BLUE JAY BJ-PR240 Series User manual

User Manual
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BJ-PR240 series
Motor Protect Relay
User Manual
Version 3.7
Revision 2022-8

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Read me
When you use BJ-PR240 series intelligent motor protection relay, be sure to read this user
manual carefully, and be able to fully understand the implications, the correct guidance of
operations in accordance with user manual, which will help you make better use of BJ-
PR200 series motor protector, and help to solve the various problems at the scene.
1. Before the meter turning on the power supply, be sure that the power supply within the provisions
of the instrument;
2. When installation, the current input terminal must non-open, voltage input terminals must Non-
short circuit;
3. Communication terminal (RS232/RS485 or Ethernet) is strictly prohibited to impose on high
pressure;
4. Be sure the instrument wiring consistent with the internal system settings;
5. When communicating with the PC, instrument communication parameters must be consistent
with the PC.
●Please read this user manual carefully
●Please save this document

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Directory
1. - SUMMARIZE.................................................................................................................................- 4 -
2. - FEATURES ...................................................................................................................................- 4 -
3. - SPECIFICATIONS ........................................................................................................................- 5 -
4.- INSTALLATION AND START-UP ..................................................................................................- 9 -
4.1.- INSTALLATION ............................................................................................................................ - 9 -
4.1.- TERMINAL DEFINITION ...............................................................................................................- 11 -
TERMINAL DEFECATION .....................................................................................................................- 11 -
5. OPERATION MODE......................................................................................................................- 12 -
5.1- LCD DISPLAY SCREEN ............................................................................................................... - 12 -
5.2- PANEL LED INDICATOR ............................................................................................................. - 12 -
5.3- MOTOR CONTROL BUTTONS ...................................................................................................... - 13 -
5.3- CONFIGURATION BUTTONS ........................................................................................................ - 14 -
5.4- MEASUREMENT INTERFACE ....................................................................................................... - 15 -
5.5- CONFIGURATION INTERFACE ...................................................................................................... - 16 -
6. - RS485 COMMUNICATION PORTOCOL....................................................................................- 23 -
6.1.- MODBUS © PROTOCOL .......................................................................................................... - 23 -
6.1.1- Modbus RTU Frame Format:...........................................................................................- 23 -
6.1.2.- Modbus function code ....................................................................................................- 24 -
6.2.- MOTOR STATUS PARAMETER (READ ONLY, CODE 04) ................................................................ - 26 -
6.3.- MOTOR BASIC CONFIGURATION (READ AND WRITE)................................................................... - 29 -
6.4.- MOTOR PROTECTION FUNCTIONS CONFIGURATION (READ AND WRITE)....................................... - 30 -
6.5.- MOTOR START MODE CONFIGURATION (READ AND WRITE)......................................................... - 32 -
6.5.- SEQUENCE OF EVENT RECORD (READ ONLY, CODE 04)............................................................. - 33 -
6.5.- MOTOR ADVANCED CONTROL (READ AND WRITE)...................................................................... - 34 -
7.- PORTECTION FUNCTION INTRODUCTION .............................................................................- 35 -
7.1- START OVERTIME PROTECTION ................................................................................................. - 35 -
7.2- OVERLOAD PROTECTION........................................................................................................... - 36 -
7.3- JAM IN RUNNING PROTECTION (STALL)...................................................................................... - 40 -
7.4- JAM IN STARTING PROTECTION (ROTOR LOCKED)....................................................................... - 40 -
7.5- PHASE FAILURE PROTECTION.................................................................................................... - 40 -
7.6- CURRENT IMBALANCE PROTECTION ........................................................................................... - 41 -
7.7- GROUND FAULT PROTECTION.................................................................................................... - 41 -
7.8- UNDER POWER PROTECTION .................................................................................................... - 42 -
7.9- OVER TEMPERATURE PROTECTION............................................................................................ - 42 -
7.10- SHORT CIRCUIT PROTECTION .................................................................................................. - 42 -
7.11- OVER VOLTAGE PROTECTION .................................................................................................. - 43 -
7.12- UNDER VOLTAGE PROTECTION ................................................................................................ - 43 -

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7.13- ABNORMAL FREQUENCY PROTECTION ..................................................................................... - 44 -
7.14- ABNORMAL POWER FACTOR PROTECTION................................................................................ - 45 -
7.15.- TE PROTECTION .................................................................................................................... - 45 -
8- MOTOR START MODE INTRODUCTION....................................................................................- 47 -
8.1.- ONLY PROTECTION MODE ......................................................................................................... - 47 -
8.2.- FULL VOLTAGE START MODE...................................................................................................... - 49 -
8.3.- FORWARD AND REVERSE START MODE....................................................................................... - 50 -
8.4.- TWO-WINDING START MODE ..................................................................................................... - 51 -
8.5.- WYE-DELTA TRANSITION MODE................................................................................................. - 52 -
8.6.- AUTOTRANSFORMER CLOSED TRANSITION MODE ...................................................................... - 53 -
8.7- CIRCUIT BREAKER DIRECTLY START MODE .................................................................................. - 54 -
9. - SAFETY CONSIDERATIONS.....................................................................................................- 55 -
10. - MAINTENANCE........................................................................................................................- 55 -

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1. - SUMMARIZE
PR240 motor protection relay is an all-in-one solution designed to continuously monitor 3-phase
power lines for abnormal conditions. It can use with motors less than 690V/820A. It can realize a
variety of control operation, as well as measurement, self-diagnosis, maintenance management,
field bus communication and other functions.
The series of products through the real-time monitoring of the scene signal, provide various
protection trip to avoid motor failure. Option RS485 communication port can upload the monitor
data and alarm status to remote control system.
Protection function
(Details please refer to chapter 7)
Real-time monitor parameter
Start Overtime (Max. Start time),
Over Load,
Phase Failure (Phase loss),
Jam in starting(Stall),
Current imbalance,
Under power,
Jam in running,
Ground fault,
Over temperature,
Short circuit,
Over voltage,
Under voltage,
Abnormal frequency,
Abnormal power factor,
tE protection (Increased safety motor
overload)
Automatic restart,
Three-phase current,
Three-phase line voltage,
Frequency,
Active power,
Reactive power,
Apparent power,
Power factor,
Electrical energy,
Ground residential current
2. - FEATURES
-. Various electrical parameter real-time detect, Dot matrix LCD display.
-. Built-in 4-channels relay, provide various start methods: Direct start, positive & negative start,
star - delta start, autotransformer start, 2-speed motor start, circuit breaker direct start and
protection trip logic.
-. User free to set each protection function act off, alarm or trip.
-. Build in Sequence of Event function, can logger last 100 trip records.
-. With programmable analog output function, user option RS-485 communication interface.

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3. - SPECIFICATIONS
Working environment:
Motor rated voltage:
AC380V / AC660V
Motor rated current:
0.5-820A
Working temperature:
-10C ~ +55C
Storage temperature:
-25C ~ +70C
Relative humidity:
< 93% RH
Elevation:
not more than 3000 m
Atmospheric conditions:
installation site does not allow the explosive medium,
containing gas to corrode metal and damage the insulation
and conductive medium.
Measuring accuracy:
Current:
±0.5% @ 10% to 200% of Ie
Voltage:
±0.5% @ 10%~150%Ue
Frequency:
±0.1% @ 45 ~ 65Hz
Power factor:
±1.0% @ 0 ~ 1.000
Active Power
±1.0% @ 0 ~ 500kW
Leakage current:
± 1% @10% to 100% of Ir
Analog Output:
±1% @4 ~20mA
Electrical parameters:
Auxiliary Power:
AC90-240Vac/dc
Power consumption:
<10 VA
Insulation resistance:
>100MΩ
Relay:
Alarm relay @ 5A / 250VAC, 5A / 30VDC (NO node)

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Electrical test:
IEC 61000-4-2
level III
IEC 61000-4-4
level III
IEC 61000-4-5
level III
IEC 61010-1
AC2kV/1min Between power / input / output
Product standards
GB / T 14048.1
(IEC 60947-1)
Low-voltage switchgear and control equipment General Provisions
GB /T14048.4
(IEC 60947-4)
Low voltage electromechanical contactors and motor starters
requirements
JB / T 10613-2006
General specification for digital motor combined protection
equipment
JB /T10736-2007
Low voltage motor protection

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Product selection guide
PR240- □-□□□-□-□
HMI cable
(Chart 3.3)
Optional function
(Chart 3.2)
Rated
current/volt(Power)
(0.5-820A)
Motor start method
(Chart 3.1)
SN
Preset Motor Start method
Code
1
Protect only
A
2
Full voltage
B
3
Forward and reverse start
C
4
Two-Winding start
S
5
Wye-Delta Transition
D
6
Autotransformer Closed Transition
G
Chart 3.1
HMI cable length
Code
1-meter cable
D1
3-meters cable
D3
3-meters cable
D5
Chart 3.3
External protection CT selection guide, typical in 380V grid:
Motor rated
power (Kw)
Rated
current (A)
Internal
CT range
0.06
0.22
10A
0.12
0.42
0.37
1
0.55
1.5
0.75
2
1.1
2.5
2.2
5
3
6.5
5.5
11
100A
7.5
14.8
11
21
15
28.5
18.5
35
22
42
30
57
37
69
45
81
55
100
Motor rated
power (Kw)
Rated
current
(A)
Internal
CT
External
CT
75
135
10A
500/5
90
165
110
200
132
240
160
285
200
352
220
420
250
480
Notes: If motor rated current over 100A, need to connect
an external CT, Blue Jay suggest use 500/5A CT. In
Configuration menu-[CT ratio] set to 100.(See chapter
5.6.2)
SN
Optional function
Code
1
With Zero sequence CT
L
2
4 ~ 20mA analog port
M
3
Temperature probe
T
4
SOE record
R
Notes: Standard type without additional function,
If need multiple additional functions the coded
arranged in sequence after main code.
Chart 3.2

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Residual current sensor
If PR240 choose ground fault protection, need external LCT05/30 series CT for detect leakage
current.
LCT05 rated current of 500mA, the current range (50 ~ 500mA)
LCT30 rated current of 30A, the current range of (3 ~ 30A)
Each PR240 need 1pcs, please contact sales team for purchase issue.
Wiring core for cable type
Current
range
Dimension (mm)
φ
A
B
C
D
E
F
G
H
16-100A
45
77
85
24
38
54
9
64
54
100-250A
80
112
122
28
56
80
14
89
80
250-400A
100
131
136
24
66
96
14
108
107
400-800A
150
200
209
28
100
145
16
184
177
Wiring core for cooper bar type
Current
range
Dimension (mm)
A1
B1
A
B
C
D
E
F
G
0-63A
100
20
133
50
16
144
140
3
2.0
0-100A
100
25
133
60
24
154
143
9
2.5
0-225A
140
32
172
72
24
189
184
9
2.5
0-250A
180
32
212
72
24
229
224
9
2.5
0-400A
220
45
254
86
24
269
264
11
2.5
0-630A
260
45
294
86
24
309
304
11
2.5
0-1600A
300
45
334
86
24
349
344
11
2.5
0-4000A
420
45
454
86
24
469
464
11
2.5
Notes: Protection function please refer Chapter 7.7

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4.- INSTALLATION AND START-UP
The manual you hold in your hand contains information and warnings that the user
should respect in order to guarantee a proper operation of all the instrument functions
and keep it in safety conditions. The instrument must not be powered on and used until
its definitive assembly is on the cabinet’s door.
If the instrument is not used as manufacturer’s specifications, the protection of the
instrument will be damaged.
When any protection failure is suspected to exist (for example, it presents external visible
damages), the instrument must be immediately powered off. In this case contact a qualified
service representative.
4.1.- Installation
Mounting
PR240 series motor protection relay designed as separate 2 parts, one for din-rail mounting body,
another is panel mounting HMI.
Note that with the instrument powered on, the terminals could be dangerous to touch and cover
opening actions or elements removal may allow accessing dangerous parts. Therefore, the
instrument must not be used until this is completely installed.
Note: This connection drawing is for reference only; the actual connecting terminal please refer to
the label on the rear part.

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4.1.- Terminal Definition
LED indicator Introduction
Run/Stop:
Always ON when motor stopped;
Flicker when motor running.
COMM:
Flicker when RX/TX.
Alarm/Failure
Always ON when device have failure;
Flicker when motor in alarm threshold trigged.
Notes:
1. PR240 provide 7 digital input terminals, external signal sampling interval >= 100ms. 15Vdc
internal feeder, external can be controlled by passive contacts.
2. DI status can be set in NO or NC.
3. PR240 provide 4 relay outputs, DO status can be set in NO or NC, support Level output or
Pulse output.
Caution:
1. Forbidden to connect external feed voltage to DI terminals!
2. Do not wire the DI terminal in the same tube or twist it with high voltage cable!
3. If distance more than 2 meters must use shielded cable! The maximum distance of the DI
pinout should not exceed 300 meters!
Terminal defecation
Terminal No.
Description
11
A-phase voltage
12
B-phase voltage
13
C-phase voltage
4
A-phase current
6
B-phase current
8
C-phase current
10
Zero sequence current input
42
Leakage current input+
43
Leakage current input-
44
NTC -
45
NTC +
58
RS485A
59
RS485B
19-20
DO1
21-22
DO2
23-24
DO3
25-26
DO4
15
4~20 mA-
16
4~20mA +
70
DI COM Terminal
71
DI 1
72
DI 2
73
DI 3
74
DI 4
75
DI 5
76
DI 6
77
DI 7
1
Aux - L
90~240Vac/dc
2
Aux - N

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5. OPERATION MODE
PR240 have a HMI, wired to relay
body by DB9 cable;
It used for parameter display and
configuration, also can use operation
button to control motor working or
stop.
LED indicator show motor status.
5.1- LCD display screen
Screen area adopts a large size dot-matrix LCD, backlight is gray. The backlight time free to
configuration. When there is a key operation, the backlight will be re-lit, and will go out after the set
interval.
After device be powered, HMI default screen is measurement interface. In this interface, pressing
the " " button can enter password and switch to configuration interface.
In this configuration menu, user can set the protection mode, system parameter, view fault alarm
record, operation information etc.
5.2- Panel LED Indicator
Indicator mark
Description
Stop
Motor in working status
Motor stopped
Start
Motor in non-start status
Motor in starting period
Runs
Motor in non-runs status
Motor in running
Alarm
Motor in normal status
Alarm threshold trigged
Failure
DO in non-trip status
DO tripped

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5.3- Motor Control Buttons
There have 4 key buttons for motor operation:
Local direct control
Under remote
control mode
In “Protect only” mode
Invalid
In “Panel control start/stop” mode
Motor start
Invalid
In “Forward and reverse start” mode
Motor start in forward rotation
Invalid
In “Two-Winding start” mode
Motor start in low winding-1(low speed)
Invalid
In “Wye-Delta Transition” mode
Motor start
Invalid
In “Autotransformer Closed Transition” mode
Motor start
Invalid
Local direct control
Under remote
control mode
In “Protect only” mode
Invalid
In “Panel control start/stop” mode
Motor start
Invalid
In “Forward and reverse start” mode
Motor start in reverse rotation
Invalid
In “Two-Winding start” mode
Motor start in low winding-2(high speed)
Invalid
In “Wye-Delta Transition” mode
Invalid
Invalid
In “Autotransformer Closed Transition” mode
Invalid
Invalid
Local direct control
Under remote
control mode
In “Protect only” mode
Invalid
In “Panel control start/stop” mode
Stop motor immediately
Invalid
In “Forward and reverse start” mode
Stop motor immediately
Invalid
In “Two-Winding start” mode
Stop motor immediately
Invalid
In “Wye-Delta Transition” mode
Stop motor immediately
Invalid
In “Autotransformer Closed Transition” mode
Stop motor immediately
Invalid
Press to release alarm and reset DO port to non-tripped status when motor in Stopped status.

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5.4- Configuration Buttons
In HMI right are have 4 buttons for configuration operations:
Under measurement interface: Switch to former parameter displayed.
Under configuration interface: Move cursor to left and increase value.
Under measurement interface: Switch to next parameter displayed.
Under configuration interface: Move cursor to right and decrease value.
Under measurement interface: Switch to configuration interface (password requested).
Under configuration interface: Exit or switch to measurement interface.
Confirmed the enter value or setting changes.
5.4.1- Enter configuration menu
In normal monitor status, press , screen will ask Password,
Press into password screen, use and to enter password
Notes: Default user password is 0001),
Then press key to confirm enter, in password correct can into the menu screen,
Notes: If password changed and enter error, screen still ask password again.
5.4.2- Exit configuration menu
After parameter set, press , protector screen show “SAVE”, then press for save the
change and exit, press key for exit without save.

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5.5- Measurement Interface
Notes:
1. Thermal resistance parameter is only valid when access temperature probe;
2. Symbol of DI/DO status:
Hollow circle means no digital input or no relay trigged;
Solid circle means digital signal looped in or relay be trigged;
3. When the measured current > 1.3 * Protect CT, the display value of measurement error will be
increasing.
4. Press Enter button can switch to Motor status screen:

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5.6- Configuration Menu
5.6.1- Protection mode configuration
There have 15 different protection mode can configuration, detail function descriptions please refer
to Chapter 7:
Start over time (chapter 7.1):
Over time (chapter 7.2):

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Jam in running (chapter 7.3):
Jam in running (chapter 7.4):
Phase failure (chapter 7.5)
Current imbalance (chapter 7.6)
Ground fault (chapter 7.7)
Under power (chapter 7.8)

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Over temperature (chapter 7.9)
Short circuit (chapter 7.10)
Over voltage (chapter 7.11)
Under voltage (chapter 7.12)
Abnormal Frequency (chapter 7.13)

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Abnormal Power factory (chapter 7.14)
tE protection (chapter 7.15)