Eaton MP-4000 Assembly Instructions

IB02602002E www.eaton.com
IB02602002E
Rev. F
MP-4000 Motor Protection Relay
Instruction Bulletin for Installing, Operating, and Maintaining the
Eaton MP-4000 Motor Protection Relay

IB02602002E MP-4000
www.eaton.com IB02602002E
Copyright © 2012 by Eaton Corporation. All rights reserved.
Specications contained herein are subject to change without notice.
Microsoft, is a registered trademark of Microsoft Corporation.
Power Xpert and PowerVision are registered trademarks of Eaton Corporation.
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RECEIVING THIS DOCUMENT AND/OR TECHNICAL INFORMATION
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CONTRACTUAL PROVISIONS, THIS NOTICE SHALL GOVERN THE STATUS OF THIS DOCUMENT.
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The information, recommendations, descriptions, and safety notations in this document are based on Eaton Electrical
Inc. and/or Eaton Corporation’s (“Eaton”) experience and judgment and may not cover all
contingencies. If further information is required, an Eaton sales ofce should be consulted.
Sale of the product shown in this literature is subject to the terms and conditions outlined in
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of the information, recommendations and descriptions contained herein.
Revision Note: Rev. F - Added missing table information on sheet 4-6. ECO-031940 04/24/12.

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MP-4000 IB02602002E
Contents
SECTION 1 - INTRODUCTION...................................................................................................................................................................................1-1
1.0 General........................................................................................................................................................................................................1-1
1.1 Replacing the IQ 1000 II or MP-3000 with theMP-4000..............................................................................................................................1-1
1.2 MP-4000 Features and Enhancements.......................................................................................................................................................1-1
1.3 Use of This Manual .....................................................................................................................................................................................1-2
SECTION 2 - PRODUCT OVERVIEW........................................................................................................................................................................2-1
2.0 General Overview........................................................................................................................................................................................2-1
2.1 Optimum Motor Protection ..........................................................................................................................................................................2-1
2.2 Motor Starting and Control Functions..........................................................................................................................................................2-2
2.3 User Interface..............................................................................................................................................................................................2-2
SECTION 3 - MP-4000 TECHNICAL SPECIFICATIONS...........................................................................................................................................3-1
SECTION 4 - OPERATOR PANEL .............................................................................................................................................................................4-1
4.0 General Description.....................................................................................................................................................................................4-1
4.1 Default Mode...............................................................................................................................................................................................4-1
4.2 Monitor Mode ..............................................................................................................................................................................................4-2
4.3 View Setting and Program Mode.................................................................................................................................................................4-2
4.4 History Mode...............................................................................................................................................................................................4-2
4.5 Log Mode ....................................................................................................................................................................................................4-2
SECTION 5 - PROGRAMMING THE MP-4000 ..........................................................................................................................................................5-1
5.0 General .......................................................................................................................................................................................................5-1
5.1 Page 1, SP MOTOR, Settings P1L1 to P1L8..............................................................................................................................................5-1
5.2 Page 2, SP RTD, Settings P2L1 to P2L10..................................................................................................................................................5-3
5.3 Page 3, SP TRIP, Settings P3L1 to P3L14..................................................................................................................................................5-4
5.4 Page 4, SPALARM, Settings P4L1 to P4L8...............................................................................................................................................5-5
5.5 Page 5, SP START, Settings P5L1 to P5L12 ..............................................................................................................................................5-6
5.6 Page 6, SP DI 1...........................................................................................................................................................................................5-7
5.7 Page 7, SP DI 2...........................................................................................................................................................................................5-8
5.8 Page 8, SPAREL, Settings P8L1 to P8L22................................................................................................................................................5-8
5.9 Page 9, SPAUX1, Settings P9L1 to P9L25................................................................................................................................................5-8
5.10 Page 10, SPAUX2, Settings P10L1 to P10L23 .........................................................................................................................................5-9
5.11 Page 11, SPA OUT.....................................................................................................................................................................................5-9
5.12 Page 12, SP SYS, Settings P12L1 to P12L18............................................................................................................................................5-9
5.13 Page 13, SP TEST, Settings P13L1 to P13L8...........................................................................................................................................5-11
5.14 Page 14, SP RESET, Settings P14L1 to P14L4........................................................................................................................................5-11
5.15 Page 15, SPVUTRP, Settings P15L1 to P15L7.........................................................................................................................................5-12
5.16 Page 16, SPVUTRP, Settings P16L1 to P16L5.........................................................................................................................................5-12
5.17 Page 17, SP OFTRP, Settings P17L1 to P17L5........................................................................................................................................5-12
5.18 Page 18, SP OVTRP, Settings P18L1 to P18L7 .......................................................................................................................................5-12
5.19 Page 19, SP UVTRP, Settings P19L1 to P19L7........................................................................................................................................5-13
5.20 Page 20, SP UPTRP, Settings P20L1 to P20L5........................................................................................................................................5-13
5.21 Page 21, SP PFTRP, Settings P21L1 to P21L12......................................................................................................................................5-13
5.22 Page 22, AREL, Settings P22L1 to L7 ......................................................................................................................................................5-14
5.23 Page 23, SP UPTRP, Settings P23L1 to P23L7........................................................................................................................................5-14
5.24 Page 24, SP2 AUX 2, Settings P24L1 to L7..............................................................................................................................................5-14
5.25 Page 25, SP2 SYS, P25L1 to L9, WATT Hours Display ...........................................................................................................................5-15
5.26 Page 26, SP COMM Settings for RS232 Communications.......................................................................................................................5-15
SECTION 6 - INSTALLATION AND WIRING .............................................................................................................................................................6-1
6.0 Mounting the MP-4000 Motor Protection Relay ..........................................................................................................................................6-1
6.1 Wiring - General Information.......................................................................................................................................................................6-1

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IB02602002E MP-4000
SECTION 7 - STARTUP..............................................................................................................................................................................................7-1
7.0 General........................................................................................................................................................................................................7-1
7.1 Power-Off Checks.......................................................................................................................................................................................7-1
7.2 Initial AC Power Checks..............................................................................................................................................................................7-1
7.3 Initial Checking with AC Power to Relay .....................................................................................................................................................7-1
7.4 Further Checking of the Relay with AC Power ............................................................................................................................................7-2
7.5 Checking Data Communications.................................................................................................................................................................7-2
7.6 Entering Relay Settings...............................................................................................................................................................................7-2
7.7 Checking Contact Outputs ..........................................................................................................................................................................7-2
7.8 Checking the Complete Motor Drive System ..............................................................................................................................................7-3
SECTION 8 - MOTOR THERMAL PROTECTION BASICS............................................................................................................................................8-1
8.0 General........................................................................................................................................................................................................8-1
8.1 Sensing Inputs.............................................................................................................................................................................................8-1
8.2 Protective Functions....................................................................................................................................................................................8-1
SECTION 9 - APPLICATIONS AND SETTINGS ........................................................................................................................................................9-1
9.0 General........................................................................................................................................................................................................9-1
9.1 Motor Protection..........................................................................................................................................................................................9-1
9.2 Motor Cycle Monitoring ...............................................................................................................................................................................9-4
9.3 AC Line Interruptions...................................................................................................................................................................................9-5
SECTION 10 - DATA COMMUNICATIONS ..............................................................................................................................................................10-1
10.0 General......................................................................................................................................................................................................10-1
10.1 Choosing a PONI ......................................................................................................................................................................................10-1
10.2 Mounting the PONI....................................................................................................................................................................................10-1
10.3 Connecting the PONI to the Relay............................................................................................................................................................10-1
10.4 Connecting the PONI to the Network or Host............................................................................................................................................10-1
10.5 PowerNet INCOM Communications Protocol............................................................................................................................................10-2
SECTION 11 - TESTING...........................................................................................................................................................................................11-1
11.0 General......................................................................................................................................................................................................11-1
11.1 What to Test ..............................................................................................................................................................................................11-1
11.2 Tests on a Running Motor .........................................................................................................................................................................11-1
11.3 Verifying Current Inputs.............................................................................................................................................................................11-1
11.4 Bench Test of Current Inputs.....................................................................................................................................................................11-1
11.5 Testing the Trip Relay................................................................................................................................................................................11-1
11.6 Testing the Alarm Relay.............................................................................................................................................................................11-1
11.7 Testing the AUX1 Relay.............................................................................................................................................................................11-1
11.8 Testing the AUX2 Relay.............................................................................................................................................................................11-1
11.9 Testing the Analog Output .........................................................................................................................................................................11-1
11.10 Checking Discrete Input 1 .........................................................................................................................................................................11-2
11.11 Checking Discrete Input 2 .........................................................................................................................................................................11-2
11.12 Verify Voltage Inputs..................................................................................................................................................................................11-2
SECTION 12 - TROUBLESHOOTING......................................................................................................................................................................12-1
12.0 General......................................................................................................................................................................................................12-1
12.1 Panel Operations.......................................................................................................................................................................................12-1
12.2 Troubleshooting MP-4000 Monitored Equipment.......................................................................................................................................12-1
12.3 Troubleshooting the MP-4000 ...................................................................................................................................................................12-2
12.4 Technical Assistance.................................................................................................................................................................................12-2

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MP-4000 IB02602002E
SECTION 13 - DRAWOUT CASE OPTION FOR THE MP-4000 MOTOR PROTECTION RELAY..........................................................................13-1
13.0 Introduction................................................................................................................................................................................................13-1
13.1 General Description...................................................................................................................................................................................13-1
13.2 Installation.................................................................................................................................................................................................13-1
13.3 Wiring and Setup.......................................................................................................................................................................................13-2
13.4 Application Considerations........................................................................................................................................................................13-2
13.5 Drawout Operation ....................................................................................................................................................................................13-4
13.6 Warranty and Liability Information.............................................................................................................................................................13-4
13.7 Technical Assistance.................................................................................................................................................................................13-4

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IB02602002E MP-4000
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MP-4000 IB02602002E
SECTION 1 - INTRODUCTION
1.0 General
The MP-4000 is an advanced microprocessor-based motor protection
relay that is easy to set up and use. It monitors, controls, and protects
motors against overload, thermal damage to rotor or stator, electrical
faults, and excessive starting, and many process equipment failures.
Advanced algorithms and thermal models give safe operation over a
wide range of conditions.
The MP-4000 protects 50 or 60 Hz three-phase motors of any size or
voltage level. It can protect induction or synchronous motors, with or
without RTDs. It is frequently installed in motor starters or switchgear.
The MP-4000 Motor Protection relay provides the following protection,
alarm, and control functions. ANSI device numbers are in parenthe-
ses.
Protection
Intel-I-Trip I2t overload protection (49/51)
Locked rotor protection (49S/51)
Ultimate trip current (51)
Negative sequence current/phase unbalance and reverse
phase protection (46)
Instantaneous overcurrent trip (50)
Ground fault protection (50G)
RTD trip with accessory URTD module (49/38)
Underload trip power and current (37)
Phase unbalance (47)
Under voltage (27)
Over voltage (59)
Over and under frequency (81)
Power factor (55)
Starts per time limit (66)
Jam or stall trip (51R)
Zero speed switch trip (14)
I2t auto or manual reset (86)
Fail-safe or non-fail-safe trip modes
Current unbalance (46)
Voltage unbalance (47)
Alarming
Ground fault
I2t overload
Jam / stall
Underload
Phase unbalance
RTD temperature with URTD module
Power factor under and over voltage
Under and over frequency
Under power
Control Features
Transition control for reduced voltage starters
Incomplete sequence (process feedback) detection and trip
Permits User-set number of cold starts
Limits number of starts per time
User sets minimum time between starts
Antibackspin (time from stop to next start) delay
Current-based process load shedding and restoration
Long acceleration timing feature
Motor stop input for synchronous motor and condenser
applications
Remote trip input
Differential trip input
Emergency override clears blocks to motor restarting (if
enabled)
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Program settings while motor runs, with controlled change-
over (if enabled)
Disarmed mode for commissioning and checking in a run-
ning process.
1.1 Replacing the IQ 1000 II or MP-3000 with the
MP-4000
The MP-4000 Motor Protection Relay serves as a direct replacement
for the prior-generation Westinghouse or Cutler-Hammer IQ 1000 II or
MP-3000. The cutout and mounting are compatible. The relay termi-
nal conguration and wiring connections are similar. When replacing
the IQ 1000 II or MP-3000 with the MP-4000, additional terminals are
provided for voltage inputs.
CAUTION
TERMINAL 6 (SEE FIGURE 6.3) WAS REMOTE COMMON IN THE
IQ1000II. THIS TERMINAL PROVIDED A CONNECTION TO NEU-
TRAL IF 120 VAC CONTROL POWER WAS USED, AND A 120 VAC
SOURCE IF 240 VAC CONTROL POWER WAS USED. THE IQ1000
II HAD A FACTORY INSTALLED JUMPER BETWEEN TERMINAL 6
AND TERMINAL 9 - THE COMMON RETURN OF THE DISCRETE
INPUT CHANNELS. DO NOT INSTALL THIS JUMPER ON THE MP-
4000. THE MP-4000 USES TERMINAL 6 FOR DISCRETE SOURCE
AND IT IS A CONNECTION TO 120 VAC IN BOTH CASES OF 120
VAC AND 240 VAC CONTROL POWER USE. REFER TO SECTION
6, INSTALLATION AND WIRING FOR PROPER WIRING OF THE
DISCRETE INPUTS.
1.2 MP-4000 Features and Enhancements
The MP-4000 Motor Protection Relay incorporates the eld proven
motor thermal models and sequence component measurement
techniques that were pioneered in the MP-3000 and IQ 1000 II relay
thermal models. The MP-4000 also adds several enhancements.
Signicant enhancements and features include:
1. Phase voltage monitoring and protection (new for MP-4000).
2. Power and Power Factor monitoring and protection (new for
MP-4000).
3. Frequency monitoring and protection (new for MP-4000).
4. Optional Quick Release Drawout Case that makes removal and
replacement fast and easy.
5. New Armed/Disarmed feature for trip-free installation with Quick
Release Drawout Case.
6. User selectable trip or alarm only on relay internal failure detec-
tion.
7. Real time clock for date and time stamping of trips, alarms, and
events (Y2K compliant).
8. Expanded memory for extensive recording and logging of events,
trips, alarms, history, and motor starting current proles.
9. Motor starting prole plot versus protection limits.
10. Easy-to-use faceplate and User interface. Settings and data are
organized into pages under six main modes. The modes are
Default (motor state), Monitor, View Settings, History, Logs, and
Program (change settings).
11. Intel-I-Trip Intelligent Overload Protection with adaptive trip char-
acteristics based on RTD readings and motor operating history.
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IB02602002E MP-4000
12. RTD diagnostics and communications error checking for addi-
tional security against operation from RTD failures.
13. Mechanical Process Load Shedding feature provides overload
indication to control upstream processes, averting unnecessary
motor overload shutdown or jam trips, and maintaining process
continuity.
14. Download settings or retrieve metered and historical values via
the communications port.
15. Flexible User-congurable inputs and outputs for broader applica-
tion.
16. Options for transition function control and monitoring on time
and/or current.
17. Emergency override function resets jogging limit functions and
clears thermal-model bucket to permit restart with a time-tagged
event log. Unit uses a secured button; this function can be dis-
abled.
18. MP-4000 can be programmed while the motor runs, and new set-
tings are all put into effect at once in a controlled fashion. Or, the
User can set the unit so programming is allowed only after motor
stop.
1.3 Use of This Manual
This manual contains the following sections:
Section 1 - Introduction - Describes the upgrade changes
from the existing MP-3000 to the MP-4000 including retrot
and new features list.
Section 2 - Product Overview - Includes benets, feature
list, use of manual, and list of options.
Section 3 - Specications - Provides hardware specics
Section 4 - Operator Panel - Describes the pushbuttons,
LEDs, display window, and security door on the MP-4000’s
faceplate plus the different modes of operation and detailed
mode description tables.
Section 5 - Programming the MP-4000 - Gives specic guid-
ance for selecting and setting values.
Section 6 - Installation and Wiring - Outlines procedures for
the plant electrician to follow when installing and wiring the
MP-4000.
Section 7 - Start-Up - Lists step-by-step procedures for
energizing the MP-4000 for the rst time after installation.
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Section 8 - Motor Thermal Protection Basics–Gives an over-
view of how the hardware and software function together to
control, monitor, and protect the motor.
Section 9 - Application and Settings - Is intended as an aid
to the application engineer considering how and when to
apply the various features of the MP-4000.
Section 10 - Data Communications - Describes what is
needed for the MP-4000 to communicate with host com-
puter systems.
Section 11 - Testing - Describes how to use the MP-4000
test functions and details recommended maintenance.
Section 12 - Troubleshooting - Provides information on how
to use the Operator Panel to recognize malfunctions. Also,
gives specic troubleshooting procedures.
Section 13 - Drawout Case Option - Describes installing and
using MP-4000 drawout case models.
Once the User is familiar with the basics of operating the MP-4000,
Tables 4.1 through 4.5 can be used as guides to program and monitor
the MP-4000.
The following accessories and options are covered in other instruction
manuals:
Table 1.1 MP-3000 Accessories and Options.
URTD module for
connecting RTDs
to the MP-4000 (1)
I.L. 17367
IQ DC Power Supply,
100-150 Vdc I.L. 17286
INCOM PONI (IPONI) I.L. 17547
Ethernet PONI (EPONI) I.L. 17560
Other PONI Types Consult Eaton distributor or
Eaton.com website
DPONI Types I.L. 17559
(1) This MP-4000 Instruction Manual (IM) gives all basic information
on installing the URTD module.
NOTE: Some manuals will be supplied electronically on the CD
shipped with the MP-4000.
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MP-4000 IB02602002E
Table 1.2 MP-4000 Motor Protection Relay Ordering Information.
Catalog Number Description Style Number
MP4010 Fixed Case, 5A CT 66D2206G01
MP4010INCOM Fixed Case, 5A CT, with INCOM Communications 66D2206G02
MP4010MODBUS Fixed Case, 5A CT, with Modbus Communications 66D2206G03
MP4010DEVICEN Fixed Case, 5A CT, with DeviceNet Communications 66D2206G04
MP4110 Fixed Case, 1A CT, Communications Capable with PONI 66D2206G05
MP4110INCOM Fixed Case, 1A CT, with INCOM Communications 66D2206G06
MP4110MODBUS Fixed Case, 1A CT, with Modbus Communications 66D2206G07
MP4110DEVICEN Fixed Case, 1A CT, with DeviceNet Communications 66D2206G08
MP4011 Drawout Case, 5A CT, No Communications 66D2209G01
MP4012 Drawout Case, 5A CT, with INCOM Communications 66D2209G02
MP4013 Drawout Case, 5A CT, with Modbus Communications 66D2209G03
MP4014 Drawout Case, 5A CT, with DeviceNet Communications 66D2209G04
MP4111 Drawout Case, 1A CT, No Communications 66D2209G05
MP4112 Drawout Case, 1A CT, with INCOM Communications 66D2209G06
MP4113 Drawout Case, 1A CT, with Modbus Communications 66D2209G07
MP4114 Drawout Case, 1A CT, with DeviceNet Communications 66D2209G08
MP4010VPI Fixed Case, 5A CT, with INCOM, URTD and FOC 66D2143G11
MP4010VPM Fixed Case, 5A CT, with Modbus, URTD and FOC 66D2143G12
MP4010VPD Fixed Case, 5A CT, with DeviceNet, URTD and FOC 66D2143G13
MP4110VPI Fixed Case, 1A CT, with INCOM, URTD and FOC 66D2143G14
MP4110VPM Fixed Case, 1A CT, with Modbus, URTD and FOC 66D2143G15
MP4110VPD Fixed Case, 1A CT, with DeviceNet, URTD and FOC 66D2143G16

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IB02602002E MP-4000
Table 1.4 MP-4000 Renewal Parts.
Catalog Number Description Style Number
MP4011-IC MP-4011 Inner Chassis, 5A CT, No Communications 66D2210G11
MP4012-IC MP-4012 Inner Chassis, 5A CT, with INCOM Communications 66D2210G12
MP40013-IC MP-4013 Inner Chassis, 5A CT, with Modbus Communications 66D2210G13
MP4014-IC MP-4014 Inner Chassis, 5A CT, with DeviceNet Communications 66D2210G14
MP4111-IC MP-4111 Inner Chassis, 1A CT, No Communications 66D2210G15
MP4112-IC MP-4112 Inner Chassis, 1A CT, with INCOM Communications 66D2210G16
MP4113-IC MP-4113 Inner Chassis, 1A CT, with Modbus Communications 66D2210G17
MP4114-IC MP-4114 Inner Chassis, 1A CT, with DeviceNet Communications 66D2210G18
MP4X11-OC MP-4XXX Outer Chassis, for Use with No Communications or INCOM Communications
Inner Chassis 66D2139G01
MP4X13-OC MP-4XXX Outer Chassis, for Use with Modbus Communications Inner Chassis 66D2139G02
MP4X14-OC MP-4XXX Outer Chassis, for Use with DeviceNet Communications Inner Chassis 66D2139G03
Table 1.3 MP-4000 Motor Protection Relay Accessories.
Catalog Number Description Style Number
URTD Module Universal RTD Module 2D78559G01
IQDCPS IQ DC dc to ac power supply converter, 100 - 150 Vdc 66C2462G01
MPFO-1 1 Meter precut optical ber link for URTD with connectors 66D2037G01
MPFO-5 5 Meter precut optical ber link for URTD with connectors 66D2037G02
MPFO-10 10 Meter precut optical ber link for URTD with connectors 66D2037G03
MPFO-25 25 Meter precut optical ber link for URTD with connectors 66D2037G04
MPFO-50 50 Meter precut optical ber link for URTD with connectors 66D2037G07
MPFO-75 75 Meter precut optical ber link for URTD with connectors 66D2037G10
MPFO-76 76 Meter precut optical ber link for URTD with connectors 66D2037G11
MPFO-100 100 Meter precut optical ber link for URTD with connectors 66D2037G13
MPFO-120 120 Meter precut optical ber link for URTD with connectors 66D2037G14
MP3BRACKET PONI Mounting Bracket 66D2053G01
MPML Relay mounting plate adapter with 0.50 in. Stud - ts GE Multilin® 269 cutout 66D2044G01
MPML-L Relay mounting plate adapter with 1.0 in. Stud - ts GE Multilin® 269 cutout 66D2044G02
EPONI Ethernet communications module 66D2028G01
EPONIF Ethernet optical ber communications module 66D2028G02
IPONI INCOM communications module 8793C36G03
DPONI Data communications module 6D2132G01
RS-485 PONI Modbus RTU communications module 66D2042G01
MD3000 Motor/Generator Differential Relay Fixed Case 66D2126G01
MD3000 Motor/Generator Differential Relay Drawout Case 66D2127G01