Rockwell Automation 193-592-EC1, 193-592-EC3, 193-592-EC5 User Manual

E3 and E3 Plus Solid-State

Overload Relay

Quick Start Guide

(Bulletins 193 and 592)

ATTENTION

This guide does not replace the User Manual, publication 193-UM002_-EN-P, and is intended for qualified service personnel responsible for setting up and servicing these devices. You must have previous experience with and a basic understanding of electrical terminology, configuration procedures, required equipment, and safety precautions. The user manual can be downloaded from http://

literature.rockwellautomation.com.

Important User Information

Because of the variety of uses for the products described in this publication, those responsible for the application and use of this control equipment must satisfy themselves that all necessary steps have been taken to assure that each application and use meets all performance and safety requirements, including any applicable laws, regulations, codes, and standards.

The illustrations, charts, sample programs and layout examples shown in this guide are intended solely for purposes of example. Since there are many variables and requirements associated with any particular installation, Rockwell Automation does not assume responsibility or liability (to include intellectual property liability) for actual use based upon the examples shown in this publication.

Rockwell Automation publication SGI-1.1, Safety Guidelines for the Application, Installation and Maintenance of Solid-State Control (available from your local Allen-Bradley distributor), describes some important differences between solid-state equipment and electromechanical devices that should be taken into consideration when applying products such as those described in this publication.

Reproduction of the contents of this copyrighted publication, in whole or part, without written permission of Rockwell Automation, is prohibited.

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IMPORTANT

General Precautions

In addition to the specific precautions listed throughout this manual, the following general statements must be observed.

The purpose of this publication is to serve as a guide for proper installation. The National Electrical Code and any other governing regional or local code overrules the information in this publication.A hazard of personal injury/equipment damage exists if codes are ignored during installation. Rockwell Automation cannot assume responsibility for the compliance or proper installation of the E3 Overload Relay or associated equipment.

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/equipment damage.

An incorrectly applied or installed E3 Overload Relay can result in damage to the components or reduction in product life. Wiring or application errors, such as incorrectly configuring 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.

The E3 Overload Relay contains ESD (electrostatic discharge) sensitive parts and assemblies. Static 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 8200-4.5.2, Guarding Against Electrostatic Damage, or any other applicable ESD protection handbook.

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Introduction

Follow these steps to successfully commission the E3 Overload Relay:

Table 1: Commissioning Procedure

Step Description

1 Hardware Installation

2 Wiring Installation

3 DeviceNet Commissioning

4 Setup Requirements

– Typical Motor Connections – External Current Transformer Applications (193-EC_ZZ or 592-EC_ZZ) – External Ground Fault Sensor Applications (193-EC3_ _ , 592-EC3_ _ and 193-EC5_ _ , 592-EC5_ _)

Setup for Bulletin 193 or 592-EC1/EC2/EC3/EC5 Overload Relay

– Protective Trip and Warning Summaries – Parameter Group Listing

Setup for Cat. No. 193-EC4 Current Monitor Relay

– Trip and Warning Summaries – Parameter Group Listing

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Hardware Installation

CLICK

The following figures illustrate the starter assembly instructions.

Starter Assembly Instructions

Figure 1: 100-C09…C43 Starter Assembly Instructions (for use with Cat. Nos.

193-EC_ _B and -EC_ _D)

/tN

22 lb-in.

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/tN

35 lb-in.

Figure 2: 100-C60…C85 Starter Assembly Instructions (for use with Cat. No.

193-EC_ _E).

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Figure 3: 100-D95...D860 Starter Assembly Instructions (for use with Cat. Nos.

193-EC_ _F, 193-EC_ _G, and 193-EC_ _H).

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E3 PLUS

LED Status Indicators

DeviceNet Port

Input Terminals

Test/Reset Button

Node Address Switches (Series B and later)

Output and PTC Terminals

Ground Fault Sensor Input

Voltage Input Module Connection (193/592 EC5 only)

Wiring Installation

Typical Motor Connections

Refer to the product nameplate or user manual for power lug termination information including:

• Terminal wire size and torque specifications

• Maximum wire lengths

• Lug kit catalog numbers (108…1250 A)

For reliable input signal processing, input wiring should be routed in raceways separate from power cabling.

Terminal Designations

Figure 4: E3 and E3 Plus Feature Overview

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Control Terminals

The following table defines the E3 Overload Relay control terminal designations.

Table 2: Control Terminal Designation

Ter mi na l

Designation

1 IN 1 General-purpose sinking input number 1 2 IN 2 General-purpose sinking input number 2 3 IN 3 General-purpose sinking input number 3 ➊➋ 4 IN 4 General-purpose sinking input number 4 ➊➋ 5V+ 6V+ 7 IN 5 General-purpose sinking input number 5 ➋ 8 IN 6 General-purpose sinking input number 6 ➋

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

➊ Features are available only with the E3 Plus Overload Relay (cat. nos. 193/592-EC2and 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 electromagnetic

compatibility requirements.

➍ The use of shielded cable is recommended for the positive PTC thermistor circuit to assist in obtaining

compliance with electromagnetic compatibility requirements.

➎ Available only on cat. nos. 193/592-EC3_ _ and 193/592-EC4_ _.

Reference Description

+24V DC supply for inputs

End Earth Ground ➌

DeviceNet Terminals

The following table defines the DeviceNet connector terminal designations.

Table 3: 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+ Power Supply Red

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ATTENTION

Grounding

The following grounding recommendations are provided to ensure electromagnetic compatibility compliance during installation:

• 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

Wiring Diagrams

When working on energized circuits, do not rely on the voltage and current information provided by the E3 and E3 Plus for personal safety. Always use a portable voltage or current measurement device and measure the signal locally.

Figure 5: Three-Phase D.O.L & Single-Phase Wiring Diagrams

L1 L2 L3

Voltage Input Module

(For 193/592-EC5 only)

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Three-Phase Direct-On-Line

Wiring Diagram

L2 L3

E3/E3Plus

2/T1 4/T2 6/T3

T1T2T3

S.C.P.D.

Single-Phase Full-Voltage

Wiring Diagram

L1 L2 L3

E3/E3Plus

2/T1 4/T2 6/T3

2/T1 4/T2 6/T32/T1 4/T2 6/T3

2/T1 4/T2 6/T3

L1 L2

Voltage Input Module

(For 193/592-EC5 only)

IMPORTANT

Parameter 27, Single/Three Ph, should be set to single-phase for single-phase devices and three-phase for three-phase devices.

In single-phase devices, traditional single-phase wiring (connecting T2 to L3) will result in a vector imbalance of current flowing through the E3 Plus Overload Relay. This will result in inaccurate ground fault reporting and protection.

External Current Transformer Application (Cat. No. 193-EC_ZZ)

E3 and E3 Plus Overload Relays (Cat. No. 193-EC_ZZ) are designed for use with separately mounted, customer-supplied current transformers (CTs) as required in higher-current applications. The FLA setting range is 9…5000 A for these units, with a legal setting range per the user’s manual. Parameter 78, CT Ratio, is provided for setting the current transformer ratio to be installed.

Current Transformer Specifications

The 193-EC_ZZ Overload Relays are intended for use with a CT having a secondary current rating of 5 A. The installer shall provide one CT for each motor phase and shall connect the CT secondary leads to the appropriate E3 Overload Relay power terminals as shown in Figure 7: on page 13. The CT shall have an appropriate ratio rating as detailed in the user’s manual. Additionally, the CT shall be selected to be capable of providing the required VA to the secondary load, which includes the E3 Overload Relay burden of 0.1 VA at the rated secondary current and the wiring burden.

Finally, the CT shall be rated for protective relaying to accommodate the high inrush currents associated with motor startup and shall have an accuracy of range.

≤±2% over its normal operating

ANSI (USA) Class C5 B0.1 CSA (Canada) Class 10L5 IEC (Europe) 5 VA Class 5P10

The improper selection of a current transformer can result in the E3 Overload Relay reporting inaccurate motor operational data and possible motor damage. The selected current transformer must be rated for protective relaying applications.

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