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Commissioning Instructions

MotorMaster 200Motor Protection Relays

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HANDLING OF ELECTRONIC EQUIPMENT

A persons normal movements can easily generate electrostatic potentials of several thousand volts.

Discharge of these voltages into semiconductor devices when handling electronic circuits can cause serious

damage, which often may not be immediately apparent but the reliability of the circuit will have been reduced.

The electronic circuits of ALSTOM T&D Protection and Control Ltd. products are immune to the relevant levels ofelectrostatic discharge when housed in their cases. Do not expose them to the risk of damage by withdrawing

modules unnecessarily.

Each module incorporates the highest practicable protection for its semiconductor devices. However, if it

becomes necessary to withdraw a module, the following precautions should be taken to preserve the high

reliability and long life for which the equipment has been designed and manufactured.

1. Before removing a module, ensure that you are at the same electrostatic potential as the equipment by

touching the case.

2. Handling the module by its front-plate, frame, or edges of the printed circuit board. Avoid touching the

electronic components, printed circuit track or connectors.3. Do not pass the module to any person without first ensuring that you are both at the same electrostatic

potential. Shaking hands achieves equipotential.

4. Place the module on an antistatic surface, or on a conducting surface which is at the same potential as

yourself.

5. Store or transport the module in a conductive bag.

More information on safe working procedures for all electronic equipment can be found in BS5783 and

IEC 60147-0F.

If you are making measurements on the internal electronic circuitry of an equipment in service, it is preferable

that you are earthed to the case with a conductive wrist strap.

Wrist straps should have a resistance to ground between 500k 10M ohms. if a wrist strap is not available

you should maintain regular contact with the case to prevent the build up of static. Instrumentation which may

be used for making measurements should be earthed to the case whenever possible.

ALSTOM T&D Protection and Control Ltd. strongly recommends that detailed investigations on the electronic

circuitry, or modification work, should be carried out in a Special handling Area such as described in BS5783

or IEC 60147-0F.

Commissioning Instructions

MotorMaster 200Motor Protection Relays

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Contents

SAFETY SECTION 5

1. INTRODUCTION 81.1 Application 8

2. COMMISSIONING 13

2.1 System connections 132.2 Current settings (red switches) 132.3 Overload operating time settings (orange switches) 142.4 Reset time setting (yellow switches) 142.5 Earth fault time setting (green switches) 152.5 Common errors associated with commissioning 15

3. TEST PROCEDURES 163.1 Thermal overload testing 16

3.1.1 Cold curve testing 163.1.2 Hot curve testing 163.2 Single phase testing 163.3 Earth fault testing 163.4 Resetting 17

4. DC AUXILIARY SUPPLY 18

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SAFETY SECTION

This Safety Section should be read before commencing any workon the equipment.

Health and safety

The information in the Safety Section of this manual is intended to ensure that

products are properly installed and handled in order to maintain them in a safecondition. It is assumed that everyone who will be associated with the equipmentwill be familiar with the contents of the Safety Section.

Explanation of symbols and labels

The meaning of symbols and labels which may be used on the equipment or inthis manual, are given below.

Caution:refer to product documentation Caution:risk of electric shock

Protective/safety *earth terminal

Functional *earth terminal.Note: this symbol may also be used for a protective/

safety earth terminal if that terminal is part of aterminal block or sub-assembly eg. power supply.

*Note: The term Earth is the equivalent of the North American term Ground.

Installing, Commissioning and Servicing

Personnel installing, commissioning or servicing this equipment should be awareof the potential hazards. This service manual should be read before installing,

commissioning or servicing the equipment.Terminals exposed during installation, commissioning and maintenance maypresent a Hazardous Live voltage unless the equipment is electrically isolated.

If there is unlocked access to the rear of the equipment, care should be taken byall personnel to avoid electric shock or energy hazards.

The equipment should be operated within specified electrical and environmentallimits.

Before energising the equipment it must be earthed using the protective earth

terminal. The recommended minimum earth wire size is 1.0 mm2. Omitting ordisconnecting the equipment earth may cause a safety hazard.

The recommended maximum rating of the external protective fuse for thisequipment is 6A, Red Spot type or equivalent.

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General warnings

Current transformer circuits

Do not open the secondary circuit of a live CT since the high voltage producedmay be lethal to personnel and could damage insulation.

Insulation and dielectric strength testing

Insulation testing may leave capacitors charged up to a hazardous voltage.

At the end of each part of the test, the voltage should be gradually reduced tozero, to discharge capacitors, before the test leads are disconnected.

Insertion and withdrawal of pcb cards

Care must be taken when inserting or removing PCB cards since Hazardous Livevoltages may be accessible, unless the equipment is electrically isolated.

Output monitoring sockets

Care must be taken when using the output monitoring sockets since Hazardous

Live voltages may be accessible. It is recommended that the equipment should beelectrically isolated before making connections to the output monitoring sockets.

Use of source monitoring and extender cards

Care must be taken when using the source monitoring and extender cards sinceHazardous Live voltages may be accessible.

Disposal

It is recommended that incineration and disposal to water courses is avoided.The product should be disposed of in a safe manner.

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Technical Specifications

Insulation class: IEC 601010-1:1990/A2:1995 This equipment does notClass II require a Protective (Safety)EN 61010-1:1993/A2:1995 Earth connection.Class II

Installation IEC 601010-1:1990/A2:1995 Distribution level, fixed

Category Category III installation. Equipment in this(Overvoltage): EN 61010-1:1993/A2:1995 category is qualification

Category III tested at 5kV peak,1.2/50s, 500, 0.5J,between all supply circuitsand earth and also betweenindependent circuits.

Environment: IEC 601010-1:1990/A2:1995 Compliance is demonstratedPollution degree 2 by reference to genericEN 61010-1:1993/A2:1995 safety standards.Pollution degree 2

Product Safety: 73/23/EEC Compliance with theEuropean Commission LowVoltage Directive

EN 61010-1:1993/A2:1995 Compliance is demonstratedEN 60950:1992/A11:1997 by reference to generic

safety standards

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Section 1. INTRODUCTION

There is a warning symbol on the equipment, an exclamation mark within atriangle. This warns the user to refer to the Commissioning Instructions (I9-057P)and the Operation and Maintenance manual (I9-106P) before installing,commissioning or operating the equipment.

WARNINGS

1. Installation, commissioning and maintenance should only be carried out bysuitably qualified personnel.

2. Terminations exposed during installation, commissioning and maintenancemay present a hazard unless the equipment is electrically isolated.

3. The equipment should only be operated as intended within the specifiedelectrical and environmental limits.

4. Susceptibility to Electrostatic Discharge 8kV air discharge/4kV contact.

This specification applies for direct contact with the terminals and via airdischarge on or around the manual reset relay only. When setting the DILswitches and using the test button, appropriate ESD protection must be taken.

1.1 Application

Features MotorMaster 200

201 202 202S 203 204

Single phase protection Thermal overload protection

Earth fault protection

Single phase inhibit (soft start applications)

Mechanically latched output relay for earthfault and single phase protection

Mechanically latched output relay for earth

fault, single phase and thermal overloadprotection with separate relay for thermaloverload alarm

6 x overload test facility

Connection diagrams are shown in Figures 1 to 5.

In some applications, 3 line current transformers are used. Refer to Figure 6 forthe connections to the MotorMaster for these applications.

For the selection of line current transformers and core balance transformers, referto the MotorMaster 200 catalogue Publication number I7-013.

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Figure 1 - Wiring diagram for MotorMaster 201

Figure 2 - Wiring diagram for MotorMaster 202

12 11 10 9 8 7

1 2 3 4 5 6

MotorMaster 201

RL1-1 RL1-2

SW3

c

SW1

SW2F

AlarmCircuit

AuxiliarySupply

SW4

I IsolatorF Fuses

C Contactorc Contactor coilSW1 StartSW2 StopSW3 Reset - momentary pushbuttonSW4 Single phase trip inhibit - close

to inhibit

Relay shown in the tripped state.Relay picks up when auxiliary supply isenergised

S1 S2

P1 P2

P1 P2

S1 S2

Line CTs

To LoadA

B

C

I F C

12 11 10 9 8 7

1 2 3 4 5 6

MotorMaster 202

RL1-1 RL1-2

SW3

c

SW1

SW2F

AlarmCircuit

AuxiliarySupply

I IsolatorF FusesC Contactor

c Contactor coilSW1 StartSW2 StopSW3 Reset - momentary pushbutton

Relay shown in the tripped state.Relay picks up when auxiliary supply isenergised.

S1 S2

P1 P2

P1 P2

S1 S2

Line CTsA

B

C

I F C

S1 S2

To LoadP1 P2

E/F Core Balance CT

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Figure 3 - Wiring diagram for MotorMaster 202S

Figure 4 - Wiring diagram for MotorMaster 203

AlarmCircuit

AuxiliarySupply

Relay shown in the tripped state.Relay picks up when auxiliarysupply is energised.

E/F Core Balance CT

A

B

C

MotorMaster 202S

SW3I IsolatorF FusesC Contactorc Contactor coilSW1 StartSW2 StopSW3 Reset - momentary pushbuttonSW4 Single phase trip inhibit -

Close to inhibit

Line CTs

S1 S2

To Load

SW1

SW2F

I F C

c

RL1-1 RL1-2

7 8 9 10 11 12 13 14 15 161 2 3 4 5 6

32 31 30 29 28 27 26 25 24 23 22 21 20 19 18 17

SW4S1 S2

S1 S2P1

P1 P2

P2

P2

P1 P2

AuxiliarySupply

Relay shown in the tripped state.Thermal alarm only picks up whenauxilary supply is energised.

E/F Core Balance CT

A

B

C

MotorMaster 203S

SW3I IsolatorF FusesC Contactorc Contactor coilSW1 Start

SW2 StopSW3 Reset - momentary pushbuttonSW4 Single phase tr ip inhibi t -

Close to inhibit

Line CTs

S1 S2

To Load

SW1

SW2F

I F C

c

RL1-1 RL1-2

7 8 9 10 11 12 13 14 15 161 2 3 4 5 6

32 31 30 29 28 27 26 25 24 23 22 21 20 19 18 17

SW4S1 S2

S1 S2P1

P1 P2

P2

P2

P1 P2

RL2-1 RL2-2

E/F1 Alarm Thermal Alarm

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Figure 5 - Wiring diagram for MotorMaster 204

Figure 6 - Wiring diagram for connection of 3 CTs

AuxiliarySupply

Relay shown in the tripped state.Thermal alarm only picks up whenauxilary supply is energised.

E/F Core Balance CT

A

B

C

MotorMaster 204

SW3I IsolatorF Fuses

C Contactorc Contactor coilSW1 StartSW2 StopSW3 Reset - momentary pushbuttonSW4 Single phase trip inhibit -

Close to inhibit

Line CTs

S1 S2

To Load

SW1

SW2

F

I F C

C

RL1-1 RL1-2

7 8 9 10 11 12 13 14 15 161 2 3 4 5 6

32 31 30 29 28 27 26 25 24 23 22 21 20 19 18 17

SW4S1 S2

S1 S2P1

P1 P2

P2

P2

P1 P2

RL2-1 RL2-2

Thermal AlarmTripping OutputAlarm

L1

L2

L3

P1 P2S1 S2

P1 P2S1 S2

P1 P2S1 S2

Star Deltaand Line

Contactors

Core balanceCT (note2) Line CTs (note1)

MotorWinding

(a) For star-delta starting the following external CT connections apply:

S1A S1B S1C

P1 P2S1 S2

P1 P2S1 S2

P1 P2S1 S2

S1A S1B S1C

Core balanceCT (note1) Line CTs (note2) Motor

WindingL1

L2

L3

(b) Direct on l ine starting using 3 CTs (specific applications)

Notes:

1. Connect line CTs between motor windings and contactors inseries with motor windings.

2. Connect core balance CT (if required) between contactors andincoming supply.

Connections of line CTs to relay:

MM201 and MM202 S1A - 12S1B - 11S1C - 10

MM202S, MM203 S1A - 29and MM204 S1B - 27S1C - 26 and 28

Notes:

1. Connect core balance CT, if required, betweencontactor and incoming supply.

2. Connection with 3 CTs is only required by certainnational standardsMotorMaster will operate correctly for DOL startingwith only 2 CTs

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Figure 7 - Overload operating characteristic

100.0

10.0

1.0

0.10 1 2 3 4 5 6 7 8 9 10 11

Current (multiples of motor FLC)

Operatingtim

e,multipleo

f6xoverloadtriptime

Cold

75%

Hot

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Section 2. COMMISSIONING

To programme a MotorMaster 200 protection relay for the protection of anythree phase induction motor, four settings are required:

Current setting (red switches), which is the % of primary CT rating. This can beset anywhere between 68% and 131% of the CT rating.

Trip time settings (orange switches), the time for the relay to trip on overloadwhen the actual current is six times the current setting.

Reset time (yellow switches), the time required to reset after a thermal trip.

Earth fault time delay (green switches).

2.1 System connections

Refer to Figures 1 to 6 for wiring diagrams of typical applications.Two transformers are normally sufficient for a three phase three wire connectedload. Three transformers are required for a three phase four wire connected loador when the current transformers are connected in series with the winding of themotor for star/delta starting (Figure 6).

2.2 Current settings (red switches)

Current setting Is (% of CT primary rating)

1. Type of motor (see 4 below)

2. Motor full load current If

For star/delta start,

If=full load current

1.732

3. Line CTs primary current rating Ip

4. Calculation:

For a continuously maximum rated (CMR) motor, the current setting is

Is = (If/Ip) x 100%

For totally enclosed motors, increase setting by 5%.

For open motors increase setting by 20%.

5. Subtract 68 from Is.

6. Adjust the appropriate red coloured switches to summate the numbercalculated in 5. above, leaving the other red switches set to zero.

Example:

(I) Motor type - CMR

(ii) Full load current If= 120A

(iii) Primary CT rating Ip = 100A

(iv) Is = (120A/100A) x 100 = 120%

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(v) 120 68 = 52%

(vi) Switch in: 32 + 16 + 4 = 52

2.3 Overload operating time settings (orange switches)

The typical overload operating characteristics of the relay are shown in Figure 7.This sets the relay trip time from a cold start and, once set, overload protection isassured. To set up, first establish:

1. Motor full load current If

2. Starting current on full load Ic

3. Starting time on full load tc

Calculate the multiple of full load current on starting (Ic/If).

Plot this current on the cold curve of graph, Figure 7, to find an operating time ofM as a multiple of the 6 x overload time. The optimum time setting of the relaymust be chosen so that it is greater than (tc/M) in order to avoid spurious tripping

on a healthy start.Example:

(i) Motor FLC If= 100A

(ii) Motor starting current Ic = 500A

(iii) Starting time tc = 15 seconds

(iv) Starting current in multiples of FLC = 500/100 = 5

(v) From the cold curve, this gives a value for M of approximately 1.5.

(vi) The overload time setting must now be greater than:(tc / M) = 15/1.5 = 10 seconds

(vii) Increasing t by 15% to allow for tolerance gives t = 11.5 seconds.

(viii) Programme t into the relay using the orange coloured switches. With allswitches moved to the left, the relay is on its lowest in-built setting of 0.5seconds. For this example, move switches 8, 2, and 1 only to the right toincrease the in-built time by 11 seconds to give a total of 11.5 seconds.

(ix) This setting can be checked by using the test button to simulate a 6 x

overload condition and by measuring the time for the thermal trip tooperate.

2.4 Reset time setting (yellow switches)

The reset time is programmed into the relay using the yellow coloured DILswitches. With all the switches set to the left the relay has an inherent minimumreset time of one minute.

Moving the switches to the right will increase the time by the values marked onthe switches.

Example - moving switches 8 and 16 to the right while leaving switches 32, 64,2 and 4 and the left gives a reset time of 1 + 8 + 16 = 25 minutes.

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Optimum reset time setting is governed by the motors thermal characteristic andits environmental conditions. As a general guide, typical reset times comparedwith run up times at 6 x overload are:

6 x overload trip time (seconds) Reset time (minutes)

63.5 85

31.5 4515.5 25

7.5 15

3.5 11

1.5 9

2.5 Earth fault time setting (green switches)

Earth fault delay time (models MM202, 202S, 203 and 204 only). With allswitches set to 0, the operating time is 0.25 seconds. By moving these switchesfrom left to right, delay times of 0.75 seconds, 1.45 seconds or 1.95 secondsmay be selected. The time delay should be selected to ensure that, for very highlevel earth faults, the back up protection (fuse or circuit breaker) operates beforethe MotorMaster 200 trips the motor contactor.

2.5 Common errors associated with commissioning

The polarity of the two line current transformers must be in the correct orientation.

If the secondary of one current transformer is reversed, the MotorMaster will tripas for a single phase fault. The current transformer secondaries should beearthed at one point only, for example terminal 10 (MM201/202) and terminals26 and 28 (MM202S/203/204).

The output leads from the core balance CT carry less than 10mA. These leadsshould not be run close to heavy current cables where an inductive pick upcurrent could be induced. If this is unavoidable then adequate screening shouldbe employed. Terminal 7 (MM201/202) and terminal 17 (MM202S/203/204)

may be earthed if required.

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Section 3. TEST PROCEDURES

Every MotorMaster 200 relay is comprehensively tested before despatch but,should the need arise for on-site testing, the following procedure is suggested.

WARNING: IF INPUT CURRENT IS TAKEN FROM A CT, THETRANSFORMER SECONDARY SHOULD BE SHORT-CIRCUITED BEFORE THE CONTROLLER INPUTS AREDISCONNECTED.

3.1 Thermal overload testing

3.1.1 Cold curve testing

The tripping time set on the orange switches is the 6 x overload tripping time onthe cold curve. The easiest way to check this is to press and hold the test pushbutton on the front of the relay, after first switching on the auxiliary supply.The relay will trip in the set time. This test proves all the thermal circuitry except

for the input CTs inside the relay.To carry out a full test, a three phase current injection test set is required.Inject two currents at an angle of 120 into the line inputs of the relay. Injecting6A into a 1A relay or 30A into a 5A relay, from cold, will trip the relay in the set(6 x overload) trip time.

3.1.2 Hot curve testing

The simplest and most convenient way to check the relay operation at 75% fullload rating. To determine this trip time, inject two line currents as above at 75%full load rating. Wait at least 60 times the selected 6 x overload trip time for therelay to stabilise (75% stabilisation curve - refer to Figure 7). Now apply thenormal 6 x overload currents. The relay should trip in half the set trip time andthis can be read directly off the 75% stabilisation curve (Figure 7).

3.2 Single phase testing

Apply 100% primary full load current into one line CT only or 100% secondaryfull load current, direct into one of the relay CT inputs. The relay should trip in2 seconds (25%) at 50Hz or 1.7 seconds (25%) at 60Hz.

3.3 Earth fault testing

Connect the circuit as shown in Figure 8, and arrange for a current I1 to flow inthe circuit such that I1 = 1.5 x the core balance sensitivity. Switch on theauxiliary supply and the relay should trip in the selected earth fault trip time(20%).

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Figure 8 - Earth fault trip testing

3.4 Resetting

After every one of the above tests, the relay will require resetting as described insection 2.1 - Reset facilities. Note the time delay upon energisation following atrip.

The internal electrically reset relay in every MotorMaster 200 has a time delayon pick up of up to 0.5 seconds on connection of the auxiliary supply. The relayis energised when healthy and drops off following loss of voltage.

The mechanically latched relay does not change state when the auxiliary supplyis applied or removed.

AC test supplyMotorMaster

relay

I1

Core balance CT

Refer to Figures 1 to 5for connections

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Section 4. DC AUXILIARY SUPPLY

For applications where a dc auxiliary supply is used to power a MotorMaster200 relay, a separate dc/dc converter is required. Figure 9 shows theconnection diagram.

Note: The output of the dc/dc converter is suitable for powering oneMotorMaster 200 relay dc auxiliary supply.

Figure 9 - Single output dc/dc converter

Electromagnetic Compatibility Directive 89/336/EEC

Emissions standard EN50081-2 1994 Industrial environment

Immunity standard EN50082-2 1995 Industrial environment(IEC 60801 parts 2, 3 and 4)

Susceptibility toElectrostatic Discharge 8kV air discharge/4kV contact.

WARNING: This specification applies for direct contact with the terminals

and via air discharge on or around the manual reset relay only.When setting the DIL switches and using the test button, appropriate ESDprotection must be taken.

Low Voltage Directive 72/23/EEC

Designed to EN61010-1 1993 safety requirements.

DC output DC output

DC supply

10 9 7 6

4 5

3 B * 0 0 3

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ALSTOM T&D Protection & Control Ltd St Leonards Works, Stafford, ST17 4LX EnglandTel: 44 (0) 1785 223251 Fax: 44 (0) 1785 212232

Email: pcs.enquiries@tde.alstom.com Internet: www.alstom.com

Our policy is one of continuous product development and the right is reservedto supply equipment which may vary from that described.

1999 ALSTOM T&D P t ti & C t l Ltd