Allen-Bradley E100 User manual

E100 Electronic Overload Relay
Catalog Numbers 193, 592
User Manual
Original Instructions

Important User Information
Read this document and the documents listed in the additional resources section about installation, configuration, and
operation of this equipment before you install, configure, operate, or maintain this product. Users are required to
familiarize themselves with installation and wiring instructions in addition to requirements of all applicable codes, laws,
and standards.
Activities including installation, adjustments, putting into service, use, assembly, disassembly, and maintenance are
required to be carried out by suitably trained personnel in accordance with applicable code of practice.
If this equipment is used in a manner not specified by the manufacturer, the protection provided by the equipment may
be impaired.
In no event will Rockwell Automation, Inc. be responsible or liable for indirect or consequential damages resulting from
the use or application of this equipment.
The examples and diagrams in this manual are included solely for illustrative purposes. Because of the many variables and
requirements associated with any particular installation, Rockwell Automation, Inc. cannot assume responsibility or
liability for actual use based on the examples and diagrams.
No patent liability is assumed by Rockwell Automation, Inc. with respect to use of information, circuits, equipment, or
software described in this manual.
Reproduction of the contents of this manual, in whole or in part, without written permission of Rockwell Automation,
Inc., is prohibited.
Throughout this manual, when necessary, we use notes to make you aware of safety considerations.
Labels may also be on or inside the equipment to provide specific precautions.
WARNING: Identifies information about practices or circumstances that can cause an explosion in a hazardous
environment, which may lead to personal injury or death, property damage, or economic loss.
ATTENTION: Identifies information about practices or circumstances that can lead to personal injury or death, property
damage, or economic loss. Attentions help you identify a hazard, avoid a hazard, and recognize the consequence.
IMPORTANT Identifies information that is critical for successful application and understanding of the product.
SHOCK HAZARD: Labels may be on or inside the equipment, for example, a drive or motor, to alert people that dangerous
voltage may be present.
BURN HAZARD: Labels may be on or inside the equipment, for example, a drive or motor, to alert people that surfaces may
reach dangerous temperatures.
ARC FLASH HAZARD: Labels may be on or inside the equipment, for example, a motor control center, to alert people to
potential Arc Flash. Arc Flash will cause severe injury or death.Wear proper Personal Protective Equipment (PPE). Follow ALL
Regulatory requirements for safe work practices and for Personal Protective Equipment (PPE).

Rockwell Automation Publication 193-UM013B-EN-P - December 2019 3
Table of Contents
Preface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
About This Publication. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Summary of Changes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Terminology. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Additional Resources . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Chapter 1
Product Overview Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Chapter 2
System Operation and
Configuration
Before You Begin. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Configure the Device. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Set the Trip Current. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Configure Accessory Modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Cat. No. 193-1EGJ Universal Protection Expansion Module. . 11
Cat. No. 193-1ERR Electronic Reset and
Indication Display Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Cat. No. 193-ERID or 193-1ERIDN Remote
Indication and Display Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Chapter 3
Troubleshooting E100 Electronic Overload Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Accessory Modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Universal Protection Module and Remote Reset Module . . . . . 15
Remote Indication Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Appendix A
Wiring Diagrams E100 Wiring Configurations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

4Rockwell Automation Publication 193-UM013B-EN-P - December 2019
Table of Contents
Notes:

Rockwell Automation Publication 193-UM013B-EN-P - December 2019 5
Preface
About This Publication This manual describes how to install, configure, operate, and troubleshoot the
E100™ Electronic Overload Relay.
Summary of Changes
Terminology Throughout this publication, we also refer to the E100 Electronic Overload
Relay as the E100 overload relay and E100 relay. These terms are interchangeable.
Additional Resources These documents contain additional information concerning related products
from Rockwell Automation.
You can view or download publications at rok.auto/literature.
Topic Page
Corrected Ground Fault trip adjustment range 11
Added footnotes to 193-ERID and 193-E1ERIDN Remote Indication and Display Module Fault/Status
Codes table.
17
Resource Description
E100 Electronic Overload Relay Specifications, publication
193-TD013
Provides complete specifications for the E100 Electronic
Overload Relay.
Bulletin 193 Core Balanced Ground Fault Sensor Application
and Installation Instructions, publication 193-IN047
Provides instruction about how to install and apply
193-CBCT core balanced ground fault sensors.
E100 Overload Relay Application and Installation
Instructions (IEC), publication 193-IN081
Provides instruction about how to install the E100
Overload Relay onto 100-C and 100-D contactors.
E100 Ground Fault/Jam and Remote Reset Module
Application and Installation, publication 193-IN082
Provides instruction about how to install and apply the
ground fault/jam and remote reset module.
E100 Overload Relay with Pass-thru Wiring Application and
Installation Instructions, publication 193-IN083
Provides instruction about how to install the E100
Overload Relay with the pass-thru wiring option.
E100 External Current Transformer Overload Relay
Application and Installation Instructions, publication
193-IN084
Provides instruction about how to install the Advanced
E100 Overload Relay.
E100 Overload Relay Remote Reset Installation, publication
193-IN085
Provides instruction about how to install and set up the
remote reset module.
E100 DIN Rail or Panel Adapter Installation,
publication 193-IN086
Provides instruction about how to install the E100 relay
onto DIN Rail or the panel adapter.
E100 Remote Indication Display Application and
Installation, publication 193-IN087
Provides instruction about how to install and set up the
remote status indication module.
E100 Overload Relay Application and Installation
Instructions (NEMA), publication 592-IN021
Provides instruction about how to install the E100
Overload Relay onto 500 line contactors.
Industrial Automation Wiring and Grounding Guidelines,
publication 1770-4.1
Provides general guidelines for installing a Rockwell
Automation industrial system.
Product Certifications website: rok.auto/certifications Provides declarations of conformity, certificates, and other
certification details.

6Rockwell Automation Publication 193-UM013B-EN-P - December 2019
Preface
Notes:

Rockwell Automation Publication 193-UM013B-EN-P - December 2019 7
Chapter 1
Product Overview
This chapter provides an overview of the E100™ Electronic Overload Relay.
Description The E100 Electronic Overload Relay is the newest technology for overload
protection, and supports both single- and three-phase operation in a single
component.
The device is split between two offerings: a Basic (Cat. No. 193-1EE) and
Advanced (Cat. No. 193-1EF, 592-1EF) version. The Basic offering allows
adjustable trip current and limited trip class selection. The Advanced version
offers the same adjustable trip current, a larger selection of trip classes, and the
ability to add additional accessory modules.
The E100 relay provides the following benefits:
•Electronic overload detection
•Simple configuration
•Selectable trip class
•Adjustable trip current
•Integration with both IEC and NEMA contactors
•Test and Reset buttons
•Auto/Manual reset selection
•RMS Current sensing (50/60 Hz)
•External current transformers
•Direct and Pass-through mounting
The E100 relay lets you add accessory modules through the front-mounted
communication port. Accessories include:
•Ground Fault/Jam Protection Module (193/592-1EF only)
•Remote Reset Solenoid
•Anti-Tamper Shield
•Reset Adapter
•Panel Adapter
•Remote Indication Display, with or without Reset (193/592-1EF only)

8Rockwell Automation Publication 193-UM013B-EN-P - December 2019
Chapter 1 Product Overview
Notes:

Rockwell Automation Publication 193-UM013B-EN-P - December 2019 9
Chapter 2
System Operation and Configuration
This chapter provides instructions about how to operate and configure an E100™
Electronic Overload Relay system. It contains instructions about how to set the
Trip Current and Trip Class. This chapter also describes the accessory modules
that are available for the Advanced (193/592-1EF) E100 relay.
Before You Begin Before you configure the E100 relay, you must install it onto a contactor or DIN
Rail, or mount it on a panel. See page 5 for a list of related installation
instructions. You can search for and download literature at rok.auto/literature.
Configure the Device Use the rotary dials on the front of the unit to select the trip class and adjust the
trip current.
Figure 1 - E100 Overload Relay Settings
Basic Unit, 193-1EE… Advanced Unit, 193/592-1EF…
Trip Current Selection (1)
Trip Current
Selection(1)
Trip Class Selection (2)
Trip Class Selection (2)
Reset Reset
Push to Stop Push to Stop
Push to Test
Push to Test
Trip Indicator Window (3)
Trip Indicator
Window(3)
Note Number Feature Information
1 Trip Current Selection To adjust the trip current, turn the dial until the desired current is aligned with the pointer. Trip rating is 120% of dial setting value.
Minimum setting is 0.1 FLA.
2 Trip Class Selection Use this setting to select the desired trip class. Basic units only support manual reset operations. Manual DIP switch position is
independent of relay function and trip class. On advanced units, use this setting to select between automatic and manual reset modes.
3 Trip IndicatorWindow The red status indicator is illuminated when the unit has tripped.

10 Rockwell Automation Publication 193-UM013B-EN-P - December 2019
Chapter 2 System Operation and Configuration
Set the Trip Current
When you set the trip current, you must consider the motor service factor and
FLA. You can find this information on the motor nameplate, as shown in Table 1
and Table 2.
Table 1 - Service Factor/Motor FLA Dial Settings
Table 2 - Service Factor/Motor FLA Dial Settings
Service Factor Trip Current Setting
<1.15 0.9 x FLA
≥ 1.15 1 x FLA
YΔ(Star-Delta) FLA/1.73
Service Factor Trip Current Setting
YΔ(Star-Delta) FLA/1.73
Direct-on-line 1 x FLA
Service Factor FLA
FLA

Rockwell Automation Publication 193-UM013B-EN-P - December 2019 11
System Operation and Configuration Chapter 2
Configure Accessory
Modules
This section describes how to configure the accessory modules for the Advanced
version (193/592-1EF) of the E100 relay. You must correctly install the
accessories before you configure them. See page 5 for a list of related installation
instructions.
Cat. No. 193-1EGJ Universal Protection Expansion Module
The Cat. No. 193-1EGJ E100 Universal Protection expansion module adds
Ground fault and Jam protection to the Advanced version (193/592-1EF) of the
E100 relay. The add-on module lets you select the jam current level, jam trip
delay, and ground fault level.
Figure 2 - Cat. No. 193-1EGJ Universal Protection Expansion Module Settings
Wiring
Figure 3 and Figure 5 show the basic wiring for the 193-1EGJ Module.
Note Number Feature Information
1 Jam Level Selection Set the FLA percentage for Jam Protection. Selectable from 125…600% FLA.
2 Jam Delay Selection Set the time delay for a Jam Trip to occur. Customizable from 0.1…10 seconds.
3Ground Fault Level
Selection
Set the current level for a Ground Fault Trip to occur. Customizable from
0.02…5 A.
4Accessory Diagnostic
LED For more information about the diagnostic LED codes, see Chapter 3.
Jam Level (1)
Jam Delay (2)
Ground Fault Level (3)
Accessory Diagnostic LED (4)

12 Rockwell Automation Publication 193-UM013B-EN-P - December 2019
Chapter 2 System Operation and Configuration
Figure 3 - Cat. No. 193-1EGJ Universal Protection Expansion Module Wiring
Cat. No. 193-1ERR Electronic Reset and Indication Display Module
The Cat. No. 193-1ERR Electronic Reset and Indication Display Module lets
you use the Cat. No. 193-ERID and 193-ERIDN Remote Indication and Display
module with your Advanced version (193/592-1EF) of the E100 relay.
Figure 4 - Cat. No. 193-1ERR Electronic Reset and Indication Display Module
Wiring
Figure 3 and Figure 5 show the basic wiring for the 193-1ERR Module.
Note Number Information
1 Terminals R1 and R2 are used with 193-ERID and 193-1ERIDN modules.
2 External power must be user supplied. 24…240V, 47…63 Hz or DC.
3 Reserved for 193-CBCT external ground fault current sensor.
Note Number Feature Information
1 Accessory Diagnostic LED For more information about the diagnostic LED codes, see Chapter 3.
R1
R2 S1
S2
A1
A2
(1)
(2)
(3)
Accessory Diagnostic LED(1)

Rockwell Automation Publication 193-UM013B-EN-P - December 2019 13
System Operation and Configuration Chapter 2
Figure 5 - Cat. No. 193-1ERR Electronic Reset and Indication Display Module Wiring
Cat. No. 193-ERID or 193-1ERIDN Remote Indication and Display
Module
The remote indication and display modules let you view the status of the
E100 relay from the front of a panel. Cat. No. 193-ERID also features a
reset button. The light-emitting diode (LED) status indicators notify you of the
status of the overload relay.
Figure 6 - Cat. No. 193-ERID and 193-1ERIDN Remote Indication and Display Module Features
See page 17 for information about the fault and status codes for the remote
indication and display modules.
Figure 3 and Figure 5 show the basic wiring for the 193-ERID and 193-1ERIDN
Modules.
Note Number Information
1 Cat. No. 193-ERID or 193-1ERIDN Remote Indication and Display module.
2 External power must be user supplied. 24…240V, 47…63 Hz or DC.
R2 R1
A1
A2
(1)
(2)
Reset (193-ERID only)
Module Power/Status
Fault Status
Phase Loss
Overload

14 Rockwell Automation Publication 193-UM013B-EN-P - December 2019
Chapter 2 System Operation and Configuration
Notes:

Rockwell Automation Publication 193-UM013B-EN-P - December 2019 15
Chapter 3
Troubleshooting
This chapter helps you troubleshoot the E100™ Electronic Overload Relay by using the
diagnostic LED status indicators. It also guides you through troubleshooting associated
accessory modules.
E100 Electronic Overload
Relay
All E100 relay units include a trip indicator window on the front of the unit
labeled “Status”. If the red indicator is not visible, the overload relay is not
tripped. If the red indicator is visible, the overload relay is tripped.
Accessory Modules Universal Protection Module and Remote Reset Module
The Universal Protection Module and the Remote Reset Module both include an
LED status indicator that shows the state of the E100 relay. The modules are
supplied with external power, so in the event of a fault event, the status LEDs still
operates.
ATTENTION: Servicing energized industrial control equipment can be
hazardous. Electrical shock, burns, or unintentional actuation of controlled
industrial equipment may cause death or serious injury. For safety of
maintenance personnel and others who may be exposed to electrical
hazards associated with the maintenance activities, follow the local safety-
related work practices (for example, the NFPA 70E, Part II, Electrical Safety
for Employee Workplaces, in the United States) when working on or near
energized equipment. Maintenance personnel must be trained in the safety
practices, procedures, and requirements that pertain to their respective job
assignments. Do not work alone on energized equipment.
ATTENTION: Do not attempt to defeat or override fault circuits. The cause of
a fault indication must be determined and corrected before attempting
operation. Failure to correct a control system or mechanical malfunction may
result in personal injury and/or equipment damage due to uncontrolled
machine system operation.

16 Rockwell Automation Publication 193-UM013B-EN-P - December 2019
Chapter 3 Troubleshooting
Table 3 - 193-1EGJ and 193-1ERR Remote Indication and Display Module Fault/Status Codes
The status LED indicates the module status by flashing a red trip code. The
number of flashes followed by a pause identifies the specific trip code as shown in
Table 4
Table 4 - Trip Code Identification
Remote Indication Display
There are four LED status indicators on the front of the Cat. No. 193-ERID and
193-1ERIDN modules. These status indicators show Module Power/Status,
Overload, Phase Loss, and Fault Status. See Figure 7
Figure 7 - Cat. No. 193-ERID and 193-E1ERIDN Remote Indication and Display Module Features
StatusIndicator
Color Solid/Flashing Description Solution
Green Flashing Module powered —
Solid Module powered and motor current present —
Amber Flashing Warning
Red
Flashing Fault detected and overload relay tripped
Solid Hardware fault; internal hardware fault
detected and overload relay trip attempted
•Recover fault by cycling overload relay accessory supply voltage
•Verify that the supply voltage is within limits
•Verify the wiring to the terminals is correct
•Verify that the pins that connected the accessory to the overload
relay are not damaged or misaligned
•Verify the operating temperature of the devices is within
specification limits
No. of Flashes Trip Type
1OverloadTrip
2PhaseLoss
3 Ground Fault
5Jam
8ShortCircuit
10 COM Loss(1)
(1) If you experience repeated COM Loss trips, this may be due to a damaged communication
interface cable. To test whether this is the case, unplug the communication interface cable
from the communication port and wait at least 3 seconds before re-connecting. If the
issue persists, consider replacing the communication interface cable.
11 Test Trip
Reset (193-ERID only)
Module Power/Status
Fault Status
Phase Loss
Overload

Rockwell Automation Publication 193-UM013B-EN-P - December 2019 17
Troubleshooting Chapter 3
Table 5 lists the fault and status codes for the remote indication and display
modules.
Table 5 - 193-ERID and 193-E1ERIDN Remote Indication and Display Module Fault/Status Codes
Status Indicator Symbol Status Indicator Color Solid/Flashing Description
Module Power/Status Green Flashing Module powered Solid Module powered and motor current present
Red Solid Hardware fault
Overload Red Solid Overload trip
Amber Flashing Overload warning(1)
Phase Loss Red Solid Short CircuitTrip Flashing Phase Loss Trip
Amber Flashing Phase Loss Warning(2)
Fault Status
Red 3 Flashing Ground Fault Trip(3)
Amber 3 Flashing Ground Fault Warning
Red 5 Flashing Jam Trip
Amber 5 Flashing Jam Warning(4)
Red 9 Flashing Welded Contact(5)
Red 10 Flashing Comm Loss
Amber 10 Flashing Comm Warning
Red 11 Flashing Test Trip
(1) An Overload warning occurs when the E100 overload reaches 90% thermal capacity utilization (TCU ).The overload trips at 100% TCU.
(2) Phase Loss warning is active if the overload detects a Phase Loss condition. The warning is maintained for 3 seconds before a Phase
Loss Trip occurs.
(3) A Ground Fault trip occurs if the configured Ground Fault Level is reached for 100 ms.
(4) A Jam warning is active if the measured FLA is greater than the set Jam Level.The warning is active until the Jam Delay is reached. At this point,
the overload relay trips.
(5) Does not apply to the E100 relay.

18 Rockwell Automation Publication 193-UM013B-EN-P - December 2019
Chapter 3 Troubleshooting
Notes:

Rockwell Automation Publication 193-UM013B-EN-P - December 2019 19
Appendix A
Wiring Diagrams
E100 Wiring Configurations The following pages illustrate various wiring configurations for the E100™ Electronic
Overload Relay.
Figure 8 - 3-Phase, Full-voltage Direct-on-line Starter, NEMA Symbology
Figure 9 - 3-Phase, Full-voltage Direct-on-line Starter, IEC Symbology
95
L2 L3 13L1
14
A1
A2
T2 T3T1
96 97 98
T1 T3
T2
Connection must be
fitted by the user
Short-circuit
Protection Device
95
3
13
1
14
A1
A2
46296
U
V
5
97 98
W
Connection must be
fitted by the user
Short-circuit
Protection Device

20 Rockwell Automation Publication 193-UM013B-EN-P - December 2019
Appendix A Wiring Diagrams
Figure 10 - 1-Phase, Full-voltage Direct-on-line Starter, NEMA Symbology
Figure 11 - 1-Phase, Full-voltage Direct-on-line Starter, IEC Symbology
Figure 12 - E100 Overload Relay with External Current Transformer
95
L2 L3 13L1
14
A1
A2
T2 T3T1
96 97 98
T1 T2
Connection must be
fitted by the user
Short-circuit
Protection Device
Connection must be
fitted by the user
95
35
13
1
14
A1
A2
462
96 97 98
U1 U2
Connection must be
fitted by the user
Short-circuit
Protection Device
Connection must be
fitted by the user
M
L1/1
L1/1
T1/2 T2/4 T3/6
L2/3 L3/5
L2/3 L3/5
H1(Dot) H1(Dot) H1(Dot)
H2 H2 H2
X1 X1 X1
X2X2X2
CT1
T1/2 T2/4 T3/6
CT2 CT3
Overload Relay
For more information about how to install an external Current Transformer, see Bulletin 193 Core Balanced Ground
Fault Sensor Application and Installation Instructions, publication 193-IN047.