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Leading Motor Protection into the Next Century Electronic Motor Protection Selection Guide Since its earliest days, Allen-Bradley has been rooted in the development and delivery of innovative motor control solutions. The first product to wear the Allen-Bradley badge, the carbon disc compression type controller, provided stepless speed control for motors – performance unobtainable with other technologies at the time. Allen-Bradley pioneered again in the development of solenoid operated motor starters, setting the standard for across- the-line starting. One hundred years later, the pursuit of motor control technology leadership continues to be a driving force for Allen-Bradley. This is no more evident than in the area of electronic motor protection: >> The E1 Plus, Allen-Bradley’s next generation self-powered solid-state overload relay, features the industry’s widest FLA setting adjustment range. One device spans the range of up to four bimetallic devices or nineteen heater elements. >> Integration is key to the E3 and E3 Plus electronic overload relays featuring advanced protective functions, integrated inputs and outputs, and built-in DeviceNet ™ communications. What traditionally required a handful of devices can now be cost effectively accomplished with one compact device. >> The 825-P Modular Protection System for motors is uniquely expandable so that its configuration can be matched to application requirements. Comprehensive protective functions are available that continually monitor for the damaging effects of current, voltage and temperature. E1 Plus E3 and E3 Plus � Self-Powered: wires the same as traditional electromechanical designs – no additional wiring required. � Solid-State: provides precise, reliable and repeatable operation. � Enhanced Protection: current measurement based design delivers accurate thermal overload performance that is ambient insensitive with responsive phase loss protection. � Flexible Adjustments: wide 5:1 adjustment range and DIP switch settings for trip class and reset mode on EE versions offer application flexibility. � Insert Molded Power Stabs: Rockwell Automation exclusive feature delivers unmatched robust connections in starter assemblies. � Modular: patented design allows for easy expansion of capabilities with side mount accessories compatible with the EE version devices. � Advanced Protection: a broad range of motor and load protective functions that extends well beyond traditional overload relays. Warning functions alert production personnel of impending trips, allowing for corrective action to be taken in order to avoid downtime. � Patented, State-of-the-Art Current Sensing: hall-effect current sensing delivers precise, true RMS current measurement over a broad frequency range of 20 to 250 Hz. � DeviceNet™ Communications: built-in network connectivity enables the ability to control and monitor motor operation. No additional hardware is required. � Integrated I/O: conveniently provides input and output points of connection where they’re needed – at the motor starter, simplifying installation wiring and the control architecture. � Data and Diagnostics: a wealth of motor performance data in addition to device status and diagnostic information is network accessible so that control system performance can be optimized. � Insert Molded Power Stabs: Rockwell Automation exclusive feature delivers unmatched robust connections in starter assemblies. 825-P � Comprehensive Protection: gain optimal motor utilization through the 825-P’s comprehensive monitoring of motor performance in relation to a motor’s specific design criteria for current, voltage, temperature and time. � Modular: uniquely configurable to match an application’s initial requirements with flexibility for future expansion. � Full Metering: insight into machine performance is offered with operational data provided for current, voltage, power, and temperature. � Intuitive Interface: front panel operation is made easy through an organized menu structure that provides quick access to monitoring parameters and settings. The built-in LCD provides clear, informative text. � Network Communications: integration into the automation architecture is made easy with the optional DeviceNet or Modbus communication cards. � Integrated I/O: configurable inputs and outputs increase application flexibility and versatility. � Control: DeviceLogix™ component technology available in the DeviceNet option card can simplify control with the ability to perform logic operations at the device level. DeviceLogix can also be employed to allow machine operation to continue in the event of a network failure. Electronic Motor Protection 5 Product Overview S = Standard O = Open Feature E1 Plus(193-ED) E1 Plus (193/592-EE) E3 (193/592-EC1) E3 Plus (193/592-EC2) 825-P General Current Range (A) 0.1…27 0.1…90A 0.4…5000 0.4…5000 0.5…5000 Contactor Compatibility 100-C 100-C, 500 100-C, -D, 500 100-C, -D, 500 100-D Self-Powered S S - - - Manual Reset S - - - - Automatic or Manual Reset - S S S S Adjustment Range 5:1 5:1 5:1 5:1 - Protection Overload Trip Class 10 10, 15, 20, 30 5…30 5…30 1…600 Phase Loss / Current Imbalance S S S S S Stall (Start Time Monitoring) - - S S S Jam (Overcurrent) - - S S S Underload (Undercurrent) - - S S S Ground Fault - - - S S Short Circuit - - - - S Starts / Hr. Monitoring - - - - S PTC Thermistor Monitoring - - - S S RTD Monitoring - - - - O Phase Reversal - - - - S Under and Over-Frequency - - - - S Under and Over-Voltage - - - - O Underpower - - - O Power Factor - - - - O Metering Current Values - - S S S % Thermal Capacity Used - - S S S Voltage Values - - - - O Power Values - - - - O Temperature Values - - - - O Communications DeviceNet - - S S O DeviceLogix - - - S (series B) O Modbus RTU - - - - O I/O Trip Relay 1 – N.C., 1 – N.O. (isolated) 1 – N.C., 1 – N.O. (isolated) 1 – Form A 1 – Form A 1 – Form C Auxiliary Relay Outputs - - 1 2 2 + 4 (O) Inputs - - 2 4 2 + 3 (O) 4…20mA Analog Output (isolated) - - - - 1 (O) Bulletin 193 and 592 E1 Plus Solid-State Overload Relays 6 Product Overview/Catalog Number Explanation Description Accurate, Reliable Performance • Current measurement based protection While electromechanical overload relays pass motor current through heating elements to provide an indirect simulation of motor heating, the E1 Plus Overload Relay directly measures motor current. Current measurement based overload protection more accurately models a motor’s thermal condition. Furthermore, ambient temperature does not impact the performance of current measurement-based designs over the specified temperature operating range. • Electronic design Thermal modeling is performed electronically with precision solid-state components, where at the heart of the E1 Plus Overload Relay is an application specific integrated circuit (ASIC). The ASIC continually processes motor current data to accurately maintain the time-current status of the motor thermal capacity utilization value. • Thermal memory A thermal memory circuit allows the E1 Plus Overload Relay to model the heating and cooling effects of motor on and off periods. This ensures accurate protection for both hot and cold motors. • Enhanced phase loss protection A separate phase loss detection circuit incorporated into the E1 Plus Overload Relay allows it to respond quickly to phase loss conditions; typical reaction time is 3 seconds. Easy to Select and Apply • Straightforward installation The self-powered design means that the E1 Plus Overload Relay installs in the same manner as traditional overload relays. Device setup is accomplished by simply dialing the setting potentiometer to the motor FLA rating. The low energy consumption of the electronic design minimizes temperature rise issues inside control cabinets. • Wide adjustment range A wide 5:1 adjustment range results in the need for half as many catalog numbers as the bimetallic alternative in order to cover the same current range. This helps to reduce inventory carrying costs and affords greater installation flexibility for dual voltage machines. Evenly spaced setting tick marks enhance the ease of installation setup. Rugged Construction • Insert molded power connections The unique line-side insert molded power connections make for a sturdy two- component starter assembly that is unmatched in the industry. The pre- formed power connections allow easy starter assembly—every time. • Current transformers The current transformers are secured separately in the overload housing to ensure the greatest degree of resistance to shock and vibration conditions. Varnished laminations ensure consistent performance and provide additional protection against corrosion. • Latching relay The robust design of the bi-polar latching relay provides reliable trip and reset performance for the most demanding of applications. The self-enclosed relay offers additional environmental protection for use in industrial applications. Application Flexibility • Isolated Contacts The isolated contact configuration allows the N.C. and N.O. contacts to be applied in circuits operating at different voltage levels and without polarity restrictions. The B600 contact rating affords application in circuits rated to 600V. • DIP switch settings 193-EE devices offer DIP switch settings to select the trip class (10, 15, 20 or 30) and the reset mode (manual or automatic), making these devices extremely versatile. E1 Plus Solid-State Overload Relays • Self-Powered • Phase Loss Protection • Wide Adjustment Range (5:1) • Insert-Molded Power Connections • 1 N.O. and 1 N.C. Isolated Auxiliary Contacts (B600 Rated) • Low Energy Consumption (150 mW) • Ambient Temperature Compensation • Visible Trip Indication 193-ED version offers: • 0.1…27 A Current Range • Fixed Trip Class 10 • Manual Reset 193-EE and 592-EE versions offers: • 0.1…90 A Current Range • Selectable Trip Class (10, 15, 20 or 30) • Selectable Manual/Auto-Manual Reset • Single- and Three-Phase Devices • Optional Cage Clamp Control Terminals (193-EE only) Table of Contents Product Overview . . . . . . . . . 5 Product Selection . . . . . . . . . 8 Accessories. . . . . . . . . . . . . . 8 Specifications . . . . . . . . . . . . 9 Wiring Schematics . . . . . . . 10 Trip Curves . . . . . . . . . . . . . 11 Approximate Dimensions. . 12 Standards Compliance IEC EN 60947-4-1 EN 60947-5-1 CSA 22.2 No. 14 UL 508 Approvals CE CSA Certified UL Listed ATEX (pending) C-Tick Cat. No. Explanation 193 - EE C B Type ED1 EE Adjustment Range (A) Three-Phase Single-Phase A 0.1…0.5 P 1.0…5.0 B 0.2…1.0 R 3.2…16 C 1.0…5.0 S 5.4…27 D 3.2…16 T 9…45 E 5.4…27 U 18…90 F 9…45 G 18…90 Bulletin 100 Contactor Size Bulletin 509 Starter Size B C09…C23 T 00 D C30…C43 C 0…2 E C60…C85 D 3 Bulletin Number Phase 193 IEC Three-Phase 193R IEC Three-Phase,Cage Clamp 193S IEC Single-Phase 592 NEMA Three-Phase 592S NEMA Single-Phase Bulletin 193 and 592 E1 Plus Solid-State Overload Relays 7 Product Selection Bulletin 193-ED – Three Phase Devices • Fixed Trip Class 10 • Manual Reset • Screw-Type Control Terminals Bulletin 193-EE – Three-Phase Devices • Selectable Trip Class (10, 15, 20, 30) • Selectable Auto/Manual-Auto Reset • Screw-Type Control Terminals ➊ Cage Clamp Control Terminals – To order, change the Bulletin number in the listed Cat. No. from 193 to 193R (Example: 193R-EEFD). Bulletin 193S-EE – Single-Phase Devices • Selectable Trip Class (10, 15, 20, 30) • Selectable Auto/Manual-Auto Reset • Screw-Type Control Terminals Bulletin 592-EE – Three Phase Devices • Selectable Trip Class (10, 15, 20, 30) • Selectable Auto/Manual-Auto Reset Bulletin 592S-EE – Single-Phase Devices • Selectable Trip Class (10, 15, 20, 30) • Selectable Auto/Manual-Auto Reset Mounts to Contactor Adjustment Range (A) Cat. No. 100-C09…100-C23 0.1…0.5 193-ED1AB 0.2…1.0 193-ED1BB 1.0…5.0 193-ED1CB 3.2…16 193-ED1DB 5.4…27 193-ED1EB Mounts to Contactor Adjustment Range (A) Cat. No. ➊ 100-C09…100-C23 0.1…0.5 193-EEAB 0.2…1.0 193-EEBB 1.0…5.0 193-EECB 3.2…16 193-EEDB 5.4…27 193-EEEB 100-C30…100-C43 5.4…27 193-EEED9…45 193-EEFD 100-C60…100-C85 18…90 193-EEGE Mounts to Contactor Adjustment Range (A) Cat. No. 100-C09…100-C23 1.0…5.0 193S-EEPB 3.2…16 193S-EERB 5.4…27.0 193S-EESB 100-C30…100-C43 9…45 193S-EETD 100-C60…100-C85 18…90 193S-EEUE Mounts to Contactor Adjustment Range (A) Cat. No. 00 0.1 … 0.5 592-EEAT 0.2 … 1.0 592-EEBT 1.0 … 5.0 592-EECT 3.2 … 16 592-EEDT 0…2 0.2 … 1.0 592-EEBC 1.0 … 5.0 592-EECC 3.2 … 16 592-EEDC 5.4 … 27 592-EEEC 9 … 45 592-EEFC 3 9 … 45 592-EEFD18 … 90 592-EEGD Mounts to Contactor Adjustment Range (A) Cat. No. 00 1.0 … 5.0 592S-EEPT 3.2 … 16 592S-EERT 5.4…27 592S-EEST 0…2 1.0 … 5.0 592S-EEPC 3.2 … 16 592S-EERC 5.4…27 592S-EESC 9…45 592S-EETC 3 18…90 592S-EEUD Bulletin 193 and 592 E1 Plus Solid-State Overload Relays 8 Accessories Marking Systems ➊ Must be ordered in multiples of package quantities. Description For Use With Pkg. Qty. Cat. No. DIN Rail/Panel Adapter For separate mounting – can be mounted to top-hat rail EN 50 02-35. 193-ED1_B, 193-EE_B 1 193-EPB 193-EE_D 193-EPD 193-EE_E 193-EPE Current Adjustment Shield Prevents inadvertent adjustment of the current setting 193-ED (all) 193-EE (all) 592-EE (all) 10 193-BC8 External Reset Adapter For enclosed, through-the-door reset applications. Use with External Reset Button 800ES-R611WTR08. 193-ED (all) 193-EE (all) 1 193-ERA External Reset Button For enclosed, through-the-door reset applications. Metal construction IP66, non-illuminated with rod (length: 142 mm, adjustable range 141…159 mm). Refer to the 800E catalog pages for additional types. 193-ED (all) 193-EE (all) 1 800ES-R611WTR08 Description Pkg. Qty. ➊ Cat. No. Label Sheet • 10 sheets with 105 self-adhesive paper labels each, 6 x 17 mm 10 100-FMS Marking Tag Sheet • 10 sheets with 160 perforated paper labels each, 6 x 17 mm • To be used with a transparent cover 10 100-FMP Transparent Cover • 100 each • To be used with marking tag sheets 100 100-FMC Marking Tag Adapters • 100 each • To be used with marking tag: System V4 / V5 System Bul. 1492W 100 100 100-FMA1 100-FMA2 Bulletin 193 and 592 E1 Plus Solid-State Overload Relays 9 Specifications Cat. No. 193-ED1_B, 193-EE_B, and 592-EE_T 193-EE_D and 592-EE_C 193-EE_E and 592-EE_D Main Circuits Rated Insulation Voltage Ui 690V AC Rated Impulse Strength Uimp 6 kV AC Rated Operating Voltage Ue 690V AC (IEC) / 600V AC (CSA/UL) Terminal Cross-Sections: Terminal Type Terminal Screw M5 M5 M8 Flexible-Stranded with Ferrule Single Conductor Torque 2.5…16 mm2 2.5 N·m 2.5…16 mm2 2.5 N·m 4…35 mm2 24 N·m Two Conductor Torque 2.5…10 mm2 ➊ 3.4 N·m 2.5…10 mm2 ➊ 3.4 N·m 4…25 mm2 4 N·m Coarse-Stranded / Solid Single Conductor Torque 2.5…25 mm2 2.5 N·m 2.5…25 mm2 2.5 N·m 4…50 mm2 4 N·m Two Conductor Torque 6…16 mm2 ➊ 3.4 N·m 6…16 mm2 ➊ 3.4 N·m 4…35 mm2 4 N·m Stranded / Solid Single Conductor Torque 14…6 AWG 22 lb-in 14…6 AWG 22 lb-in 12…1 AWG 35 lb-in Two Conductor Torque 14…6 AWG ➊ 30 lb-in 14…6 AWG ➊ 30 lb-in 6…2 AWG 35 lb-in Pozidrive Screwdriver Size 2 2 — Slotted Screwdriver (mm) 1 x 6 1 x 6 — Hexagon Socket Size (mm) — — 4 Control Circuits Rated Insulation Voltage Ui 690V AC Rated Impulse Strength Uimp 6 kV AC Rated Operating Voltage Ue 690V AC (IEC) / 600V AC (CSA/UL) Rating Designation B600 Rated Operating Current Ie N.O. / N.C. AC-15 12…120V 220…240V 380…480V 500…600V 3 / 2 1.5 / 1.5 0.75 / 0.75 0.6 / 0.6 DC-13, at L/R ≤ 15 ms 24V 110V 220V 440V 1.1 / 1.1 0.4 / 0.4 0.2 / 0.2 0.08 / 0.08 Thermal Current Ithe 5 A Contact Reliability 17V, 5 mA Screw Terminal Cross-Sections: Terminal Screw M3 Flexible-Stranded with Ferrule Single Conductor Torque 0.5…2.5 mm2 0.55 N·m Two Conductor Torque 0.25…1.5 mm2 0.55 N·m Coarse-Stranded / Solid Single Conductor Torque 0.5…4 mm2 0.55 N·m Two Conductor Torque 0.2…2.5 mm2 0.55 N·m Stranded / Solid Single Conductor Torque 24…10 AWG 5 lb-in Two Conductor Torque 24…12 AWG 5 lb-in Screwdriver (mm) #1 Pozidrive / 0.6 x 3.5 slotted Cage Clamp Cross-Sections: Flexible-Stranded with Ferrule 0.25…1 mm2 Coarse-Stranded / Solid 0.2…1.5 mm2 Stranded / Solid 24…14 AWG ➊ For multiple conductor applications, the same style and size of wire must be used. Bulletin 193 and 592 E1 Plus Solid-State Overload Relays 10 Specifications, Continued/Wiring Schematic Wiring Schematic Environmental Ratings Ambient Temperature Storage Operating -40…85°C (-40…185°F) -20…60°C (-4…140°F) Humidity Operating Damp Heat 5…95%, non-condensing per IEC 68-2-3 and IEC 68-2-30 Vibration (per IEC 68-2-6) 3 G Shock (per IEC 68-2-27) 30 G Maximum Altitude 2000 m Pollution Environment Pollution Degree 3 Degree of Protection IP20 Protection Type of Relay Ambient Compensated, Time Delay, Phase Loss Sensitive Nature of Relay Solid-State Trip Rating 120% FLA Trip Class Type ED Type EE 10 10, 15, 20, 30 Reset Mode Type ED Type EE Manual Automatic or Manual Electromagnetic Compatibility Electrostatic Discharge Immunity Test Level Performance Level 8 kV Air Discharge 6 kV Contact Discharge 1 ➊ ➋ RF Immunity Test Level Performance Level 10 V/m 1 ➊ ➋ Electrical Fast Transient/Burst Immunity Test Level Performance Level 4 kV1 ➊ ➋ Surge Immunity Test Level Performance Level 2 kV (L-E) 1 kV (L-L) 1 ➊ ➋ ➊ Performance Criteria 1 requires the DUT to experience no degradation or loss of performance. ➋ Environment 2. General Standards UL508, CSA C22.2 No. 14, NEMA ICS 2-1993 Part 4, EN 60947-4-1, EN 60947-5-1 Approvals CE, CSA, UL, ATEX (pending), C-Tick Weight (unpackaged) kg Lb 0.25 0.55 0.25 0.55 0.52 1.06 96 98 95 97 2 4 6 9795 96 98 L1/1 L2/3 L3/5 T1/2 T2/4 T3/6 Typical IEC Wiring Schematic Typical NEMA Wiring Schematic 1 3 5 2 4 6 T1 T2 T3 M A1 A2 K1 Typical Wiring for 1-Phase Applications Bulletin 193 and 592 E1 Plus Solid-State Overload Relays 11 Trip Curves Typical reset time for 193-EE devices set to automatic reset mode is 120 seconds. Trip Class 15 0.1 1 10 100 1000 1 10 FLA Multiple Ti m e (s ec on ds ) Trip Class 30 0.1 1 10 100 1000 1 10 FLA Multiple Ti m e (s ec on ds ) Trip Class 20 0.1 1 10 100 1000 1 10 FLA Multiple Ti m e (s ec on ds ) Trip Class 10 0.1 1 10 100 1000 1 10 FLA Multiple Ti m e (s ec on ds ) Cold Trip Hot Trip Cold Trip Hot Trip Cold Trip Hot Trip Cold Trip Hot Trip Bulletin 193 and 592 E1 Plus Solid-State Overload Relays 12 Approximate Dimensions Dimensions are shown in millimeters (inches). Dimensions are not intended to be used for manufacturing purposes. 100-C Mounted Overload Cat. No. Contactor Cat. No. A Width B Height C Depth D E1 E2 F H1 H2 193-ED__B 193-EE__B 193R-EE__B 193S-EE__B 100-C09 100-C12 100-C16 100-C23 45 (1-25/32) 146.6 (5-25/32) 85.2 (3-23/64) 4.5 (3/16) 13.9 (35/64) 24.5 (31/32) 86.5 (3-13/32) 60 (2-23/64) 35 (1-3/8) 193-EE__D 193R-EE__D 193S-EE__D 100-C30 100-C37 45 (1-25/32) 146.6 (5-25/32) 101.2 (3-63/64) 4.5 (3/16) 13.9 (35/64) 24.5 (31/32) 104 (4-3/32) 60 (2-23/64) 35 (1-3/8) 193-EE__D 193R-EE__D 193S-EE__D 100-C43 54(2-1/8) 146.6 (5-25/32) 101.2 (3-63/64) 4.5 (3/16) 18.9 (3/4) 24.5 (31/32) 104 (4-3/32) 60 (2-23/64) 45 (1-25/32) 193-EE__E 193R-EE__E 193S-EE__E 100-C60 100-C72 100-C85 72 (2-53/64) 192.3 (7-37/64) 120.4 (4-3/4) 5.4 (7/32) 23.8 (15/16) 29 (1-9/64) 125.5 (4-15/16) 100 (3-15/16) 55 (2-11/64) A D H2 E2 E1 H1 B TO RESET FROM CONTACTOR MOUNTING HOLETO RESET FROM CONTACTOR MOUNTING HOLE 2 T1 4 T2 6 T3 F C Bulletin 193 and 592 E1 Plus Solid-State Overload Relays 13 Approximate Dimensions, Continued Dimensions are shown in millimeters (inches). Dimensions are not