MMPPRR--66

MMoottoorr PPrrootteeccttiioonn RReellaayy

IInnssttrruuccttiioonn MMaannuuaall Ver. 1.0 / 2003

1

Table of Contents

Page Subject 2 Introduction 3-4 Terminal Review and Wiring Diagrams 5-6 Front Panel and LCD Displays 7-8 Menu Configuration 9-14 Parameter Settings 15 Trip/Alarm and Reset Options 16-17 Setting Summary 18 Actual Data 19 Statistical Data 20 Test Messages 21 Flash & Constant Massages 22 Communication 23-24 Technical Specification 25 Dimensions

Safety Read this manual carefully before operating the equipment and follow its instructions Installation, operation and maintenance should be in strict accordance with this manual, national

codes and good practice. Installation or operation not performed in strict accordance with these instructions will void manufacturers warranty.

Disconnect all power inputs before servicing the MPR-6.

Attention 1. This product was designed for compliance with IEC 947-4-2 for class A equipment. 2. The MPR-6 is are designed to meet UL requirements 3. For further information, see Technical Specification

Warnings Internal components and P.C.Bs are at main potential when the MPR-6 is connected to main. This

voltage is extremely dangerous and will cause death or severe injury if contacted. Unit must be grounded to ensure correct operation, safety and to prevent damage.

The company reserves the right to make any improvements

Or modifications to its products without prior notice.

Introduction

2

The MPR-6 Motor Protection Relay is a new generation of microprocessor based relay designed to protect three phase induction motors. The MPR-6 incorporates two main functions. a. Motor protection. b. Supervision and communication. Motor Protection AC motors are very rugged and reliable when operating within their limits. However, they are usually designed to operate close to their rated limits with minimal margins for operating under abnormal conditions. A comprehensive protection device is required to accurately create a Thermal Model for the motor to run safely up to its limits. This relay should protect the motor from abnormal conditions in the power supply, motor and cable faults as well as operator malfunctions. The MPR-6 monitors three phase and ground currents (true RMS line currents are measured at a sampling rate of 0.5 mSec) and one temperature (thermistor) input . In all, the MPR-6 provides a comprehensive protection package. Protection - Too many starts - Maximum start time, - Under current (*) - Load increase - Thermal level (Overload) (*) - Over-current Jam / Stall & Short circuit (*) - Unbalanced current (*) - Ground fault current (*) - Temperature- PTC/NTC Thermistor (*) - External fault 1- N.O/N.C contacts - External fault 2 - N.O/N.C contacts Two separate levels (*) Each of the these faults has 2 separate levels. Normally level 1 will be used as an Alarm and level 2 as a Trip. It is possible to use both as Alarms or as Trips with different time delays. Field settings Protection levels and time delay settings are individually configured through the key pad on the front panel or through the communication port. Configurable operation Unique Tripping/Alarm options, makes it possible to designate any of the above faults as an Alarm, Trip, both or none. Further more, two auxiliary relays can be designated to operate with any of the faults.

"Time To Trip" and "Time To Start" When current exceeds the overload setting a built-in unique algorithm calculates the time until motor will be tripped (when thermal capacity is 100%), enabling the operator or host computer to take corrective actions before tripping. After the MPR-6 has tripped the motor it will calculate the time delay until motor can be restarted, after it has cooled down. Informative data An illuminated LCD (Liquid Crystal Display) with 2 lines and 16 characters each provides clear status and statistical information. Identical information is available through the communication Actual Data - Phase currents, Ground fault current and Thermistor resistance, Motor load in % of FLC, Thermal Capacity, Time to trip, Time to start, Unbalanced current. Statistical Data - Motors running hours, Total number of starts, Total number of trips, Last start time, last start current peak, Last Trip, Last Alarm, Phase currents, Ground fault current, all at time of trip. Communication RS485 serial link with Modbus communication protocol, operating at baud rate of 1200 to 9600 bits/sec enables monitoring of setpoints and actual parameters. Modifications of the setpoint parameters through the serial link make it very easy to enter user setpoints in place of the factory default parameters. The serial link enables remote control of both the MPR-6 and the motor. Up to 32 MPR-6 relays can be connected on the same link to the host computer. When a need for more than 32 units arises, using MMI & Data highway equipment, an unlimited number of relays can be connected to the host computer. Easy setting and operation The front panel LCD together with a Keypad and LEDs enables user friendly interface, accurate digital parameters setting, actual parameters reading, and detailed trip and alarm messages display. Unauthorized setting changes can easily be prevented by the software setting

Wiring Diagram & Terminals Review

3

MPR - 6

1513

Program Input - 1 (Reset, External Fault)

1415 Program Input - 2 (Reset, External Fault)

15 Common, 110 or 230 Vac

Alarm Relay: Fail-safe Logic8A/250V/2000VA

1

32

4

65

7

98

10

1211

Trip Relay: Prog. Trip/ Trip Fail-safe8A/250V/2000VA

Relay C: Prog. Dedicated Faults8A/250V/2000VA

Relay D: Prog. Dedicated Faults8A/250V/2000VA

Fail-Safe Alarm, when MPR mainsis connected and no alarm existsterminals 1 & 2 are closed.

* Connect all shield wiresto terminal 37. (A shortbusbar may be used).Thermistor

A

L3 L2 L1

MainContactor

21

22

(5A)

23

24

(5A)

26

27

(5A)25

29

30

(5A)

373635

Motor

RS 485403938

* Aux. Power Supply 110V/240VAC

20 ~

19 N

18

+-

28

Wiring Diagram & Terminals Review

4

Output Relays (C/O, 8A/250VAC, 2000VA) Alarm Relay (Fail-Safe logic) Common .................................................................... 1 N.C ............................................................................ 2 N.O ........................................................................... 3 Fail safe logic - when MPR-6 is energized Alarm Relay is energized (changing contacts position). Upon fault which is designated as "Alarm" the relay de-energized (contacts return to original position). Trip Relay Can be designated (by parameter setting) as one of: * Trip relay (changes contact position upon fault which is designated as "Trip"). * Trip relay with Fail-Safe logic. Common .................................................................. 4 N.C ............................................................................ 5 N.O ........................................................................... 6 Programmable Relay C Can be designated (by parameter setting) as auxiliary relay - dedicated for a fault or group of faults. Common .................................................................. 7 N.C ............................................................................ 8 N.O ........................................................................... 9 Programmable Relay D Can be designated (by parameter setting) as auxiliary relay - dedicated for a fault or group of faults. Common ................................................................ 10 N.C .......................................................................... 11 N.O ......................................................................... 12 Discrete inputs Input 1....................................................................... 13 Programmable: Reset, External Fault (N.O or N.C). Input 2 ...................................................................... 14 Programmable: Reset, External Fault (N.O or N.C). Common ................................................................. 15 Control power supply (115, 230VAC to be specified, at 50/60 Hz). Ground ..................................................................... 18 Neutral ..................................................................... 19 Phase ..................................................................... 20 Analogue Inputs (from 5A C/T, or 1A by special order) Line Currents Phase L1 ........................................................... 21 ,22 Phase L2 ..................................................... 23 ,24 ,25 Phase L3 . .................................................... 26, 27, 28 Terminals 25 and 28 are for convenience when residual wiring is used Ground Fault Current ........................................ 29, 30

C/T Wiring Diagrams Note: It is advisable to use differential C/T.

3 phase C/Ts + differential C/T

3 phase C/Ts in a residual Ground Fault connection.

Note: In case of residual Ground Fault connection, It is recommended to increase the Ground fault levels 1 & 2 to avoid nuisance tripping.

Optional wiring: Three phase protection using 2 C/Ts. Where: I3=-(I1+I2)

Note: This connection is not recommended. In case this connection must be used, accuracy will be reduced.

Thermistor Input Thermistor 0.1K-30K ................................35 & 36 Shielded cables must be used, connect shield to ground Ground .................................................................... 37 Note: If thermistor is not used leave terminals 35 - 37 open Serial Link Standard RS485 Half Duplex, with MODBUS protocol. Twisted shielded pair should be used for wiring. Serial Port (shield) ................................................... 38 Serial Port (-) ............................................................ 39 Serial Port (+) ........................................................... 40 Note: In order to match the line, connect 120 resistor

between (+) and (-) at the end and beginning of the line.

5A 5A 5A 5A

21 22 23 24 26 27 29 30

L1

L2

L3

CT1 CT2 CT3 CT4

5A

21 22 23 24 25 27 29 30

L1

L2

L3

5A

CT1

5A

CT2 CT3

5A

CT4

26 28

5A

21 22 23 24 25 27 29 30

L1

L2

L3

5A

CT1

5A

CT2 CT3

5A

CT4

26 28

Front Panel &LCD Displays

5

LEDs and LCD On - Illuminates when control power supplyis connected. Start/ Run - Flashes during starting, illuminates continuously after completion of starting Alarm /Trip - Flashes in Alarm condition, illuminates continuously at Trip condition . Turns off after resetting. LCD Display Illuminated two lines of 16 characters each, presenting all data and messages. Operation Upon initiation the On LED lights and the LCD displays:

Communication ***Settings***

In order to review above page press Select key. Messages are displayed on the LCD in two lines. Upper line describes

parameter's name. Lower line shows its value.

To change settings, press or keys and save the new value by pressing Store key. Once data was properly stored in the non-volatile memory the LCD displays the 2 sec. flash message:

DATA SAVED OK

Notes : 1. A new parameter setting

becomes effective when set, even before storing it in the non-volatile memory. Setting a parameter without storing, and moving to another page, will return the parameter to its previously stored value.

2. Any setpoint parameters can be viewed, altered and stored at any time (provided that Parameters Lock set to No). However, it is not recommended to change and store parameters while motor is starting or running.

3. Any stored parameter is kept indefinitely in the non-volatile memory.

Keys Page - Press to change setpoint pages in positive cyclical order. Select - Press to scroll parameters within page. If key is pressed for more than 0.5 sec, parameters will be displayed at a fast rate.

- Press to increase / decrease parameter value. Press and hold to fast rate changing (*). Store - Press to store displayed parameter value in the non-volatile memory (*). Reset - Press for more then 0.5 Sec. to cancel displayed Alarm or Trip (*). Short press on the RESET key will toggle the direction of massage display. At up direction a " __ " character is displayed at the bottom left hand side of the LCD. Pressing on Page key or leaving the keypad with no action for 10 Sec returns scroll direction to forward (down) direction. Notes: If "Parameters Lock" is set to Yes, parameters can be only viewed. When Parameters lock is set to No, it is possible to view, change and store any setting parameter.

Front Panel &LCD Displays

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Five types of information displays are available. 1. Parameter Settings By pressing Page key the LCD displays the following headers:

SYSTEM PARAMETER ***SETTINGS***

PROTECTION

***SETTINGS***

TRIPPING / ALARM ***OPTIONS***

2. Informative Data By continuing pressing Page the LCD displays the following headers:

ACTUAL DATA

3. Test Messages

By pressing Page and keys the LCD displays the following header:

TEST / MAINTENANCE *** OPTIONS ***

4. Flash Messages Flash messages are displayed as a response to an event. For example, the flash message after storing is:

DATA SAVED OK

5. Constant Messages Messages which are displayed upon fault. For example, when starting process is too long and MAX START TIME is enabled as Trip the following constant message will appear.

TRIP: MAX START TIME

Notes : 1. Pressing Store key while the LCD displays an

"Actual Data" parameter, will store this parameter as default display. If no key is pressed for more than five minutes, this parameter will be constantly displayed.

2. Pressing Store key while the LCD displays a

header, will store this header as the default display. If no key is pressed for more than five minutes this header will be constantly displayed

Returning to Factory Default Values Press Page and simultaneously, the LCD will display:

TEST/MAINTENANCE ***OPTIONS***

Press Select key three times, the LCD will display:

STORE NOW ? DEFAULT SETTINGS

Press Store and Page keys simultaneously, the LCD will display:

DATA SAVED OK

Attention : Storing Default parameters erases all previously updated parameters. Clearing Statistical Data Values Press Page and simultaneously, the LCD will display:

TEST/MAINTENANCE ***OPTIONS***

Press Select key four times, the LCD will display:

CLEAR STATISTICAL DATA

Press Store and Reset keys simultaneously, the LCD will display:

DATA SAVED OK

Attention : Clearing statistical data erases all previously stored statistical data.

Menu Configuration

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Menu Configuration

8

Run Self Test ? Push Value Up

Program Version SMP260596-Modbus

Store Now ? Default Settings

Clear Statistical Data

Test/Maintenance *** Options ***

Select

PPage 1

PPress Select + Key to enter Test / Maintenance mode

Key to select the required parameters

Press Key to run Self Test

PPress Page + Store Key to Store Default Settings

PPress Select + Store Key to Clear statistical Data

Parameter Settings

9

SYSTEM PARAMETERS ***SETTINGS***

Parameter & Default Value Description Range Increments

LINE FREQUENCY 50 HZ

Rated frequency 50 / 60 Hz

MOTOR FLC 100 Amp. Motor Full Load (name plate) Current. 1 - 1000A

1A to 100A 5A above 100A

CT PRIMARY 100 Amp. Primary rated current of Current Transformer. 1 - 1000A.

1A to 100A 5A above 100A

GND CT PRIMARY 100 Amp.

Primary rated current of Ground Fault Transformer.

1 - 1000A 1A to 100A 5A above 100A

Inhibits Trip command thus preventing opening of motor contactor when current exceeds a set value, to prevent contactor's damage. The fault must be cleared by an upstream circuit breaker or fuses. When contactors are not used (circuit breaker application) set to OFF. Note: Thermal Level 2 Trip overrides trip inhibit setting.

TRIP INHIBIT OFF

WARNING The MPR-6 will not protect the motor against high current above the current inhibit setting. It is the customer's responsibility to ensure that the motor is protected against fault current, above Current Inhibit by external protection.

400-1000% of Motor FLC, OFF 10%

CONFIG. TRIP REL Designation of Output Relay B as: Trip Trip fail-safe

CONFIG. INPUT 1 Remote Reset Designation of Input -1 as:

Remote Reset Ext. fault 1 N/O Ext. fault 1 N/C

CONFIG. INPUT 2 Remote Reset Designation of Input -2 as:

Remote Reset Ext. fault 2 N/O Ext. fault 2 N/C

PARAMETERS LOCK No

Set to Yes to prevent setting parameters changes, resetting Thermal Capacity, storing and self testing.

No / Yes

MOTOR NUMBER 0

For customer convenience only, This parameter has no effect on MPR-6 operation. 0 - 320 1

ADDRESS NUMBER 248

MPR-6 Address on Serial Link. RS485 Allows a maximum of 32 MPR's on a twisted pair. For user convenience in programming the number of serial links is extended to 3 digits.

1-247, 248 = Off 1

Baud Rate 9600

Serial Link communication speed in bps. Disconnect and then reconnect control supply after any change of baud rate.

1200, 2400, 4800, 9600

Parameter Settings

10

PROTECTION ***SETTINGS***

Parameter & Default Value Description Range Increments

MAX. START TIME 10 sec.

Maximum permitted starting time. End of starting is assumed when motor's current decreases below 110% of Overload Pickup value.

1 - 250 sec. 1 sec.

NUMBER OF STARTS 10 At fault LCD displays: TOO MANY STARTS

Maximum Permitted number of starts during "Starts Period". Auto Reset, when Enabled, occurs after "#St Auto Rst Dly" time has elapsed.

1 - 10 1

STARTS PERIOD 30 min.

Time period during which the number of starts is counted. 1 - 60 min. 1 min.

#ST AUTO RST DLY 15 min

Auto reset (when enabled) delay after Too many starts faults. 1 - 60 min. 1 min.

U/C LEVEL 1 50% of FLC

Under Current level-1 for a running motor. Fault occurs when current decreases below the set value for more than U/C Lvl 1 Delay.

10 - 90 % of Motor FLC. 1%

U/C LVL 1 DELAY 2 sec.

Under Current level-1 delay. 1 - 60 sec. 1 sec.

U/C LEVEL 2 40% of FLC

Under Current level-2 for a running motor. Fault occurs when current decreases below the set value for more than U/C Lvl 2 Delay.

10 - 90 % of Motor FLC. 1%

U/C LVL 2 DELAY 5 sec.

Under Current level-2 delay. 1 - 60 sec. 1 sec.

LOAD INCREASE 120% of FLC

Load Increase Alarm. Operative after start process ended (after current decreased below 110% of Overload pickup). Fault occurs when motors average current increases above the set value for more than 5 sec.

60 - 150% of Motor FLC 5%

O/C LEVEL 1 - JAM 400% of FLC

Over Current Level-1. Stall / Jam protection, operative after end of starting process. Fault occurs when motors average current increases above set value for more than O/C Lvl 1 Delay.

100 - 500 % of Motor FLC. 10%

O/C LVL 1 DELAY 2.0 sec.

Time delay for over current level-1. 0.5 - 10 sec. 0.5 sec.

O/C LEVEL 2-SHORT 800% of FLC

Over Current Level-2. Short circuit protection, operative during starting and running. Indicates that current exceeded set value for more than O/C Delay. Note: O/C Level 2" Trip is prevented when the highest of any of the line currents exceeds Trip Inhibit setting. It is designed to prevent opening of motor contactor under high short circuit conditions to protect it's contacts from being damaged.

400 - 1200 % of Motor FLC. 10%

O/C LEVEL 2 DELAY 0.5sec.

Time delay for over current level -2. Note: When set to 0 actual delay is less than 90 mSec.

0 4 sec. 0.1 sec.

Parameter Settings

11

Parameter & Default Value Description Range Increments

OVERLOAD PICKUP 105% of FLC

Lower threshold for Thermal Level 1 / 2 protection. Thermal trip is not possible as long as current is below the set value. When current increases above the set value a trip will occur after a time delay that depends on the present value of the current level, the Thermal Capacity and on the t6x setting

60 130 % of Motor FLC. 1%

THERMAL LEVEL 1 80% of Capacity

Simulation of motors thermal condition, stored in a thermal register. The heating of the thermal register (i.e. its increment) is related to the square of the current (the highest of the three line currents). The rate of cooling of the thermal register is directly related to motors present Thermal condition. Thermal capacity of 100% is equivalent to a motor running at the maximum allowed temperature. At this point the motor must be tripped (Thermal level 2). Thermal Level 1 is adjustable from 50-99% of Thermal Trip. The following three parameters are used to calculate the Thermal Capacity.

50 99 % of max. thermal capacity.

1%

t6X TIME 10.0 sec

Overload trip time of cold motor at 6 times Motor FLC. (The time required to heat Thermal Capacity from 0 to 100% at 6 x FLC).

0.5 120 sec. 0.5

HOT/COLD RATIO 50%

The ratio between thermal Capacity available for a hot motor and thermal capacity available for a cold motor. (A higher setting allows for a longer time before tripping hot motor due to high current).

20- 100% of Thermal Capacity.

1%.

COOL TIME FACTOR 5

The Ratio between cooling time constant of stopped motor to the heating/cooling time constant of running motor.

1 15 1

UNBALANCE LVL 2 15% of FLC

Unbalance Current The difference between maximum and minimum values of motors three line currents, divided by motors maximum current or motors FLC (this method prevents nuisance alarms at low currents). Fault occurs only if actual Unbalance is greater than the set value. See figure 6 for time delay. This parameter has no influence on unbalance level 2 time delay. Note: Unbalance Level 1 is automatically set to 50 % of Unbalance Level 2 setting.

10 40% see curve on page 15

U/B. LVL-2 MAX T 30 sec.

Unbalance curve selection. Time delay at 10 % of Unbalance. Fault time inversely relates to the actual unbalance (See page 15).

20 120 sec. 1 sec.

GND FAULT LVL 1 5% of FLC

Ground fault current level-1. Fault occurs when Ground Current exceeds the set value for more than G/F Lvl 1 Delay.

1-100% of Motor FLC 1 %.

G/F LVL 1 DELAY 10 sec.

Ground fault current level-1 Delay. 1 60 sec. 1 sec.

Parameter Settings

12

Parameter & Default Value Description Range Increments

GND FAULT LVL 2 5% of FLC

Ground fault current level-2. Fault occurs when Ground Current exceeds the set value for more than G/F Lvl 2 Delay.

1-100% of Motor FLC 1 %

G/F LVL 2 DELAY 0.5 sec.

Ground fault current level-2 Delay. Note: When set to 0 actual delay is less than 90 mSec.

0 - 2 sec. 0.1 sec.

THERMISTOR TYPE PTC

Determines type of Thermistor (when used) . PTC - Positive Temperature Coefficient NTC - Negative Temperature Coefficient

NTC/ PTC

THERMISTOR LVL 1 3000 OHM

Thermistor Level-1. Fault occurs when measured resistance increases above the set value for PTC (decreases below the set value for NTC).

100 - 30.000 fixed delay - 2 Sec.

100

THERMISTOR LVL 2 4000 OHM

Thermistor Level-2. Fault occurs when measured resistance increases above the set value for PTC (decreases below the set value for NTC).

100 - 30.000 fixed delay - 2Sec.

100

UNSTABLE CURRENT 5% of FLC

Current fluctuation exceeding pre-set value Delay: 120 sec

1-10% of Motor FLC 1%

Parameter Settings

13

Figure 4 - Overload Protection - Cold Motor Figure 5 - Overload Protection - Hot Motor (hot/cold ratio = 0.5)

I/In1098765432

11

2

3

45

6

10

100

1000

10000

Tim

e (S

ec)

t6x=120

t6x=60

t6x=30

t6x=20

t6x=10

t6x=5

I/In

1098765432

1

1

2

3

4

56

10

100

1000

10000

Tim

e (S

ec)

t6x=120

t6x=60

t6x=30

t6x=20

t6x=10t6x=5

100

Parameter Settings

14

Actual Unbalance (%)

1009080706050403020101

2

3

45

10

120

1000

Para

met

er: U

/B L

VL

2 M

ax T

ime

(Sec

)

80

60

40

20

Figure 6 - Unbalance Protection

Unbalance Level Value Selection: Diagonal selected line intersects with the vertical axis at U/B LVL 2 MAX T, as set at Protection Settings page. Unbalance greater then Unbalance LVL 2 will Alarm / Trip after time delay that depends on the severity of the unbalance and the selected curve. Example: Assume that the user requires the MPR-6 to trip the motor at 40% Unbalance current after a delay of 5 sec. The intersection point of 5 sec and 40 % is on a diagonal line which intersects the X axis at 80 sec. Hence, set U/B LVL 2 MAX T parameter to 80 sec. Please note that at 60 % unbalance the MPR-6 will trip after approximately 2.5 sec. Unbalance LVL 2 parameter will set the lower threshold under which the MPR-6 will not trip.

Additional Protection

Parameter & Default Value Description Range

PHASE SEQUENCE No

Fault occurs when the phase sequence is reversed. Phase sequence is tested only for short period after starting. Detection of wrong phase sequence accomplished in less then 0.5 Sec. Note: The phase sequence is designed to operate properly only in DOL starting. If for example motor is started by electronic soft starter, VFD, etc. Phase Sequence protection must be set to Off.

Yes / No

EXTERNAL FAULT 1 If config. input 1 is set to Ext. Fault 1 N/O then Fault occurs when Programmable Input-1 closes. If config. input 1 is set to Ext. Fault 1 N/C then Fault occurs when Programmable Input-1 opens.

EXTERNAL FAULT 2 If config. input 2 is set to Ext. Fault 2 N/O then Fault occurs when Programmable Input-1 closes. If config. input 2 is set to Ext. Fault 2 N/C then Fault occurs when Programmable Input-1 opens.

INTERNAL FAILURE The MPR-6 incorporates a built in Test program. The test program is constantly running in the background. It can also be operated from Test/Maintenance page. Fault occurs when the MPR-6 detects an internal fault.

Communication Port Failed At fault LCD displays COMM FAILURE

Fault occurs when the MPR-6 detects three consecutive transmissions from the host computer, in which a parity bit, and/or the CRC word are wrong. Auto reset, when Enabled, occurs when a transmission from the host computer is received properly.

Trip / Alarm Options

15

Protection function Each of the MPR -6 Protection has five setting: 1. Trip 2. Alarm 3. Auto Reset 4. Relay C 5. Relay D

With this five setting any the MPR-6 protection can be assigned to each of the following functions : 1. Trip only 2. Alarm only 3. Alarm and Trip 4. Disabled 5. Enabling Auto Resetting 6. Operating Aux relay C 7. Operating Aux relay D

When Trip only is required 1. Set Trip: Enable, Alarm: Disable. Upon fault:

Trip LED illuminates. Trip relay: if designated as "Trip", energizes. if

designated as "Trip-Fail Safe", de-energizes. Relays C and/or D (if assigned to function in this

fault) energize. 2. When Alarm only is required set Trip: Disable,

Alarm: Enable. Upon fault: Alarm LED illuminates. Alarm relay: De-energizes (fail-safe operation) Aux relay C and/or D (if assigned to function in

this fault), energize. 3. When Alarm and Trip are required set Trip:

Enable, Alarm: Enable. Upon fault: Trip and Alarm LEDs illuminate. Trip relay: if designated "Trip", energizes. if

designated to "Trip-Fail Safe", de-energizes. Alarm relay: De-energizes (fail-safe operation) Aux relays C and/or D (if assigned to function in

this fault) , energize. 4. To Disable this protection set Trip: Disable, Alarm:

Disable 5. Operating Aux relay C

The relay can be assigned for one or more of the 20 faults. It will operates for a certain fault only if Trip or Alarm are enabled.

6. Operating Aux relay D The relay can be assigned for one or more of the 20 faults. It will operates for a certain fault only if Trip or Alarm are enabled.

More than One Alarm or Trip. The MPR-6 is designed to accept and store the first Alarm it detects. If this alarm has not been reset and an additional alarm occurs, the MPR-6 will not display the second alarm on the LCD nor assign it to the Fault Data page. Example: If "Unbalance Level 1" occurs and then a "Thermal Level 1" occurs, the MPR-6 will continue displaying "Unbalance Alarm" message on both LCD and Statistical Data page. This is to assist the user in establishing the cause of the alarm. In case a trip occurs after an alarm, the trip message will override the alarm message. Resetting Reset after fault can be either through the Reset key on the front panel or remotely through Input -1 or 2, when designated as Remote Reset, or through the Serial link. The MPR-6 can also be assigned to have Auto Reset Auto Reset - When required set "Auto Rst: Enable" If not required set "Auto Rst: Disable" The MPR-6 resets itself automatically when the fault cause disappears. The Auto Reset is activated after a 2 sec. delay. Note: It is recommended to avoid unnecessary

Autoreset On some faults, when Auto Reset is enabled, the MPR-6 trips and after a 2 sec. delay resets itself automatically. The fault message on the LCD disappears after 2 sec. Example: On "U/C Level 2", when Auto Reset function is Enabled, the contactor opens. After 2 sec. automatic Reset occurs. The motor stops and the "U/C Level 2" message is displayed for only 2 sec. Thermal Capacity Reset method (to enable emergency restart) Due to the importance of the Thermal protection a different reset method is used. Thermal Capacity fault can be reset only from the front panel Reset key. It is not possible to reset this fault through Input-1 or Input-2 and not through the communication. It is impossible to reset a "Thermal Level 2" condition until "Thermal Capacity " has reduced bellow 50%. If urgent starting is needed (while parameters lock=N0), before thermal capacity has reduced below 50%, press Reset key. The LCD will display: "Reset Thermal Capacity??? Pressing Reset key again after 1 second resets the Thermal Capacity.

Setting Summary

16

The following table summarizes the ranges and factory default settings for each of the parameters. New settings can be marked in the empty spaces ( ). In this table, (+) stands for "Enabled", (-) for "Disabled" and - to not applicable. Motor Number (___________) Application Name (____________________________________________)

Function No. Function Name Range Default Settings Field Settings

1 Line frequency 50-60Hz 50HZ 2 Motor FLC 1-1000A 100A 3 C/T Primary 1-1000A 100A 4 GND C/T Primary 1-1000A 100A 5 Trip Inhibit 400-1000% FLC, Off Off 6 Config. Trip Relay Trip/Trip - Fail-safe Trip 7 Config Input 1 Reset, Ext Fault N.O or N.C Reset 8 Config Input 2 Reset, Ext Fault N.O or N.C Reset 9 Parameters lock Yes / No No 10 Motor Number 0-320 0 11 Adress No 1-247, 248=Off 248

Syst

em P

aram

eter

s Set

tings

12 Baud Rate 1200-9600 9600 13 Max Start Time 1-250 sec 10 sec 14 No of Starts 1-10 10 15 Starts period 1-60 min 30 min 16 #St Auto Rst Dly 1-60 min 15 min 17 U/C Level 1 10-90% FLC 50 % 18 U/C Level 1 delay 1-60 sec 2 sec 19 U/C Level 2 10-90% FLC 40 % 20 U/C Level 2 delay 1-60 sec 5 sec 21 Load Increase 60-150% FLC 120 % 22 O/C Level 1- (Jam) 100-500% FLC 400 % 23 O/C Level 1 delay 0.5-10 sec 2 sec 24 O/C Level 2 - (Short) 400-1200% FLC 800% 25 O/C Level 2 delay 0-4 sec 0.5 sec 26 Overload pickup 60-130% FLC 105 % 27 Thermal Level 1 50-99% FLC 80 % 26 t6x (curve selection) 0.5-120 sec 10 sec 27 Hot to Cold Ratio 20-100% 50 % 28 Cool Time Factor 1-15 5 29 Unbalance Level 2 10-40% of FLC 15% 30 U/B Level 2 Max T 20-120 Sec 30 sec 31 G/F Level 1 1-100% FLC 5 % 32 G/F Level 1 delay 1-60 sec 10 sec 33 G/F Level 2 1-100% FLC 10 % 34 G/F Level 2 delay 0-2 sec 0.5 sec 35 Thermistor type NTC / PTC PTC 36 Thermistor Level 1 100-30000 3000 Ohm 37 Thermistor Level 2 100-30000 4000 Ohm

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38. Unstable Current 1-10% FLC 5%

Setting Summary

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Trip/ Alarm Options:

Trip Alarm Auto Reset Relay C Relay D Protection Description Dflt New Dflt New Dflt New Dflt New Dflt New

ANSI Code Standards

1 Max Start Time - + - - - 48 2 Too Many Starts - - - - - 66 3 U/C Level 1 - + - - - 37 4 U/C Level 2 - - - - - 37 5 Load Increased - + - - - 51L 6 O/C Level 1-Jam + + - - - 51R 7 O/C Lvl 2 - Short + + - - - 50 8 Thermal Level 1 - + - - - 49S/51 9 Thermal Level 2 + + - - - 49S/51

10 Unbalance Lvl 1 - + - - - 46 11 Unbalance Lvl 2 + + - - - 46 12 Phase Sequence - - - - - 47 13 GND Fault Lvl 1 - + - - - 50G, 64 14 GND Fault Lvl 2 + + - - - 50N, 64 15 Comm Port Fail - - + - - 3 16 Internal Failure - + - - - --- 17 External Fault 1 - - - - - --- 18 External Fault 2 - - - - - --- 19 Thermistor Lvl 1 - - - - - 49R 20 Thermistor Lvl 2 - - - - - 49R 21 Unstable Current - - - - - ---

Note: Disable - Enable +

Actual Data

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To enter Actual Data press Page key until Actual data header is displayed Note: Values given below are examples only.

ACTUAL DATA - -

Parameter & Example Value Description Range

I1 I2 I3 345 343 346 A

Line (motor) currents. 1A - 12KA.

GROUND CURRENT 0 Amp.

Ground fault current. 1A - 12KA

THERMISTOR RES. 2.3 KOHM

Thermistor measured resistance. Note: if Thermistor is not connected display shows: ?????

Thermistor 100 -30,000

MOTOR LOAD CURR. 90 % of FLC

Motor current as a percentage of Motor FLC. 0 - 1200% FLC

UNBALANCE CURR. 1%

Unbalance current, the difference between max. and min. of motor's three line currents, related to the larger between motor's max. line current and Motor FLC.

0 - 100%

THERMAL CAPACITY 20% of Capacity

Thermal register capacity. Trip level = 100% 0-250% of max. Thermal Capacity

TIME TO TRIP- O/L No Trip Expected

Expected time to trip (reaching 100% Thermal Capacity) at the present current value.

No trip expected, 0 - 4 hours

TIME TO START 0 sec.

Expected time to re-start is displayed on the LCD in one of the following cases: * After "Thermal Trip" - in this case it is the expected time of

the Thermal Capacity to decay to 50% of its the maximum "Thermal Capacity".

* After "Too Many Starts" Trip - it is the time until Auto Reset will be performed (if enabled)

After "Thermal Trip": 0 - ... minutes After "Too Many Starts" : 1 - few hours.

CURRENT FLUCTUAT 5%

Current fluctuation exceeding pre-set value Delay: 120 sec 1 - 10%

Statistical Data

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STATISTICAL DATA - -

Parameter & Example Value Description Range

LAST STRT PERIOD 5 sec.

Last start time duration. 0-255 seconds.

LAST START MAX I 350 amp.

RMS maximum current (highest of three phases) during last start. 0-24000 amp.

LAST TRIP Temp. 1 Trip

Last active fault that was Enabled as a Trip. all 20 faults

LAST ALARM Temp. 1 Alarm

Last active fault that was Enabled as an Alarm. all 20 faults.

Trip I1, I2, I3 110 112 109 A

Values of three line (motor) currents before last trip. 0-12000 amp.

TRIP GND CURRENT 0 amp.

Values of Ground Fault current before last trip. 0-12000 amp.

TOTAL RUN TIME 10137.5 hours

Total run time since commissioning. 0-60,000 hours.

TOTAL # OF START 1017

Total number of starts since commissioning. 0-65535

TOTAL # OF TRIPS 12

Total number of trips since commissioning. 0-65535

Test Messages

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TEST MAINTENANCE OPTIONS

Parameter & Example Value Description

RUN SELF TEST ? Push "Value - up"

Press key to initiate the built in test procedure. Automatic test program is constantly running in the background

PROGRAM VERSION SMP140796-Modbus

Program version description.

STORE NOW ? Default settings

Stores All factory default parameters in the non-volatile memory. Press Store and Set Page keys simultaneously, to store. "Data Saved Ok" message will be displayed for about two seconds. Resets and stores "0" for all the statistical data. Press Reset and Store keys simultaneously, to reset and store zero values in the non-volatile memory. The parameters are: * Total run time , * Total # of starts, * Total # of trips, * Last start period * Last start peak I, * Trip I1, I2, If, * Trip GND current, * Thermal capacity " Data Saved OK" message will be displayed for about two seconds.

CLEAR Statistical Data

Warning Resetting Statistical Data resets all previous statistical data values ! ! ! The last two actions (default storing and resetting statistical data ) should be done with care, since retrieving previous setpoint parameters or statistical data is impossible.

Flash & Constant Messages

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Flash Messages The message is displayed for a short while only. Display than returns to the previous message. Flash messages are usually displayed as a response to an operator action. It is used either to confirm activation of the requested operation, or to indicate reason for not doing so.

Parameter & Example Value Description

DATA SAVED OK

Displayed after pressing Store key. If an error is found during store process, then next message is shown.

STORAGE ERROR

Displayed when an error is found in the store process.

WRONG PARAMETERS

Displayed after power-up, if the non-volatile parameter check sum is found to be wrong.

UNAUTHORIZED ACCESS

Displayed when Parameters lock is set to yes, and a parameter change is attempted. Also displayed after Unauthorized Store action.

RESET THERMAL CAPACITY ???

Displayed as a response to pressing Reset key while parameters lock is set to No. It indicates that a second press on Reset key after 1 Sec. will reset thermal capacity to 0. Note : This should be done with care !! Resetting Thermal Capacity may prevent the MPC from tripping for thermal overload while justified

THERMAL CAPACITY RESET PERFORMED

Displayed after second press on Reset Key, as explained in the previous message.

SELF TEST PASSED

Displayed as a response to running the built-in test procedure, provided all tests were "O.K.".

SELF TEST FAILED Error Code = 32

Displayed as a response to finding an error during the operation of Test procedure. Error code should be reported to Authorized Factory representative.

Constant Messages Displayed, as a response to an event and not as a result of an operator action.

Parameter & Example Value Description

ALARM THERMAL LEVEL 1

Displayed when the Alarm LED illuminates. The lower line displays the fault name.

TRIP THERMAL LEVEL

Displayed when the Trip LED illuminates. The lower line displays the fault name.

Communications Communications Manual is supplied upon request

22

The MPR-6 incorporates RS485 serial link and uses a Modbus RTU protocol (The protocol is not included in this document) to provides high-speed data acquisition to supervisory computers. Data formats have been carefully structured to provide fast notification of alarms and continuous updates of performance parameters. Load control can be performed from host computers or by PLCs. The following can be performed through the communication. * Read and modify all MPR-6 Settings Read all Actual and Statistical Data parameters Reset

System security is exceptionally high, meeting the highest standards of protected communication in the industry. Included in each message is a 16 bit CRC. RS-232 to RS-485 Converter

For programming and supervision of single units via IBM-PC or compatible.

Small System Up to 32 MPRs can be connected to the PLC or host computer via a twisted shielded pair. Note: Terminate serial link cable with 120-Ohm resistors at both ends. The MPR-6 system is user expandable. No special engineering skills or tools are required. For larger systems a Data Highway enables multiple MPR-6 connection. The system also performs high-speed data acquisition Users therefore have a simple and friendly means of building a fully integrated monitoring and control systems Optional, communication components is available, includes: 1. Two meter cable with RS-232 to RS-485 point to point single unit Converter 2. Communication Manual 3. For setting software Consult Factory

Technical Specifications

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Auxiliary Power Supply 230VAC (165 - 260V), 115VAC (88 - 125V), (to be specify). 45 to 65Hz. Power consumption: 10VA Current Measurement (three currents) Method : True rms, sample time 0.5mS. Range: 0.05 to 12 * phase CT Primary amps setting. Full scale: 12 * phase CT Primary amps setting. Accuracy : 1.5% , for 0.9 to 1.5 * CT Primary amps setting.

5% above 1.5 * CT Primary (3% + 0.02 * CT Primary) below 0.9 * CT Primary

Power consumption: 0.1VA per 1A at 1Amp. input, (Input impedance 100m) 0.5VA per 5A at 5Amp. input, (Input impedance 20m)

Ground Fault Current measurement (one current) Method : True rms, sample time 0.5mS. Range: 0.05 to 1.0 * E/F CT Primary amps setting. Full scale: 1.0 * E/F CT Primary amps setting. Accuracy : 3% of full scale. Power consumption: 0.1VA per 1A at 1Amp. input, (Input impedance 100m)

0.5VA per 5A at 5Amp. input, (Input impedance 20m) Thermistor Input Range: 0.1 - 30K. Accuracy: 0.1K up to 5K, 3% above 5K. Time delay: 0.5 0.2 Sec. Overload Alarm and Trip Curves (both heating and cooling) Fault time accuracy: 1 Second up to 10 seconds.

1 second 2% above 10 seconds. Threshold current level : OVERLOAD PICKUP 1.5%. Total Run Time Accuracy: 2%. Current Unbalance Alarm and Trip Method: Unbalance = 100 * (Imax - Imin) / Ir [%] Where: Imax = max. of the three phase currents.

Imin = min. of the three phase currents. Ir = larger of (Imax , Motor FLC setting).

(to prevent nuisance tripping at low current levels) Alarm Threshold unbalance alarm level: 50% of Unbal Current setting 2%. Alarm (fixed) time delay: 1.0 0.5 Sec. Trip Curves Threshold unbalance trip Level: Unbal Current setting 2%. Trip time accuracy: 1 Second up to 10 seconds. 1 second 2% above 10 seconds. Fault Time Delays Accuracy: 0.5 Sec. or 2% of time, which ever is greater, for all but the above mentioned faults and the

following exceptions: - O/C Level 2: -0.1/+0.2 Sec. for less than 1Sec. delay.* - Ground Fault Level 2: -0.1/+0.2Sec. for less than 1Sec. delay.* * When adjusted to 0 60 mS 30mS.

Relays Contacts Rated load: 8A/250VAC 1800VA. 48Vdc, 0.25A Inductive 48Vdc, 1.0A Resistive Maximum voltage: 250VAC. 125Vdc, 0.15A 125Vdc, 0.4A

Technical Specifications

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Dielectric Strength 1500VAC, for 1 minute, Between Ground (terminal 18) and:

* Current inputs. * Auxiliary power supply inputs * Control terminals

Temperature Range 0C to +50C (default - all units), -10C to +60C (by special order) Standards Impulse : Meets IEC 255-4 (1976) & Amend #1 (1979)

Meets IEC 255-5 (1977) 5 kV common-mode test

5 kV transverse-mode test Surge withstand :

Oscillatory 2.5 kV peak Fast transient 4 kV crest voltage In accordance with: ANSI C37.90.1 (1990), IEC 55-4 (1976) & Amend #1 (1979) Class III, IEC 255-22-2 (1988) Class III

RFI : In accordance with EMI standard ANSI C37.90.2

Dimensions (mm)

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