GE 169 User manual

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GE Power Management
215 Anderson Avenue, Markham, Ontario, L6E 1B3
Tel: [phone] Fax: [phone]
www.GEindustrial.com/pm
169
MOTOR MANAGEMENT RELAY
Instruction Manual
Software Rev: 169.E7.5
Manual P/N: 1601-0003-A4
Copyright 2000 GE Power Management

INTENT
This manual describes the function, operation and use of the GE Power Management Model 169 and 169 Plus Motor
Management Relays.
REVISION HISTORY
Manual Part No. 169 / 169 Plus Software Revision Release Date (M/D/Y)
M17/03/86 - all Rev. A, B, C, Rev. D1 3/17/86
M01/08/86 - Rev. D2 8/1/86
M21/08/86 - Rev. E1 8/21/86
M14/10/86 - Rev. E2, E3 10/14/86
M17/07/87-E4 - Rev. E4 (preliminary) 7/17/87
M05/08/87-E4 - Rev. E4 8/5/87
M02/11/87-E4 - Rev. E4 (D/O hardware rev.) 11/2/87
M04/11/87-E4 - Rev. E4 11/4/87
M22/01/89-E5 - Rev. E5 1/22/89
M01/02/90-E5 - Rev. E5 1/2/90
M23/02/90-E6 - Rev. E6 2/23/90
M18/09/91-E7 - Rev. 169.E7.0 9/18/91
M30/10/91-E7.1 - Rev. 169.E7.1 10/30/91
M02/12/91-E7.2 - Rev. 169.E7.2 12/2/91
1601-0003-A1 - Rev. 169.E7.2 10/12/93
1601-0003-A2 - Rev. 169.E7.2 01/23/95
1601-0003-A3 - Rev. 169.E7.3 08/22/95
1601-0003-A4 - Rev. 169.E7.4 03/11/98
1601-0003-A4 - Rev. 169.E7.5 12/14/99

TABLE OF CONTENTS
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1.1 Motor Protection Requirements........................................................................................................... 1
1.2 169 Relay Features................................................................................................................................. 1
1.3 Typical Applications............................................................................................................................... 3
1.4 Technical Specifications ....................................................................................................................... 4
2.1 Physical Dimensions............................................................................................................................. 7
2.2 Mounting ................................................................................................................................................. 9
2.3 External Connections .......................................................................................................................... 10
2.4 Control Power....................................................................................................................................... 15
2.5 Phase C.T.s............................................................................................................................................ 15
2.6 Ground Fault C.T. ................................................................................................................................. 16
2.7 Trip Relay Contacts.............................................................................................................................. 16
2.8 Alarm Relay Contacts .......................................................................................................................... 16
2.9 Auxiliary Relay #1 Contacts (169 Plus).............................................................................................. 17
2.10 Auxiliary Relay #2 Contacts (169 Plus)............................................................................................ 17
2.11 RTD Sensor Connections.................................................................................................................. 17
2.12 Emergency Restart Terminals .......................................................................................................... 18
2.13 External Reset Terminals .................................................................................................................. 18
2.14 Analog Output Terminals................................................................................................................... 18
2.15 Differential Relay Terminals (169 Plus)............................................................................................ 19
2.16 Speed Switch Terminals (169 Plus).................................................................................................. 19
2.17 Programming Access Terminals...................................................................................................... 19
2.18 RS-422 Serial Communications Terminals (169 Plus)................................................................... 19
2.19 Display Adjustment............................................................................................................................ 20
2.20 Front Panel Faceplate........................................................................................................................ 20
2.21 Spare Input Terminals (169 Plus) ..................................................................................................... 20
2.22 169 Drawout Relay............................................................................................................................. 21
3.1 Controls and Indicators....................................................................................................................... 26
3.2 169 Relay Display Modes .................................................................................................................... 30
3.3 ACTUAL VALUES Mode........................................................................................................................30
3.4 SETPOINTS Mode ................................................................................................................................41
3.5 HELP Mode .......................................................................................................................................... 58
3.6 TRIP/ALARM Mode............................................................................................................................... 58
3.7 Phase C.T. and Motor Full Load Current Setpoints.......................................................................... 61
3.8 Acceleration Time Setpoint................................................................................................................. 61
3.9 Number of Starts/Hour Setpoint......................................................................................................... 61

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3.10 Unbalance Setpoints.......................................................................................................................... 62
3.11 Ground Fault (Earth Leakage) Setpoints......................................................................................... 63
3.12 Undercurrent Setpoints..................................................................................................................... 63
3.13 Rapid Trip / Mechanical Jam Setpoints........................................................................................... 64
3.14 Short Circuit Setpoints...................................................................................................................... 64
3.15 Immediate Overload Alarm Level Setpoint...................................................................................... 64
3.16 Stator RTD Setpoints......................................................................................................................... 64
3.17 Other RTD Setpoints.......................................................................................................................... 65
3.18 Overload Curve Setpoints................................................................................................................. 65
3.19 Phase Reversal Protection................................................................................................................ 69
3.20 Thermal Memory ................................................................................................................................69
3.21 Emergency Restart............................................................................................................................. 71
3.22 Resetting The 169 Relay.................................................................................................................... 71
3.23 169 Relay Self-Test............................................................................................................................. 72
3.24 Statistical Data Features ................................................................................................................... 72
3.25 Factory Setpoints............................................................................................................................... 73
4.1 Primary Injection Testing..................................................................................................................... 76
4.2 Secondary Injection Testing ............................................................................................................... 76
4.3 Phase Current Input Functions .......................................................................................................... 76
4.4 Ground Fault Current Functions ........................................................................................................ 79
4.5 RTD Measurement Tests ..................................................................................................................... 79
4.6 Power Failure Testing.......................................................................................................................... 79
4.7 Analog Current Output ........................................................................................................................ 80
4.8 Routine Maintenance Verification ...................................................................................................... 80
5.1 Hardware............................................................................................................................................... 81
5.2 Firmware ............................................................................................................................................... 83
6.1 169 Relay Powered from One of Motor Phase Inputs...................................................................... 85
6.2 Loss of Control Power Due to Short Circuit or Ground Fault......................................................... 85
6.3 Example Using FLC Thermal Capacity Reduction Setpoint ........................................................... 86

LIST OF TABLES
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Table 1-1 Model 169 and 169 Plus Relay Features..................................................................................................... 2
Table 2-1 169 External Connections.......................................................................................................................... 10
Table 3-1 Controls and Indicators............................................................................................................................... 26
Table 3-1 Controls and Indicators............................................................................................................................... 31
Table 3-3 SETPOINTS ............................................................................................................................................... 42
Table 3-5 Standard Overload Curve Trip Times (in seconds).................................................................................... 66
Table 3-6 PRE-STORED FACTORY SETPOINTS (169 SETPOINT PAGES 1-3) ...................................................74
Table 3-7 Preset Factory Relay Configurations and Functions ................................................................................. 75
Table 4-1 RTD Resistance vs. Temperature.............................................................................................................. 79

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1.1 Motor Protection Requirements
Three phase AC motors have become standard in modern industry. These motors are generally rugged and very
reliable when used within their rated limits. Newer motors, however, tend to be designed to run much closer to these
operational limits and thus, there is less margin available for any type of abnormal supply, load, or operating
conditions.
To fully protect these motors, a modern protective device is required. Accurate stator and rotor thermal modeling is
necessary to allow the motor to operate within its thermal limits and still give the maximum desired output. As well,
other features can be incorporated into a modern relay to fully protect the motor, the associated mechanical system,
and the motor operator from all types of faults or overloads.
Motor thermal limits can be exceeded due to increased current from mechanical overloads or supply unbalance.
Unbalance can greatly increase heating in the rotor because of the large negative sequence current components
present during even small voltage unbalances. A locked or stalled rotor can cause severe heating because of the
associated large currents drawn from the supply. Many motor starts over a short period of time can cause
overheating as well. Phase-to-phase and phase-to-ground faults can also cause damage to motors and hazards to
personnel. Bearing overheating, loss of load, and phase reversal can cause damage to the mechanical load being
driven by the motor.
The ideal motor protection relay should monitor the rotor and stator winding temperatures exactly and shut off the
motor when thermal limits are reached. This relay should have an exact knowledge of the temperature and proper
operating characteristics of the motor and should shut down the motor on the occurrence of any potentially
damaging or hazardous condition.
The Multilin Model 169 Motor Management Relay uses motor phase current readings combined with stator RTD
temperature readings to thermally model the motor being protected. In addition, the 169 takes into account the
heating effects of negative sequence currents in the rotor, and calculates the cooling times of the motor. The relay
also monitors the motor and mechanical load for faults and problems.
1.2 169 Relay Features
The Multilin Model 169 Motor Management Relay is a modern microcomputer-based product designed to provide
complete, accurate protection for industrial motors and their associated mechanical systems. The 169 offers a wide
range of protection, monitoring, and diagnostic features in a single, integrated package. All of the relay setpoints
may be programmed in the field using a simple 12 position keypad and 48 character alphanumeric display. A built-in
"HELP" function can instruct the user on the proper function of each of the programming keys and on the meaning of
each displayed message.
One 169 relay is required per motor. Phase and ground fault currents are monitored through current transformers so
that motors of any line voltage can be protected. The relay is used as a pilot device to cause a contactor or breaker
to open under fault conditions; that is, it does not carry the primary motor current.
The relay comes in two different models, thus allowing for choice of the most cost effective relay for each application.
The 169 Plus has the following features which the model 169 does not: custom curve selectability, motor statistical
records, speed switch input, differential relay input, two auxiliary output relays, two additional RTD inputs, single shot
emergency restart feature, an RS 422 communications port, unbalance input to thermal memory, start inhibit feature,
and spare input terminals.
The custom curve feature of the model 169 Plus gives the user additional flexibility. If one of the eight standard
overload curves is not suitable for the application under consideration, the user can enter his own breakpoints to
form a custom curve. This means that the 169 Plus can offer optimum motor protection in situations where other
relays cannot. Such applications include induced fan drives where the motor stator and rotor thermal capacities can
differ significantly.
An important feature of the Multilin 169 Plus relay, is its ability to "learn" individual motor parameters. The relay
actually adapts itself to each application by "learning" values of motor inrush current, negative sequence current K
factor, cooldown rates, and acceleration time. These values may be used to improve the 169's protective
capabilities (when enabled) and are continually updated. The model 169 learns inrush current only.
The 169 Plus calculates both positive and negative sequence currents. The equivalent motor heating current is
calculated based on the "learned" K factor. This, combined with RTD temperature readings by a motor thermal
modeling algorithm, gives the 169 Plus a complete thermal model of the motor being protected. Thus, the 169 Plus
will allow maximum motor power output while providing complete thermal protection.

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The 169 Plus relay provides a complete statistical record of the motor being protected. The total motor running
hours, the number of motor starts, and the total number of relay trips since the last commissioning are stored and
can be viewed on the display. As well, the number of short circuit, RTD, ground fault, unbalance, overload, start, and
rapid trips can be recalled by simple keypad commands. These values are stored along with all of the relay
setpoints in a non-volatile memory within the relay. Thus, even when control power is removed from the 169 Plus,
the statistical record and all relay setpoints will remain intact.
The 169 can provide one of various output signals for remote metering or programmable controller attachment.
Analog signals of motor current as a percentage of full load, hottest stator RTD temperature, percentage of phase
CT secondary current, or motor thermal capacity are available by simple field programming. A total of four output
relays are provided on the 169 Plus, including a latched trip relay, an alarm relay, and two auxiliary relays. The
model 169 provides a latched trip relay and an alarm relay. All output relays may be programmed via the keypad to
trip on specific types of faults or overloads.
When an output relay becomes active, the 169 will display the cause of the trip, and if applicable, the lock-out time
remaining. Pre-trip values of motor current, unbalance, ground fault current, and maximum stator RTD temperature
are stored by the 169 and may be recalled using the keypad.
The correct operation of the Multilin 169 relay is continually checked by a built-in firmware self-test routine. If any
part of the relay malfunctions under this self-test, an alarm indication will tell the operator that service is required.
Table 1-1 Model 169 and 169 Plus Relay Features
Protection Features
•Overloads
•Stator Winding Overtemperature (Alarm and Trip)
•Multiple Starts
•Short Circuit
•Locked Rotor
•Rapid Trip/Mechanical Jam
•Unbalance/Single Phasing
•Ground Fault (Alarm and Trip)
•Phase Reversal
•Bearing Overtemperature (Alarm and Trip)
•Undercurrent
•Variable Lock-Out Time
Operational Features
•Microcomputer controlled
•Keypad programmable
•48 character alphanumeric display
•Built-in "HELP" function
•Eight selectable standard overload curves
•User defined custom overload curve capability (169 Plus)
•Continual relay circuitry self-check
Monitoring and Display Features
•Negative sequence phase current unbalance measurement
•Ground fault (earth leakage) current measurement
•Up to six stator RTD inputs
•Two additional RTD inputs on the model 169, four on the 169 Plus
•Monitoring of motor ambient air temperature
•Display of all SETPOINTS or ACTUAL VALUES upon request
•Display of relay TRIP/ALARM and HELP messages

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Communications and Control Features
•One latched, main trip relay
•One alarm relay
•Emergency restart capability
•Pre-trip alarm warnings
•4-20mA output of motor current as a percentage of full load, motor thermal capacity, hottest stator RTD
temperature, or percentage of phase CT secondary current
•Two auxiliary relays (169 Plus)
•Optional single-shot restart on running overload trip (169 Plus)
•Speed switch, differential relay, and spare input (169 Plus)
•RS 422 port for connection to programmable controllers and computers (169 Plus)
Statistical and Memory Features
•Recall of all pre-trip motor values
•Tamperproof setpoints stored in non-volatile memory
•Microcomputer "learns" motor inrush current, acceleration time*, cooldown rates*, and negative sequence
current heating K factor* (* 169 Plus only)
•Complete record of motor statistical data: motor running hours, number of starts, number and type of relay trips
(169 Plus)
1.3 Typical Applications
The many features of the 169 make it an ideal choice for a wide range of motor protection applications. Versatile
features and controls allow the relay to protect associated mechanical equipment as well as the motor. The 169
should be considered for the following and other typical uses:
1. Protection of motors and equipment from operator abuse.
2. Protection of personnel from shock hazards due to winding shorts or earth leakage current from moisture.
3. Protection of gears, pumps, fans, saw mills, cutters, and compressors from mechanical jam.
4. Indication of loss of suction for pumps or loss of air flow for fans using the undercurrent feature.
5. Protection of motor and load bearings from excessive heat buildup due to mechanical wear.
6. Protection of motors operated in environments with varying ambient temperatures.
7. Communication with programmable controllers and computers for integrated plant control.
8. Protection of high inertia, long acceleration drive systems using a custom overload curve.
9. Statistical record-keeping for effective maintenance programs.
10. Complete protection, allowing maximum motor utilization with minimum downtime, for all AC motors.

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1.4 Technical Specifications
Phase Current Inputs
conversion: calibrated RMS
range: 0.05 to 12 ×phase CT primary amps setpoint
full scale: 12 × phase CT primary amps setpoint
accuracy: ±0.5% of full scale (0.05 to 2 X phase CT primary amps setpoint)
±1.0% of full scale (over 2 X phase CT primary amps setpoint)
Ground Fault Current Input
conversion: calibrated RMS
range: 0.1 to 1.0 X G/F CT primary amps setpoint (5Amp secondary CT)
1.0 to 10.0 amps (2000:1 CT)
full scale: 1 ×G/F CT primary amps setpoint (5 Amp secondary CT)
10 amps (2000:1 CT)
accuracy: ±4% of G/F CT primary amps setpoint (5 Amp secondary CT)
± 0.3 amps primary (2000:1 CT)
Overload Curves
trip time accuracy: ±1 sec. up to 13 sec.
±8% of trip time over 13 sec.
detection level: ±1% of primary CT amps
Unbalance
display accuracy: ±2 percentage points of true negative sequence unbalance (In/Ip)
Relay Lock-out Time
accuracy: +/- 1 minute with control power applied
+/- 20% of total lock-out time with no control power applied
Trip/Alarm Delay Times
accuracy: ±0.5 sec. or 2% of total time, whichever is greater with the exception of:
1. "INST."setpoints: less than 50 msec.
2. Ground Fault 0.5 Second delay: ±150 msec.
3. Ground Fault 250 msec delay: +75 msec, -150 msec.
Phase Reversal Trip Time
relay response time: within 3.5 sec. of motor start attempt
Differential Relay Input
relay response time: 100 msec. maximum (contact closure to output relay activation)

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RTD Inputs
sensor types: 10 Ωcopper
100 Ωnickel
120 Ωnickel
100 Ωplatinum (specified with order)
display accuracy: ±2 C
trip/alarm setpoint range: 0 to 200°C
dead band: 3°C
maximum lead resistance: 25% of RTD 0°C resistance
Relay Contacts
type: form C
rated load: 10 A @ 250 VAC / 10A @ 30 VDC (resistive load)
7.5 A @ 250 VAC / 5 A @ 30 VDC (inductive load)
0.5 A @ 125 VDC (resistive load)
0.3 A @ 125 VDC (inductive load)
maximum operating voltage: 380 VAC, 125 VDC
maximum operating current: 10 Amps
minimum permissible load: 5 VDC, 100 mA
NOTE: AC inductive load PF = 0.4
DC inductive load L/R = 7 msec.
Analog Current Output (4-20 mA standard)
output: 4-20 mA / 0-20 mA / 0-1 mA
maximum load resistance: 300 Ω300 Ω2000 Ω
maximum output (saturation): 20.2 mA 20.2 mA 1.01 mA
accuracy: ±1% of full scale reading
polarity: terminal 58 ("-") must be at ground potential (ie. output is not isolated)
Control Power
AC nominal: 120 VAC, range: 90-150 VAC
240 VAC, range: 180-270 VAC
frequency: 50/60 Hz
maximum power consumption: 40 VA
DC nominal: 24 VDC, range: 20-30 VDC
48 VDC, range: 30-55 VDC
125 VDC, range: 80-150 VDC
250 VDC, range: 160-300 VDC
maximum power consumption: 30 W
Environment
operating temperature range: –10°C to +60°C
display operational range: 0°C to +55°C

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CT Burden Due to Connection of 169 Relay
phase CT: 1 amp or 5 amp input: less than 0.50 VAat rated load
ground fault CT: 5 amp input: less than 0.50 VAat rated load
2000:1 input: can be driven by GE Power Management 2000:1 CT
Running Hours Counter
accuracy: ±1%
Note: It is recommended that all 169 relays be powered up at least once per year to avoid deterioration of
electrolytic capacitors in the power supply.
Due to updating technology, specifications may be improved without notice.

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2.1 Physical Dimensions
The 169 relay is contained in a compact plastic and metal housing with the keypad, display, and all indicators located
on the front panel. The physical dimensions of the 169 unit are given in Figure 2-1.
Multilin also provides phase and ground fault CTs if required. Dimensions for these are shown in Figure 2-2. Note:
Dimensions of Figure 2-2 are for 100:5 to 1000:5 phase CT's, for the dimensions of 50:5 and 75:5 CT's, consult
factory.
Figure 2-1 Physical Dimensions

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Figure 2-2 CT Dimensions

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2.2 Mounting
The 169 should be positioned so that the display is visible and the front panel keypad is accessible. A cut-out is
made in the mounting panel and the unit is mounted as shown in Figure 2-3. Four washers and 10-32 X 3/8"
mounting screws are provided.
Although the 169 circuitry is internally shielded, to minimize noise pickup and interference the relay should be placed
away from high current conductors or sources of strong magnetic fields.
Connections to the relay are made through terminal blocks and CTs located on the rear of the unit.
Figure 2-3 Relay Mounting

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2.3 External Connections
The connections made to the 169 relay will vary depending on the programming of the unit. It is not necessary to
use all of the connections provided; a minimal configuration would include supply power, three phase current CT
inputs and the Trip relay contacts wired in series with the contactor control relay or circuit breaker shunt trip coil.
Connections to these and the other terminals outlined below will be explained in the following sections. Figures 2-4,
2-6, 2-7 show typical connections to the 169 relay.
NOTE: The rear of the 169 relay shows output relay contacts in their power down state. Figures 2-4, 2-6, 2-7 show
output relay contacts with power applied, no trips or alarms, Factory Configurations, i.e. TRIP - fail-safe, ALARM -
non-fail-safe, AUX.1 - non-fail-safe, AUX.2 - fail-safe). See Figure 2-5 for a complete list of all possible output relay
contact states. See page 62 for a description of the RELAY FAILSAFE CODE.
Table 2-1 169 External Connections
Inputs
•Supply Power L, G, N
•Phase CTs
•Ground Fault CTs
•6 Stator RTDs
•2 additional RTDs on the 169, 4 on the 169 Plus
•Emergency Restart keyswitch
•External Reset pushbutton
•Programming Access jumper or keyswitch
•Speed Switch input on the 169 Plus
•Differential Relay input on the 169 Plus
•Spare Input on the 169 Plus
Outputs
•2 Sets of Relay Contacts (NO/NC) on the 169, 4 on the 169 Plus
•Programmable Analog Current Output Terminals
•RS 422 Serial Communication Port on the 169 Plus

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Figure 2-4 Relay Wiring Diagram (AC control power)

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Figure 2-5 Output Relay Contact States
WARNING: In locations where system voltage disturbances cause voltage levels to dip below the range
specified in specifications (1.5), any relay contact programmed failsafe may change state. To avoid tripping
the motor in this case, trip relay contacts should be programmed non-failsafe.

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Figure 2-6 Relay Wiring Diagram (Two Phase CTs)

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Figure 2-7 Relay Wiring Diagram (DC Control Power)