., 17 mm
140 lb.-in., 16 Nm
630 Lug 2/0 AWG…500 MCM, 70…240 mm
400 lb.-in., 45 N
Terminal 3/4 in, 19 mm
600 lb.-in., 68 Nm
860 Lug 2/0 AWG…500 MCM, 70…240 mm
400 lb.-in., 45 Nm
Terminal 3/4 in, 19 mm
600 lb.-in., 68 Nm
2
2
2
2
2
2
Control, DeviceNet, & Voltage Input Module Terminals
Table 5 - Wire Size & Torque Specification
Wire Type Conductor Torque All Cat. No. Types
Stranded/Solid [AWG] Single 24...12 AWG
Multiple
(stranded only)
Rockwell Automation Publication 193-UM002I-EN-P - December 2011 27
24...16 AWG
5 lb-in
Chapter 2 Installation & Wiring
Wire Type Conductor Torque All Cat. No. Types
Flexible-Stranded with Ferrule Metric Single 0.25…2.5 mm
Multiple 0.5...0.75 mm
2
2
0.55 Nm
Coarse-Stranded/Solid Metric Single 0.2...2.5 mm
Multiple 0.2...1.5 mm
2
2
0.55 Nm
Table 6 - Maximum Wire Length (PTC & input)
Minimum Cross Section mm
2
0.5 0.75 1.5 2.5 4.0
AWG 20 18 16 14 12
Maximum Length ➊ meters 160 250 400 600 1000
feet 525 825 1300 1950 3200
➊ The use of shielded cable is recommended for the PTC thermistor circuit to assist in
obtaining compliance with Electromagnetic Compatibility (EMC) requirements.
Shielded cable is recommended for the input circuits, where wire lengths exceed 200
meters (656 feet).
NOTE: For reliable input signal processing, input wiring should be routed in raceways
separate from power cabling.
Table 7 - Ground Fault Sensor Terminals (S1 & S2)
Wire Type Shielded, Twisted Pair
Cross Section 0.2…4.0 mm
Torque 0.55 N·m (5 lb.-in.)
2
(#24…12 AWG)
28 Rockwell Automation Publication 193-UM002I-EN-P - December 2011
Installation & Wiring Chapter 2
Terminal Designations
Control Terminals
Table 8 - Control Terminal Designation
Terminal Reference Description
1IN 1
2IN2 2
3IN 3 3
4IN 4 4 ➊➋
5V+ +24V
6V+
7IN 5
8IN 6 6 ➋
END Earth Ground ➌
13/14 OUT A Output A
23/24 OUT B Output B ➊➋
95/96 Trip Relay Trip Relay
IT1/IT2 PTC Thermistor (PTC) Input ➊➍
S1/S2 — External Ground Fault Sensor Input ➋➎
General Purpose Sinking Input Number:
General Purpose Sinking Input Number:
1
➊➋
5 ➋
➊
Features are available only with the E3 Plus Overload Relay (Cat. No. 193/592-EC2 and
193/592-EC3).
➋ Available only on Cat. Nos. 193/592-EC5_ _.
➌ An earth ground connection to this terminal will assist in obtaining compliance with
EMC requirements.
➍ The use of shielded cable is recommended for the positive PTC thermistor circuit to
assist in obtaining compliance with EMC requirements.
➎ Available only on Cat. No. 193/592-EC3_ _ and 193/592-EC4_ _.
DeviceNet Terminals
Table 9 - DeviceNet Terminal Designation
Terminal Signal Function Color
1 V- Common Black
2 CAN_L Signal Low Blue
3 Drain Shield Non-Insulated
4 CAN_H Signal High White
5 V+ Po9wer Supply Red
Grounding
The following grounding recommendations are provided to ensure EMC
requirements during installation.
Rockwell Automation Publication 193-UM002I-EN-P - December 2011 29
Chapter 2 Installation & Wiring
• The earth ground terminal of the E3 Overload Relay shall be connected to
a solid earth ground via a low-impedance connection.
• Installations employing an external ground fault sensor shall ground the
cable shield at the sensor with no connection made at the E3 Plus Overload
Relay.
• The PTC thermistor cable shield shall be grounded at the E3 Plus
Overload Relay with no connection made at the opposite end.
Short-Circuit Ratings
The E3 Overload Relay is suitable for use on circuits capable of delivering not
more than the RMS symmetrical amperes listed in the following tables.
Short-Circuit Ratings
Table 10 - UL
Cat. No. Maximum
193-EC_ _ 592-EC_ _ Available Fault Current [A] Voltage [V]
B T 5,000 600
DC
ED10,000
F
G 18,000
H 42,000
Z 5,000
Table 11 - IEC
Cat. No.
B T 1,000 100,000 690
D C 3,000
E D 5,000
Prospective
Current I
r
[A]
Conditional Short-Circuit
Current Iq [A]193-EC_ _ 592-EC_ _ Maximum Voltage [V]
30 Rockwell Automation Publication 193-UM002I-EN-P - December 2011
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