Industrial Control - Bulletin 193
Contents
1. DIN Rail Panel Mount Power Terminals NEMA Contactors Control Communication and Expansion Modules Current Range A 0 55 30 05 50 6 60 055930 0 5 30 0 5 30 0797520 0 5 30 0559930 For Use With 100 09 23 100 C30 C55 100 C30 C55 Line and load side power conductor terminals Directly replaces 193 ECPM_ NEMA Size 0 2 100 09 23 100 C30 C55 100 C30 C55 Line and load side power conductor terminals Directly replaces 193 ECPM_ NEMA Size 0 2 Cat No 193 ESM 1 30A C23 193 ESM 1 30A C55 193 ESM 1 60A C55 193 ESM 1 30A E3T 193 ESM 1 60A E3T 592 5 30 52 592 ESM 1 60A S2 193 ESM 1G 30A C23 193 5 16 30 55 193 ESM 1G 60A C55 193 ESM IG 30A E3T 193 ESM IG 60A E3T 592 ESM 1G 30A S2 592 ESM 1G 60A S2 Description No of Inputs Outputs Rated Control Voltage V Control Module I O Module 4 In 3 Out 4 In 3 Out Communication Module EtherNet IP Communication Module Expansion Module Digital Expansion Module 120V AC 4 In 2 Out Digital Expansion Module 240V AC 4 In 2 Out Digital Expansion Module 24V DC 4 In 2 Out Expansion Power Supply Accessories Description For Use With Starter Control Station with 3 Meter Cable Contactor Coil Module 100 C23 contactors 100 C55 contactors 1 Meter Expansion Module Cable 3 Meter Expansion Module Cable Replacement Connector 120 240V AC 4 3 Control Modules Digital Ex2. 1 E300 Expansion Power Supply 193 EXP PS __ Le 45 1 77 4x 4 5 0 18 dia i 98 87 3 86 3 43 80 75 3 18 1 i m 12 0 47 00 Starter Control Station 193 EOS SCS 0 3 145 5 42 8 0 309 120 il 4 73 120 4 73 22 5 0 89 dia Copyright 2014 Rockwell Automation Inc Rights Reserved
3. 104 F Humidity Operating 5 95 Non condensing Damp Heat Steady State per IEC 68 2 3 92 r h 40 104 F 56 days Damp Heat Cyclic per IEC 68 2 30 93 r h 25 40 C 77 F 104 F 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 30 G Maximum Altitude 2000 m Pollution Environment Pollution Degree 3 Terminal Marking EN 50012 Degree of Protection 20 Exception Any 00 Overload Relay that uses external ground fault sensor is limited to 50 60 Hz detection Note The E300 Electronic Overload Relay expansion power supplies Cat Nos 193 5 193 EXP PS DC surrounding air temperature must not exceed 55 131 F Electromagnetic Compatibility Specifications Electrostatic Discharge Immunity Test Level Performance Criteria RF Immunity Test Level Performance Criteria Electrical Fast Transient Burst Immunity Test Level Performance Criteria Surge Immunity Test Level Performance Criteria Radiated Emissions Conducted Emissions 8kV Air Discharge 6kV Contact Discharge 1x 10V m 15 4kV Power 2kV Control amp Comm Performance Criteria 1 requires the DUT to experience degradation loss of performance Environment 2 Protection Protection Trip Warning Overload Yes 1255 Phase 1055 Yes Ground Fault Yes Yes Stall Yes N
4. AC 40V AC Off State Current 1 5 mA 2 5 mA 2 5 mA Transition Voltage Sraa LIV DC 20 74V AC 40 159V Transition Current 1 5 2 0 mA 2 9 MA f 2 5 5 mA 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 Expansion Digital Modules Expansion Digital 1 0 Modules 193 EXP DIO 42 24D 193 EXP DIO 42 120 193 EXP DIO 42 240 Digital Output Rated Operational Voltage 250V AC 250V AC 250V AC Digital Output Rated Insulation Voltage U 2000Vrms for 1s 2000Vrms for 1s 2000Vrms for 1s Rated Impulse Withstand Voltage Uimp NA NA NA Conditional Short Circuit Current 1000 A 1000 A 1000 A Recommended Control Circuit Fuse KTK R 6 A 600V KTK R 6 A 600V KTK R 6 A 600V Utilization Category AC15 DC13 AC15 DC13 AGIS Pollution Degree 5 3 Expansion Power Supply Modules Expansion Power Supply Modules 193 EXP PS AC Rated Operational Voltage 06 100 250V Rated Insulation Voltage Uj 2640Vrms for 1s Rated Impulse Withstand Voltage Uimp 4 kV Conditional Short Circuit Current NA Protection Against Short Circuits NA Utilization Category NA Pollution Degree 3 Environmental Specifications Ambient Temperature Storage 40 85 C 40 185 F Operating Open 20 55 4 131 F Enclosed 20 40 C 4
5. 65 rl HENE 371471 FROM HE fci COMTACTOR e ET MiG HOWE aT CI AE CONTACTOR Mit E300 Overload Relay Mounted on Bulletin 100 C30 C23 Contactor C37 Contactor 5112351 190 7 59 5 mmi Sin FOR CONTAC TOR COM ON LINE SIDE 5 2655 i48 FROM CONTACTUR WTG HOLE 1521594 Hz AIH FROM CONTACTUR MTG PERLE 1960 7 449 ADD 5 mm 0 19 inp FOR CONTACTOR COR UNE SIDE m ord 55 L748 FROM CONTACTOR POLE 152 508 FROM CONTACTOR MTG HOLE eor r 35 11 574 E is BO 2 35 680 2 34 E300 Overload Relay Mounted on Bulletin 500 NEMA Size 0 and Size 1 Contactor 90 3 56 n 6 0 22 dn folie 180 7 06 E B Li pr 2 2 157 6 17 T _ T El i 249 9 78 Too _ 58 E Em i TH ML fv e 12 0 46 35 1 38 n 6 0 22 184 7 24 219 8 63 276 10 85 12 0 46 40 1 58 80 3 15 E300 Overload Relay DIN Rail Panel Mounted 45 1 764 46 12 ai TA 1484583 4014 E300 Digital Expansion Module 193 EXP DIO ___ 225 943 2 x 4 5 0 18 dia P m i e 98 3 86 87 3 43 80 75 3 18 e 1 1
6. An overload trip occurs when the value reaches 10096 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 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 even
7. Relay Outputs Inputs Relay Outputs 110 120 AC 50 60 Hz 4 3 2 2 220 240 50 60 Hz 4 3 2 2 Includes Thermistor 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 e 24V DC e 120V AC e 240V AC 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 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 reports this calculated value and can be read via a communications network
8. Rockwell Automation STEN THINK SOLVE Bulletin 193 E300 Electronic Overload Relays 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 make this the ideal overload for motor control applications in an automation system e Intelligent motor control EtherNet IP enabled e Scalable solution e Diagnostic information e Integrated I 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 C tick Product Overview I ls t Allen Bradley TRP WARN MS NS TEST RESET un Lune EtherNetv P 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 Current ground fault e Current Current Range A e 0 5 30 e 6 60 Control Module Control Voltage 1 0 I O and Protectionx Inputs
9. 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 Overcurrent 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 Addi
10. ip 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 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 is afforded in both cases EtherNet IP Communications The E300 EtherNet communication module has two 45 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 SMPT server for trip and warning events e Embedded EDS file RSLogix 5000 add on profile For more information on operation and maintenance of this product please reference the user manual publication 193 UM0015 Bulletin 193 592 E300 Electronic Overload Relays Sensing Modules Description Mounting Options Current Sensing Module IEC Contactors DIN Rail Panel Mount Power Terminals NEMA Contactors Current Ground Fault Sensing IEC Contactors Module
11. o Jam Yes Yes Underload Yes es Thermistor PTC VESER ES Current Imbalance Yes fyes Communication Fault Yes Yes Communication Idle Yes Yes Remote Trip Yes Blocked Start Start Inhibit Yes No Under Voltage L L Yes Yes Over Voltage L L Yes Yes Voltage Unbalance Yes Yes Phase Rotation Yes Yes Overload Protection Type of Relay Nature of Relay Solid State FLA Setting See user manual Trip Rating 12096 FLA Trip Class 55 30 Reset Mode Automatic or Manual Overload Reset Level 1 100 TCU Ambient Compensated Time Delay Phase Loss Sensitive Ground Fault Protection External Ground Fault Module Type Core Balanced Intended Use Equipment Protection Classification Per UL 1053 Class Protection Range 20 100 mA 100 500 mA 200 mA 1 0 A 1 0 5 0 A amp Warning Time Delay 0 1 25 0 5 Protection Inhibit Time 0 250 s Accuracy Metering The E300 Electronic Overload Relay metering accuracy is listed below Current 2 of Sensing Module Current Range Protection Timers All E300 Electronic Overload Relay trip timers a resolution of 0 1 5 or 0 1 5 25 5 whichever is greater Approximate dimensions are shown in millimeters inches Dimensions are not to be used for manufacturing purposes E300 Overload Relay Mounted on Bulletin 100 C09 m et D m 190774 ADOS em 19 in FOR CONTACTOR COR ON LINE SIDE nm 67 2
12. pansion Modules Expansion Power Supply Wiring Diagrams Control Module RELAY 1 RELAY 2 Expansion Digital Modules 193 EXP DIO 110 120V 50 60 Hz 220 240V AC 50 60 Hz 110 120V AC 50 60 Hz 220 240V AC 50 60 Hz 24V DC 110 240V AC 50 60 Hz 24V DC Cat No 193 EOS SCS 193 ElO CM C23 193 ElO CM C55 193 EXP CBL 1M 193 EXP CBL 3M 193 NCIO 43 CNT 193 NCXP DIO CNT 193 NCXP PS CNT Cat No 193 ElO 43 120 193 ElO 43 240 193 ECM ETR 193 EXP DIO 42 120 193 EXP DIO 42 240 193 EXP DIO 42 24D 193 EXP PS AC 193 EXP PS DC 000 i A w B A 00 00 os Ria Source Tw T 2 Expansion Power Supplies 193 5 0 ti 0000 0000000000000 009000009900000900 000 Electrical Specifications Motor Load Ratings Terminals Rated Insulation Voltage Ui Rated Operating Voltage Ue Rated Impulse Voltage Uimp Rated Operating Current Ze Rated Frequency Short Circuit Ratings Number of Poles Application LAPS L2 i y TZ GTS 690V AC 690V AC 600V AC 6 kV See Catalog Number Explanation 45 65 Hz See user manual 3 Single phase or Three phase Exception Any E300 Overload Relay that uses an external ground fault sensor is limited to 50 60 Hz detection Power S
13. rmal 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 trip e Trip snapshot 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 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 Al 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 tr
14. t 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 factory set at a current imbalance measurement of 100 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
15. tionally 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 Current Imbalance Asymmetry The E300 Electronic Overload Relay offers current imbalance trip and warning settings adjustable 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 the
16. upply Ratings Rated Supply Voltage US 120V AC Operating Range 85 132V Maximum Inrush Current 6A Maximum Power Consumption E300 6 W E300 with expansion 8 W Maximum Power Interruption Time Vmin 10 ms Vmax 10 ms 159 265V AC 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 Form A SPST NO Rated Thermal Current Ahe 5A Rated Insulation Voltage Ui 300V AC Rated Operating Voltage U 250V AC Rated Operating Current Ze 3A 120V AC 1 5 A 240V AC 0 25 A 110V DC 0 1A 220V DC Minimum Operating Current 10 mA 5V DC Rating Designation B300 Utilization Category AC 15 Resistive Load Rating p f 1 0 5 A 250V AC 5 A 30V DC Inductive Load Rating p f 20 4 2 250V L R 27 ms 2 A 30V DC Short Circuit Current Rating 1 000 A Recommended Control Circuit Fuse KTK R 6 6 A 600 V Rated Number of Operations Relay 0 Relay 1 and Relay 2 5 000 000 W 100 C09 100 C43 2 500 000 W 100 C60 100 C97 1 000 000 W NEMA Size 0 2 300 000 W NEMA Size 3 Input Ratings Control Module and Expansion Digital Module Terminals Input 0 INO Input 1 Input 2 IN2 Input 3 IN3 Input 4 IN4 Input 5 5 Supply Voltage 24V DC 120V AC 240V AC Type of Inputs Current Sinking On State Voltage 74V 159V AC On State Current turn on 2mA 5mA 5mA Off State Voltage 5V DC 20V
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