MMPPRR 22000000 ((55 TThheerrmmaall SSeennssoorrss))

MMoottoorr PPrrootteeccttiioonn RReellaayy ((IInncclluuddeess VVeerrssiioonn DD))

IInnssttrruuccttiioonn MMaannuuaall

Ver. 1.0 / 2001

Table of Contents

Page Subject 3 Introduction to MPR 4 Wiring Diagram 5 Rear Panel Layout 6- 7 Control Terminals, DIP Switch Selection and Location 8 Front Panel - Layout 9 - Settings 10-11 LCD Displays 12-13 Menu Configuration 14 Parameter Settings - Communication Settings 15-16 - System Parameter Settings 16 - Voltage Settings 17-18 - Current Settings 19 - Temperature Settings 20-28 Tripping/Alarm Options 29 Trip and Alarm Default Setting & Activity Table, ANSI Codes 30 Actual Data - Measured and Calculated Data 31 - Logical Inputs, Statistical Data and Fault Data 32 - Statistical and Fault Data 33 Messages -Test Messages 34 - Flash Messages, Constant Messages 35 Communication 36-38 Technical Specification 38 Case and Cutout Details

Note Installation, operation and maintenance should be in strict accordance with the instructions in this manual, national codes, and good practice. Installation or operation not performed in strict accordance with these instructions shall void the manufacturers warranty.

Warning Unit must be grounded prior to connection of any power. Disconnect all power inputs before wiring or servicing the equipment.

Warranty SOLCON warrants the Product to be free from defects in workmanship and material. Product which prove defective within one year of operation, but no later than 18 months from date of shipment, shall be repaired or replaced free of charge, FOB factory. This is providing the customer promptly sends to Solcon a notice of defect and satisfactory proof thereof; establishing that the product had been correctly applied, installed, maintained and operated in accordance with Solcon's written instructions, appropriate codes, regulations and good practice, within the limits of rated capacity and normal usage; and assumes the obligation of all expenses of returning the defective product to the factory.

The company reserves the right to make any improvements or modifications to its products without prior

notice.

1

Introduction The MPR 2000 Motor Protection Relay is a new generation of microprocessor based relay designed to operate with 3 phase induction motors. True RMS voltages and currents are measured at a sampling rate of 0.5 msec. This enables the MPR to be used with variable speed drives and soft starters. The MPR incorporates two main functions.

a. Motor protection. b. Supervision and communication.

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 Modelling for the motor to run safely up to its limits. This relay protects the motor from abnormal conditions in the power supply, motor and cabling faults as well as operator malfunctions. The MPR monitors three phase voltages, three phase + earth fault currents and temperature inputs from 5 sensors. All are combined to provide the most comprehensive protection package. The MPR can interpret as many as 31 different trips / alarms. Voltage based protection - Undervoltage, Overvoltage*, Phase loss, Phase sequence. Current based protection - Too many starts, Maximum start time, Under current *, Load increase, Low-set overcurrent (Stall / Locked protection) , High set overcurrent (Short circuit), Thermal Overload*, Unbalanced current *, Earth fault current*. Voltage/Current based protection - Under power. Temperature based - Temperature protection for 5 sensors*. General based protection - Serial port failure. * 2 levels - for Alarm and Trip. Protection levels and time delay settings are individually configured through a key pad on the front panel or through the communication port.

Unique Tripping / Alarm options, make it possible to designate any fault as an Alarm, Trip, both or none. This unique facility also enables controlled fault Reset possibilities. Authorized key enlarges the reset possibilities. A unique "Time To Trip" algorithm enables the operator or host computer to take corrective actions before tripping. Optically isolated logic input is used as Authorized Key input and as input control through RS485 serial link. The MPR incorporates four output relays. Two relays are used for E/F and O/L (dedicated). Two additional relays can be designated as Trip or Alarm. Supervision and Communication A Liquid Crystal Display (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 correct use of the Authorized key input terminals. Measured data - Phase and line voltages, Phase currents, Earth fault current, Power, Power factor and RTD/Thermistor channel resistance/°C. Calculated data - Motor load in % of FLC, Thermal Capacity, Time to trip, Time to start, Unbalanced current. Logic input status - Individual status of Authorized key contact. Statistical data - Motor running hours, Total number of starts, Total number of trips, Last start period, last start peak current. Fault data - Last Trip, Last Alarm, Phase currents, Earth fault current, Phase voltages, all at time of trip. 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 makes it easy to modify setpoints in place of the factory default parameters. RS485 enables 32 MPR units to be connected on the same link to the host computer. When a need for more than 32 units arises, using HMI & Data highway equipment, a n unlimited number of MPR units can be connected to the host computer.

2

Wiring Diagram

3

Rear Panel Layout

4

Control Terminals Auxiliary Power Supply AC power supply : 115 / 230 VAC, 50/60 Hz (switchable). Phase ........................................................................ 29 Neutral ................................................................... 30 Ground ................................................................... 28 DC Power Supply (optional): 19-60 or 85-300 VDC. DC(+) ...................................................................... 29 DC (-) ...................................................................... 30 Ground..................................................................... 28 Analog Inputs The MPR can measure : three voltages, four currents and three thermistors or up to five RTDs. True RMS measurement is both for voltages and currents. Frequency should be in the range of 45-66Hz. All current and voltage inputs incorporate internal isolating transformers. Line Voltages Direct connection of line to line voltages up to 690 VAC. For higher voltages, up to 25 KV, use P/Ts. Phase L1 .................................................................. 33 Phase L2 ................................................................. 34 Phase L3 .................................................................. 35 Neutral (When used)............................................... 36 For single phase voltage measurement, connect phase to 33, 34 & 35 and Neutral to 36. Notes: 1. Line voltages must be connected for frequency

sensing. When system voltage measurement is not available and AC power supply is used, connect auxiliary power supply, 29 to phase (33, 34, 35) and 30 to neutral input (36).

2. Power and Power factor can be calculated only if three voltage inputs and three current inputs are applied to the MPR in the correct sequence, eg : V1 to 33 with I1 to 37/38 or V2 to 34 with I2 to 40/41 etc

3. In V connection (medium and high voltage) networks, connect the two phase output to 33 and 34, where the center of the V output will be connected to terminal 35 (see page 16 for calculation of voltage and P/T values).

Line Currents Currents measured through C/T secondary of 1 or 5 A. Phase L1 ... 1 A, 5 A, Common ............... 37, 38, 39 Phase L2 ... 1 A, 5 A, Common ................ 40, 41, 42 Phase L3 ... 1 A, 5 A, Common ................ 43, 44, 45 Note: Power and Power factor can be calculated only if three voltage inputs and three current inputs are applied to the MPR in the correct sequence (see note 2 - above).

Earth Fault Current Currents measured through a differential C/T with a secondary of 5 A or 1 A. All phases ..1 A, 5 A, Common ................. 46, 47, 48 Note: It is recommended to use differential C/T. If a differential C/T is not available, Earth Fault can be measured using C/T Wiring Diagrams on Page 7. Thermal Sensors The MPR can accept inputs from : * Up to 5 RTDs (PT100) * Up to 3 Thermistors + 2 RTDs (PT100) Resistances (To configure the MPR see "DIP Switch Location" on page 7 ) * RTD 100�-240� * Thermistor 0.1K�-30K� RTD or Thermistor selection is done by removing rear panel to set Dip Switches SW1.1 - SW1.8 on analog PCB. Set all 8 ON for Thermistors and OFF for RTDs. LCD display in °C for RTD use only. Selected by removing rear panel to set dip switch on CPU PCB, SW1.3 = ON RTDs three wire measurement system is used to compensate for cable resistance. See temperature table on page 25 (max. allowed cable resistance is 25�). Temperature sensors are connected as follows: Five RTDs: RTD 1 .......................................................... 17, 18, 19 RTD 2 .......................................................... 21, 22, 23 RTD 3 .......................................................... 25, 26, 27 RTD 4 .......................................................... 51, 52, 53 RTD 5 .......................................................... 55, 56, 57 Three Thermistors and Two RTDs: Thermistor 1 ..................................................... 18, 19 Thermistor 2 ..................................................... 22, 23 Thermistor 3 .................................................... 26, 27 RTD 4 .......................................................... 51, 52, 53 RTD 5 .......................................................... 55, 56, 57 Note: If Thermistors/RTDs are not used, leave terminals open, and disable all relevant Trip and Alarms. Shielded cables must be used, connect shield to External ground terminal ..................................... 28

5

Control Terminals Dip Switch Location Remove Rear Panel. P.C.B's are located as follows:

Authorized Key ............................................... 60&61 Open -Disabled Closed -To enable the following: * Change of parameters (through keyboard). * Reset of any alarm/trip, regardless setting. * Reset of the thermal capacity. * Run self test. * Store default settings. * Reset and store of statistical data. Output Relays The MPR incorporates four output relays. Each has a C/O contact, rated 8A/250VAC, 2000VA. O/L Relay. Operates unconditional when O/L is detected N.C. ...................................................................... 4&5 N.O. ...................................................................... 4&6 Note: In MPR 2000/5-D O/L relay is slave relay to

Alarm relay. E/F Relay. Operates unconditional when E/F is detected N.C. ...................................................................... 7&8 N.O. ...................................................................... 7&9 Note: In MPR 2000/5-D E/F relay is slave relay to Trip

relay. Auxiliary-1 Relay (Alarm) Must be designated (by parameter setting) as Alarm relay with Fail-Safe logic. N.C. .................................................................. 10&11 N.O. .................................................................. 10&12 Note: When set as Alarm, relay is energized when

MPR is powered (closing 10-12 N.O contact) and de-energized upon alarm (closing 10-11 N.C contacts).

Auxiliary-2 Relay (Trip) Must be designated (by parameter setting) as one of: * Trip relay. * Trip relay with Fail-Safe logic. N.C. ...................................................................13&14 N.O. ..................................................................13&15 Serial Link Standard RS485 Half Duplex, with MODBUS protocol. Twisted shielded pair should be used for wiring. Acceptable baud rates: 1200, 2400, 4800 and 9600 BPS. Serial Port (+) ............................................................ 3 Serial Port (-) ............................................................. 2 Serial Port (shield) ................................................. 28 Notes:

1. Auxiliary Power Supply must be turned Off after changing baud rate value.

2. To match the line, connect 120� resistors between (+) and (-) at the end and beginning of the line. C/T Wiring Diagrams

Three C/Ts + One differential. (Recommended wiring).

Three C/Ts in a residual Earth Fault Connection

Note: When using this wiring diagram it is

recommended to increase the offset levels of Alarm and Trip to avoid nuisance tripping.

6

Front Panel Layout

LEDs and Display Overview On Illuminates when auxiliary power supply voltage is connected. Stopped Illuminates in stop position. Indicates that both contactors A and B are open. Starting Illuminates as a response to start command. Indicates that command is still "ON" and motor's average current is above 115% of rated current. Running Illuminates after completion of starting process. Indicates that motor's average current decreased below 115% of rated current. O/L Trip Illuminates when O/L is detected (O/L relay is closed). E/F Trip Illuminates when E/F is detected (E/F relay is closed). Alarm Illuminates in Alarm condition. Stays lit even if alarm condition disappears, turns off after resetting. Trip Illuminates in Trip condition. Stays lit even if trip condition disappears, turns off after resetting. Internal Failure Illuminates upon internal fault detection. Stays lit even if internal fault disappears turns off after resetting. LCD Display Two lines of 16 characters each, presenting all data and messages.

Keys Overview

Press to change setpoint pages in positive cyclical order.

Press to change the data page in positive cyclic order.

Press to forward parameters within page. If key is pressed for more than 0.5 sec, parameters will be displayed at a fast rate. Press to reverse parameters within page. If key is pressed for more than 0.5 sec, previous parameters will be displayed at a fast rate.

Press once to increase parameter value. Press and hold to increase parameter value at a fast rate (*).

Press once to decrease parameter value. Press and hold to decrease parameter value at a fast rate (*).

Press to cancel displayed Alarm or Trip (*).

Enables MPR self test and storing default parameters (*).

Press to store displayed parameter value in the non-volatile memory (*).

SET PAGE

DATA PAGE

SELECT FWD.

SELECT REV.

RESET

TEST

STORE

(*) Note: If Authorized Key is locked out (open), only

viewing is possible. When the Key is closed, it is possible to view, change and store any set parameter.

7

Front Panel Settings Upon initiation of the MPR, the following occurs: On and Stopped LEDs will turn on. The LCD will display:

COMMUNICATION ***SETTINGS***

In order to review above page settings, press Select FWD. key. Messages are displayed on the LCD in two lines. * Upper line describes the parameter's name. * Lower line shows its value. When Authorized key terminals are open, it is possible to view parameters but not to change or store them.

An attempt to change a value by , or store keys, will result in "Unauthorized Access" message. To change settings, when Authorized key is closed,

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 only after storing it in the non-volatile memory. Setting a parameter without storing, and moving to another parameter, will return the parameter to its previously stored value.

2. Any setpoint parameters can be viewed, altered and stored at any time. However, it is not recommended to change and store important parameters while the motor is starting or running.

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

Returning to Factory Default Values: Press Test key once, the LCD will display:

TEST/MAINTENANCE ***OPTIONS***

Press Select FWD. key three times, the LCD will display:

STORE ENABLE DEFAULT SETTINGS

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

DATA SAVED OK

Note: Storing Default parameters erases all previously updated parameters

8

LCD Display

9

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

COMMUNICATION ***SETTINGS***

SYSTEM PARAMETER

***SETTINGS***

VOLTAGE ***SETTINGS***

CURRENT

***SETTINGS***

TEMPERATURE ***SETTINGS***

TRIPPING/ALARM

***OPTIONS*** 2. Data Review By pressing Data Page key the LCD displays the following headers:

MEASURED DATA -✱✱✱ -

CALCULATED DATA

-✱✱✱ -

LOGICAL INPUTS - CONTACT STATUS

STATISTICAL DATA

-✱✱✱ -

FAULT DATA -✱✱✱ -

3. Test Messages By pressing Test key and then Select key the LCD displays the following headers:

TEST/MAINTENANCE ***OPTIONS***

RUN SELF TEST ? PUSH (+) TO RUN

PROGRAM VERSION MPC060995MODBUS

STORE ENABLE

DEFAULT SETTINGS

RESET & STORE STATISTICAL DATA

4. Flash Messages Flash messages are displayed as a response to an event. Examples:

DATA SAVED OK

WRONG DATA SAVED

WRONG PARAMETERS

DATA SAVED OK

5. Constant Messages Messages which are displayed upon fault. Examples:

TRIP: MAX START TIME

ALARM:

THERMAL PREALARM

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.

LCD Display

10

Menu Configuration

11

Menu Configuration

12

Parameter Settings

COMMUNICATION ✱✱✱ SETTINGS✱✱✱

Display Description Drive Number 0

This parameter has no effect on MPR operation. (For customer convenience only). Range: 0 – 320 Increments of: 1

Baud Rate 9600

Serial Link communication speed in BPS. Disconnect and then reconnect auxiliary supply after any change of baud rate. Range: 1200, 2400, 4800, 9600.

Serial Link No. 248

MPR Address on Serial Link. RS485 Allows a maximum of 32 MPRs on a twisted pair. For convenience in programming the number of serial links is extended. Range: 1 – 247, 248 = Off. Increments of: 1

Common Address 1 Not Used

Common Address 1, for future enhancement Range: Not used / Used

Common Address 2 Not Used

Common Address 2, for future enhancement Range: Not Used / Used

Common Address 3 Not Used

Common Address 3, for future enhancement Range: Not Used / Used

13

Parameter Settings

SYSTEM PARAMETER ✱✱✱ SETTINGS✱✱✱

Display Description Line Voltage 415 Volt

Rated Line to Line Mains Voltage. Range: 100V - 22KV Increments of : 5V to 1KV 100V above 1KV

VT Primary VT not connected

Primary voltage of mains Voltage Transformers. Transformer should be used for line voltages above 690V. Range: not connected, 100V - 22KV Increments of : 10V to 1KV 100V above 1KV

Note: When only one VT is used for voltage measurement decrease VT primary voltage setting by a factor of √3) . eg .1.73.( Example : If mains voltage, line to line is 3300V and only one VT is used, set "VT Primary" 3300/1.73 ≅1900V VT secondary VT not connected

Secondary voltage of mains Voltage Transformer Range: not connected, 95V - 660V Increments of : 5V

Motor FLC 100 AMP.

Motor Full Load (rated) Current.

Range: 1 - 2000A Increments of : 1A to 100A 5A above 100A

CT Primary 100 Amp

Primary rated current of Current Transformer. (Secondary 1A or 5A terminals). Range: 1 - 2000A. Increments of : 1A to 100A 5A above 100A

E/F CT Primary 100 Amp.

Primary rated current of Earth Fault Transformer. (Secondary 1A or 5A terminals). Range: 1 - 2000A Increments of : 1A to 100A 5A above 100A

Note: When three C/Ts are connected in residual earth fault connection (see page 7) the E/F CT Primary value is the same as CT Primary value

Display Description E/F Alarm 5% of FLC

Earth Fault current initiating an Alarm (in % of Motor FLC) Increments of: 1%

E/F Alarm Delay 10 sec.

Earth Fault Alarm Delay. Range: 1 - 60 sec. Increments of: 1 sec.

E/F Trip 10% of FLC

Earth Fault current initiating a trip (in % of Motor FLC) Range: 1-100% of Motor FLC Increments of: 1 %.

E/F Trip Delay 0.5 sec.

Earth Fault Trip Delay. Range: 0 - 2 sec. Increments of: 0.1 sec.

Current Inhibit OFF

Inhibits opening of Aux.2 (Trip) Relay when short circuit current exceeds a set value, to prevent contactor's damage. Range: 400-1000% of Motor FLC, OFF Increments of : 10%

Note : When contactors are not used to trip the motor (circuit breaker application) set to OFF. WARNING The MPR 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. Start/Stp Signal Momentary

Not in use

Starting Method Direct on Line

Note in use.

14

Parameter Settings

SYSTEM PARAMETER ✱✱✱ SETTINGS✱✱✱

Display Description Max Time in Star 10 sec.

Not in use

Transition Time 200 msec.

Not in use

Star to Delta at 150% of FLC

Not in use

Lo Spd Motor FLC 10 AMP.

Not in use

Low Spd t6x Time 10.0 sec.

Not in use

Designate AUX.1 Alarm

Enables Designation of Aux. Relay no. 1 as Alarm- Fail Safe operation (options other then Alarm can not be used).

AUX.1 Delay 0 sec.

Time delay for AUX.1 relay. Range: 0 - 120 sec. Increments of : 1 sec.

Designate AUX.2 Trip

Enables Designation of Auxiliary Relay no. 2 as: * Trip. * Trip - Fail Safe (other options then the above can not be used).

AUX.2 Delay 0 sec.

Time delay for AUX.2 relay. Range: 0 - 120 sec. Increments of : 1 sec. Note: Aux. 2 delay has no effect when configured as Trip or Trip-Fail Safe

Protection Only Yes

Must be configured as "Yes". Range: Yes No

Rated PWR Factor 0.880

Motor rated (Nameplate) power factor. Required for calculating rated power. (based on Motor FLC and Line Voltage). Range : 0.5 - 0.99 Increments of : 0.01

KWH per PULSE Off

When enabled, O/L relay initiates number of KWH per pulse. Range : Off, 1 – 100

Increments of: 1.

15

Parameter Settings

VOLTAGE ✱✱✱ SETTINGS✱✱✱

Display Description U/V Setting 80% of Un

Under Voltage level, (in % of nominal voltage). Fault occurs when voltage is below set value for more than U/V delay. Range: 50 - 95 % of Un Increments of : 1 %

Note: MPR 2000 version D is factory set so Under Voltage protection is also active when the motor is stopped. (Dip Sw. 4 on CPU PCB at ON position - see page 7) U/V Delay 5.0sec.

Under Voltage time delay. Range: 0.2 - 10 sec. Increments of : 0.1 sec.

U/V Auto Restart No.

Not in use

Restart Delay

Not in use

O/V Alarm

Over Voltage alarm level. Fault

occurs when voltage is above set value for more than 1 second (fixed delay).

115% of Un

Range: 100 - 120 % of Un. Increments of : 1% Note: O/V ALARM delay is

preset to 1 sec. O/V Trip 120% of Un

Over Voltage trip level. Fault occurs when voltage is above set value for more than O/V Trip Delay. Range: 100 - 120% of Un. Increments of: 1%.

O/V Trip Delay 1 sec.

Over Voltage trip delay. Range: 1 – 100 sec. Increments of: 1 sec.

16

Parameter Settings

17

CURRENT ✱✱✱ SETTINGS✱✱✱

Display Description Max. Start Time 10 sec.

Maximum permitted starting time. End of starting is assumed when motor's current decreases below 110% of Overload Setting value. Example: for 105% Overload Setting (default value), end of starting is assumed when current decreases below 115% of Motor FLC. (110% x 105%=115.5%) Range: 1 – 250 sec. Increments of: 1 sec.

Number of Starts 10

Maximum Permitted number of starts during "Starts Period". Alarm/Trip screens will display "Too Many Starts" Range: 1 - 10 Increments of : 1

Starts Period 30 min.

Time period during which the number of starts is counted. Range: 1 – 60 min. Increments of: 1 min.

Start Inhibit 30 min

Time period during which starting is disabled after "Too Many Starts" trip. After Start Inhibit time, Auto Reset will operate (if enabled), in order to reset "Too Many Starts" trip. Range: 1 - 60 min. Increments of: 1 min.

U/C Alarm 50% of FLC

Under Current alarm level. Fault occurs when current decreases below set parameter for more than U/C Alarm Delay. Range: 10-90 % of Motor FLC. Increments of: 1%

U/C Alarm Delay 2 sec.

Under Current alarm delay. Range: 1 – 60 sec. Increments of: 1 sec.

U/C Trip 40% of FLC

Under Current trip level. Fault occurs when current decreases below set parameter for more than U/C Trip Delay. Range: 10 - 90% of Motor FLC. Increments of : 1%

U/C Trip Delay 5 sec.

Under Current trip delay. Range: 1 - 60 sec. Increments of: 1 sec.

Load Increase Al 120% of FLC

Load Increase Alarm. Fault occurs when current increases above set parameter for more than fixed time period of 5 sec.

Display Description Range: 60-150% of Motor FLC.

Low Set Setting 400% of FLC

Low Set current - Stall / Jam protection. Operative after start process ended. Indicates that current exceeded set value for more than Low Set Delay. Range:100-500%of Motor FLC. Increments of : 10%

Low Set Delay 2.0 sec.

Time delay for Low Set current. Range: 0.5 - 10 sec. Increments of: 0.5 sec.

High Set Setting 800% of FLC

High Set Current - Short circuit protection. Operative during starting and running. Indicates that current exceeded set value for more than High Set Delay. Range:400-1200%of Motor FLC Increments of: 10%

High Set Delay 2.0 sec.

Time delay for High Set current. Range: 0 - 4 sec. Increments of: 0.1 sec.

Note: When set to 0, actual delay is less than 70 msec.

Overload Setting 105% of FLC

Lower threshold for O/L protection Range: 60 – 130 % of Motor FLC. Increments of : 1%

Thermal Alarm 80% of Capacity

Thermal Capacity alarm value. Range: 50 - 99 % of maximum thermal capacity. Increments of : 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). Range: 0.5 - 120 sec. Increments of : 0.5 sec.

Hot/Cold Ratio 50%

The ratio between thermal Capacity available for starting a hot motor and thermal capacity available for starting a cold motor. (A higher setting allows for a longer starting time of hot motor before tripping). Range:20-100% of Thermal Capacity Increments of: 1%.

Parameter Settings

18

CURRENT ✱✱✱ SETTINGS✱✱✱

Display Description Cool Time Factor 5

The Ratio between cooling time constant of stopped motor to the heating/cooling time constant of running motor. Range: 1 - 15 Increments of: 1

Stall Time Fact. 50%

Stall Time Factor. The ratio between motor thermal time constant when speed switch is closed (indicating slow speed) to thermal time constant with open speed switch - (indicating high speed). Operative when speed switch is used. Range: 20 - 100 % Increments of: 1%

O/L Reset Method Hand

Selects Auto or Manual resetting method after thermal capacity decreases below 50%. Auto: Automatic resetting Hand: Manual resetting Range: Hand / Auto.

Note: O/L Reset Method can also be set through Tripping/Alarm Page, the latest setting will be valid. Unbal. Current (Trip) 15% of FLC

Unbalance Current trip level. Fault occurs only if actual Unbalance is greater than the set value. See figure 6 for time delay. Range: 10 - 40 % of Motor FLC. Increments of : 1%

Notes : 1. Unbalance Current (Alarm) automatically sets itself to 50% of "Unbalance Current" trip, (figure 6 for time delays) 2. Unbalance Current alarm will be activated when Unbalance Current exceeds 50% of the Unbalance Current trip level for more than 1 second (fixed time period). Unbal. Max. Time 30 sec.

Unbalance curve selection. Time delay at 10 % of Unbalance. Fault time inversely relates to the actual unbalance (See page 28). Range: 20 - 120 sec. Increments of: 1 sec.

Under Power 25%

Under power level. In percent of rated power. Range : 5 - 99%

Note: Rated Power is calculated through: P = √3 * Line Voltage * Motor FLC * Rated Power Factor Under Power Del. 30 Sec.

Under Power time delay. Range: 1 - 120 Sec. Increment of: 1 Sec.

TEMPERATURE ✱✱✱ SETTINGS✱✱✱

Display Description Ch. 1 2 3 Sensor RTD

Determines type of Temperature sensor (when used) for channels 1, 2 and 3. Range: Thermistor RTD (PT100)

See DIP SWITCH selection to display °C or � (pg. 6) Thermistor Type NTC (-Ve)

Determines the type of thermistor (In case Thermistor was selected above). Range: NTC (-Ve) PTC (+Ve)

Ch. 1 2 3 Alarm 140 °C

Alarms when actual resistance (Temperature) increases above the set value. Range : 100 - 240 � or 0 – 200 °C. Increments of: 1 � or 1°C

Channel 4 Alarm 140 Ohm

Alarm values - channel 4. Same as CH. 1 2 3 Alarm. Note: Channel 4 can be connected only to sensor of type RTD.

Channel 5 Alarm 140 Ohm

Alarm values - channel 5. Same as CH. 1 2 3 Alarm. Note: Channel 5 can be connected only to sensor of type RTD.

Channel 1 2 3 Trip 150 °C

Trips when actual resistance increases above the set value. Range: 100-240 � or 0 – 200 °C Increments of : 1 � or 1°C

Channel 4 Trip 150 °C

Trip value for channel 4. See previous explanation for CH. 1 2 3 Trip.

Channel 5 Trip 150 °C

Trip value for channel 5. See previous explanation for CH. 1 2 3 Trip.

Notes : 1. Channels 4 and 5 are for RTD's only. 2. RTD functions have a fixed time delay of 2 Sec. 3. Open (unconnected) RTD causes Alarm fault while Trip fault is blocked.

Tripping/Alarm Options

TRIPPING / ALARM ✱✱✱ OPTIONS✱✱✱

FUNCTIONAL ASSIGNMENT

Protection function Each of the MPR Protection can be assigned to each of the following functions : 1. Trip only 2. Alarm only 3. Alarm and Trip 4. Disabled

1. Trip only - Set Trip: Enable Set Alarm: Disable Upon fault:

• Trip LED illuminates. • Aux.2 Relay: if designated "Trip", energizes. if

designated to "Trip - Fail Safe", de-energizes.

2. Alarm only- Set Trip: Disable Set Alarm: Enable

19

Upon fault: • Alarm LED illuminates. • Aux.1 Relay, if designated to "Alarm",

de-energizes (Fail-Safe operation).

3. Alarm and Trip- Set Trip: Enable Set Alarm: Enable Upon fault:

• Trip and Alarm LEDs illuminate. • Aux.1 Relay, if designated to "Alarm",

de-energizes. • Aux.2 Relay, if designated to "Trip", energizes.

If designated to "Trip - Fail Safe", de-energizes.

4. Disable- Set Trip: Disable Set Alarm: Disable

Resetting Each MPR Protection can be assigned to any of the following functions:

1. Auto Reset 2. Panel Reset 3. Communication Reset

(See notes on page 35 and Communication Manual)

1. Auto Reset -When required Set"Auto Rst: Enable" If not required Set "Auto Rst: Disable" The MPR resets itself automatically when the fault cause disappears. The Auto Reset is activated after a 2-sec. delay.

Note: It is recommended to always Disable Auto Reset.

On some faults, when Auto Reset is enabled, the MPR trips and after a 2-sec. delay resets itself automatically. The fault message on the LCD disappears after 2 sec. Example: On "U/C Trip", when Auto Reset function is Enabled, the contactor opens. After 2 sec. automatic Reset occurs. The motor stops and the "U/C Trip" message is displayed for only 2 sec. 2. Panel Reset - Set Panel RST: EN. When Panel resetting is not permitted set Panel RST: DIS. For critical faults, such as "Overload" and "Earth Fault", it is good practice to prevent Panel Resetting. An authorized person (key holder) can always reset any fault. Notes: If Authorized Key is locked, front panel Resetting is active when:

a. Panel Reset parameter is "enabled", and b. Local/Remote input is in "Local" mode, and c. There is no Start signal.

3. PLC Reset - Not in use.

Tripping/Alarm Options

20

1. Maximum Start Time Fault occurs when starting time is longer then "Maximum Start Time" setting. The MPR assumes end of starting process, when motor current decreases below 110% of the "Overload Setting" value. For a default value of 105%, end of starting process is detected at 115% of motor Full Load Current (FLC).

Note: The following describes the four options available for Max Start Time (Trip, Alarm, Auto Reset, Panel Reset). The same options with their settings are applicable for all other faults.

Display Description Max. Start Time Trip: Disable

When Enabled, and in case of starting time exceeds "Max Start Time" setting, the internal relays A and B will open, opening motor contactors. If "Designate Aux.2" parameter was set to Trip, Aux.2 relay energizes. If "Designate Aux.2" parameter was set to Trip - Fail Safe, Aux.2 relay de-energizes. Trip condition is latched. Reset can be done using any Reset method. Range: Disable Enable

Max. Start Time Alarm: Enable

When Enabled, and in case of starting time exceeds Max Start Time setting, Aux.1 relay de-energizes (if Designate Aux.1 parameter was set to Alarm). Alarm condition is latched. Reset can be done using any Reset method. Range: Disable Enable

Max Start Time Auto RST: DIS.

When Enabled, Automatically resets Max Start Time fault after motor stops, enabling restarting. Range: Disable Enable.

Max Start Time Panel RST: En.

When Enabled, allows front panel resetting. Range: Disable Enable.

2. Too Many Starts Fault occurs when number of starts exceeds "Number of Starts" setting during "Starts Period" time. Auto Reset, when Enabled, occurs after "Start Inhibit" time elapsed

3. Under Current Pre-Alarm (U/C PRE-ALARM) For a running motor, fault occurs when current decreases below "U/C Pre-Alarm" setting for a time longer than "U/C Alarm Delay" setting. Auto reset, when Enabled, occurs when the current increases above "U/C Pre-Alarm" level, or when motor stops or trips.

4. Under Current Trip (U/C TRIP)

For a running motor, fault occurs, when current decreases below U/C Trip setting for a time longer than U/C Trip Delay setting. Auto reset, when Enabled, occurs when the current increases above U/C Trip level, or when motor stops or trips.

5. Load Increase Alarm (LOAD INCREASED)

Operative only after start process ended (after current decreased below 110% of "Overload Setting" value). Fault occurs when motor average current is above "Load Increase Alarm" setting for more than 5 seconds . Auto reset, when Enabled, occurs when current decreases below the Load Increase Alarm setting, or when motor stops or trips.

6. Low Set Overcurrent (LOW SET O/C)

Identifies Stall condition for a "running" motor. Fault occurs when starting process has ended and motor average current increases above Low Set Setting value for more than "Low Set Delay" time. Auto reset, when Enabled, occurs when current decreases below "Low Set Setting" level, or when motor stops or trips.

7. High Set Overcurrent (HIGH SET O/C) Identifies short circuit condition. Fault occurs when any of the motor's line currents exceeds "High Set Setting" value, for more than "High Set Delay" time. Auto reset, when Enabled, occurs when current decreases below High Set Setting value, or when motor stops or trips

Notes: 1. True RMS line currents are measured,

disregarding the average "DC" value. It is designed to prevent nuisance tripping at the very beginning of the starting process (during which DC decaying current is superimposed on the AC Current).

2. Minimum setting of "High Set Delay" is 0. At 0 setting, the actual time delay is less than 70 mSec.

Tripping/Alarm Options

21

3. "High Set Overcurrent" trip is prevented when the highest of any of the line currents exceeds Current Inhibit setting. It is designed to prevent opening of motor contactor under high short circuit conditions to protect it's contacts from being damaged. Fault display: "High Set O/C".

4. Overload Trip overrides current inhibit setting. 8,9. Thermal Prealarm and Thermal Trip

The MPR simulates the thermal condition of the motor and stores it in a thermal register. The "heating" of the thermal register (i.e. it's increment) is related to the square of the current (the highest of the three line currents). The rate of "cooling" of the thermal register (i.e. it's decrement) is directly related to the motor's present Thermal condition. The content of the thermal register is called "Thermal Capacity" simulating motor temperature. Thermal capacity of 100% is equivalent to a motor running at the absolute maximum allowed temperature. At this point the motor must be tripped. "Thermal Trip" is defined by the t6x setting. "Thermal Prealarm" have a range of 50-99% of "thermal Trip". The following parameters are used to calculate the "Thermal Capacity". Overload Setting Thermal trip is not possible as long as current is below the "Overload Setting" value. For a standard motor, leave "Overload Setting at it's default value of 105%. When current increases above this value a trip will occur after some time. This time depends on the present value of the "Thermal Capacity" on the current level and on "t6x Time" parameter. t6x Time Tripping time of a "Cold" motor carrying a current of 6 times FLC (when "Overload Setting" value is set to 105%). See figure 4 and 5. Hot/Cold Ratio This parameter, determines the ratio of the available "Thermal Capacity" for a Hot motor and a Cold motor. The "Thermal Capacity" of a hot motor, is: (100% - Hot/Cold Ratio) Cold Condition - When the motor is stopped for a long time, it's "Thermal Capacity" is zero. Therefore, for a cold motor, all the 100% of "Thermal Capacity" are available for heating (before a trip occurs). Hot Condition - When a motor is running, it's temperature increases, and after it has been running for a long time at a current, slightly below the Overload Setting value, a "Hot Condition" has been created. Now, less than 100% of the "Thermal Capacity" is available.

Example: If Hot/Cold Ratio is set to 60%, then for a "Hot" motor, 40% of the "Thermal Capacity" were used, leaving 60% for additional heating. For a motor, running for prolonged time, at lower than "Overload Setting" current value, the "Thermal Capacity" is related to the square of the current. For Example, if motor current is only ½ of the Overload Setting level, then (K=(½)²*40%=10%) only 10% of the "Thermal Capacity" has been used, leaving 90% for additional heating. Cool Time Factor The ratio between the cooling time constant of a stopped motor and heat/cool time constant of a running motor. Stall Time Factor The ratio between motor thermal time constant when speed switch is closed (indicating slow speed) to thermal time constant (an open speed switch - indicating high speed). Operative when speed switch is used. Range: 20 - 100 % Increments of: 1% Speed Switch Not in use

Thermal Capacity Reset Method Due to the importance of the Thermal protection a different reset method is used. Reset of Thermal Prealarm is prevented until Thermal Capacity "cools down" below 50 % of motor thermal capacity. If urgent starting is needed before thermal capacity has reduced below 50% press Reset key twice within 1 second, which will reset the thermal register back to 0. Notes: 1. It is impossible to reset a "Thermal Trip"

condition until "Thermal Capacity " has reduced below 50%.

2. Only "Authorized key" holder can reset the Thermal Capacity. It is not possible to reset thermal capacity through PLC hard wires and communication.

3. If no data is available from the motor manufacturer, it is recommended to leave all the above parameters to their default values. The last value of the Thermal Capacities stored in the non-Volatile memory during auxiliary supply failure or disconnection. On restoration of supply, the previous value will be re-established. Figures 4 and 5 specify overload trip time delay for several cases. Thermal Pre-alarm fault display: "Thermal Prealarm". Thermal trip fault display : "Thermal Trip".

4. "Thermal Trip" overrides "Current Inhibit" settings.

Tripping/Alarm Options 10. Unbalance Alarm

Current unbalance is the difference between maximum and minimum values of the motor's three line currents, divided by the larger motor's maximum line current or Motor FLC. This method prevents nuisance alarming at low currents. The MPR automatically initiates an alarm, one second after the actual unbalance value increases above 50% of "Unbalance Current Trip" setting. Auto reset, when Enabled, occurs when the actual unbalance decreases below 50% of "Unbalance Current Trip" setting, or when motor stops or trips.

11. Unbalance Trip

Unbalance Current setting determines the minimum value of calculated unbalance for tripping. If the actual unbalance exceeds Unbalance Current setting, a time delay is initiated. The time delay is related to Unbal. Max. Time parameter, and to the inverse of the square of the actual unbalance (smaller delay for larger unbalance). Minimum value of the time delay is 1 second. Auto reset, when Enabled, occurs when the actual unbalance decreases to below Unbal. Current setting or when motor stops or trips. Use figure 6 (page 28) to select the required trip time for any unbalance value. Select the required tripping time at 10% unbalance (on the Time axis between 20 and 120 sec). Draw a line, beginning at the selected point of your time axis towards the unbalance percent line, parallel and between the 20sec and 120sec lines. Example: Selecting 80 seconds delay at 10% unbalance will cause a Trip at 40% unbalance after 5 seconds delay.

12. Undervoltage Operative after start signal Fault occurs when the average of the three line to line voltages decreases below "U/V Setting" value, for more than "U/V Delay" setting. It is possible to connect single phase voltage to the line voltage inputs (terminals 33, 34, 35) and link them together (see page 6 - Line Voltage). Auto reset, when Enabled, occurs when average line voltage increases above the U/V Setting value, or when motor stops or trips.

13. Over Voltage Pre-Alarm (O/V PRE-ALARM) Operative only after motor is started. Fault occurs when the average of three line to line voltages increases above "O/V Alarm" setting, for more than 1 second. Auto reset, when Enabled, occurs when average line voltage decreases below "U/V Alarm" value, or when motor stops or trips.

14. Over Voltage Trip

Operative after start signal. Fault occurs when the average line to line voltage increases above "Overvoltage Trip" setting, for more than Overvoltage Trip Delay setting. Auto reset, when

Enabled, occurs when average line voltage decreases below Overvoltage Alarm value, or when motor stops or trips.

15. Phase Loss

The MPR calculates voltage unbalance according to the difference between maximum and minimum values of the line to line voltages, related to the "Line Voltage" setting. Fault occurs when the unbalance level exceeds 20% for more than 2 seconds. Auto reset, when Enabled, occurs when the actual Unbalance decreases below 20%.

16. Phase Sequence

Always operative. Fault occurs when the phase sequence is reversed for more than 2 seconds. Disable Phase Sequence both for Trip and for Alarm, if only a single phase is connected to the voltage input terminals. Auto reset, when Enabled, occurs when a correct phase sequence is detected.

17,18,19. Temperature Pre-Alarm (TEMP n PREALARM) n=1-5 High temperature condition is detected according to the measured resistance of the temperature sensors (RTD or Thermistor). RTD is a positive temperature coefficient device. Thermistor, however, can be either a positive (PTC) or negative (NTC) temperature coefficient type. For RTD or PTC Thermistor, temperature pre-alarm level is detected when the measured resistance of any channel exceeds it's pre-Alarm setting. For NTC Thermistor, temperature pre-alarm level is detected when measured resistance is below it's Channel Alarm setting. Fault occurs, when temperature, of any channel, exceeds the pre-alarm value for more than 1 sec. Auto reset, when Enabled, occurs when the temperature decreases to below the Pre-Alarm level.

Notes: 1. � or �C is selected by removing rear panel

to set dip switch on CPU board, SW1.3 = ON (RTD only)

2. Refer to page 25 for conversion table between � and �C

22

Tripping/Alarm Options 20,21,22 Temperature Trip

(TEMP n TRIP) n=1-5 See previous paragraph on Temperature Pre-Alarm. For RTD or PTC Thermistor, temperature trip level is detected when measured resistance of any channel exceeds it's Channel Trip setting. For NTC Thermistor, temperature trip level is detected when measured resistance is below it's Channel Trip Setting. Fault occurs, when temperature, of any channel, exceeds the trip value for more than 0.5 sec. Auto reset, when Enabled, occurs when the temperature decreases below the trip level.

23. Earth Fault Pre-Alarm (E/F PRE-ALARM) Fault occurs when Earth current exceeds "E/F Alarm" setting for more than "E/F Alarm Delay" setting. Auto reset, when Enabled, occurs when Earth current decreases below "E/F Alarm" setting.

24. Earth Fault Trip (E/F TRIP)

Fault occurs when Earth current exceeds "E/F Trip" setting for more than "E/F Trip Delay" setting. Minimum setting of "E/F Trip Delay" is 0. At 0 setting, the actual time delay is less than 70 msec. Auto reset, when Enabled, occurs when Earth current decreases below "E/F Trip" setting.

Note: "E/F Trip" is prevented when the highest of

any of the line currents Exceeds "Current Inhibit" value It is designed to prevent opening of motor contactor under high short circuit conditions, to protect it's contacts from being damaged.

25. Serial Port Failure (SER. PORT FAILURE) Fault occurs when the MPR 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.

26. Internal Failure The MPR incorporates a Built In Test program. Operating the self-test program is done from a special "Test/Maintenance Options" page. "Self Test Passed" message, after completion of the built in test, indicates that the MPR functions properly. "Self Test Failed", together with an error code (for factory use only) and Internal Fault LED "ON" indicates a fault condition. Auto reset, when Enabled, occurs when a successful test was performed and its result is "Self Test Passed" message.

27. External Fault 1

Not in use

28. Control Circuit Open Not in use

29.Welded Contactor

Not in use 30. External Fault 2

Not in use 31. External Fault 3 (Test)

Not in use 32,33. RTD 4 & 5 Temperature Pre-Alarm

(TEMP 4 PREALARM) (TEMP 5 PREALARM) High temperature condition is detected according to RTD measured resistance. Fault occurs, when measured resistance of any channel exceeds it's Channel Pre-Alarm value for more than 1 sec. Auto reset, when Enabled, occurs when RTD resistance decreases below the pre-alarm level.

34,35. RTD 4 & 5 Temperature Trip

(TEMP 4 TRIP) (TEMP 5 TRIP) High temperature condition is detected according to RTD measured resistance. Fault occurs, when measured resistance of any channel exceeds it's Channel Trip value for more than 0.5 sec. (factory set). Auto reset, when Enabled, occurs when the RTD resistance decreases below the trip level.

Note: Input 4 & 5 can be only RTD's.

23

Tripping/Alarm Options 36. Under Power

For a running motor, fault occurs when motor power decreases below "Under Power" settings for a period of time longer than "Under Power Delay" settings. Auto reset, when Enabled, occurs when the power increases above "Under Power" level or when motor stops or trips. Note: All Power measurements and protection depend upon MPR receiving all 3 line voltages and currents.

Resistance-Temperature-Device Conversion Table (Pt.100=Platinum 100 �) TEMP IN Pt.100 OHMS (�) (�C) (DIN 43760)

0 100.00 10 103.90 20 107.79 30 111.67 40 115.54 50 119.40 60 123.24 70 127.07 80 130.89 90 134.70 100 138.50 110 142.29 120 146.06 130 149.82 140 153.58 150 157.32 160 161.04 170 164.76 180 168.46 190 172.16 200 175.84

Note: Maximum cable resistance allowed must be �25% of RTD resistance.

More than One Alarm or Trip

The MPR 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 will not display the second alarm on the LCD nor assign it to the Fault Data page. Example: If "Unbalance Alarm" occurs and then a "Thermal Pre-alarm" occurs, the MPR will continue displaying "Unbalance Alarm" message on both, LCD and Fault 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.

24

Tripping/Alarm Options Figure 4 - Overload Protection - Cold Motor

25

Tripping/Alarm Options

26

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

Tripping/Alarm Options Figure 6 - Unbalance Protection

Unbalance Level Value Selection:

1. Select the required trip/alarm time on the vertical axis (at 10% Unbalance). 2. Draw a horizontal line at the selected point (eg. 5 Sec.). 3. Select an unbalance point (eg. 40%). 4. Draw a vertical line at the selected point (the two lines intersect). 5. Draw a parallel line to the diagonal lines at the intersection point. 6. The new parallel line will intersect with the vertical axis (at 10 % Unbalance). 7. Insert the value of the time at the intersection point (from 6) into parameter "UNBAL. MAX TIME" (eg. 80

sec).

27

Tripping/Alarm Default Settings The following table summarizes the five factory default settings for each of the faults, and describes when is each fault active. Notes: It is recommended that prior to modifying this table, create a photocopy and do not scribe on the original. Mark your settings in the empty space available for each value. For operation in "Protection Only" mode, disable all PLC reset faults. MOTOR NUMBER (___________), APPLICATION NAME (________________________________)

In this table, (+) stands for "Enabled", (-) for "Disabled".

Fault No. Pages in manual Trip Alarm Auto

Reset Panel Reset

Plc* During Active Code ANSI

1. Max Start Time 21, 17 ( - ) ( ) ( + ) ( ) ( - ) ( ) ( + ) ( ) ( + ) ( ) Start 48 2. Too Many Starts " ( - ) ( ) ( - ) ( ) ( - ) ( ) ( + ) ( ) ( + ) ( ) Start 66 3. U/C Pre-Alarm " ( - ) ( ) ( + ) ( ) ( - ) ( ) ( + ) ( ) ( + ) ( ) Run 37 4. U/C Trip " ( - ) ( ) ( - ) ( ) ( - ) ( ) ( + ) ( ) ( + ) ( ) Run 37 5. Load Increased " ( - ) ( ) ( + ) ( ) ( - ) ( ) ( + ) ( ) ( + ) ( ) Run 51L 6. Low Set O/C " ( + ) ( ) ( + ) ( ) ( - ) ( ) ( + ) ( ) ( + ) ( ) Run 51R 7. High Set O/C 22, 17 ( - ) ( ) ( - ) ( ) ( - ) ( ) ( + ) ( ) ( + ) ( ) Always 50 8. Thermal Prealarm " ( - ) ( ) ( + ) ( ) ( - ) ( ) ( + ) ( ) ( + ) ( ) Always 49S/51 9. Thermal Trip 22 ( + ) ( ) ( + ) ( ) ( - ) ( ) ( + ) ( ) ( + ) ( ) Always 49S/51 10. Unbalance Alarm 23, 18 ( - ) ( ) ( + ) ( ) ( - ) ( ) ( + ) ( ) ( + ) ( ) Always 46 11. Unbalance Trip " ( + ) ( ) ( + ) ( ) ( - ) ( ) ( + ) ( ) ( + ) ( ) Always 46 12. Undervoltage 23, 16 ( - ) ( ) ( + ) ( ) ( - ) ( ) ( + ) ( ) ( + ) ( ) Run + Start 27 13. O/V Pre-Alarm " ( - ) ( ) ( + ) ( ) ( - ) ( ) ( + ) ( ) ( + ) ( ) Run + Start 59 14. O/V Trip " ( + ) ( ) ( + ) ( ) ( - ) ( ) ( + ) ( ) ( + ) ( ) Run + Start 59 15. Phase Loss 23 ( + ) ( ) ( + ) ( ) ( - ) ( ) ( + ) ( ) ( + ) ( ) Always 47 16. Phase Sequence " ( + ) ( ) ( + ) ( ) ( + ) ( ) ( + ) ( ) ( + ) ( ) Always 47 17. Temp. 1 Prealarm 19, 24 ( - ) ( ) ( - ) ( ) ( - ) ( ) ( + ) ( ) ( + ) ( ) Always 49R 18. Temp. 2 Prealarm " ( - ) ( ) ( - ) ( ) ( - ) ( ) ( + ) ( ) ( + ) ( ) Always 49R 19. Temp. 3 Prealarm " ( - ) ( ) ( - ) ( ) ( - ) ( ) ( + ) ( ) ( + ) ( ) Always 49R 20. Temp. 1 Trip 19, 24 ( - ) ( ) ( - ) ( ) ( - ) ( ) ( + ) ( ) ( + ) ( ) Always 49R 21. Temp. 2 Trip " ( - ) ( ) ( - ) ( ) ( - ) ( ) ( + ) ( ) ( + ) ( ) Always 49R 22. Temp. 3 Trip " ( - ) ( ) ( - ) ( ) ( - ) ( ) ( + ) ( ) ( + ) ( ) Always 49R 23. E/F Pre-Alarm 15, 24 ( - ) ( ) ( + ) ( ) ( - ) ( ) ( + ) ( ) ( + ) ( ) Always 50G, 64 24. E/F Trip " ( + ) ( ) ( + ) ( ) ( - ) ( ) ( - ) ( ) ( - ) ( ) Always 50N, 64 25. Ser. port Failure 24 ( - ) ( ) ( - ) ( ) ( + ) ( ) ( + ) ( ) ( + ) ( ) Always 03 26. Internal Failure " ( - ) ( ) ( + ) ( ) ( - ) ( ) ( - ) ( ) ( - ) ( ) Always 27. External Fault 1* 28. Control Cir. open* 29. Welded Contactor* 30. External Fault 2* 31. External Fault 3* 32. Temp. 4 Prealarm 19, 24 ( - ) ( ) ( - ) ( ) ( - ) ( ) ( + ) ( ) ( + ) ( ) Always 49R 33. Temp. 5 Prealarm " ( - ) ( ) ( - ) ( ) ( - ) ( ) ( + ) ( ) ( + ) ( ) Always 49R 34. Temp. 4 Trip " ( - ) ( ) ( - ) ( ) ( - ) ( ) ( + ) ( ) ( + ) ( ) Always 49R 35. Temp. 5 Trip " ( - ) ( ) ( - ) ( ) ( - ) ( ) ( + ) ( ) ( + ) ( ) Always 49R 36. Under Power 18, 25 ( - ) ( ) ( - ) ( ) ( - ) ( ) ( + ) ( ) ( + ) ( ) Run 37

Additional options available in the MPR which correspond to ANSI codes Lock-Out on thermal Trip 86 Controller Time Delays 02, 03 Annunciator 30

* Not in use

28

Actual Data

29

MEASURED ✱✱✱ DATA✱✱✱

Note: Values given below are examples only.

Display Description Vp1 Vp2 Vp3 240 240 240 V

Phase to Neutral voltages. Range: 100V - 12.7KV.

VL12 VL23 VL31 415 415 415 V

Line to Line Voltages. Range: 100V - 25KV.

I1 I2 I3 345 343 346 A

Line (motor) currents. Range: 1A - 24KA.

Earth Fault Cur. 0 Amp.

Earth fault current. Range:1A - 2000A

Power 48.9KW

Total motor power. Range : 0 - 30MW.

Power Factor 0.89

Total (Average of three phases) motor power factor. Range : 0.0 - 1.00

T1 T2 T3 120 120 120 °C

RTD/Thermistor measured resistance. RTD Can be presented as � or °C. Range: For RTD 100 - 240� or 0°C - 200°C Thermistor 100 -30,000�

T4 T5 120 120 °C

RTD measured resistance. RTD Can be presented as � or °C. Range: For RTD only : 100-240� or 0°C - 200°C

Note: All Power measurements and protection depend

upon MPR receiving all 3 line voltages and currents.

CALCULATED ✱✱✱ DATA✱✱✱

Display Description Motor Load 90 % of FLC

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

Thermal Capacity 20% of Capacity

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

Time to Trip No Trip Expected

Expected time to trip at the present current value that is above overload setting. Range: No trip expected 0-4 hrs

Time to Start 0 sec.

Expected time to start, displayed in one of the following cases: * After "Thermal Trip". This

is the expected time of the Thermal Capacity to decay to 50% of the maximum "Thermal Capacity".

* After "Too Many Starts" Trip. In this case maximum value of "Time to Start" equals "Start Inhibit" Time.

Range: After "Thermal Trip": 0 - ... min After "Too Many Starts": 1-60 min

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.

"Time to Trip" The expected time until motor trips. (i.e. the time to reach 100% of Thermal Capacity if the present current value is maintained). This value is calculated and displayed on the LCD. The host computer may read this value through the serial link, and takes corrective actions. "Time to Start" The expected time until it is possible to re-start after Thermal Trip or Too Many Starts. (i.e. the time to reach 50% of Thermal Capacity). This value is calculated and displayed on the LCD. Reset of the Thermal Capacity (different from Thermal Trip Reset), overriding time delay for re-starting, can be done only if Authorized Key is Enabled. Pressing Reset on front panel while Authorized Key is Enabled, displays "Reset Thermal Capacity???" message. Pressing Reset again within 1 second resets the Thermal Capacity.

Actual Data

30

LOGICAL INPUTS CONTACT STATUS

It is possible to check the of logical input status. Used for checking system wiring for maintenance and debugging purposes.

Display Description Drive Status

Available if:

* Motor is stopped. * There is no active trip. * Stop contact is closed. * Interlock and Isolator

inputs are not locked out. Note: In "Protection Only" mode, Stop, Interlock and Isolator inputs have no effect. Range: Available Running

Not Available Speed Switch Open = High Speed

Not in use

Authorized Key Open = Locked

Authorized Key input contact status. Range: Open = Locked Closed = Unlocked

External Fault 1 Open = Stop

Not in use

External Fault 2 Open = Stop

Not in use

External Fault 3 Open = Stop

Not in use

STATISTICAL ✱✱✱ DATA✱✱✱

Note: The following values are examples only.

Display Description Total Run Time 10137.5 hours

Total run time since commissioning. Range: 0-30,000 hours.

Total # of Start 1017

Total number of starts since commissioning. Range: 0-65535

Total # of Trips 12

Total number of trips since commissioning. Range: 0-65535

Last St. Period 5 sec.

Last start time duration. Range: 0-255 seconds.

Last St. Peak I 350 amp.

Peak current (highest of three phases) during last start. Range: 0-24000 Amp.

Energy* 234 KWH

Total Energy accumulated since last statistical data reset. * Available on special order

Actual Data

FAULT ✱✱✱ DATA✱✱✱

Display Description Last Trip Temp. 1 Trip

Last active fault that was Enabled as a Trip. Range: all 31 faults.

Last Alarm Temp. 1 Alarm

Last active fault that was Enabled as an Alarm. Range: all 31 faults.

Trip I1, I2, I3 110 112 109 A

Values of three line (motor) currents at time of last trip. Range: 0-24000 amp.

Trip I0 0 amp.

Values of Earth Fault current at time of last trip. Range: 0-24000 amp.

Trip V1, V2, V3 277 277 277 V

Values of phase to neutral voltages at time of last trip. Range: 0-25000 volt.

31

Test Messages Test page Test page can be used for initiating a built-in test procedure, displaying program version, storing factory default parameters into the non volatile memory, and for resetting and storing statistical data (when Authorized key is enabled). Unauthorized personnel can only view test screens.

TEST/MAINTENANCE ✱✱✱ OPTIONS✱✱✱

Display Description Run Self Test ? Push (+) to Run

Press key to initiate the built in test procedure.

Program Version

Program version description. MPC060995Modbus

Store Enable 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.

Reset & Store Statistical Data

Resets and stores "0" for all the statistical data. Press Reset and Data Page 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 * Last trip and pre-alarm voltages and currents "Data Saved ok" message will be displayed for about two seconds. 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.

32

Flash Messages Constant Messages

33

Display Description The message is displayed for a short while only. Display then 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. Flash messages are : Data Saved OK

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

Wrong Data Saved

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 after trying to Store, Reset or change value of parameters while Authorized Key is open (locked)

Reset Thermal Capacity ???

Displayed as a response to pressing Reset key while Authorized Key is closed (unlocked). It indicates that a second press on Reset key within 1 Sec. will reset thermal capacity to 0.

Note : This should be done with care !! Resetting Thermal Capacity may prevent the MPR from tripping for thermal overload while justified. Thermal Capacity Reset Performed

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

Unable to Start Check System

Not in use.

Self Test Passed

Displayed as a response to running the built-in test procedure, provided all other 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.

Display Description Displayed, as a response to an event and not as a result of an operator action. Hard-Wired Start

Not in use

Hard-Wired Stop

Not in use

Alarm: Thermal Prealarm

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

Trip: Thermal O/L Trip

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

Communications

34

The MPR is equipped with a powerful data communication system, operating beyond a motor protection controller into the realm of a complete motor management system. This communication system is unmatched in its reliability, flexibility and ease of use providing the ideal basis for the design of a modern motor management system. The MPR incorporates RS485 serial link and uses a MODBUS RTU protocol (The protocol is not included in this document) to provide 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 information and control can be accessed through the communication. * All Actual data parameters * All MPR Settings (Read & Write) * All the control commands (such as Start A, Start B, Stop etc.) * Reset The MPR system is user expandable. No special engineering skills or tools are required. For small systems, the Host computer can communicate directly with the MPR via a twisted shielded pair. For larger systems a Data Highway enables multiple MPR connection. Up to 32 MPRs can be added on each twisted pair of the Host serial link with full access to all MPR's.

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. System security is exceptionally high, meeting the highest standards of protected communication in the industry. Included in each message is a 16 bit CRC. Small System MPR basic configuration with any host computer, available protocols : 1. MODBUS RTU (binary) 2. SOLCON Note: Terminate

serial link cable with 120 Ohm resistors at both ends.

Large System

Technical Specification

35

Auxiliary Power Supply Ac Power Supply: Dc Power Supply: Switch set to 115 VAC: 80 - 135VAC Low voltage version: 19 - 60VDC. Switch set to 230 VAC: 160 - 270VAC High voltage version: 85 - 300VDC. Frequency: 45 to 65Hz. Power consumption: ≤ 20VA Phase Current Inputs (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�)

Earth Fault Current Inputs (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�) Line Voltage Inputs (three voltages, with or without neutral) Method : True rms, sample 0.5mS. Power consumption: ≤ 0.2VA Without VT transformer: range: 50 - 750 volts. Full scale: 750 volts. Accuracy: ± 1.0% of full scale. With VT transformer: range: 50 - 750 volts * (VT Primary / VT Secondary), limited to 25KV. Full scale: 750 volts * (VT Primary / VT Secondary), limited to 25KV. Accuracy: ± 1.0% of full scale. Thermistor / RTD Inputs (Three Thermistors/RTDs & Two optional RTDs) Time delay: 0.5 ± 0.2 Sec. 3 Thermistors (two wires) 3 or 5 RTDs (three wires) Range: 0.1 - 30K�. Range: 100 - 240� or 0°C - 200°C Accuracy: ± 0.1K� up to 5K�, ± 3% above 5K�. Accuracy: ± 3% of resistance.

Max wire resistance: 25�. 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 SETTING ± 1.5%. Total Run Time Accuracy: ±2%. Auto Restart Circuit Accuracy: ±20%.

Technical Specification

36

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: * High set overcurrent: When adjusted to 0 >>> 60mS ± 20mS. -0.1/+0.2Sec. up to 1 sec. * Earth fault trip: -0.1/+0.2Sec. for less than 1Sec. delay.

Relays Contacts

Rated load 8A/250VAC 1800VA 48Vdc, 0.25A Inductive 48Vdc, 1.0A Resistive Maximum voltage 250VAC 125Vdc, 0.15A 125Vdc, 0.4A Dielectric Strength 1500VAC, for 1 minute, Between Ground (terminal 63) and:

* Current inputs. * Auxiliary power supply inputs - only without 1000pF suppression capacitors. * Voltage inputs. * Control terminals - only without 1000pF suppression capacitors.

True R.M.S. Measurements Voltage, Current, and Resistance - Sampling Speed is 0.5mSec . Power Measurement Method: True RMS over three phase voltages and currents. Range: 0.1KW - 30MW Full Scale: 30MW Resolution: 0.1KW below 1MW, 0.01MW above 1MW. Accuracy: For V�90 * VT Primary / VT Secondary & Power factor�0.5 Two Ranges: 1. For (10% < I�150%) of CT primary, accuracy is : ± (2% +0.01 * CT Primary/ Motor FLC.) of

motor rated Power 2. For ( I�150%) of CT primary, accuracy is: ± 7% of the display reading Power Factor Method: Ratio between total power (P) to total apparent power (VA). Range: 0.0 - 1.0 lagging. Resolution: 0.001 Accuracy: For V�90 * VT Primary / VT Secondary & I � 50% of CT Primary & Power factor�0.7 it is

±0.03 Temperature Range 0�C to +50�C (default - all units), -10�C to +60�C (by special order)

Technical Specification

37

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 Case and Cutout Details (C:\WINDOWS\DESKTOP\MPR2000\MPR-2000-5-IM_FNL.DOC June 8, 2003)