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MPR2000 Digital Motor Protection Relay P&B Engineering Belle Vue Works Boundary Street Manchester M12 5NG Tel: 0161 230 6363 Fax: 0161 230 6464 E-mail [email protected] Issue I Contents CONTENTS ...................................................................................................................................................................... 1 1. INTRODUCTION...................................................................................................................................................... 1 2. SUMMARY OF MPR2000 FEATURES.................................................................................................................. 1 2.1 PROTECTIVE FUNCTIONS ........................................................................................................................................ 1 2.2 DISPLAYED DATA ................................................................................................................................................... 2 2.3 FEATURES .............................................................................................................................................................. 2 3. TECHNICAL SPECIFICATION ............................................................................................................................. 3 3.1 TECHNICAL DATA .................................................................................................................................................. 3 3.1.1 AUXILIARY POWER SUPPLY................................................................................................................................. 3 3.1.2 PHASE CURRENT INPUTS ..................................................................................................................................... 3 3.1.3 EARTH FAULT CURRENT INPUTS ......................................................................................................................... 3 3.1.4 LINE VOLTAGE INPUTS ........................................................................................................................................ 3 3.1.5 THERMISTOR/RTD INPUTS (3 OR 5 CHANNEL) ................................................................................................... 3 3.1.6 OVERLOAD ALARM AND TRIP CURVES................................................................................................................ 3 3.1.7 CURRENT UNBALANCE ALARM AND TRIP ........................................................................................................... 3 3.1.8 FAULT TIME DELAYS .......................................................................................................................................... 4 3.1.9 RELAY CONTACTS ............................................................................................................................................... 4 3.1.10 DIELECTRIC STRENGTH ..................................................................................................................................... 4 3.2 MPR2000 IMMUNITY AND EMISSIONS TESTS ............................................................................................ 4 4. MPR2000 SCHEMATIC DIAGRAM ...................................................................................................................... 4 5. MPR2000 MEASURED INPUTS ............................................................................................................................. 6 5.1 POWER SUPPLY ...................................................................................................................................................... 6 5.2 VT INPUTS ............................................................................................................................................................. 6 5.3 CT PHASE INPUTS .................................................................................................................................................. 6 5.4 EARTH FAULT CT INPUTS ...................................................................................................................................... 6 5.5 TEMPERATURE INPUTS ........................................................................................................................................... 6 5.6. POWER. ................................................................................................................................................................. 6 6. MPR2000 CONTROL INPUTS/OUTPUTS ............................................................................................................ 7 6.1 OUTPUT RELAYS .................................................................................................................................................... 7 6.2 CONTROL INPUTS ................................................................................................................................................... 7 6.3 AUTHORISE KEY .................................................................................................................................................... 7 6.4 SERIAL PORT .......................................................................................................................................................... 7 6.5 SPEED SWITCH ....................................................................................................................................................... 7 6.6 EXTERNAL FAULT 2................................................................................................................................................ 7 6.7 EXTERNAL FAULT 3................................................................................................................................................ 7 6.8 EMERGENCY STOP.................................................................................................................................................. 7 7. MPR2000 FACEPLATE FUNCTIONS ................................................................................................................... 8 7.1. LED STATUS PANEL ............................................................................................................................................. 8 8. MPR2000 FUNCTIONAL KEYPAD & DISPLAY................................................................................................. 9 Page 1 9. MPR2000 SETTING AND DATA PAGES ............................................................................................................ 11 9.1 MPR2000 COMMUNICATION SETTINGS ............................................................................................................... 11 9.2 SYSTEM SETTINGS ................................................................................................................................................ 11 9.3 VOLTAGE SETTINGS ............................................................................................................................................. 12 9.4 CURRENT SETTINGS ............................................................................................................................................. 13 9.5 TEMPERATURE SETTINGS ..................................................................................................................................... 16 9.6 TRIPPING/ALARM OPTIONS................................................................................................................................... 16 9.7 MPR2000 SETTING PAGES SUMMARY ................................................................................................................. 17 9.8 MPR2000 DATA PAGES SUMMARY ..................................................................................................................... 19 10. MPR2000 COMMUNICATIONS......................................................................................................................... 19 11. MPRSET SOFTWARE ......................................................................................................................................... 20 12. MPR2000 FLASH/CONSTANT MESSAGES..................................................................................................... 20 13. MPR2000 INTERNAL TEST ROUTINES .......................................................................................................... 20 14. MPR2000 FAULT FINDING ................................................................................................................................ 21 15. MPR2000 THERMAL OVERLOAD PROTECTION........................................................................................ 22 16. MPR2000 INSTALLATION ................................................................................................................................. 26 16.1 CASING............................................................................................................................................................... 26 16.2 MPR2000 TERMINATIONS ................................................................................................................................. 27 17. FAST SCAN ANALOGUE DATA........................................................................................................................ 28 18. CHANGES TO THE MANUAL. .......................................................................................................................... 28 Page 2 1. Introduction The MPR2000 Motor Protection Relay is a highly sophisticated microprocessor based motor protection relay specifically designed to be used on motors with full load currents up to 2000 Amps, at any voltage and as an integral part of any type or manufacture of Motor Control Centre. All of the latest features are included in the MPR2000 to allow total protection and monitoring of motor starters. The MPR2000 can be used to protect Direct on Line, Star Delta, Reversing and Two speed motor starters. The MPR2000 can be used in conjunction with A.C. Variable Speed Drives or Soft Starters without any affect on the protection performance. The MPR2000 monitors current, voltage and temperature inputs to provide the most comprehensive motor protection package ever produced by P & B Engineering. This combined with it's monitoring functions and a high speed communications facility make the MPR2000 the most attractive Motor Protection device available today. All MPR2000 setting parameters are programmed independently for each unit via the integral keypad and liquid crystal display on the front plate or via the RS485 communications port and the IBM PC based MPCSET software package available with the MPR2000. During operational conditions the LCD also gives access to accurate running, statistical and fault data such as; Phase Volts, Phase Amps, Thermal capacity, Time to Trip, Phase unbalance, Motor hours run, No. of starts and many more. Light Emitting Diodes mounted on the front plate give visual indication of the motor status such as Motor Running, Motor Stopped, Alarm or Trip conditions etc. Flexible high speed communications to PLC or DCS systems is obtained through the MPR2000's RS485 communications port, allowing computer access to full monitoring of motor data, including : running data, motor statistical data and input status. All MPR2000 protective functions can be individually configured to enable or disable tripping and alarm functions, enabling protection to be simplified for the very lowest motor ratings. In addition each protective function can be set to allow self or manual reset after alarm or trip and manual reset can be set to allow resets after an alarm or trip to be made locally, or remotely via the RS485 port, or by authorised personnel only. The MPR2000 has Power Indication. This gives Power (Watts and VA) and Power Factor read-outs in the measured data page. It requires a 3 phase voltage input. 2. Summary of MPR2000 Features 2.1 Protective Functions Voltage Based: 3 Phase Undervoltage Protection 3 Phase Overvoltage Protection Phase Sequence Protection Phase Loss Protection Current Based: Motor Starts Limitation Thermal Overload Protection Load increase Alarm Thermal Capacity Pre-Alarm Locked Rotor/Stall Protection 2 Stage Undercurrent Protection High Set Overcurrent Protection Low Set Overcurrent Protection 2 Stage Current Unbalance Protection 2 Stage Earth Fault Protection Excess Starting Time Protection Excess No. of Starts Protection Issue I 29/08/03 Page 1 MPR2000 RTD/Thermistor Based: 3 Channel RTD/Thermistor Temperature Protection 5 Channel RTD/Thermistor Temperature Protection (Optional) 2.2 Displayed Data Measured Data Both Phase Volts and Line Volts Earth Fault Phase Current Total Real Power Total VA Power Power Factor RTD/Thermistor Channel resistance Calculated Data Motor Load - Percentage FLC Thermal Capacity Used Time to Trip Time to Start Unbalance Current Logical Input Status Motor Available Indication Individual Status of all Input Contacts Statistical Data Motor Hours Run Number of Motor Starts No.of Motor Trips Last Start Time Last Peak Starting Current Fault Data Last Fault Last Alarm Phase Currents at Time of Trip Earth Fault Current at Time to Trip Phase Volts at Time of Trip 2.3 Features • • • • • • • LCD Display for Setting Parameters and Displayed Data Functional Keypad enables settings to be made independent of communications. IBM PC based MPCSET software enables Setting Parameters to be configured via RS485 Port. All functions operate fully independently of communications Non Volatile Memory for all setting parameters calculated, statistical and fault data Full self diagnostics and internal watchdog facility RS485 port enables full monitoring by remote DCS/PLC systems Issue I 29/08/03 Page 2 MPR2000 3. Technical Specification 3.1 Technical Data 3.1.1 Auxiliary Power Supply AC Nominal: DC Optional Frequency: Maximum Power Consumption: 3.1.2 Phase Current Inputs Method: Range: Full Scale Accuracy: 3.1.3 Earth Fault Current Inputs Method: Range: Full Scale: Accuracy: 3.1.4 Line Voltage Inputs Method: Without VT Transformer Range: Accuracy: With VT Transformer Range: Accuracy: 110V AC, Range: 80 - 135V AC 240V AC, Range: 160 - 270V AC 30v DC, 110v DC (other values on request) 45/65 Hz 6 - 8VA True RMS, Sample time 0.5mS 0.05 to 12 x Phase CT Primary Amps 12 x Phase CT Primary Amps setting +/- 1.5% for 0.9 to 1.5 x CT Primary +/- 5% above 1.5 x CT Primary +/- 3% + 0.02 below 0.9 x CT Primary True RMS, sample time 0.5mS 0.05 to 1.0 x E/F CT Primary 1.0 x E/F CT Primary Amps Setting +/- 1.5% of Full Scale True RMS, sample time 0.5mS 90 - 660V AC +/- 1.0% of Full Scale 90 - 660V x (VT Primary/VT Secondary) Limited to 25kV +/- 1.0% of Full Scale 3.1.5 Thermistor/RTD Inputs (3 or 5 Channel) Time Delay: 0.5 +/- 0.2 seconds Thermistor Range: 0.1 - 30 Kilo-Ohms Accuracy: +/- 0.1 Kilo-Ohm up to 5 Kilo-Ohm +/- 3% above 5 Kilo-Ohm RTD Range: 100 to 240 Ohms Accuracy: +/- 3% Max. Wire Resistance: 25 Ohms 3.1.6 Overload Alarm and Trip Curves Fault Time Accuracy: Threshold Current Level: +/- 1 second up to 10 seconds +/- 1 second +/- 2% above 10 seconds Overload Setting +/- 1.5% 3.1.7 Current Unbalance Alarm and Trip Method: Unbalance = 100 x (Imax - Imin) / Ir % Where Imax = max. of 3 phase currents Imin = min. of 3 phase currents Ir = Larger of Imax or Motor FLC Alarm Threshold Unbalance Level: 50% of Unbalance current +/- 2% Fixed Time Delay Accuracy: 1.0 +/- 0.5 seconds Trip Curves Threshold Unbalance Level: Unbalance Current Setting +/- 2% Trip Time Accuracy: +/- 1 second up to 10 seconds +/- 1 second +/- 2% above 10 sec. Issue I 29/08/03 Page 3 MPR2000 3.1.8 Fault Time Delays Accuracy: Exceptions High Set Over-current: Earth Fault Trip: Accuracy: 3.1.9 Relay Contacts Rated Load: Maximum Operating Voltage: Maximum Operating Current: Minimum Permissible Load: Note: +/- 0.5 seconds or +/- 2% of time -0.1 to +0.2 sec. up to 1 second -0.1 to +0.2 sec. for less than 1 second delay Total Run Time +/- 2% 8A @ 250V AC/8A @ 30V DC (Resistive) 6A @ 250V AC/3A @ 30V DC (Inductive) 280V AC, 125V DC 8 Amps 5V DC, 100mA AC Inductive load PF = 0.4 DC Inductive Load L/R = 7mS 3.1.10 Dielectric Strength 2000V AC for 1 minute, between ground and: * Current Inputs * Voltage Inputs * Auxiliary Power Supply, with 1000pF Suppression Capacitors removed * Control Terminals, with 1000pF Suppression Capacitors removed. 3.2 MPR2000 IMMUNITY AND EMISSIONS TESTS The MPR2000 was successfully tested at the ERA Technology Centre in Leatherhead on the 7th April 1992 to comply with the European Standards on Emissions (EN50081-1) and Immunity (EN50082-2). 4. MPR2000 Schematic Diagram The following diagram shows a typical installation schematic diagram of the MPR2000 unit. The following points should be noted: Although not shown on the diagram it is recommended that the 3 phase input voltage should be fused after the take off point from the system voltage or in the case of HV systems where a voltage transformer is used the secondary should be also be fused. When using the residually connected Earth Fault scheme it may be necessary to fit a swamping resistor between the common connection and the earth connection. It is generally advisable to use Core balance ct's whenever possible. If an externally mounted Emergency Stop push-button is fitted to the motor starter it may be beneficial, so that the MPR2000 reads Emergency Stop as a trip, to connect a contact from the button to the External Emergency Stop terminals shown on the diagram. The case earth must be externally grounded to earth. The terminals 11, 12 and 54 are internally connected and one of them should be connected to either the case earth or separate earth if a separate instrument earthing is required. This can be done as shown in the diagram. Issue I 29/08/03 Page 4 MPR2000 f hm hl de g hk hj de h f g h de i h h de i h 110/240V AC [80-265V DC OPTIONAL] INDICATION ONLY E/F TRIP OVERLOAD TRIP w v { \ X z y rx RTD. [100-240 OHMS] [0-200 deg C] a THERMISTOR [0.1K-30K] ^_` CHANNEL NOT IN USE h M E O G O NK L GK JK G EF M I I HI ALTERNATIVE RESIDUAL EARTH FAULT CONNECTION WZ UV W[ W W\ WZ UV WY WX ~ { U SWAMPING RESISTOR hp fq p n W W [ jn INTERNAL POWER SUPPLY ON => ip jo n ]W W W np fm WY WX p jn gp U jn ~v ~} u ~y ~ x } GND AUTHORISE KEY (CLOSED = AUTHORISED) ?@ AUX 1 RELAY [ALARM] || LOGIC SUPPLY CONTACT SHOWN IN DE-ENERGISED STATE EXTERNAL FAULT 2 (NO) AB ALT. AUX POWER SUPPLY EXTERNAL FAULT 3 (NO) T T T QR P 1 - 3 , 2 / / / . / SPEED SWITCH (OPEN = HIGH) 3 RTD OR 3 THERMISTORS / / / CHANNEL 2 ON [THERMISTOR] r tsr j ru g CHANNEL 5 8 7 ;: 9 < . 0 . 1 5 / / j j . h i 2 OPTIONAL 2 RTD INPUTS SCREEN RS485 SERIAL PORT EXTERNAL EMERGENCY STOP (NC) DIP SWITCH SETTINGS FOR CHANNELS 1,2&3 CHANNEL 4 . OFF [RTD] CT2 CT1 CT4 CT3 3 NOTE: RELAY SUPPLIED AS 1 AMP OR 5 AMP AS REQUIRED. MEASURMENT VOLTAGES ,0 ,. 6- 6 ,/ 6 , / ,- . SHIELD NOTE TERMINALS 11,12 & 54 ARE INTERNALLY CONNECTED. FOR SEPERATE INSTRUMENT EARTHING TERMINAL 11 MUST BE CONNECTED TO A SEPERATE EARTH FROM THE CASE. OTHERWISE CONNECT TO THE CASE. (SEE SECTION 4.0) bc CHANNEL 3 / / P&B ADVISE THAT A SHORTING LINK BE APPLIED ACROSS THE INPUT TERMINALS OF EACH CHANNEL TO PRODUCE A ZERO READING. CHANNEL 1 4 0 FOR MOTOR APPLICATIONS WITHOUT THE USE OF THE RTD INPUTS: THE CHANNEL INPUTS ARE FAIL-SAFE i.e, WHEN 'OPEN' THE READING WILL BE 'HIGH' S AD AC AUX 2 RELAY [TRIP] *+ "' & "% $ "( # " #) "# ! MOTOR Issue H 1/5/98 Page 5 MPR2000 5. MPR2000 Measured Inputs 5.1 Power Supply The MPR2000 requires a 110v or 240v A.C. voltage to supply the unit and provide the A.C. voltage to the external inputs. A DC version (80-265V DC) can also be supplied as an optional extra. 5.2 VT Inputs The MPR2000 monitors single or three phase voltage, which can be directly connected for voltages up to 660v and via a suitable voltage transformer for system voltages above 660v . In order that the MPR2000 can measure and display actual volts, the system volts and VT primary and secondary volts must be set in the 'System Settings' page. If single phase voltage reference only is available this is connected to L1 and N with L1,L2,L3 commoned. The System Voltage setting in the 'System Settings' page must then be set to 1.732 x the line voltage. In addition the Phase Sequence and Phase Loss protective functions must be disabled 5.3 CT Phase Inputs The MPR2000 can be supplied for use with either 5A or 1A CT secondaries.(To be specified.) 5.4 Earth Fault CT Inputs The MPR2000 can detect earth faults using either a separate core balance CT or by connecting the 3 phase CT's residually. Either 5A or 1A CT secondaries must be specified. When residually connected phase CT's are used a swamping resistor may have to be fitted across the common connection. Please note that the Earth Fault value is not displayed on the MPR2000 till it reaches a value greater than 50% of the lowest Earth Fault Trip value.Refer to P & B Engineering for further information. 5.5 Temperature Inputs Thermistors of either positive or negative temperature coefficients can be directly connected to the MPR2000 by selecting either PTC or NTC in the default menu. The alarm and tripping range can be adjusted between 100 ohms and 30,000 ohms. RTD's can also be directly connected to the MPR2000 and selecting between the two inputs is via the front plate keypad. As the resistance of RTD's is relatively low, the MPR2000 use a three wire measurement system for each RTD, the third wire is required to compensate for the wire resistances. The alarm and tripping range of the RTD's can be adjusted between 100 ohms and 240 ohms. Default setting is for RTD inputs. In addition to selection of Thermistor or RTD temperature inputs via the Temperature setting page, dip switches located behind the rear cover of the MPR2000 require setting. This can be carried out on site, however it is advisable to specify the type being used, at the time of order such that the change can be made prior to the unit being despatched. The earth for the RTD’s are on terminals 11, 12 and 54. These are internally connected so only terminal 11 need be wired to an external earth if requested. See Section 4. For further details. As an optional extra a 5 channel version is available, with this version 3 channels have common alarm and trip settings and 2 channels have individual alarm and trip settings. The 2 channels are always RTD’s but the 3 channels are RTD’s (default) or Thermistors (Optional). 5.6. Power. The Power applied to a motor is displayed on the MPR2000 and is calculated from the Current and Voltage inputs to the relay. Please note that due to this calculation the Power and Power Factor is less accurate for Motors with a CT Primary of less than 10 Amps. Issue H 1/5/98 Page 6 MPR2000 6. MPR2000 Control Inputs/Outputs 6.1 Output Relays The MPR2000 has 4 output relays which can be assigned as follows: Pins 5,7,9 - Overload Trip (Indication) Pins 6,8,10 - Earth Fault Trip (Indication) Pin 33,35,37 - Aux. Relay 1 = Alarm con A con B start/run Pins 34,36,38 - Aux. Relay 2 = Trip (Trip fail safe) cont A Cont B 6.2 Control Inputs The MPR2000 provides several inputs to provide full protection for the motor. The supply to these terminals is derived from the Power Supply to the relay. The live side of each inputs is commoned to enable simplified wiring to the unit, however it should be noted that the common terminals are always live when power is connected to the MPR2000 and the should always be isolated prior to working on the wiring at the rear of the unit. The condition of all these inputs can be viewed at any time via the Logic Inputs/Contacts Data page which enables complete wire checking without the need to disconnect or even gain access to wiring. 6.3 Authorise Key When this input is open it prevents unauthorised access to alter the parameter settings of the MPR2000. All settings can be viewed via the LCD display irrespective of the state of this input. However with the input open, an attempt to adjust a setting will result in the " Unauthorised Access" message being displayed. In addition this input can be used to restrict fault and alarm reset, if the Auto and Panel reset options of protective functions are disabled a fault can only be reset from the panel if the authorised input is closed. 6.4 Serial Port The Serial Port utilises a half duplex RS485 protocol allowing up to 32 MPR2000's to be daisy-chained together with a single shielded twisted pair cable . Refer to P&B for details on communications. 6.5 Speed Switch This input is used when the safe stall time of the motor is less than or equal to the normal run up time of the motor, in which case the thermal overload feature will not provide adequate protection against stalling. Connection of a motor speed switch, open when at high speed and closed when at low speed or standstill enables the MPR2000 to enable or disable the locked rotor characteristic which is given under the Stall Time Factor setting. 6.6 External Fault 2 This inputs allows for tripping or alarming of external protective devices or interlocks. When closed the fault is healthy and when opened a trip and/or alarm occurs depending on the Tripping/Alarm settings. Auto-Reset when enabled, occurs when the input contact closes. 6.7 External Fault 3 This inputs allows for tripping or alarming of external protective devices or interlocks. When closed the fault is healthy when opened a trip and/or alarm occurs depending on the Tripping/Alarm settings. Auto-Reset when enabled, occurs when the input contact closes. 6.8 Emergency Stop This input allows the MPR2000 to monitor the status and provide indication of the state of any of the external Emergency Stop buttons which are normally directly wired to the contactor closing circuit. Opening of the input causes a trip or alarm depending on the Tripping/Alarms Settings. Issue I 29/08/03 Page 7 MPR2000 7. MPR2000 Faceplate Functions The MPR2000 Faceplate has been designed to provide all of the required information to the operator for the drive for which the unit is being used. This is achieved by using a LED Status Panel and a Functional Keypad with a LCD display. This eliminates the need for additional indication devices on the front of the motor starter panel such as Lamps, Ammeter, Voltmeter, Hours Run Indicator, Operations Counter, etc. which helps reduce the cost of the motor starter panel and gives improved reliability by reduction of separate components. The following section details the function of the Frontplate devices. 7.1. LED Status Panel This panel incorporates 9 LED indicators which provide the main status indications for the Motor Starter panel MPR POWER ON STOPPED The LED's operate as follows: STARTING green LED MPR2000 POWER ON This illuminates when the auxiliary supply voltage to the MPR2000 unit is connected. RUNNING OVERLOAD EARTH FAULT This green LED MOTOR STOPPED illuminates on power up and also when the motor current is less than 12% of FLC and also when a stop or fault signal is present. ALARM FAULT INT. RELAY FAULT MOTOR STARTING This amber LED is illuminated only when the motor is starting and remains illuminated providing the average motor current is 110% or above of the Overload Setting. This red LED illuminates after a motor has started providing the average motor current has MOTOR RUNNING decreased to below 110% of the Overload Setting and is above 12% of FLC OVERLOAD This red LED illuminates when a Thermal Overload trip has occurred. EARTH FAULTThis red LED illuminates when an earth fault trip has occurred. This red LED indicates that one of the MPR2000 Alarm functions has operated and remains MOTOR ALARM lit until the condition no longer exists and a reset has been performed. This red LED illuminates when one or more of the MPR2000 Fault functions has operated MOTOR FAULT and stopped the motor. It remains lit until the condition no longer exists and a reset has been performed. This red LED illuminates when an internal fault has been detected by the MPR2000 INTERNAL FAULT watchdog feature and remains lit until the fault condition is no longer present and if required by the Alarm/Tripping settings, a reset has been performed. Issue I 29/08/03 Page 8 MPR2000 8. MPR2000 Functional Keypad & Display The MPR2000 is fitted with a functional keypad and a 32 character Alpha-Numeric LCD (Liquid Crystal Display). This enables all settings to be viewed and configured on each individual unit and enables the display of any of the MPR2000 drive data. The following pages explain the function of the LCD display and the function of each key: TIME TO TRIP NO TRIP EXPECTED MOTOR PROTECTION RELAY Liquid Crystal Display The MPR2000 has been equipped with a 2 line, 16 character per line liquid crystal display. The display is used for the following functions: Viewing and Changing of Setting Parameters Viewing Data Parameters Flash and Constant Messages Any Data parameter can be selected as the default display by pressing the STORE key whilst displaying the desired parameter. The MPR2000 will always return to display this parameter if no key is pressed or no Flash/Constant Message is displayed for 5 minutes. SET PAGE LINE DOWN DATA PAGE LINE BACK VALUE RESET TEST STORE VALUE Set Page Key This key when pressed enables the operator to select a page of the MPR2000 Setting parameters, for convenience the setting parameters are grouped into logical pages. Each time the key is pressed the LCD display will show one of the pages titles as follows: Communication Settings System Parameter Settings Voltage Settings Current Settings Temperature Settings Tripping/Alarm Options Pressing the SET PAGE key again after the Tripping/Alarms Options title has been displayed will result in the display returning to the Communications Settings title and so on. Data Page Key This key when pressed enables the operator to select a page of the MPR2000 Displayable Data. For convenience the data are grouped into logical pages. Each time the key titles as follows: Measured Data Calculated Data Logical Inputs - Contacts Status Statistical Data Fault Data Pressing the DATA PAGE key again after the Fault Data title has been displayed will result in the display returning to the Measured Data title and so on. Issue I 29/08/03 Page 9 MPR2000 Line Down Key Pressing the LINE DOWN key enables the operator to scroll forward or down the particular page. The display will move down one item at a time unless the button is held for over half a second in which case the scroll speed will increase. Line Back Key Pressing the LINE BACK key enables the operator to scroll backwards or up the particular page of Settings or Data. The display will move back one item at a time unless the button is held for over half a second in which case the scroll speed will increase. VALUE Key Pressing this key enable the operator to increase the value of the parameter displayed. The value will be increased by one increment every time the key is pressed unless the key is held down for half a second in which case the rate of change will increase. If the Authorise input is open and the key is pressed the flash message ' Unauthorised Access' will be displayed and the setting parameter will not be changed. VALUE Key Pressing this key enable the operator to decrease the value of the parameter displayed. The value will be decreased by one increment every time the key is pressed unless the key is held down for half a second in which case the rate of change will increase. If the Authorise input is open and the key is pressed the flash message ' Unauthorised Access' will be displayed and the setting parameter will not be changed. Store Key This key is used to store a setting parameter to the non-volatile EEPROM memory after a change has been made using the above mentioned keys. After the key has been pressed the flash message ' DATA SAVED OK' will be displayed. If for any reason the change has not been correctly stored the message ' WRONG PARAMETER SAVED' will be displayed If the STORE key is pressed whilst the display shows a Data parameter then the parameter currently being displayed will be set as the default display which the MPR2000 will always revert to if no key is pressed for 5 minutes and provided a flash or constant message is not being displayed. If the value of a parameter is changed but not stored and the display is scrolled to another page the parameter value will be returned to the value stored in the EEPROM memory. Note: It is possible to adjust and store setting parameters at any time , even whilst the motor is running. Changing the value of a displayed parameter has no effect on the operation of the units until the STORE key is pressed. After setting parameters have been stored to the EEPROM memory they are kept indefinitely, this feature does not rely on a battery backup system. Reset Key This key enables the operator to reset MPR2000 Fault or Alarm conditions. Pressing of this key can only perform a reset if the following conditions are met: 1 The Tripping/ Alarm Options for the specific fault or alarm re set to allow panel resets. 2. The condition that caused the Fault or Alarm to occur no longer exists Providing condition 2 is met an operator can override the settings in the Tripping/Alarm Options by closing the Authorise input and pressing the reset button. Note if the reset key is pressed and the Authorised input is closed a flash message 'RESET THERMAL CAPACITY' is displayed and if the RESET button is pressed again whilst the message is displayed the level of Thermal Capacity will be reset to zero. Issue I 29/08/03 Page 10 MPR2000 Test Key The pressing of this key will cause the unit to display the Test/Maintenance menu. Using the LINE DOWN/LINE BACK keys the following options are displayed Run Self Test Program Version Store Enable Default Settings Reset Statistical Data For instructions on the use of these options refer to the Test Maintenance Options section later in this manual 9. MPR2000 Setting And Data Pages 9.1 MPR2000 Communication Settings Drive Number This setting range 0-320 with a default setting of 0, identifies the MPR2000 by an overall system number . This does not affect the communications which uses the Serial Link Number. Baud Rate This setting range 110,300,1200,4800,9600 Bits/Second with a default setting of 9600, determines the speed of communications between the PCX or when directly connected the Host system and the MPR2000. This is normally set to the highest speed 9600 Bits/Second. Serial Link No. This setting range 1-33 with a default setting of 33, identifies the MPR2000 unit to the PCX unit to which the RS485 Data Highway is connected, and is also required to be set if the MPRSET software is to be used . Fast Scan Anal 1,2 & 3 This setting range 0-201 determines the data that is sent to the PCX regardless of whether it asks for it. The settings refer to the address's of the data in the software of the relay. Fast Scan Update. This setting range 0-30 s, in steps of 1 sec, determines the Fast Scan Update Time, i.e. the timeframe that the PCX asks for the Fast Scan Data from the MPR2000. To see the data that can be assigned to the Fast Scan Analogues please refer to section 17. 9.2 System Settings Line Voltage This setting range 0-660V in steps of 5v, or 1-22kv in steps of 100v, with a default setting of 415v, enables the MPR2000 to display the measured voltages in exact volts. When only single phase voltage reference is available this setting must be set to root 3 times the system voltage in order for the under and over voltage protective functions to operate correctly. Primary VT Voltage This setting, range ‘Not Connected’ or 100V - 22kv in steps of 10v upto 1000v and 100v above 110v, with a default setting of ‘Not Connected’, allows for systems with voltages above 660V , where the voltage reference to the MPR2000 must be via a voltage transformer and the VT primary voltage is set with this function. VT Secondary Voltage This setti ng, range ‘Not Connected’ or 95V-660V in steps of 5v, with a default setting of ‘Not Conneted’,allows for systems with voltages above 660V , where the voltage reference to the MPR2000 must be via a voltage transformer and the VT secondary voltage is set with this function. Issue I 29/08/03 Page 11 MPR2000 Motor Full Load Current This setting, range 1-2500 Ams in steps of 1 Amp upto 100 Amps and 5 Amps above, with a default setting of 100 Amps, determines the normal running full load current of the motor and enables protective functions to be set in terms of percentage FLC and enables the MPR2000 to display running current in terms of percentage FLC. CT Primary This setting, range 1-2500 Amps in steps of 1Amp upto 100 Amps and 5 Amps above, determines the primary ratio for the phase current transformers. When using motors with FLC up to 5 Amps which are direct connected (i.e. without CT's this setting should be set to 5 Amps). E/F Primary This setting, range 1-2500 Amps in steps of 1 Amp upto 100 Amps and 5 Amps above, determines the primary ratio of the core balance earth fault CT if used. If a residual connection of phase CT's is used this setting must be the same as for the phase CT primary setting. Earth Fault Alarm This setting range 1-100% Inom in steps of 1%, with a default setting of 5%, specifies the level of earth fault current before an alarm occurs. Earth Fault Alarm Delay This setting is used to select the time between an earth fault being registered and an alarm signal being activated.Range 1-60 seconds in steps of 1s with a default setting of 10s. Earth Fault Trip This setting range 1-100% Inom in steps of 1% , with a default setting of 10% specifies the level of earth fault current before an trip occurs. Earth Fault Trip Delay This setting is used to select the time between an earth fault being registered and an trip signal being activated. Range 0-2 Seconds in steps of 0.1 Seconds with a default setting of 0.5 seconds. Current Inhibit This setting , range Off, or 400-1000% FLC in steps of 10%, with a default setting of ‘off’, determines the level at which the Earth Fault feature will be inhibited from operating. Starting Method Not applicable to this “protection only” relay. Notes The setting options for Aux 1 and Aux 2 output relays should always be set to alarm and Trip respectively. 9.3 Voltage Settings Undervoltage Setting This setting range 50-95% in steps of 1% with default setting of 80% of line voltage determines the pick up level of the Undervoltage protection. When the measured voltages reaches this level for the period equal to the Undervoltage Delay period a trip will be performed, unless the Undervoltage Restart feature is selected. Undervoltage Delay This setting range 0.2 - 10 seconds in steps of 0.1s with a default setting of 5s determines how long an Undervoltage condition must be, before a trip occurs. Overvoltage Alarm This setting range 100-120% in steps of 1%, with a default setting of 115% of line voltage determines the pick up voltage for the Overvoltage alarm function. When the measured voltage reaches this level and remains for 1 second an alarm will occur. Overvoltage Trip This setting range 100-120% in steps of 1%, with a default setting of 120% of line voltage determines the pick up level for the Overvoltage trip function. When the measured voltage reaches this level and is maintained for the Overvoltage Trip Delay a trip will occur. Issue I 29/08/03 Page 12 MPR2000 Overvoltage Trip Delay This setting range 1-100 seconds in steps of 1 second, with a default setting of 1 second determines how long an Overvoltage must be present before a trip will occur. 9.4 Current Settings Maximum Start Time This setting with a range of 1 to 250 seconds in steps of 1 s with a default setting 10 seconds determines the time that the motor is allowed to take to complete it's starting sequence. Number of Starts The number of starts the motor will make can be limited by the MPR2000 from anywhere between the range 1 to 10 in steps of 1, with a default setting of 10. Start Period This specifies the time, within which the number of motor starts will be allowed to occur. Should the number of starts selected be exceeded the motor will be inhibited from starting for a pre-selected time specified by the Start Inhibit Time value. The start period can be between the range of 1 to 60 minutes in steps of 1 minute, with a default setting of 15 minutes. Start Inhibit Time This details the time that must elapse before the motor can be restarted after previously exceeding the number of starts set within the start period. This is adjustable between the range of 1 to 60 minutes in steps of 1 minuts, with a default setting of 15 minutes. Undercurrent Alarm If current falls the MPR2000 will sense this and an alarm will be signalled at a set percentage of FLC. This setting has a range 10 - 90% in steps of 1% of FLC, with a default setting of 50%. Undercurrent Alarm Delay Linked to the undercurrent alarm this function can be pre-set to determine how long an undercurrent below the setting can occur before an alarm will be signalled. It may be set between the range of 1 and 60 seconds in steps of 1s, with a default value of 2 seconds. Undercurrent Trip This setting specifies below what undercurrent level the unit will trip. It is adjustable between the range of 10 and 90% of FLC in steps of 1%, with a default value of 40% of FLC. Undercurrent Trip Delay This sets a time between the unit registering an undercurrent level and the actual tripping of the unit. Adjustable by the user between the range of 1 and 60 seconds in steps of 1s, with a default setting of 5 seconds. Load Increase Alarm Should the load on the motor increase during operation the MPR2000 can sense this and signal an alarm. The pick up level is adjustable between the range of 60 and 150% of FLC and has a default setting of 120% of FLC, with a fixed time delay of 5 seconds. Low Set Overcurrent This setting is not in service during starting. It can be set between the range of 100 and 500% in steps of 10% of FLC to afford the user a faster tripping time for overcurrent conditions than that available from the overload curve. The default for this etting is 400% of FLC. This feature can also used to provide a fast operating definite time stall protection after the motor is running. Low Set Delay This setting determines the time of the delay between the unit registering a low set overcurrent to it's alarm or trip point. The setting is adjustable between the range of 0.5 and 10 seconds in steps of 0.5s, with a default setting of 2.0 seconds. Issue I 29/08/03 Page 13 MPR2000 High Set Overcurrent This feature is normally enabled when the motor is being controlled by a circuit breaker rather than a fuse contactor. The High Set Overcurrent unit can be set between the range of 400 and 1200% in steps of 10% of FLC, with a default value of 800%. High Set Delay User set from the keypad, this setting determines the time between registering a High Set Overcurrent and an alarm or trip being signalled. Adjustable between the range of instantaneous to 4 seconds in steps of 0.1s with a default setting of 'Instantaneous'. Overload Setting Pre-settable overload setting range 60 to 130% in steps of 1% of FLC, with a default and P&B Engineering's recommended setting of 105% of FLC. For further information refer to section 'MPR2000 Thermal Overload Protection' Thermal Capacity Alarm User settable to specify a thermal capacity alarm value between the range of 50 and 99% in steps of 1% of capacity, with a default setting of 80%. t6x Time This setting specifies the time the MPC2000 will take to trip at 6 times FLC and determine the basic thermal characteristic. This time range 0.5 and 120 seconds, with a default setting of 10 seconds. For further information refer to section 'MPR2000 Thermal Overload Protection' Hot/Cold Ratio Adjustable between 20 and 100% in steps of 1%, with a default setting of 50%. For further information refer to section 'MPR2000 Thermal Overload Protection' Cool Time Factor This setting specifies the time factor at which the running motor will cool down once it has been stopped. Adjustable between the range of 1 to 15 in steps of 1 times the heating constant with a default setting of 5. For further information refer to section 'MPR2000 Thermal Overload Protection'. Stall Time Factor To cater for stalling on starting particularly when the motor locked rotor characteristic is close to that normally seen during a start. To achieve adequate protection the thermal characteristic may be switched to a lower value. The feature is activated by connecting a speed switch between terminals 32 and 9 which enables or disables the stalling characteristic which is adjustable between the range of 20 and 100% in steps of 1% of the thermal trip times, with a default setting of 50%. Overload Reset Method With the exception of the Thermal Overload Protection all of the MPR2000 protective functions can be disabled. When set to Auto the Overload trip will be self-reset when the thermal capacity has cooled to below 50% of the motor capacity without the need for an operator reset. When set to Hand the fault will not reset until an operator reset is performed but only if the thermal capacity used has reduced to 50%. Aux 1 Designate, Alam, Contactor A, Contactor B, Run. Aux 2 Designate Trip, Trip Fail Safe, Contactor A, Contactor B. Issue I 29/08/03 Page 14 MPR2000 Unbalance Current This user adjustable setting allows the specifying of the amount of current unbalance that the motor can tolerate. This can be set between the range of 10 and 40% in steps of 1% of FLC, with a default setting of 15%. Current Unbalance Time Constant This setting determines the time that the current may be unbalanced before a trip is initiated. The setting is adjustable via the keypad. The value To has the range 20 - 120 seconds in steps of 1 second, the default value being 30 seconds, and it refers to the inverse slope of the time verses %unbalance characteristic which has a reference point corresponding to an Unbalance of 10%. The unbalance trip function is an inverse-time characteristic of the form T = 100 To (uB)2 where To = time constant setting uB = The unbalance in %. However the minimum trip time is 1 second and the minimum pick up is the same as the setting “unbalance Current” above. LOWER LIMIT UPPER LIMIT EXAMPLE 20 % 5% 40% 120 70 To=20 To=70 20 10 To=120 1 0.1 5 10 20 30 40 50 100 200 % UNBALANCE Issue I 29/08/03 Page 15 MPR2000 9.5 Temperature Settings RTD/Thermistor This determines whether Resistance Temperature Detectors or Thermistor are being used for temperature monitoring. In addition to this setting a change in the setting of an internal group of dip switches is required, refer to notes given in the MPR Measured Inputs section. Thermistor Type This setting, range PTC or NTC is only applicable if Thermistor is set above. It determines whether positive or negative coefficient Thermistor are being used. Channel 1 Alarm This determines the resistance level at which an alarm will occur. Channel 2 Alarm This determines the resistance level at which an alarm will occur. Channel 3 Alarm This determines the resistance level at which an alarm will occur. Channel 1 Trip This determines the resistance level at which an trip will occur. Channel 2 Trip This determines the resistance level at which an trip will occur. Channel 3 Trip This determines the resistance level at which an trip will occur. 9.6 Tripping/Alarm Options This page contains the following settings for each protective function incorporated in the MPR2000. Trip This determines whether operation of the protective function cause a trip to the motor or not. This can be applied to an alarm such that an alarm can be made to trip. Alarm The option, whether the protective functions cause an alarm to occur and is applicable to both alarm and trip protective functions. Auto Reset This allows self resetting of a fault or alarm once the fault is no longer present. In the case of Thermal Overload or Too Many Starts faults the self reset will not occur until the capacity has cooled to 50% or the Starts inhibit period has passed. Panel Reset This allows reset of a latched fault by pressing the reset button on the MPR2000 functional keypad, irrespective of the state of the Authorise input. If this feature and the Auto Reset functions are disabled the only way to reset the fault locally is by use of the Reset button when the Authorise input is closed. The above options are provided individually for all of the MPR2000 protective functions: Issue I 29/08/03 Page 16 MPR2000 9.7 MPR2000 Setting Pages Summary The diagrams that follow summarise all of the MPR2000 Setting and Data pages and gives the factory default setting for all settings. COMMUNICATION SETTINGS SETTING RANGE DEFAULT Drive Number Baud Rate Serial Link No. Fast Scan Anal 1 Fast Scan Anal 2 Fast Scan Anal 3 Fast Scan Update 1 - 320 110,300,1200,2400,4800,9600 1 - 33 0 - 201 0 - 201 0 - 201 0-30s 0 9600 33 0 1 2 0 100v-22kv Not Connected, 100v-22kv " " , 95-660v 1-2500A 1-2500A 1-2500A 1-100% Inom 1-60 Sec 1-100% Inom 0-2 Sec off, 400-1000% FLC Momentary, Maintained DOLNR,Star/Delta,Reversing 2 Speed,Valve Control 1-60 Sec 0.05-2.0 Sec 75-200% FLC 1-2500A 0.5-120Sec Alarm,Contactor A, Contactor B, Run 0-120 Sec Trip, Trip Fail Safe, Contactor A, Contactor B 0-120 Sec Yes 415v Not Connected " " 100A 100A 100A 5% Inom 10 sec 10% Inom 0.5 Sec off Momentary DOLNR 50-95% 0.2-10 Sec Yes,No 0.2-120 Seconds 100-120% 100-120% 1-100 Sec 80% 5 Sec No SYSTEM PARAMETER SETTINGS Line Voltage VT Primary VT Secondary Motor FLC CT Primary E/F CT Primary Earth fault Alarm " " " Delay Earth Fault Trip " " " Delay Current Inhibit Start/Stop Signal Starting Method Max Time in Star Transition Time Star to Delta at Low Speed FLC Low Speed t6X Designate Aux 1 Aux 1 Delay Designate Aux 2 Aux 2 Delay Protection Only 10 Sec 0.2 Sec 150% FLC 10A 10 Sec Alarm 0 Trip 0 Yes VOLTAGE SETTINGS Undervoltage Setting Undervoltage Delay Undervoltage Restart Undervoltage Restart Delay Overvoltage Alarm Overvoltage Trip Overvoltage Trip Delay Issue I 29/08/03 Page 17 115% 120% 1 Sec MPR2000 CURRENT SETTINGS Maximum Start Time Number of starts Start Period Start Inhibit Time Undercurrent Alarm Undercurrent Alarm Delay Undercurrent Trip Undercurrent Trip Delay Load Increase Alarm Low Set Overcurrent Low Set Overcurrent Delay High Set Overcurrent High Set Overcurrent Delay Overload Setting Thermal Capacity Alarm t6x Time Hot/Cold Ratio Cool Time Factor Stall Time Factor Overload reset Method Unbalance Current Current Unbalance Time Constant 1-250 Sec 1-10 1-60 Min 1-60 Min 10 Sec 10 30 Min 30 Min TEMPERATURE SETTINGS SETTING RANGE DEFAULT RTD/Thermistor Thermistor Type Channel 1 Alarm Channel 2 Alarm Channel 3 Alarm Channel 1 Trip Channel 2 Trip Channel 3 Trip RTD/Thermistor PTC,NTC 0-200 deg C or 100-240 or 100-30,000 ohm 0-200 deg C or 100-240 or 100-30,000 ohm 0-200 deg C or 100-240 or 100-30,000 ohm 0-200 deg C or 100-240 or 100-30,000 ohm 0-200 deg C or 100-240 or 100-30,000 ohm 0-200 deg C or 100-240 or 100-30,000 ohm RTD TRIPPING/ALARM OPTIONS Function T 10-90% FLC 1-60 Sec 10-90% FLC 1-60 Sec 60-150% FLC 100-500% FLC 0.5-10 Sec 400-1200% FLC Inst-4 Sec 60-130% FLC 50-99% 0.5-120 Sec 20-100% 1-15 20-100% Auto,Hand 5-40 20-120 Sec A AR 2 Sec 40$ 5 Sec 120% 400$ 2.0 Sec 800% Inst 105% 80% 10 Sec 50% 5 50 Hand 15% 30 Sec PR Maximum Start Time D E D E Too Many Starts D D D E Undercurrent Pre-Alarm D E D E Undercurrent Trip D D D E Load Increase Alarm D E D E Low Set Overcurrent E E D E High Set Overcurrent D D D E Thermal Pre-Alarm D E D E Thermal Trip E E D E Unbalance Alarm D E D E Unbalance Trip E E D E Undervoltage Trip D E D E Overvoltage Pre-Alarm D E D E Overvoltage Trip E E D E Phase Loss E E D E Phase Sequence E E E E Temp 1 Channel Pre-Alarm D D D E Temp 1 Channel Trip D D D E Temp 2 Channel Pre-Alarm D D D E Temp 2 Channel Trip D D D E Temp 3 Channel Pre-Alarm D D D E Temp 3 Channel Trip D D D E Earth Fault Pre-Alarm D E D E Earth Fault Trip E E D D Serial Port Failure D D E E Internal Relay Failure D E D D Emergency Stop D D D E Control Circuit Open D D D E Welded Contactor D D D E External Fault 2 D D D E External Fault 3 D D D E E=Enabled D=Disabled, T=Trip, A=Alarm, AR=Auto-Reset, PR=Panel Reset, R=Remote Reset Issue I 29/08/03 Page 18 50% 140 deg C 140 deg C 140 deg C 150 deg C 150 deg C 150 deg C R E E E E E E E E E E E E E E E E E E E E E E E D E D E E E E E MPR2000 9.8 MPR2000 Data Pages Summary The following menus can be displayed by the Data Page Key. Under each menu title is data displayed on the MPR2000 on that data page. These are seen by pressing the Line Up and Line Down Keys. MEASURED DATA VP1, VP2, VP3 VL1, VL2, VL3 I1, I2, I3 E/F Current R1, R2, R3 T1, T2, T3 Volts Volts Amps Amps Ohms RTD Total Real Power Total VA Power Power Factor Watts VA % CALCULATED DATA Motor Load Thermal Capacity Time to Trip Time to start Unbalance Current % % Min then Sec Min then Sec % LOGICAL INPUTS Drive Status Speed Switch Authorise Key Emergency Stop External Fault 2 External Fault 3 Available/Unavailable/Running Open=high speed/closed=low speed Open=locked/closed=unlocked Closed=run enable/open=stop " " " " " " " " " " STATISTICAL DATA Total Run Time Total # of starts Total # of Trips Last ST. Period Last ST. Peak I Hours Secs Amps FAULT DATA LAST TRIP LAST ALARM FAULT I1,I2,I3 Fault IO Fault V1,V2,V3 Description Description Amps Amps Volts 10. MPR2000 Communications The MPR2000 in addition to its very comprehensive protection has been equipped with a very powerful data communications system. The relay provides high speed data acquisition to supervisory computers to form a complete motor management system. Each MPR2000 can be connected to an isolated data highway using RS485 communications. Up to 32 MPR2000 units can be connected to each data highway. For further information on the communication of the MPR2000 phone us for our booklet at Manchester 0161-230-6363. Issue I 29/08/03 Page 19 MPR2000 11. MPRSET Software . All of the MPR2000 setting parameters mentioned above can be viewed and changed through the use of the MPRSET Software offered by P & B Engineering. It is designed to configure large numbers of units quickly as well as storing and printing the MPR2000 setting parameters. For further information on the communication of the MPR2000 phone us for our booklet at Manchester 0161-230-6363. 12. MPR2000 Flash/Constant Messages The following Flash and Constant messages are displayed by the MPR2000 LCD : DATA SAVED OK to the EEPROM memory This Flash message is displayed after a setting parameter has been correctly stored If an attempt is made to change or store a setting parameter whilst the Authorise UNAUTHORISED ACCESS input is open this Flash message is displayed. This message will also be displayed if an attempt is made to reset a fault for which the panel reset has been disabled. This Flash message is displayed when the reset key is pressed if the RESET THERMAL CAPACITY ??? Authorised input is closed and if the reset button is pressed whilst the message is displayed the Thermal Capacity will be set to Zero. THERMAL CAPACITY RESET PERFORMED operation has been successfully performed. This Flash message is displayed after the above SELF TEST PASSED This Flash message is displayed if the 'Run Self Test' function of the Test/Maintenance Options is successfully performed. This Flash message is displayed if an error has been found SELF TEST FAILED ERROR CODE 32 during the operation of the 'Run Self Test' function in the Test/Maintenance Options. This is a constant message which identifies which Alarm has operated and is displayed ALARM 'XXXX' when the Alarm LED is illuminated. This is a constant message which is identifies which Fault has operated and is displayed Fault 'XXXX' when the Fault LED is illuminated. 13. MPR2000 Internal Test Routines In addition to conventional hardware and software watchdog routines, the MPR2000 has been designed to include its own internal test routines and watchdog. When the Test key is pressed the Test/Maintenance Menu will be displayed:Run Self Test Program Version Store Enable Default Settings Reset & Store Statistical Data These functions can only be performed if the Authorise input is closed, and operate as follows: Run Self Test This option checks all the monitored hardware and software routines displaying the message "SELF TEST PASSED" when completed successfully. Should this check fail then the message "SELF TEST FAILED" will be displayed including an error code. The Internal Error LED will be illuminated and if enabled in the Tripping/Alarm Options the unit will trip or alarm. The error code should be noted down and reported to P&B Engineering before returning the unit for repair. A minimum period of 20 seconds should be allowed after aux power is applied before carrying out a self test. Issue I 29/08/03 Page 20 MPR2000 Program Version correspondence. This gives the version of the software employed in your unit and should be quoted in all Store Enable Default Settings This will allow the user to reset the unit to the original factory set default settings before any customer changes were made. This option should be used with care as all previous data will be lost. Pressing of the STORE and SET PAGE keys simultaneously will affect this procedure. Reset & Store Statistical Data This allows the user to reset all statistical data and store at the reset value. Care must also be taken when using this option, as all previous statistical data will be lost when reset. Pressing of the DATA PAGE and RESET keys simultaneously will affect this procedure. 14. MPR2000 Fault Finding This procedure details some of the more common faults which may cause the MPR2000 to not operate as required. This is usually due to incorrect settings or logic and will hopefully assist to rectify the situation. Check all connections at the rear of the unit have been made correctly. Switch on the MPR2000 and ensure that the 'Power On' LED is illuminated. If not check the customer system. If the motor starts but the MPR2000 alarms immediately, check the following:Ensure 'System Parameter Settings' and 'Tripping/Alarm Options' are correct. Ensure correct temperature measurement device has been selected, i.e. Thermistor or RTD. Ensure that the RTD inputs have been earthed. These are terminals 11, 12 and 54.(See Section 4.) When selecting RTD PT100 the 100 Ohm resistance refers to the resistance at zero temperature. Ensure the normal working temperature figure is added to this value. Usual setting approximately 140 Ohm. •If selecting Thermistor set correct type, i.e. +ve or -ve. •Check that the unit passes the 'Self Test Program'. •When using the MPR2000 with a single phase input; special care needs to be given to the System Parameter Settings to obtain correct results. In particular the Line Voltage parameter should be set at 1.732 times the expected line voltage, e.g. 11KV system; set line voltage at 11Kv x 1.732 = 19KV The VT Primary and VT Secondary values are set normally, i.e. VT Primary = 11KV VT Secondary = 110V For Low Voltage systems, using for example a 240V phase to neutral input, the line voltage should be set to 415V. If the unit still will not operate or still keeps alarming and has passed its self test, then seek further assistance from our application help desks at Manchester 0161- 230-6363. Issue I 29/08/03 Page 21 MPR2000 15. MPR2000 Thermal Overload Protection MPR2000 Thermal Operating Curves 200 The curves shown are the time/current operating characteristics for the MPR2000 Thermal Overload protection. 100 t Curve 1 :Cold Curve Overload Setting =105% Curve 2 :Hot Curve Overload Setting =105% Running From 100% FLC Hot/Cold Ratio = 80% 20 10 Curve 3 : Hot Curve Overload Setting:=105% Running From 100% FLC Hot/Cold Ratio = 50% Curve 4 : Hot Curve Overload Setting:=105% Running From 100% FLC Hot/Cold Ratio = 20% 2 1 Explanation The MPR2000 simulates the thermal condition of the motor by means of a thermal register. The heating of the register is related to the square of the largest of the three line currents. The rate of cooling of the thermal register is directly related to the rate of heating. The value of the thermal register is called thermal capacity and it is used to simulate motor temperature. 0.2 0.1 100 percent thermal capacity means the motor temperature has reached the maximum allowed and is the level at which an overload trip will occur. When the motor is stopped for a long period of time the thermal capacity used is zero, this is known as the 'cold condition', and the motor has 100 percent of it's thermal0.02 capacity available for heating before a trip will occur. 0.01 1 2 3 4 5 6 7 8 9 10 15 Multiples of FLC When a motor starts and is running it's temperature increases, after running at normal FLC for a period of time the motor will have reached a hot condition and a lower value of thermal capacity will be available. The Hot/Cold Ratio setting determines the amount of available thermal capacity for a motor running at FLC i.e. hot condition, this is set as a percentage ratio of the amount of thermal capacity available at the cold condition which is always 100%. The thermal capacity available for a motor running at normal FLC i.e. Hot condition is the Hot/Cold Ratio setting. For example if the Hot/Cold ratio setting is 60% and the motor has been running at normal FLC for some time the amount of thermal capacity available is 60% then the amount displayed by the MPR2000 is the amount used which is 100 - 60 = 40%. Providing the motor running current does not exceed the overload setting ( 105% FLC default) the thermal capacity used will never reach 100% and therefore will never trip on overload Issue I 29/08/03 Page 22 MPR2000 When the running current exceeds the overload setting the thermal capacity will eventually reach 100% and trip the motor. The time taken depends on the present value of thermal capacity used and the t6x setting, which is set as the time to trip for a motor in a cold condition when the current is at 6 times the motor rated FLC. The heating constant is equal to t6x setting x 32 seconds. The expected 'Time To Trip' is the time it will take to reach 100% thermal capacity at the present running current level is calculated and can be displayed by the MPR2000. If a motor speed switch is installed and connected to the MPR2000 it is then possible to decrease the thermal trip time in the range of 20-100% of the set hot & cold curve operating times when the motor stops rotating, i.e. stalled. After a thermal overload trip it is not possible to reset the fault and restart the motor until the amount of thermal capacity available has reduced to 50%. The cooling time constant of a motor, i.e. the time taken for its temperature to drop is usually much longer than the heating constant. The Cool Time Factor setting determines the rate of cooling and is set as a ratio of the heating time factor between 1 and 15 times the heating factor. The higher the value of this setting the longer it will take for the thermal capacity to reduce to the 50% level required to enable a restart. The MPR2000 calculates the expected 'Time To Restart' and displays this value within the 'Calculated Data' page. For testing purposes the resetting of the thermal capacity register to 0% can be manually performed only if the 'Authorise Key' input is enabled, and by pressing the Reset key which will cause the display to show 'Reset Thermal Capacity ???'. If the Reset key is pressed again whilst this message is displayed i.e. within 1 second the register will be reset to 0%. The settings for 'Thermal Overload', 't6x', 'Hot/Cold Ratio' and 'Cool time Factor' should be established from data obtained from the motor manufacturer however should it not be possible then the default settings for these are typical settings for normal induction motors and may be used at the users own risk. The t6x setting can be set to 10% above the normal run up time, which can be established after the unit is installed by starting the motor and noting the 'Last Start Time' available in the MPR2000 'Statistical Data page. The present value of thermal capacity is stored in the EEPROM non-volatile memory during a failure or disconnection of the auxiliary supply. Upon restoration of the supply the former value will be maintained. Referring to the MPR2000 Thermal Operating curves shown, the operating time at a certain multiple of motor FLC can be calculated for a particular motor by multiplying the corresponding time taken from the vertical scales by the setting of t6x. Example Application As an example of applying the MPR2000 Thermal Overload protection to a motor let us establish the settings for a particular motor having the following characteristics: Rating: System Volts FLC: CT ratio Starting Start Time Cold Withstand Hot Withstand 100Kw 415 Volts 180 Amps 200/5 Amps DOL 8 sec @ 6xFLC 22 Seconds 11 Seconds The figures for Line Voltage, Motor FLC and CT Primary should be entered. For the Overload setting we will use the default setting of 105%. The t6x setting must now be calculated. This is set as the time taken to trip at 6 x FLC for the Cold Starting condition and is set in conjunction with the Hot/Cold Ratio setting. For the above typical motor the Hot Withstand time is 11 seconds, the Cold Withstand is 22 seconds, therefore the Hot/Cold ratio is calculated as 11/22 x 100 = 50%. Issue I 29/08/03 Page 23 MPR2000 As a general rule the relay should be set to trip at no closer than 80% of the Thermal withstand Time, which in this case is 80% x 22 sec = 17.6 secs. Therefore set t6x = 17 secs and set Hot/Cold Ratio = 50% From the standard MPR2000 Thermal Operating Curves the Cold curve trip times can be calculated by multiplying the setting t6x and the factor 't' for various multiples of FLC i.e.: Multiple of FLC Trip time (secs) 1.5 366 2.0 175 3.0 71 4.0 39 5.0 24 6.0 17 From the Hot Curve for Hot/Cold Ratio =50% trip times can be calculated as follows: Multiple of FLC Trip Time (secs) 1.5 230 2.0 102 3.0 40 4.0 22 5.0 14 6.0 9.5 The curves shown on the right are the actual curves for the calculated figures and show that the setting has been chosen to provide close protection to take advantage of the motors capability and allow the possibility of an immediate restart from the Hot condition. However alternative settings can be made to provide faster tripping limited by the conditions of ensuring the motor can run up speed under healthy conditions without tripping. If the Hot to Cold ratio is set to a figure other than the 3 standard curves drawn, then either the formula quoted below can be used or an approximation of the Hot curve can be drawn to calculate trip times. (Starting/Cold Condition) tc = 32.a.loge ( p2 ) -------p2 - s2 where 'p' is multiple of motor FLC (per unit value) 's' is overload setting in per unit value e.g. 105% 'a' is setting of t6x in seconds 't c is the operating time in seconds (Running/Pre-load Condition) tc = 32.a.loge ( p2 - (1-H/C)(IL)2 ) -------------------p2 - s2 where 'I L'is the steady state load prior to overload condition divided by motor FLC, e.g. if motor is running at FLC, IL=1. 'H/C' is the hot/cold ratio in per unit value e.g. 40% hot to cold ratio = 0.40. Issue I 29/08/03 Page 24 MPR2000 The cool Time Factor is factory set at 5 unless specific information is available from the motor manufacturer to calculate the actual setting it is recommended that the default setting is used. With regard to current unbalance protection the pick up time default setting is 15% and trip time is 30 seconds. This figure should be set to the motor requirements if the Negative Phase Sequence withstand can be obtained. Formula for calculating the unbalance setting can be obtained from P & B Engineering on request. Further help on the application of thermal overload protection by ringing P & B Engineering at Manchester on 061 230 6363. Issue I 29/08/03 Page 25 MPR2000 16. MPR2000 Installation 16.1 Casing The MPR2000 is supplied in a UK manufactured industry standard drawout case for flush mounting on the front of the motor starter or circuit breaker cubicles. 96 102 156 45 2 23 10 4 HOLES 4.3mm DIAMETER 168 158 PANEL CUT OUT FLUSH MOUNTING FIXING DETAILS 202 Min 28 NOTE Minimum gap between vertical spacing is required in order to PUSH BUTTON PROJECTION 10mm withdraw relay from the case above. Clearance 166.25 40 178.5 208 155.5 178 M4 STUDS Required to open case Issue I 29/08/03 25 min Page 26 NOT SHOWN TO SCALE MPR2000 16.2 MPR2000 Terminations All terminations to the MPR2000 are situated to the rear of the unit, and are suitable for use with standard crimped connectors. The rear terminal block accepts both pre-insulated screw and push-on blade type connectors. Each terminal has 1 screw type and 2 blade type connectors. Screw: Each connection uses a 4mm (M4) screw outlet and accepts standard L-shaped ring type connectors designed for 4mm screws. Blade: Each connection facilitates 2 pre-insulated push-on blades 4.8mm wide 0.8mm thick complying with BS5057. Combinations: Each terminal will accept either; 2 ring type connectors or 2 push-on blade type connectors or 1 ring type connector & 1 push-on blade type connector The following diagram shows the position of the terminals. Earth Each terminal 1 2 29 30 3 4 31 32 5 6 33 34 7 8 35 36 9 10 37 38 11 12 39 40 13 14 41 42 15 16 43 44 17 18 45 46 19 20 47 48 21 22 49 50 23 24 51 52 25 26 53 54 27 28 55 56 1 screw & 2 spade Rear terminal block connections. All information subject to change without notice Publication number MPR2000 Issue H Issue I 29/08/03 Page 27 MPR2000 17. Fast Scan Analogue Data The Fast Scan Analogue 1,2 and 3 can have the following data assigned to them to be read back to the PCX:Address 0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 23 24 25 26 Data Represented. Current in I1 Current in I2 Current in I3 Current in I0 Voltage in VP1 Voltage in VP2 Voltage in VP3 Voltage in VL12 Voltage in VL23 Voltage in VL31 Drive Status Trips Alarms Time to trip Time to start Average RMS current Motor load Unbalance Alarm fault number Frequency Resistance(4) Phase Sequence Control Input 1 Control Input 2 Control Input 3 Address 27 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 70 71 86 92 93 94 Data Represented. Hardwire Command Total run time Total starts Total trips Thermal capacity Trip fault number Logic status Pre trip I1 Pre trip I2 Pre trip I3 Pre trip I0 Pre trip VP1 Pre trip VP2 Pre trip VP3 Last start period Last start peak current Pre trip Power Fault status RTD4 RTD5 Dip Switch Average Power Power Factor Power VA 18. Changes To The Manual. From Issue G. Undercurrent is clarified, a new lower limit of 5%. From Issue F. Earth Fault Display lower range is noted. (Section 5.4.) Accuracy of Power for small motors is noted. (Section 5.6.) Fast Scan Update Time Added. (Section 9.1.) From Issue E Clarification of the external instrumental earthing inputs on pins 11,12,54. Notes are changed in section 4., 5., and 14. From Issue D FLC changed to Inom with respect to Earth Fault Trip and Alarm Power Indication is now no longer an option. 5th RTD channels Pin Out Numbers changed from 52, 53 and 51 to 53,51 and 52. Issue I 29/08/03 Page 28 MPR2000