Basic Range

XM1 : Motor protection Relay (Professional Series)

C&S Protection & Control Ltd.

Contents
Page No.
1 2 3 Applications and features Design Working principle 3.1 Overload protection 3.2 Stalling protection 3.3 Earth fault protection 3.4 Short circuit protection 3.5 Undercurrent protection 3.6 Current unbalance protection Operation and settings 4.1 Setting of DIP-switches and potentiometers 4.2 Setting of the tripping values 4.2.1 Fault indication 4.3 Thermal overload tripping characteristics 4.4 Communication via serial interface adapter XRS1 4.4.1 Serial Number Relay case and technical data 5.1 Relay case 5.2 Technical data Order from Setting - list XM1 Parameters Setting of Parameters 2 3 4-5

6-11

12-15

6 7.

15 16

1. Application
The XM1 of the BASIC RANGE is a digital relay for electrical motor protection. Besides its standard applications, the XM1 is mainly used for motors where normal CBs do not guarantee sufficient protection. When compared to conventional protection equipment all relays of the BASIC RANGE reflect the superiority of digital protection technique with the following features: High measuring accuracy by digital processing Fault indication via LEDs Extremely wide operating ranges of the supply voltage by universal wide range power supply unit Wide setting ranges with very accurately graded Data exchange with process management system by serial interface adapter XRS1 which can be retrofitted RMS measurement Compact design by SMD-technology Sealable cover for setting elements

Especially the XM1 offers the following functions : Overload protection with thermal capacity according to I2t characteristic with adjustable current/time tripping characteristic Thermal overcurrent warning via LED with relay output Locked rotor (stalling) protection Earth fault protection Short circuit protection (blocking possible) Protection against asymmetric phases (blocking possible) Underload protection (blocking possible) Automatic/manual reset Storage of starting heat load Non-volatile memory of head load Restart blocking at insufficient motor head reserve Data exchange with process management system by serial interface adapter XRS1 which can be retrofitted

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L1 L2 L3

Design

Analog inputs
Analog input signals of the motor currents are led to the protection relay via terminals 1S1-3S2. The XM1 can either be connected with three identical CTs in Holmgreen connection (Fig. 2.1) or with two phase CTs and one core balance CT (Fig. 2.2). At inputs 1S1/1S2, the XM1 measures conductor currents L1 or L3 and at input 3S1/ 3S2 the earth current. Dependent on the relay type, CTs with either 1A or 5 A can be used. Auxiliary voltage supply Unit XM1 needs a separate auxiliary voltage supply UV. Unit XM1 has an integrated wide range power supply. Voltages in the range form 19-390 V DC or 36-275 V AC can be applied at connection terminals A1 (L-) and A2 (L+). The voltage range does not need specificly to be set.

3-Ph. Motor
1S1 1S2 2S1 2S2 3S1 3S2

Connections with 3-phaseCTs

Uv

O/C

O/C

E/F

A/1 A/2

XM1

Trip

Alarm

12 11 14

22 21 24

Fig. 2.1 : Connection with 3 phase CTs

L1 L2 L3

3-Ph. Motor
1S1 1S2 2S1 2S2 3S1 3S2

Contact positions
14

12 11

11 12

24

22 24

21 34

Connections with 2-phaseCTs & a CBCT

Trip relay Alarm relay

No voltage applied or warning

Uv
14 12 11 24 22 21

O/C

O/C

E/F

A/1 A/2

XM1

Trip

Alarm

Operation without fault

12 11 14

22 21 24

14

12

11

24

22

21

Fig. 2.2 : Connectionexample with 2 phase CTs (Type and 1 core balance CT (Type of connection A)

General trip and u>95%

14 12 11 24 22 21

Type of connection A B C

1S L1 L2 L3

2S L2 L3 L1

General trip and u<95%

Fig. 2.3 Contact positions

Table 2.1 : Further connection possibilities

Output relays
The XM1 is provided with 2 output relays: Trip relay The trip relay is a normally on relay and energizes when the XM1 has detected a fault. Alarm relay The alarm relay is a normally-off relay and is energized in faultless condition, when supply voltage is applied to the XM1.

3 3.1

Working principle Overload protection

3.2

Stalling protection

When a motor is operated at its rated current IMn, normally it reaches about half of its max. thermal capacity. Operating conditions above IMn lead to futther temperature rise which is only permissible up to the max. temperature limit. The maximal steady-state temperature is indicated by the insulation class. On the basis of adjustment and current measuring data, the XM1 simulates an internal model of the motor temperature, based on I2t motor temperature characteristic. By this the heat capacity of the motor can be fully utilized for short-term overloads, providing 100% protection at the same time. Rated motor current IMn and time t6X are the adjustable parameters to define the motor model. The rated motor current is stated as percentage of the rated relay current (1A or 5A) and set as basis current IB. Time t6X indicates when the cold motor has reached the max. permissible temperature (stated by the motor manufacturer) at 6 times rated current. If the calculated motor temperature reaches 95% of its permissible value, the warning element is activated and the output relay releases. Dependent on the application, deduction of the motor load can be initiated by this signal. Otherwise the motor temperature would keep rising and when exceeding the max. temperature, the trip relay would be activated. After start up, the XM1 stores the heat load of the motor. After tripping due to overload, the XM1 can only be reset if the motor has cooled down at least by the amount of heat causing the trip. In this case the cooling constant is twice the heating constant. In normal operation, if there is no overload tripping, the XM1 computes with equal constants. The thermal memory is non-volatile, even when the aux. voltage fails.

A stalled rotor after start-up or a torque which is too high is identified by the XM1 on the motor current criterion, i.e. that it exceeds the value of 3.5 x IB for longer than 1s. This protective function can be switched off by the DIP switch 2.

3.3

Earth fault protection

The XM1 provides protection against earth fault. If the earth fault current set at the potentiometer IE>/In is exceeded for more than 1s, the trip relay picks-up. This function can be switched off. If the short circuit protection (see 3.4) is enabled, the earth fault element trips with the relays time element.

3.4

Short circuit protection

When using a circuit-breaker instead of a contactor, the short circuit element of the XM1 in case of a failure, gives XM1, the tripping command to the circuit-breaker (DIP-switch 5 ON). If the short circuit current exceeds 10 times IB, the XM1 trips with its time element. When using contactors (DIP-switch 5 OFF), this function can be switched off. If the short circuit function is switched off and a fault current of 7 times In occurs, tripping of the relay is inhibited to prevent welding of the contactors contacts. In this case the failure must be switched off by other protection devices.

3.5

Undercurrent protection

For some applications an unloaded motor is undesireable (e.g. protection against a pump running dry). In such cases the motor current must be above a minimal value. The percentage of the basic current value can be set at potentiometer I</IB in the range from 40-80%. If the motor current stays below this value for longer than 3s, the warning relay releases.

3.6

Current unbalance protection

If the motor current becomes unbalanced due to a conductor break or short circuit in the windings, the XM1 trips in accordance with a fixed time characteristic, conditional on the proportion of current unbalance. XM1 calculates the current unbalanceA from the two measured conductor currents by using the following formula : A= A Imax Imin Imax -Imin Imax = Current unbalance (100% = phase failure) = the higher one of the two conductor currents = the lower one of the two conductor currents 100%

20 16 12

t/s

8 4 0 0

10

20

30

40

50

60

70

80

90

100

Current unbalance in % Fig. 3.1 : Time characteristic of unbalance current protection

Operation and settings

LEDs
LED ON is used for display of the readiness for operation (at applied auxiliary voltage Uv). The LEDs IB and TRIP signalize warning and trip conditions of the relay. Through different blinking sequences the kind of failure can be determined (refer to chapter 4.2.1)

All operating elements needed for setting parameters are located on the front plate as well as all display elements. Because of this all adjustments of the unit can be made or changed without disconnecting the unit from the DIN-rail.

TEST/RESET button
1S1 1S2 2S1 2S2 3S1 3S2 A1

ON

ON

TEST/RES.

XM1
0.00 0.0 0 . 02 0.04 0.06 0.18 0

IB

IB In
0s 5s 10 15s s 20s 25s 0s 1s 2s 3s 4s 5s

IE> In
40% 50% 60% 70% 80%

By means of this P the relay is reset and all faults, .B. configurated to be manually reset, are acknowledged. This push button is used for test trip of the relay. A test trip can only be performed, when no current flows into the measuring inputs. After pressing the push button for 1s, the trip relay trips and LED TRIP lights up. Releasing the push button finishes the test procedure.

TRIP

t6x
A2 24 21 22 14 11

Fig. 4.1 : Front plate For adjustment of the unit the transparent cover has to be opened as illustrated. Do not use force! The transparent cover has two inserts for labels.

Fig. 4.2: How to open the transparent cover

10% 20% 30% 40% 50%

0.6 0.7 0.8 0.9 1.0 1.1

I> IB

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4.1

Setting of DIP-switches and potentiometers

The DIP-switch block on the front plate of the XM1 is used for setting of function parameters : DIPDIPswitches 1 2 3 4 5 6 7 8 Table 4.1 : Functions of DIP switches inactive inactive inactive inactive inactive Manual manual active active active active active automatic automatic Overload alarm Protection against earth fault and rotor blockage Undercurrent supervision Protection against current unbalance and phase failure Short circuit protection Reset after overload Reset after earth fault, current unbalance and rotor blockage This DIP switch must be in position OFF OFF ON Function

Overload alarm
If DIP switch 1 is in position OFF, overload alarm is OFF, blocked. Protection against earth fault and rotor blockage. If DIP switch 2 is in position ON, earth fault supervision ON, and rotor blockage protection become active.

Auto reset
By DIP switches 6 and 7 can be determined whether the trip relay shall be reset automatically or manually by pressing the RESET push button.

Underload supervision
In case the motor current drops below the set value after a start, the XM1 trips after 3 s if DIP switch 3 is in position ON. ON.

Trip relay

Alarm relay

Current unbalance protection

As from a motor current of 20% x IB, current unbalance protection becomes active. A phase failure, too is being detected by the current unbalance protection. If DIP switch 4 is in ON position, the current unbalance protection is activated. Below 0.1 x In and above 2 x In the current unbalance protection is deactivated.

Overload Trip Alarm DIP 1

Off On

Earth fault Stalled rotor Underload

DIP 2

Off On

Short circuit protection

The short circuit element is blocked, if the DIP-switch 5 is in position OFF. OFF.

DIP 3

Off On Off On Off On

Current unbal. DIP 4 Short circuit DIP 5

Fig. : 4.2 : Allocation of output relays

4.2

Setting of the tripping values

Motor time constant t6x

The motor time constant t6x can be set on the two potentimeters. Here, too values of coarse and fine setting potentiometer are added. If the motor charcteristics are not available, a value of 1.1 x start-up time can be assumed for the time constant quantity. Example : t6x = 18s

The BASIC RANGE units have the unique possibility of high accuracy fine adjustments. For this, two potentiometers are used. The coarse setting potentiometer can be set in discrete steps. A second fine adjustment potentiometer is then used for continuously variable setting. Adding of the two values results in the precise tripping value for basic current IB and motor time constant quantity t6x. All other parameters are set by individual potentiometers.

Basic current IB/In

The basic current is adjustable from 0.6-1.2 x In. If the basic current is exceeded by 5%, trip calculation starts and LED IB lights up. (The arrow of the coarse potentiometer should always be in the middle of the marked bars otherwise a definite setting value cannot be obtained.) Example: IB/In = 0.96xIn Fig. 4.4 : Setting of the motor time constant quantity

Earth fault tripping value

The earth fault tripping value is adjustable in the range of 10% to 50% In. Setting recommendation: 10% for resonant earthed systems and 50% for solidly earthed systems fig. 4.3 Setting of the basic current

Use of current transformers

When using current transformers, the transformer ratio must be taken into acount at setting of the basic current. Example: Motor Motor rated current IMn Rated current of XM1 CT ratio CTIMsec IB = In IMnsec = In 4A = 0.8 5A : 75 kW : 160 A : 5A : 200/5 : 4A

Underload tripping value

The underload tripping value is adjustable in the range of 40% to 80% IB. This setting value refers to basic current IB.

Motor rated current related to the secondary side of the That results in a setting of :

4.2.1Fault indication
When the relay alarms or trips, the LEDs on the front panel will flash indicating the type of fault the relay is seeing. The LED flashes a certain number of times very quickly, pauses then repeates the process. The LED will carry on indicating the fault until it has been cleared : For example the Trip LED flashing four times indicates that there is an unbalance fault on the relay. This then enables the user to clear the fault that is causing the trip. Function Thermal pickup LED TRIP ON LED IB ON LED

OFF Overload Pre-alarm ON OFF Overload trip ON OFF Stall protection ON 1x OFF Earth fault ON 2x OFF Underload ON 3x OFF Unbalance ON 4x OFF Short circuit ON 5x OFF Internal fault ON OFF Fig. 4.5 : Fault indication ON OFF ON OFF
Off when Manual RESET possible

4.3 Thermal overload tripping characteristics

10 10 2

The XM1 XM1simulates 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. 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 its thermal capacity available for heating before a trip will occur. When a motor starts and is running, its 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 remaining thermal capacity at previous operation at FLC is aspecific value of the motor and is called KHC. The tripping delay at overload is calculated by the following equation : t = 32.In t6x Where : In[ ] t IMn t6x I I pre-load K HC IB I2 - (1-KHC) .I2pre-load (I2 - IB2) = logarithm to bse e = Trip delay = Motor FLC = Tripping time at 6 x FLC = Overload current = Motor current before overload = Hot/cold ratio = Basic current
t/t6x

10 10 1

10 10 0

1 2 3

10 10 -1

1 I/IB

10

Tripping Fig. 4.7 : Tripping curves Curve 1 : Cold condition of the motor, pre-load = 0% Curve 2 : Pre-load = 70% Curve 3 : Hot condition of the motor, pre-load = 100% Overload pickup current : 1.05 x IB If the motor current exceeds the preset overload pickup current, the value of the thermal equivalent is reached, the relay trips depends on the remaining thermal capacity and the preset t6x time. The t6x time specifies the time, a cold motor takes to reach its maximum admissible operating temperature, when running at 6 times FLC. The heading constant of the motor is equal to the t6x time x 32 seconds. This value is usually shown in the data sheets of the motor manufacturer. If no data are available on t6x, the following settings can be assumed : For D.O.L. starters: t6x = 1.1 x starting time of the motor for star/delta starters: t6x = 0.35 x starting time of the motor

The XM1 has a fixed hot/cold ratio of 50%. So the equation is reduced to : t = 32.In t6x I2 - 0.5.I2pre-load (I2 - IB2)

The following diagram shows tripping curves at different preloads calculated by the above equation.

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4.4 Communication via serial interface adapter XRS1

4.4.1 Serial Number

To set the serial number follow the procedure below. 1. 2. 3. 4. 5. 6. Power off the unit Set DIP switch 7 to OFF and DIP switch 8 to ON. Set DIPs 1 through 5 to the required communication ID (0 = OFF, 1-31 = com. ID). Power up the unit. Press the TEST/RESET button. The LEDs TRIP and IB will flash momentarily. Power off the unit and reset the DIP switches to their previous settings. DIPDIP- switch 1 2 3 4 5 Value 1 2 4 8 16

Fig. 4.8: Communication principle For communication of the units with a superior management system, the interface adapter XRS1 is available for data transmission, including the diagnosis and setting software HTL/PL-Soft3 for our relays. This adapter can easily be retrofitted at the side of the relay. Screw terminals simplify its installation. Optical transmission of this adapter makes galvanic isolation of the relay possible. Aided by the software, actual measured values can be processed, relay parameters set and protection functions programmed at the output relays. Information about unit XRS1 in detail can be taken from the description of this unit.

Table 4.1 : Value of hte DIP-switches 1-5:

Example :
If a communication ID of 21 is required, the DIPs 1, 3 nad 5 have to be set to ON. ON.

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5 5.1

Relay case and technical data Relay case

Relay XM1 is designed to be fastened onto DIN-rail acc. to DIN EN 50022, the same as all units of the BASIC RANGE The front plate of the relay is protected with a sealable transparent cover (IP40).

110 55

75 38

33 65

Fig. 5.1 : Dimensional drawing

Connection terminals
The connection of up to a maximum 2 x 2.5 mm2 cross-section conductors is possible. For this the transparent cover of the unit has to be removed.

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5.2. Technical Data Measuring input circuit

Rated current IN: Rated frequency range Thermal withstand capability in current circuit : dynamic current withstand (half wave) for 1 s for 10 s continuously Power consumption in current circuit Basic accuracy of current : : : at ln = 1 A at ln = 5 A 0.1VA 0.1 VA 250xlN 100xlN 30xlN 4xlN : 1 A or 5 A 40 Hz-70 Hz

+3% of the setting value

Auxiliary voltage
Rated auxiliary voltage UV: Power consumption Maximal permissible interruption duration of aux. voltage tu : : : : 36-275 V AC or 19-390 V DC 4W UV = 24 V UV>60 V
DC

:tu = 8ms,

UV = 48 V

DC

:tu = 35 ms

DC

:tu = 50 ms

Common data
Dropout to pickup ratio Resetting time from pickup Returning time from trip : : : 97% <50 ms 200 ms

Output relay
Number of relays Contacts Maximum breaking capacity : : : 2 1 changeover ohmic 1250 VA/AC resp. 120 W/DC inductive 500 VA/AC resp. 75 W/DC Max. rated voltage : 250 V AC 220 V DC ohmic load lmax. = 0.2 A inductive load lmax. =0.1 A at L/R < 50ms 24 V DC Minimum load Maximum rated current Making current (16ms) Contact life span : : : : inductive load lmax. = 5 A

1 W / 1 VA at Umin > 10 V 5A 20 A 105 operations at max. breaking capacity

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System data
Overload function Setting range IB/ln Setting resolution Setting range t6x Setting resolution Prealarm Cooling down time constant quantity : : : : : : 0.6-1.2 x ln 1% 0.5-30 s 0.5 s >95% of the permissible thermal load 1 x warming-up time constant quantity after overload alarm 0.5 x warming-up time constant quantity without alarm Asymmetric protection Working range Tripping delay Rotor blockage Working range Tripping delay Undercurrent Setting range T ripping delay Short circuit Earth fault Setting range T ripping delay Ambient conditions Storage and transport Operation Design standard Constant climate class F acc. to DIN 40040 and DIN IEC 68, T.2-3 High voltage test acc. to VDE 0435, part 303 Voltage test Surge voltage test High frequency test Electrostatic discharge (ESD) acc. to VDE 0843, part 2 Radiated electromagnetic field : 8 kV : : : 2.5 kV (eff.) /50 Hz; 1 min 5 kV; 1.2/50 s, 0.5 j 2.5 kV/1 MHz : more than 56 days at 400C and 95% relative humidity : : -250C to 700C -250C to 700C : : 10% - 50% of ln, adjustable to 5% 1 s (tripping with relay time element, if short circuit function is enabled) : : : 40% - 80% of IB, adjustable to 5% 3s 10 x IB (tripping with relay time element) : : l>350% x IB 1s : : lMotor>20% x IB see characteristic fig. 3.1

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acc. to VDE 0843, part 3 Electrical fast transient (Burst) acc. to VDE 0843, part 4 Radio interference suppression test acc. to DIN57871 and VDE0871 Mechanical test Shock Vibration Degree of protection Weight Relay case material

10 V/m

4 kV/2.5kHz, 15 ms

limit value class A

: : : : :

class 1 acc. to DIN IEC 255-21-2 class 1 acc. to DIN IEC 255-21-1 IP40 (case and terminals) 250g self-extinguishing

6 Order form Motor protection relay Rated current : XM11A 5A Technical data subject to change without notice! 1 5

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Setting-list XM1
Project :_______________________________________________________ Function group :=_____________________ Location :+_______________ Relay functions :_________________________________________________ CSPC job no. :____________________ Relay code :______________________ Date :___________________________

Setting of parameters
Default Function t6x IB IE> I< Motor time constant Basic current Earth fault current Underload Unit s x ln %ln %IB settings 0 0.6 10 40 Actual settings

Dip-switch 1 2 3 4 5 6 7 8 Overload alarm

Function

Default settings disabled disabled disabled disabled disabled manual manual

Actual settings

Earth fault and stalling protection Underload protection Current unbalance and phase failure Short circuit protection Reset after overload Reset after earth fault, current unbalance and stalled rotor This DIP-switch must be in position OFF

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