Commissioning Instructions MotorMaster 200 Motor Protection Relays

Commissioning Instructions MotorMaster 200 Motor Protection Relays

HANDLING OF ELECTRONIC EQUIPMENT

A persons normal movements can easily generate electrostatic potentials of several thousand volts. Discharge of these voltages into semiconductor devices when handling electronic circuits can cause serious damage, which often may not be immediately apparent but the reliability of the circuit will have been reduced. The electronic circuits of ALSTOM T&D Protection and Control Ltd. products are immune to the relevant levels of electrostatic discharge when housed in their cases. Do not expose them to the risk of damage by withdrawing modules unnecessarily. Each module incorporates the highest practicable protection for its semiconductor devices. However, if it becomes necessary to withdraw a module, the following precautions should be taken to preserve the high reliability and long life for which the equipment has been designed and manufactured. 1. 2. Before removing a module, ensure that you are at the same electrostatic potential as the equipment by touching the case. Handling the module by its front-plate, frame, or edges of the printed circuit board. Avoid touching the electronic components, printed circuit track or connectors.

3. Do not pass the module to any person without first ensuring that you are both at the same electrostatic potential. Shaking hands achieves equipotential. 4. Place the module on an antistatic surface, or on a conducting surface which is at the same potential as yourself. 5. Store or transport the module in a conductive bag.

More information on safe working procedures for all electronic equipment can be found in BS5783 and IEC 60147-0F. If you are making measurements on the internal electronic circuitry of an equipment in service, it is preferable that you are earthed to the case with a conductive wrist strap. Wrist straps should have a resistance to ground between 500k 10M ohms. if a wrist strap is not available you should maintain regular contact with the case to prevent the build up of static. Instrumentation which may be used for making measurements should be earthed to the case whenever possible. ALSTOM T&D Protection and Control Ltd. strongly recommends that detailed investigations on the electronic circuitry, or modification work, should be carried out in a Special handling Area such as described in BS5783 or IEC 60147-0F.

Contents
SAFETY SECTION 1. 1.1 2. 2.1 2.2 2.3 2.4 2.5 2.5 3. 3.1 3.1.1 3.1.2 3.2 3.3 3.4 4. INTRODUCTION Application COMMISSIONING System connections Current settings (red switches) Overload operating time settings (orange switches) Reset time setting (yellow switches) Earth fault time setting (green switches) Common errors associated with commissioning TEST PROCEDURES Thermal overload testing Cold curve testing Hot curve testing Single phase testing Earth fault testing Resetting DC AUXILIARY SUPPLY 5 8 8 13 13 13 14 14 15 15 16 16 16 16 16 16 17 18

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SAFETY SECTION
This Safety Section should be read before commencing any work on the equipment. Health and safety The information in the Safety Section of this manual is intended to ensure that products are properly installed and handled in order to maintain them in a safe condition. It is assumed that everyone who will be associated with the equipment will be familiar with the contents of the Safety Section. Explanation of symbols and labels The meaning of symbols and labels which may be used on the equipment or in this manual, are given below.

Caution: refer to product documentation

Caution: risk of electric shock

Protective/safety *earth terminal

Functional *earth terminal. Note: this symbol may also be used for a protective/ safety earth terminal if that terminal is part of a terminal block or sub-assembly eg. power supply. *Note: The term Earth is the equivalent of the North American term Ground.

Installing, Commissioning and Servicing

Personnel installing, commissioning or servicing this equipment should be aware of the potential hazards. This service manual should be read before installing, commissioning or servicing the equipment. Terminals exposed during installation, commissioning and maintenance may present a Hazardous Live voltage unless the equipment is electrically isolated. If there is unlocked access to the rear of the equipment, care should be taken by all personnel to avoid electric shock or energy hazards. The equipment should be operated within specified electrical and environmental limits. Before energising the equipment it must be earthed using the protective earth terminal. The recommended minimum earth wire size is 1.0 mm2. Omitting or disconnecting the equipment earth may cause a safety hazard. The recommended maximum rating of the external protective fuse for this equipment is 6A, Red Spot type or equivalent.
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General warnings
Current transformer circuits Do not open the secondary circuit of a live CT since the high voltage produced may be lethal to personnel and could damage insulation. Insulation and dielectric strength testing Insulation testing may leave capacitors charged up to a hazardous voltage. At the end of each part of the test, the voltage should be gradually reduced to zero, to discharge capacitors, before the test leads are disconnected. Insertion and withdrawal of pcb cards Care must be taken when inserting or removing PCB cards since Hazardous Live voltages may be accessible, unless the equipment is electrically isolated. Output monitoring sockets Care must be taken when using the output monitoring sockets since Hazardous Live voltages may be accessible. It is recommended that the equipment should be electrically isolated before making connections to the output monitoring sockets. Use of source monitoring and extender cards Care must be taken when using the source monitoring and extender cards since Hazardous Live voltages may be accessible. Disposal It is recommended that incineration and disposal to water courses is avoided. The product should be disposed of in a safe manner.

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Technical Specifications
Insulation class: IEC 601010-1:1990/A2:1995 Class II EN 61010-1:1993/A2:1995 Class II Installation Category (Overvoltage): IEC 601010-1:1990/A2:1995 Category III EN 61010-1:1993/A2:1995 Category III This equipment does not require a Protective (Safety) Earth connection. Distribution level, fixed installation. Equipment in this category is qualification tested at 5kV peak, 1.2/50s, 500, 0.5J, between all supply circuits and earth and also between independent circuits. Compliance is demonstrated by reference to generic safety standards. Compliance with the European Commission Low Voltage Directive Compliance is demonstrated by reference to generic safety standards

Environment:

IEC 601010-1:1990/A2:1995 Pollution degree 2 EN 61010-1:1993/A2:1995 Pollution degree 2

Product Safety: 73/23/EEC

EN 61010-1:1993/A2:1995 EN 60950:1992/A11:1997

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Section 1.

INTRODUCTION

There is a warning symbol on the equipment, an exclamation mark within a triangle. This warns the user to refer to the Commissioning Instructions (I9-057P) and the Operation and Maintenance manual (I9-106P) before installing, commissioning or operating the equipment. WARNINGS 1. Installation, commissioning and maintenance should only be carried out by suitably qualified personnel. 2. Terminations exposed during installation, commissioning and maintenance may present a hazard unless the equipment is electrically isolated. 3. The equipment should only be operated as intended within the specified electrical and environmental limits. 4. Susceptibility to Electrostatic Discharge 8kV air discharge/4kV contact. This specification applies for direct contact with the terminals and via air discharge on or around the manual reset relay only. When setting the DIL switches and using the test button, appropriate ESD protection must be taken. 1.1 Application Features MotorMaster 200 201 202 202S 203 204 Single phase protection Thermal overload protection Earth fault protection Single phase inhibit (soft start applications) Mechanically latched output relay for earth fault and single phase protection Mechanically latched output relay for earth fault, single phase and thermal overload protection with separate relay for thermal overload alarm 6 x overload test facility Connection diagrams are shown in Figures 1 to 5. In some applications, 3 line current transformers are used. Refer to Figure 6 for the connections to the MotorMaster for these applications. For the selection of line current transformers and core balance transformers, refer to the MotorMaster 200 catalogue Publication number I7-013.

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A B C

C P1 S1

Line CTs P2 S2 P1 S1 To Load P2 S2

I
SW4 SW3 12 11 10 9 c 8 7 F C c SW1 SW2 SW3 SW4

MotorMaster 201 RL1-1 SW1 1 2 RL1-2 3 4 5 6

Isolator Fuses Contactor Contactor coil Start Stop Reset - momentary pushbutton Single phase trip inhibit - close to inhibit

Relay shown in the tripped state. Relay picks up when auxiliary supply is energised

F Auxiliary Supply

SW2

Alarm Circuit

Figure 1 - Wiring diagram for MotorMaster 201

A B C

C P1 S1

E/F Core Balance CT Line CTs P2 S2 P1 S1 P1 P2 S2 S1 S2 P2 To Load

I
SW3 12 11 10 9 c 8 7 F C c SW1 SW2 SW3

MotorMaster 202 RL1-1 SW1 1 2 RL1-2 3 4 5 6

Isolator Fuses Contactor Contactor coil Start Stop Reset - momentary pushbutton

Relay shown in the tripped state. Relay picks up when auxiliary supply is energised.

F Auxiliary Supply

SW2

Alarm Circuit

Figure 2 - Wiring diagram for MotorMaster 202

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A B C

Line CTs P1 P2 P1 S1 P2 S1 S2 P2 S2

E/F Core Balance CT P1 P2 To Load

I
F C c SW1 SW2 SW3 SW4

Isolator Fuses Contactor Contactor coil Start Stop Reset - momentary pushbutton Single phase trip inhibit Close to inhibit

SW4 S1 S2

SW3

32 31 30 29 28 27 26 25 24 23 22 21 20 19 18 17 c MotorMaster 202S SW1 SW2 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 RL1-1 RL1-2

Relay shown in the tripped state. Relay picks up when auxiliary supply is energised. F Auxiliary Supply

Alarm Circuit

Figure 3 - Wiring diagram for MotorMaster 202S

A B C

Line CTs P1 P2 P1 S1 P2 S1 S2 P2 S2

E/F Core Balance CT P1 P2 To Load

Isolator F Fuses C Contactor c Contactor coil SW1 Start SW2 Stop SW3 Reset - momentary pushbutton SW4 Single phase trip inhibit Close to inhibit Relay shown in the tripped state. Thermal alarm only picks up when auxilary supply is energised.

SW4 S1 S2

SW3

32 31 30 29 28 27 26 25 24 23 22 21 20 19 18 17 c MotorMaster 203S RL2-1 SW1 1 2 3 4 5 6 RL2-2 7 8 RL1-1 RL1-2

F Auxiliary Supply

SW2

9 10 11 12 13 14 15 16

E/F1 Alarm

Thermal Alarm

Figure 4 - Wiring diagram for MotorMaster 203

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A B C

Line CTs P1 P2 P1 S1 P2 S1 S2 P2 S2

E/F Core Balance CT P1 P2 To Load

F C c SW1 SW2 SW3 SW4

Isolator Fuses Contactor Contactor coil Start Stop Reset - momentary pushbutton Single phase trip inhibit Close to inhibit Relay shown in the tripped state. Thermal alarm only picks up when auxilary supply is energised.

SW4 S1 S2

SW3

32 31 30 29 28 27 26 25 24 23 22 21 20 19 18 17 C MotorMaster 204 RL2-1 SW1 1 2 3 4 5 6 RL2-2 7 8 RL1-1 RL1-2

F Auxiliary Supply

SW2

9 10 11 12 13 14 15 16

Tripping Output Alarm

Thermal Alarm

Figure 5 - Wiring diagram for MotorMaster 204

(a) For star-delta starting the following external CT connections apply: Core balance CT (note2) L1 L2 L3 Star Delta and Line Contactors Line CTs (note1) P1 P2 S2 S1 P1 S1 P1 S1 P2 S2 P2 S2 Motor Winding

(b) Direct on line starting using 3 CTs (specific applications) Core balance Line CTs (note2) Motor CT (note1) Winding P1 P2 L1 S2 S1 L2 L3 P1 S1 P1 S1 P2 S2 P2 S2

S1A S1B S1C Notes: 1. 2. Connect line CTs between motor windings and contactors in series with motor windings. Connect core balance CT (if required) between contactors and incoming supply. Connections of line CTs to relay: MM201 and MM202 S1A - 12 S1B - 11 S1C - 10

S1A S1B S1C Notes: 1. Connect core balance CT, if required, between contactor and incoming supply. 2. Connection with 3 CTs is only required by certain national standards MotorMaster will operate correctly for DOL starting with only 2 CTs MM202S, MM203 and MM204 S1A - 29 S1B - 27 S1C - 26 and 28

Figure 6 - Wiring diagram for connection of 3 CTs

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100.0

10.0

Operating time, multiple of 6 x overload trip time

1.0

Cold

75% Hot
0.1 0 1 2 3 4 5 6 7 8 9 10 11 Current (multiples of motor FLC)

Figure 7 - Overload operating characteristic

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Section 2.

COMMISSIONING

To programme a MotorMaster 200 protection relay for the protection of any three phase induction motor, four settings are required: Current setting (red switches), which is the % of primary CT rating. This can be set anywhere between 68% and 131% of the CT rating. Trip time settings (orange switches), the time for the relay to trip on overload when the actual current is six times the current setting. Reset time (yellow switches), the time required to reset after a thermal trip. Earth fault time delay (green switches). 2.1 System connections Refer to Figures 1 to 6 for wiring diagrams of typical applications. Two transformers are normally sufficient for a three phase three wire connected load. Three transformers are required for a three phase four wire connected load or when the current transformers are connected in series with the winding of the motor for star/delta starting (Figure 6). 2.2 Current settings (red switches) Current setting Is (% of CT primary rating) 1. Type of motor (see 4 below) 2. Motor full load current If For star/delta start, full load current 1.732

If =

3. Line CTs primary current rating Ip 4. Calculation: For a continuously maximum rated (CMR) motor, the current setting is

Is = (If/Ip) x 100%
For totally enclosed motors, increase setting by 5%. For open motors increase setting by 20%. 5. Subtract 68 from Is. 6. Adjust the appropriate red coloured switches to summate the number calculated in 5. above, leaving the other red switches set to zero. Example: (I) Motor type - CMR (ii) Full load current If = 120A (iii) Primary CT rating Ip = 100A (iv) Is = (120A/100A) x 100 = 120%

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(v) 120 68 = 52% (vi) Switch in: 32 + 16 + 4 = 52 2.3 Overload operating time settings (orange switches) The typical overload operating characteristics of the relay are shown in Figure 7. This sets the relay trip time from a cold start and, once set, overload protection is assured. To set up, first establish: 1. Motor full load current If 2. Starting current on full load Ic 3. Starting time on full load tc Calculate the multiple of full load current on starting (Ic/If). Plot this current on the cold curve of graph, Figure 7, to find an operating time of M as a multiple of the 6 x overload time. The optimum time setting of the relay must be chosen so that it is greater than (tc/M) in order to avoid spurious tripping on a healthy start. Example: (i) (ii) Motor FLC Motor starting current

If = 100A Ic = 500A
tc = 15 seconds

(iii) Starting time (v)

(iv) Starting current in multiples of FLC = 500/100 = 5 From the cold curve, this gives a value for M of approximately 1.5. (vi) The overload time setting must now be greater than: (tc / M) = 15/1.5 = 10 seconds (vii) Increasing t by 15% to allow for tolerance gives t = 11.5 seconds. (viii) Programme t into the relay using the orange coloured switches. With all switches moved to the left, the relay is on its lowest in-built setting of 0.5 seconds. For this example, move switches 8, 2, and 1 only to the right to increase the in-built time by 11 seconds to give a total of 11.5 seconds. (ix) This setting can be checked by using the test button to simulate a 6 x overload condition and by measuring the time for the thermal trip to operate. 2.4 Reset time setting (yellow switches) The reset time is programmed into the relay using the yellow coloured DIL switches. With all the switches set to the left the relay has an inherent minimum reset time of one minute. Moving the switches to the right will increase the time by the values marked on the switches. Example - moving switches 8 and 16 to the right while leaving switches 32, 64, 2 and 4 and the left gives a reset time of 1 + 8 + 16 = 25 minutes.

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Optimum reset time setting is governed by the motors thermal characteristic and its environmental conditions. As a general guide, typical reset times compared with run up times at 6 x overload are: 6 x overload trip time (seconds) 63.5 31.5 15.5 7.5 3.5 1.5 2.5 Reset time (minutes) 85 45 25 15 11 9

Earth fault time setting (green switches) Earth fault delay time (models MM202, 202S, 203 and 204 only). With all switches set to 0, the operating time is 0.25 seconds. By moving these switches from left to right, delay times of 0.75 seconds, 1.45 seconds or 1.95 seconds may be selected. The time delay should be selected to ensure that, for very high level earth faults, the back up protection (fuse or circuit breaker) operates before the MotorMaster 200 trips the motor contactor.

2.5

Common errors associated with commissioning The polarity of the two line current transformers must be in the correct orientation. If the secondary of one current transformer is reversed, the MotorMaster will trip as for a single phase fault. The current transformer secondaries should be earthed at one point only, for example terminal 10 (MM201/202) and terminals 26 and 28 (MM202S/203/204). The output leads from the core balance CT carry less than 10mA. These leads should not be run close to heavy current cables where an inductive pick up current could be induced. If this is unavoidable then adequate screening should be employed. Terminal 7 (MM201/202) and terminal 17 (MM202S/203/204) may be earthed if required.

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Section 3.

TEST PROCEDURES

Every MotorMaster 200 relay is comprehensively tested before despatch but, should the need arise for on-site testing, the following procedure is suggested. WARNING: IF INPUT CURRENT IS TAKEN FROM A CT, THE TRANSFORMER SECONDARY SHOULD BE SHORTCIRCUITED BEFORE THE CONTROLLER INPUTS ARE DISCONNECTED. 3.1 3.1.1 Thermal overload testing Cold curve testing The tripping time set on the orange switches is the 6 x overload tripping time on the cold curve. The easiest way to check this is to press and hold the test push button on the front of the relay, after first switching on the auxiliary supply. The relay will trip in the set time. This test proves all the thermal circuitry except for the input CTs inside the relay. To carry out a full test, a three phase current injection test set is required. Inject two currents at an angle of 120 into the line inputs of the relay. Injecting 6A into a 1A relay or 30A into a 5A relay, from cold, will trip the relay in the set (6 x overload) trip time. 3.1.2 Hot curve testing The simplest and most convenient way to check the relay operation at 75% full load rating. To determine this trip time, inject two line currents as above at 75% full load rating. Wait at least 60 times the selected 6 x overload trip time for the relay to stabilise (75% stabilisation curve - refer to Figure 7). Now apply the normal 6 x overload currents. The relay should trip in half the set trip time and this can be read directly off the 75% stabilisation curve (Figure 7). 3.2 Single phase testing Apply 100% primary full load current into one line CT only or 100% secondary full load current, direct into one of the relay CT inputs. The relay should trip in 2 seconds ( 25%) at 50Hz or 1.7 seconds ( 25%) at 60Hz. 3.3 Earth fault testing Connect the circuit as shown in Figure 8, and arrange for a current I1 to flow in the circuit such that I1 = 1.5 x the core balance sensitivity. Switch on the auxiliary supply and the relay should trip in the selected earth fault trip time ( 20%).

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Core balance CT

I1
MotorMaster relay Refer to Figures 1 to 5 for connections AC test supply

Figure 8 - Earth fault trip testing

3.4

Resetting After every one of the above tests, the relay will require resetting as described in section 2.1 - Reset facilities. Note the time delay upon energisation following a trip. The internal electrically reset relay in every MotorMaster 200 has a time delay on pick up of up to 0.5 seconds on connection of the auxiliary supply. The relay is energised when healthy and drops off following loss of voltage. The mechanically latched relay does not change state when the auxiliary supply is applied or removed.

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Section 4.

DC AUXILIARY SUPPLY

For applications where a dc auxiliary supply is used to power a MotorMaster 200 relay, a separate dc/dc converter is required. Figure 9 shows the connection diagram. Note: The output of the dc/dc converter is suitable for powering one MotorMaster 200 relay dc auxiliary supply.

DC output

DC output

10

9 3B*003

DC supply

Figure 9 - Single output dc/dc converter

Electromagnetic Compatibility Directive 89/336/EEC Emissions standard Immunity standard Susceptibility to Electrostatic Discharge EN50081-2 1994 Industrial environment EN50082-2 1995 Industrial environment (IEC 60801 parts 2, 3 and 4) 8kV air discharge/4kV contact.

WARNING: This specification applies for direct contact with the terminals and via air discharge on or around the manual reset relay only. When setting the DIL switches and using the test button, appropriate ESD protection must be taken. Low Voltage Directive 72/23/EEC Designed to EN61010-1 1993 safety requirements.

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A L S T O M T & D P ro t e c t i o n & C o n t ro l L t d St Leonards Works, Stafford, ST17 4LX England Tel: 44 (0) 1785 223251 Fax: 44 (0) 1785 212232 Email: pcs.enquiries@tde.alstom.com Internet: www.alstom.com
Our policy is one of continuous product development and the right is reserved to supply equipment which may vary from that described. 1999 ALSTOM T&D Protection & Control Ltd

Publication I9-057E

Printed in England.