E300 Electronic Overload Relay Selection Guide
Contents
1. lees 45 1 77 AB Allen Bradley Visit our website www ab com catalogs Publication 193 SG010A EN P NI 22 5 0 89 dia E a a Y f 13 Allen Bradley Rockwell Software Rockwell Automation and LISTEN THINK SOLVE are trademarks of Rockwell Automation Inc Trademarks not belonging to Rockwell Automation are property of their respective companies www rockwellautomation com Power Control and Information Solutions Headquarters Americas Rockwell Automation 1201 South Second Street Milwaukee WI 53204 2496 USA Tel 1 414 382 2000 Fax 1 414 382 4444 Europe Middle East Africa Rockwell Automation NV Pegasus Park De Kleetlaan 12a 1831 Diegem Belgium Tel 32 2 663 0600 Fax 32 2 663 0640 Asia Pacific Rockwell Automation Level 14 Core F Cyberport 3 100 Cyberport Road Hong Kong Tel 852 2887 4788 Fax 852 2508 1846 Publication 193 SGO10A EN P December 2013 Copyright 2013 Rockwell Automation Inc All rights reserved Printed in the U S A2. This LED flashes a yellow code under a warning condition and a red code when tripped Inputs Outputs Inputs allow the connection of such devices as contactor and disconnect auxiliary contacts pilot devices limit switches and float switches Input status can be monitored via the network and mapped to a controller s input image table Inputs are rated 24V DC 120V AC or 240V AC and are current sinking Power for the inputs is sourced separately with convenient customer sources at terminal A1 Relay contact outputs can be controlled via the network or DeviceLogix function blocks for performing such tasks as contactor operation Test Reset Button The Test Reset button located on the front of the E300 Electronic Overload Relay allows the user to perform the following e Test The trip relay contact will open if the E300 Electronic Overload Relay is in an untripped condition and the Test Reset button is pressed for 2 seconds or longer e Reset The trip relay contact will close if the E300 Electronic Overload Relay is in a tripped condition supply voltage is present and the Test Reset button is pressed Visit our website www ab com catalogs 4 Publication 193 SG010A EN P wy Single Three Phase Operation The E300 Electronic Overload Relay can be applied to three phase as well as single phase applications A programming parameter is provided for selection between single and three phase operation Straight through wiring
3. During an overload condition the E300 Electronic Overload Relay provides an estimated time to trip that is accessible via a communications network This allows corrective action to be taken so that production may continue uninterrupted Time to Reset Following an overload trip the E300 Electronic Overload Relay will not reset until the calculated percentage of thermal capacity utilization falls below the reset level As this value decays the time to reset which is accessible via a communications network is reported Thermal Warning The E300 Electronic Overload Relay provides the capability to alert in the event of an impending overload trip A thermal warning bit is set in the Warning Status when the calculated percentage of thermal capacity utilization exceeds the programmed thermal warning level which has a setting range of 0 100 TCU Two Speed Protection The E300 Electronic Overload Relay offers a second FLA setting for 2 speed motor protection What used to require two separate overload relays one for each set of motor windings can now be accomplished with one device Improved protection is delivered as thermal utilization is maintained in one device during operation in both speeds Phase Loss The E300 Electronic Overload Relay offers configurable phase loss protection allowing the installer to enable or disable the function plus set a time delay setting adjustable from 0 1 25 0 seconds The trip level is factor
4. FROM CONTACTOR MTG HOLE 152 5 98 34 1 34 FROM CONTACTOR MTG HOLE 4 82 E300 Overload Relay Mounted on Bulletin 500 NEMA Size 0 and Size 1 Contactor 90 b off Bato Noon nlc wal cena la 180 7 06 157 6 17 Foo lolol 249 9 78 UDI IDL IH q 3 Visit our website www ab catal Allen Bradley E e Publication 193 SG010A EN P 11 Bulletin 193 592 E300 Electronic Overload Relay Approximate Dimensions E300 Overload Relay Mounted on Bulletin 500 NEMA Size 2 Contactor 184 7 24 219 8 63 276 10 85 40 1 58 6 0 24 9 0 33 Tramm A As A I i 101 3 96 olay 4 0 154 aK 1i eiat E f n5 0 17 8 0 30 Visit our website www ab com catalogs Allen Bradle 12 Publication 193 SG010A EN P uy y E300 Digital Expansion Module 193 EXP DIO ___ Bulletin 193 592 E300 Electronic Overload Relay Approximate Dimensions fa 120 4 73 120 4 73 EER 0 89 2x4 5 0 18 dia l a0 jay I D 98 3 86 87 3 43 80 75 3 18 S T a E300 Expansion Power Supply 193 EXP PS ___ 1 77 4x 4 5 0 18 dia 7 rT N N I oO 98 87 3 86 3 43 80 75 3 18 Me T Y
5. Sensin ine si z IG 30A ied g DIN Rail Panel Mount Power 0 5 30 Line and load side power 193 ESM IG 30A E3T oaule Terminals conductor terminals Directly 6 60 replaces 193 ECPM_ 193 ESM IG 60A E3T 0 5 30 592 ESM IG 30A S2 NEMA Contactors 6 60 NEMA Size 0 2 592 ESM IG 60A S2 ee al Control Communication and Expansion Modules Description Control Module No of Inputs Outputs Rated Control Voltage V Cat No Communication Module Expansion Module Accessories VO Modul 4 In 3 Out 110 120V AC 50 60 Hz 193 ElO 43 120 sahil 4 In 3 Out 220 240V AC 50 60 Hz 193 ElO 43 240 EtherNet IP Communication Module 193 ECM ETR Digital Expansion Module 120V AC 4 In 2 Out 110 120V AC 50 60 Hz 193 EXP DIO 42 120 Digital Expansion Module 240V AC 4 In 2 Out 220 240V AC 50 60 Hz 193 EXP DIO 42 240 Digital Expansion Module 24V DC 4 In 2 Out 24V DC 193 EXP DIO 42 24D 110 240V AC 50 60 Hz 193 EXP PS AC Expansion Power Supply 24V DC 193 EXP PS DC Description Starter Control Station with 3 Meter Cable For Use With Cat No 193 EOS SCS Contactor Coil Module 100 C23 contactors 193 ElO CM C23 100 C55 contactors 193 ElO CM C55 1 Meter Expansion Module Cable 193 EXP CBL 1M 3 Meter Expansion Module Cable 193 EXP CBL 3M Replacement Connector Allen Bradley 120 240V AC 4 3 Control Modules 193 NCIO 43 C
6. C e 120V AC e 240V AC Visit our website www ab com catalogs All B di 3 Allen Bradley Publication 1938 SG010A EN P Bulletin 193 592 E300 Electronic Overload Relay Overview Thermal Overload Thermal Utilization The E300 Electronic Overload Relay provides overload protection through true RMS current measurement of the individual phase currents of the connected motor Based on this information a thermal model that simulates the actual heating of the motor is calculated Percent of thermal capacity utilization TCU reports this calculated value and can be read via a communications network An overload trip occurs when the value reaches 100 Adjustable Settings Thermal overload protection setup is accomplished simply by programming the motor s full load current FLC rating and the desired trip class 5 30 Programming of the actual values through software programming ensures the accuracy of the protection Thermal Memory The E300 Electronic Overload Relay includes a thermal memory circuit designed to approximate the thermal decay for a trip class 20 setting This means that the thermal model of the connected motor is maintained at all times even if the supply power is removed Reset Modes This flexibility allows the end user in the ability to select between manual and automatic reset for an overload trip allowing for broad application The point of reset is user adjustable from 1 100 TCU Time to Trip
7. NT Digital Expansion Modules 193 NCXP DIO CNT Expansion Power Supply Visit our website www ab com catalogs Publication 193 SG010A EN P 193 NCXP PS CNT Bulletin 193 592 E300 Electronic Overload Relay Specifications Wiring Diagrams Control Module 193 EIO Expansion Digital I O Modules 193 EXP DIO __ R04 R14 RG R04 R14 RC3 Pe RELAY 1 Source RELAY 2 INO IN1 IN2 IN3 INC ell UUUUUUUUOUUUU gt 5 UUU Expansion Power Supplies 193 EXP PS __ Source Al A2 S Visit our website www ab com catalogs Publication 193 SG010A EN P Allen Bradley Bulletin 193 592 E300 Electronic Overload Relay Specifications Electrical Specifications Motor Load Ratings Input Ratings Control Module and Expansion Digital Terminals 1 11 3 12 5 L3 2 11 4 72 6 13 Module Rated Insulation Voltage Ui 690V AC Terminals Rated Operating Voltage Ue Input 0 INO IEC 690V AC Input 1 IN1 u soov ac Input 2 n Rated Impulse Voltage Uimp 6 kV Input 4 IN4 Rated Operating Current Ze See Catalog Number Explanation I
8. Selection Guide Allen Bradley E300 Electronic Overload Relay Bulletin 193 592 LISTEN las Rockwell Allen Bradley Rockwell Software Automation Bulletin 193 592 E300 Electronic Overload Relay Overview Bulletin 193 E300 Electronic Overload Relays The E300 Electronic Overload Relay is the newest technology for overload protection Its modular design communication options diagnostic information simplified wiring and integration into Logix Table of Contents Product Overview this page Product Selection 5 Banay make this the ideal overload for motor control applications in an ACCESSOTSICS o 5 J i im S automation system Specifications 6 Il 2 e Intelligent motor control EtherNet IP enabled Approximate e Scalable solution Dimensions 0000 10 cnet e Diagnostic Information e Integrated O e Adjustable trip class 5 30 e Wide current range e Test Reset button e Programmable trip and warning settings e True RMS current voltage sensing 50 60 Hz e Protection for single and three phase motors Standards Compliance EN 60947 4 1 CSA C22 2 No 14 UL 508 UL1053 class 1 Certifications CE cULus Listed File No E14840 Guide NKCR NKCR7 File No E53935 Guide KDAX C tick NOTE Your order must include 1 the Cat No of the sensing module control module and communication module selected and 2 if required Cat No of any accesso
9. ating 1 000 A ei KTK R 6 Recommended Control Circuit Fuse 6 A 600 V Rated Number of Operations Relay 0 Relay 1 and Relay 2 W 100 C09 100 C43 Ane W 100 C60 100 C97 AA W NEMA Size 0 2 1 000 000 A 300 000 W NEMA Size 3 Allen Bradley Visit our website www ab com catalogs Publication 193 SG010A EN P Bulletin 193 592 E300 Electronic Overload Relay Specifications Low Voltage Directive The E300 Electronic Overload Relay expansion digital modules are tested to comply with EN60947 5 1 Low voltage switchgear and controlgear Part 5 1 Control circuit devices and switching elements Electromagnetic Compatibility Specifications Electrostatic Discharge Immunity Test Level 8kV Air Discharge 6kV Contact Discharge Performance Criteria 1x Expansion Digital I O Modules RF Immunity Expansion Digital 193 EXP DIO 42 193 EXP DIO 42 193 EXP DIO 42 Test Level 10V m 1 0 Modules 24D 120 240 Performance Criteria 1 e Digital Output Electrical Fast Transient Burst Immunity Rated Operational 250V AC 250V AC 250V AC Test Level AkV Power Voltage Ue 2kV Control amp Comm Digital Output Performance Criteria 1 et Rated Insulation 2000Vrms for 1s 2000Vrms for 1s 2000Vrms for 1s Surge Immunity Voltage Ui Test Level 2kV L E Rated Impulse 1kV L L Withstand Voltage NA NA NA Performance Criteria 1 t imp Radiated Emissions Class A Conditional S
10. e 0 250 s Accuracy Metering The E300 Electronic Overload Relay metering accuracy is listed below Current Protection Timers 2 of sensing Module Curren Range All E300 Electronic Overload Relay trip timers have a resolution of 0 1 s or 0 1 s 25 s whichever is greater Visit our website www ab com catalogs Publication 193 SG010A EN P Bulletin 193 592 E300 Electronic Overload Relay Approximate Dimensions Approximate dimensions are shown in millimeters inches Dimensions are not to be used for manufacturing purposes E300 Overload Relay Mounted on Bulletin 100 C09 C23 Contactor n 5 0 18 190 7 49 ADD 5 mm 0 19 in FOR CONTACTOR COIL ON LINE SIDE 37 1 47 FROM CONTACTOR MTG HOLE FA fl 152 5 98 122 4 81 29 1 14 FROM CONTACTOR MTG HOLE E300 Overload Relay Mounted on Bulletin 100 C30 C37 Contactor 190 7 49 ADD 5 mm 0 19 in FOR CONTACTOR COIL ON LINE SIDE 60 2 36 37 1 48 FROM CONTACTOR MTG HOLE 152 5 98 122 4 81 29 1 13 FROM CONTACTOR MTG HOLE 10 Visit our website www ab com catalogs Allen Bradley Publication 193 SG010A EN P Bulletin 193 592 E300 Electronic Overload Relay Approximate Dimensions E300 Overload Relay Mounted on Bulletin 100 C43 C55 Contactor 107 n 5 0 18 190 7 49 ADD 5 mm 0 19 in FOR CONTACTOR COIL ON LINE SIDE 37 1 48
11. hort 1000 A 1000 A 1000 A Conducted Emissions Class A Circuit Current Recommended Performance Criteria 1 requires the DUT to experience no degradation or Control Circuit KTK R 6 A 600V KTK R 6 A 600V KTK R 6 A 600V loss of performance Fuse Environment 2 Utilization AC15 DC13 AC15 DC13 AC15 DC13 Category Pollution Degree 3 3 3 Expansion Power Supply Modules Expansion Power Supply Modules Rated Operational Voltage Ue 193 EXP PS AC 100 250V AC Rated Insulation Voltage U 2640Vrms for 1s Rated Impulse Withstand Voltage Uim Conditional Short Circuit Current NA Protection Against Short Circuits NA Utilization Category NA Pollution Degree Environmental Specifications Ambient Temperature Storage 40 85 C 40 185 F Operating Open 20 55 C 4 131 F Enclosed 20 40 C 4 104 F Humidity Operating 5 95 Non condensing Damp Heat Steady State per IEC 92 r h 40 C 104 F 56 days 68 2 3 93 r h 25 C 40 C 77 F 104 F Damp Heat Cyclic per IEC 68 2 30 21 Cycles Cooling Method Natural Convection Vibration per IEC 68 2 6 2 5G operating 5 G non operating Shock per IEC 68 2 27 30G Maximum Altitude 2000 m Pollution Environment Pollution Degree 3 Terminal Marking EN 50012 Degree of Protection IP20 Exception Any E300 Overload Relay tha
12. is afforded in both cases EtherNet IP Communications The E300 EtherNet IP communication module has two RJ45 ports that act as an Ethernet switch to support a star linear and ring topology and supports the following e 2 concurrent Class 1 connections 1 exclusive owner 1 input only or 1 listen only e 6 simultaneously Class 3 connections explicit messaging e Embedded web server e SMPT server for trip and warning events e Embedded EDS file e RSLogix 5000 add on profile For more information on operation and maintenance of this product please reference the user manual publication 193 UM0015 Allen Bradley Bulletin 193 592 E300 Electronic Overload Relay Product Selection Bulletin 193 592 E300 Electronic Overload Relays Sensing Modules Description Mounting Options Current Range A For Use With Cat No 0 5 30 100 C09 C23 193 ESM I 30A C23 IEC Contactors 0 5 30 100 C30 C55 193 ESM I 30A C55 6 60 100 C30 C55 193 ESM I 60A C55 Current Sensing Module DIN Rail Panel Mount Power 0 5 30 abe and oaa mne powa 193 ESM I 30A E3T Terminals oo conductor terminals Directly 493 ESM I 60A E3T a replaces 193 ECPM_ 0 5 30 592 ESM I 30A S2 NEMA Contactors NEMA Size 0 2 6 60 592 ESM I 60A S2 0 5 30 100 C09 C23 193 ESM IG 30A C23 IEC Contactors 0 5 30 100 C30 C55 193 ESM IG 30A C55 6 60 100 C30 C55 193 ESM IG 60A C55 Current Ground Fault
13. nput 5 INS Rated Frequency 45 65 Hz amp Supply Voltage 24V DC 120V AC 240V AC Short Circuit Ratings See user manual Type of Inputs Current Sinking NumberotPales 3 On State Voltage 11V DC 74V AC 159V AC Application Single phase or Three phase ee 2mA 5 mA 5 mA Exception Any E300 Overload Relay that uses an external ground fault Off State Voltage 5V DC 20V AC 40V AC sensor is limited to 50 60 Hz detection Off State Current 15 mA 25 mA 25 mA Power Supply Ratings Transition Voltage 5 11V DC 20 74V AC 40 159V AC Transition Current 1 5 2 0 MA 2 5 5 MA 2 5 5 MA Rated sai Voltage 420V AC 240V AC Operating Range 85 1382V AC 159 265V AC Maximum Inrush Current 6A Maximum Power Consumption E300 6W E300 with expansion 8w Maximum Power Interruption Time Vmin 10 ms 10 ms Vmax 10 ms 10 ms Output Relay Ratings Control Module and Expansion Digital Module Terminals Relay 0 R03 R04 Relay 1 R13 R14 Relay 2 R23 R24 Type of Contacts gio oa Rated Thermal Current hne 5A Rated Insulation Voltage Uj 300V AC Rated Operating Voltage Ue 250V AC 3 A 120V AC 1 5 A 240V AC Rated Operating Current Ie 0 25 A 110V DC 0 1 A 220V DC Minimum Operating Current 10 mA 5V DC Rating Designation B300 Utilization Category AC 15 Resistive Load Rating 5 A 250V AC p f 1 0 5 A 30V DC MR an 2 A 250V AC UR 7 ms 2 A 30V DC Short Circuit Current R
14. ries Product Overview The E300 consists of three modules sensing control and communications Users have choices in each of the three with additional accessories to tailor the electronic overload for their application s exact needs Sensing Module Sensing Options e Current ground fault e Current Current Range A e 0 5 30 6 60 e 10 100 Control Module 1 0 I O and Protection Relay Relay Control Voltage Inputs Outputs Inputs Outputs 110 120V AC 50 60 Hz 4 3 2 2 220 240V AC 50 60 Hz 4 3 2 2 Includes PTC Thermistor and external ground fault Communication Module e EtherNet IP Expansion Digital I O Users can add up to four additional expansion digital modules to the E300 expansion bus e 4 Inputs 2 Relay Outputs Expansion Power Supply When more than one expansion digital module and one operator station are added to the E300 expansion bus an expansion power supply is needed to supplement power for the additional modules One expansion power supply will power a fully loaded E300 expansion bus e 120 240V AC e 24V DC Expansion Operator Station One operator station can be added to the E300 expansion bus to be used as a user interface device The operator stations provide E300 status LEDs and function keys for motor control The operator stations also support CopyCat which allows user to upload and download E300 configuration parameters e Control station e 24V D
15. stable from 10 100 The trip function also includes a trip delay time with a range of 0 1 25 0 seconds Remote Trip The remote trip function allows an external device e g a vibration sensor to induce the E300 Electronic Overload Relay to trip External device relay contacts are wired to the E300 Electronic Overload Relay discrete inputs These discrete inputs are configurable with an option for assigning the remote trip function Current Monitoring Functions The E300 Electronic Overload Relay allows the user to monitor the following operational data over a communications network e Individual phase currents in amperes e Individual phase currents as a percentage of motor FLC e Average current in amperes e Average current as a percentage of motor FLC e Percentage of thermal capacity utilized e Current imbalance percentage e Ground fault current Diagnostic Functions The E300 Electronic Overload Relay allows the user to monitor the following diagnostic information over the DeviceNet network e Device status e History of past five trips e Trip status e History of positive warnings e Warning status e Hours of operation e Time to an overload trip e Number of starts e Time to reset after an overload e Trip snapshot trip Status Indicators The E300 Electronic Overload Relay provides the following LED indicators e Power This green red LED indicates the status of the overload relay TRIP WARN
16. t uses an external ground fault sensor is limited to 50 60 Hz detection Note The E300 Electronic Overload Relay expansion power supplies Cat Nos 193 EXP PS AC and 193 EXP PS DC surrounding air temperature must not exceed 55 C 131 F Visit our website www ab com catalogs Publication 1938 SG010A EN P Allen Bradley Bulletin 193 592 E300 Electronic Overload Relay Specifications Protection Protection Trip Warning Overload Yes Yes Phase Loss Yes No Ground Fault Yes Yes Stall Yes No Jam Yes Yes Underload Yes Yes Thermistor PTC Yes Yes Current Imbalance Yes Yes Communication Fault Yes Yes Communication Idle Yes Yes Remote Trip Yes No saa heel Yes No Under Voltage L L Yes Yes Over Voltage L L Yes Yes Voltage Unbalance Yes Yes Phase Rotation Yes Yes Allen Bradley Overload Protection Type of Relay Ambient Compensated Time Delay Phase Loss Sensitive Nature of Relay Solid State FLA Setting See user manual Trip Rating 120 FLA Trip Class 5 30 Reset Mode Automatic or Manual Overload Reset Level 1 100 TCU Ground Fault Protection External Ground Fault Module Type Core Balanced Intended Use Equipment Protection Classification Per UL 1053 Class 20 100 mA 100 500 mA Protection Range 200 mA 1 0 A 1 0 5 0A Trip amp Warning Time Delay 0 1 25 0s Protection Inhibit Tim
17. urrent The E300 Electronic Overload Relay can respond quickly to take a motor off line in the event of a mechanical jam thereby reducing the potential for damage to the motor and the power transmission components Trip adjustments include a trip setting adjustable from 50 600 FLA and a trip delay time with a range of 0 1 25 0 seconds A separate warning setting is adjustable from 50 600 FLA Underload Undercurrent A sudden drop in motor current can signal conditions such as e Pump cavitation e Tool breakage e Belt breakage For these instances rapid fault detection can help minimize damage and aid in reducing production downtime Additionally monitoring for an underload event can provide enhanced protection for motors that are coded by the medium handled e g submersible pumps that pump water Such motors can become overheated despite being underloaded This can result from an absence or an insufficient amount of the medium due to clogged filters closed valves etc The E300 Electronic Overload Relay offers underload trip and warning settings adjustable from 10 100 FLA The trip function also includes a trip delay time with a range of 0 1 25 0 seconds Visit our website www ab com catalogs Publication 193 SG010A EN P 3 Bulletin 193 592 E300 Electronic Overload Relay Overview Current Imbalance Asymmetry The E300 Electronic Overload Relay offers current imbalance trip and warning settings adju
18. y set at a current imbalance measurement of 100 Allen Bradley Ground Earth Fault The E300 Electronic Overload Relay incorporates zero sequence core balance sensing into its design for low level arcing ground fault detection Trip and warning settings are adjustable from 20 mA 5 0 A For devices rated greater than 200 A and for ground fault detection less than 1 0 A the external core balance current transformer accessory is required Class protection is provided as defined by UL1053 The E300 Electronic Overload Relay provides a max trip inhibit setting offering flexibility to prevent tripping when the ground fault current magnitude exceeds 6 5 A This can be useful to guard against the opening of the controller when the fault current could potentially exceed the controller s interrupting capacity rating Note The E300 Electronic Overload Relay is not a Ground Fault Circuit Interrupter for personnel protection as defined in article 100 of the U S National Electric Code Stall Stall is defined as a condition where the motor is not able to reach full speed operation in the appropriate amount of time required by the application This can result in motor overheating as current draw is in excess of the motor s full load current rating The E300 Electronic Overload Relay provides user adjustable stall protection The trip setting has a range of 100 600 FLA and the enable time is adjustable up to 250 seconds Jam Overc
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