P&B Goldstart MPC2000 User manual

15/05/96 0MPC2000 01/96B
MPC2000
MOTOR PROTECTION CONTROLLER
P&B Engineering
Belle Vue Works
Boundary Street
Manchester
M12 5NG
Tel: [phone]
Fax: [phone]
E-mail [email protected]

15/05/96 1MPC2000 01/96B
Contents
CONTENTS.........................................................................................................................................................................................1
1. INTRODUCTION...........................................................................................................................................................................3
2. SUMMARY OF MPC2000 FEATURES......................................................................................................................................4
2.1 CONTROL FUNCTIONS..................................................................................................................................................................4
2.2 PROTECTIVE FUNCTIONS............................................................................................................................................................4
2.3 DISPLAYED DATA.........................................................................................................................................................................4
2.4 FEATURES.......................................................................................................................................................................................5
3. TECHNICAL SPECIFICATION..................................................................................................................................................5
3.1 TECHNICAL DATA.......................................................................................................................................................................5
3.1.1 AUXILIARY POWER SUPPLY...................................................................................................................................................5
3.1.2 PHASE CURRENT INPUTS..........................................................................................................................................................6
3.1.3. EARTH FAULT CURRENT INPUTS..........................................................................................................................................6
3.1.4. LINE VOLTAGE INPUTS............................................................................................................................................................6
3.1.5. THERMISTOR/RTD INPUTS......................................................................................................................................................6
3.1.6. OVERLOAD ALARM AND TRIP CURVES.................................................................................................................................6
3.1.7. CURRENT UNBALANCE ALARM AND TRIP ..........................................................................................................................7
3.1.8. FAULT TIME DELAYS...............................................................................................................................................................7
3.1.9. RELAY CONTACTS....................................................................................................................................................................7
3.1.10. DIELECTRIC STRENGTH........................................................................................................................................................7
3.1.11. AUTO RESTART CIRCUITRY.................................................................................................................................................8
3.2. MPC2000 IMMUNITYAND EMISSIONS TESTS..................................................................................................................8
4. MPC2000 SCHEMATIC DIAGRAMS .......................................................................................................................................8
5. MPC2000 MEASURED INPUTS..............................................................................................................................................11
5.1. POWER SUPPLY (LIVE-61, NEUTRAL-62, EARTH-63)...........................................................................................................11
5.2. VT INPUTS (L1-78, L2-79, L3-80, N-81-IF USED).....................................................................................................................11
5.3. CT PHASE INPUTS (82,83,8485,86,87 88,89,90).....................................................................................................................11
5.4. EARTH FAULT CT INPUTS (91,92,93)......................................................................................................................................11
5.5. TEMPERATURE INPUTS 3CHANNEL (67,68,69 71,72,73 75,76,77)....................................................................................11
6. MPC2000 CONTROL INPUTS/OUTPUTS...........................................................................................................................12
6.1. OUTPUT RELAYS.......................................................................................................................................................................12
6.2. CONTROL INPUTS......................................................................................................................................................................12
6.3. KEY SWITCH...............................................................................................................................................................................14
6.4. EMERGENCY STOP.....................................................................................................................................................................14
7. MPC2000 FACEPLATE FUNCTIONS....................................................................................................................................14
8. MPC FUNCTIONAL KEYPAD & DISPLAY..........................................................................................................................16
9. MPC2000 SETTING AND DATA PAGES..............................................................................................................................18
9.1. MPC2000 COMMUNICATION SETTINGS.................................................................................................................................18
9.2. SYSTEM SETTINGS.....................................................................................................................................................................19
9.3. VOLTAGE SETTINGS.................................................................................................................................................................21
9.4. CURRENT SETTINGS..................................................................................................................................................................21
9.5. TEMPERATURE SETTINGS........................................................................................................................................................25
9.6. TRIPPING/ALARM OPTIONS.....................................................................................................................................................25
9.7. MPC2000 DATA DISPLAY PAGES............................................................................................................................................27
9.8. MPC2000 SETTING PAGES SUMMARY....................................................................................................................................28

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9.9. MPC2000 DATA PAGES SUMMARY.........................................................................................................................................31
10. MPC2000 COMMUNICATIONS ..........................................................................................................................................32
11. MPC2000 PC SOFTWARE.....................................................................................................................................................32
11.1 MPCSET SOFTWARE ...............................................................................................................................................................32
11.2. MPC2000 ENGINEERING PC SOFTWARE..............................................................................................................................32
12. MPC2000 FLASH/CONSTANT MESSAGES .....................................................................................................................32
13. MPC2000 INTERNAL TEST ROUTINES.............................................................................................................................33
14. MPC2000 FAULT FINDING....................................................................................................................................................34
15. MPC2000 THERMAL OVERLOAD PROTECTION..........................................................................................................35
16. MPC2000 INSTALLATION....................................................................................................................................................39
16.1 CASING........................................................................................................................................................................................39
16.2. MPC2000 TERMINATIONS......................................................................................................................................................40

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1. Introduction
The MPC2000 Goldstart Motor Protection Controller is a highly sophisticated microprocessor based motor protection
and control unit, specifically designed to be used on motors with full load currents upto 2000 Amps, at any voltage
and as an integral part of any type or manufacture of Motor Control Centre. All of the latest features are included in
the MPC2000 to allow total control, protection and monitoring of motor starters either by direct hard wire inputs or via
the RS485 serial port.
The MPC2000 can be used to control Direct on Line, Star-Delta, Reversing and Two Speed motor starters and by the
use of RMS current sampling, enables the MPC2000 to be used in conjunction with A.C. Variable speed drives or Soft
Starters, without any affect on the protection performance.
The MPC2000 monitors current, voltage and temperature inputs to provide the most comprehensive motor protection
package ever produced by P & B Engineering. This combined with all the necessary control and monitoring functions
and a high speed communications facility all within a small easily installed package at a cost which is less than
previously charged for a sophisticated microprocessor motor protection relay, make the MPC2000 the most attractive
Motor Protection and Control device available today.
All hard wired control inputs are connected to, the MPC2000 via optically isolated inputs to enable all starting,
stopping and tripping commands to be carried out by the MPC2000. Status of all individual hard wired contacts is also
provided both locally via the liquid crystal display and remotely via the RS485 communications port.
All MPC2000 setting parameters are programmed independently for each unit via the integral keypad and liquid crystal
display on the front plate or via the RS485 communications port and the IBM PC based MPCSET software package
available with the MPC2000.
During operational conditions the LCD also gives access to accurate running, statistical and fault data such as;
Phase Volts, Phase Amps, thermal capacity, Time to Trip, Phase unbalance, Motor hours run, number of starts and
many more.
Light Emitting Diodes mounted on the front plate give visual indication of the motor status such as Motor Running,
Motor Stopped, Alarm or Trip conditions etc.
The MPC2000 can be supplied with Power Indication as an option. This gives Power (Watts and VA) and Power
Factorread-outs in the measured data page.
Flexible high speed control via PLC or DCS systems is obtained through the MPC2000's RS485 communications port,
allowing computer access to full control and monitoring of motor data, including : running data, motor statistical data
and control input status.
All MPC2000 protective functions can be individually configured to enable or disable tripping and alarm functions,
enabling protection to be simplified for the very lowest motor ratings. In addition each protective function can be set
to allow self or manual reset after alarm or trip and manual reset can be set to allow resets after an alarm or trip to be
made locally, remotely or by authorised personnel only.
A unique 'Protection Only' mode enables the MPC2000 to be installed for protection only purposes, this requires only
conventional current transformer and trip output wiring, enabling simple installation into existing equipment with
minimum wiring modifications. This allows users to take full advantage of the enhanced protective capability and the
RS485 communication facilities provided by the MPC2000.

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2. Summary of MPC2000 Features
2.1 Control Functions
Full Control of:
Direct on Line Motor Starters
Direct on line Reversing Motor Starters
Direct on Line 2 Speed Motor Starters
Star/Delta Motor Starters
Undervoltage Dip Restart Facility
Motor Starts Limitation
2.2 Protective Functions
Voltage Based:
3 Phase Undervoltage Protection
3 Phase Overvoltage
Phase Sequence Protection
Phase Loss Protection
Current Based:
Thermal Overload Protection
Load increase Alarm
Thermal Capacity Pre-Alarm
Locked Rotor/Stall Protection
2 Stage Undercurrent Protection
High Set Overcurrent Protection
Low Set Overcurrent Protection
2 Stage Current Unbalance Protection
Excess Starting Time Protection
2 Stage Earth Fault Protection
Excess No of Starts Protection
RTD/Thermistor Based:
3 Channel RTD/Thermistor Temperature Protection
5 Channel RTD/Thermistor Temperature Protection (Option)
2.3 Displayed Data
Measured Data
Both Phase Volts and Line Volts
Phase Currents
Earth Fault Current
Total Real Power (Optional)
Total VA Power (Optional)
Power Factor (Optional)
RTD/Thermistor Channel resistance

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Calculated Data
Motor Load -Percentage FLC
Thermal Capacity Used
Time to Trip
Time to Start
Unbalance Current
Logic Inputs Status
Motor Available Indication
Individual Status of all Input Contacts
Statistical Data
Motor Hours Run
Number of Motor Starts
No of Motor Trips
Last Start Time
Last Peak Starting Current
Fault Data
Last Fault
Last Alarm
Phase Currents at Time of Trip
Earth Fault Current at Time to Trip
Phase Volts at Time of Trip
2.4 Features
LCD Display for Setting Parameters and Displayed Data
Functional Keypad enables settings to be made independent of communications.
IBM PC based MPCSET software enables Setting Parameters to be configured via RS485 Port.
All functions operate fully independently of communications
Non Volatile Memory for all setting parameters calculated, statistical and fault data
Full self diagnostics and internal watchdog facility
RS485 port enables full control and monitoring by remote DCS/PLC systems
3. Technical Specification
3.1 Technical Data
3.1.1 Auxiliary Power Supply
AC Nominal: 110V AC, Range: 80 -135V AC
240V AC, Range: 160 -270V AC
DC [optional] 80-265V DC
Frequency: 45 -65 Hz
Maximum Power Consumption: 6 -8VA

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3.1.2 Phase Current Inputs
Method: True RMS, Sample time 0.5mS
Range: 0.05 to 12 x Phase CT Primary Amps
Full Scale 12 x Phase CT Primary Amps setting
Accuracy: +/-1.5% for 0.9 to 1.5 x CT Primary
+/-5% above 1.5 x CT Primary
+/-3% + 0.02 below 0.9 x CT Primary
3.1.3. Earth Fault Current Inputs
Method: True RMS, sample time 0.5mS
Range: 0.05 to 1.0 x E/F CT Primary
Full Scale: 1.0 x E/F CT Primary Amps Setting
Accuracy: +/-1.5% of Full Scale
3.1.4. Line Voltage Inputs
Method: True RMS, sample time 0.5mS
Without VT Transformer
Range: 90 -660V AC
Accuracy: +/-1.0% of Full Scale
With VT Transformer
Range: 90 -660V x (VT Primary/VT Secondary)
Limited to 25kV
Accuracy: +/-1.0% of Full Scale
3.1.5. Thermistor/RTD Inputs
Time Delay: 0.5 +/-0.2 seconds
Thermistors
Range: 0.1 -30 Kilo-Ohms
Accuracy: +/-0.1 Kilo-Ohm up to 5 Kilo-Ohm
+/-3% above 5 Kilo-Ohm
RTD's
Range: 100 to 240 Ohms
Accuracy: +/-3%
Max. Wire Resistance: 25 Ohms
3.1.6. Overload Alarm and Trip Curves

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Fault Time Accuracy: +/-1 second up to 10 seconds
+/-1 second +/-2% above 10 seconds
Threshold Current Level: Overload Setting +/-1.5%
3.1.7. Current Unbalance Alarm and Trip
Method: Unbalance = 100 x (Imax -Imin) / Ir %
Where Imax = max. of 3 phase currents
Imin = min. of 3 phase currents
Ir = Larger of Imax or Motor FLC
Alarm
Threshold Unbalance Level: 50% of Unbalance current +/-2%
Fixed Time Delay Accuracy: 1.0 +/-0.5 seconds
Trip Curves
Threshold Unbalance Level: Unbalance Current Setting +/-2%
Trip Time Accuracy: +/-1 second up to 10 seconds
+/-1 second +/-2% above 10 sec.
3.1.8. Fault Time Delays
Accuracy: +/-0.5 seconds or +/-2% of time
Exceptions
High Set Over-current: -0.1 to +0.2 sec. up to 1 second
Earth Fault Trip: -0.1 to +0.2 sec. for less than
1 second delayTotal Run Time
Accuracy: +/-2%
3.1.9. Relay Contacts
Rated Load: 8A @ 250V AC/8A @ 30V DC (Resistive)
6A @ 250V AC/3A @ 30V DC (Inductive)
Maximum Operating Voltage: 280V AC, 125V DC
Maximum Operating Current: 8 Amps
Minimum Permissible Load: 5V DC, 100mA
Note: AC Inductive load PF = 0.4
DC Inductive Load L/R = 7mS
3.1.10. Dielectric Strength
2000V AC for 1 minute, between ground and:

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* Current Inputs
* Voltage Inputs
* Auxiliary Power Supply, with 1000pF Suppression Capacitors removed
* Control Terminals, with 1000pF Suppression Capacitors removed.
3.1.11. Auto Restart Circuitry
Accuracy: +/-20%
3.2. MPC2000 IMMUNITY AND EMISSIONS TESTS
The MPC2000 was successfully tested at the ERA Technology Centre in Leatherhead on the 7th April 1992 to
comply with the European Standards on Emissions (EN50081-1) and Immunity (EN50082-2).
4. MPC2000 Schematic Diagrams
The following diagrams show typical installation schematic diagrams of the MPC2000 unit when used for both
Protection and Control and when used as a Protection Only device.
The following points should be noted:
Although not shown on the diagrams it is recommended that the 3 phase input voltage should be fused after the take
off point from the system voltage or in the case of HV systems where a voltage transformer is used the secondary
should be also be fused.
When using the residually connected Earth Fault scheme it may be neccessary to fit a swamping resistor between the
common connection and the earth connection. It is generally advisable to use Core balance ct's whenever possible.
If the internally mounted Emergency Stop pushbutton is installed, it may be beneficial, so the MPC2000 reads
Emergency Stop rather than Hard Wired Stop, to connect externally the output contacts 64&65 to the External
Emergency Stop input terminals 35,12 in addition to hard wiring the output to the contactor closing circuit.
For Star/Delta starters with a 3 contactor configuration the Alarm relay terminals 50,51,52 is designated to control the
Run contactor.
The schematics shown are for 1 Amp secondary CT's, for CT's with a 5 Amp secondary the terminals 82,85,88 & 91
should be moved to terminals 83,86,89 & 92 respectively.

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N
44 45 46 47 48 49
26
3
24
1
25
2
33
10
27
4
28
5
34
11
29
6
30
7
31
8
32
9
13
36 37
14
15
38 39
16
17
40 41
18
35
939291908988878685848382
L1
L2
L3
N(Not always available)
78
80
79
81
77
76
75
74
73
72
71
70
69
68
67
66
23
22
21
N
L3
L2
L1
(-)
(+)
52
51
50
55
54
53
MPC2000 WIRING DIAGRAM
MPC2000
68
72
76
69
73
77
67
71
75
68
72
76
69
73
77
616263
12
64
65
CT4CT3CT2CT1
82 83 8485 86 87 88 89 9091 92 93
42 19 2043
1A 5A C 1A 5A C 1A 5A C 1A 5A C
1A 5A C 1A 5A C 1A 5A C 1A 5A C
NOTE:
RELAY SHOWN WIRED FOR 1 AMP
CT SECONDARIES
SWAMPING
RESISTOR
STOP [NC]
START CONTACTOR A [NO]
START CONTACTOR B [NO]
PLANT INTERLOCK [OPEN=LOCKED OUT]
LOCAL/REMOTE [OPEN=LOCAL]
PLC/SERIAL PORT [OPEN=PLC]
AUTHORISED KEY [CLOSED=AUTHORISED]
PLC RESET [NO]
PLC CONTROL A [OPEN=STOP]
PLC CONTROL B [OPEN=STOP]
SPEED SWITCH [OPEN=HIGH]
CONTACTOR A STATUS
CONTACTOR B STATUS
ISOLATOR
EXTERNAL EMERGENCY STOP [NC]
ALTERNATIVE RESIDUAL FAULT CONNECTION
EXTERNAL FAULT 3
EXTERNAL FAULT 2
OR SYSTEM TEST
[SET BY DIP SWITCH 1]
DIP SWITCH 1
ON = TEST FACILITY AVAILABLE
OFF = EXTERNAL FAULT 3
CONTACTOR BCONTACTOR A
STOP B
STOP A
110/240V AC
[80-265V DC
OPTIONAL]
INTERNAL
POWER
SUPPLY ON
LOGIC SUPPLY
ALT. AUX POWER SUPPLY
3 THERMISTOR OR PT100 INPUTS
DIP SWITCH SETTINGS
ON [THERMISTOR]
OFF [RTD]
CT1 CT2 CT3 CT4
MOTOR
RS485 SERIAL PORT
SHIELD
SCREEN
MEASURMENT
VOLTAGES
SCREEN
SCREEN
AUX 2 RELAY [TRIP]
AUX 1 RELAY [ALARM]
GND
INTERNAL EMERGENCY STOP
OPTIONAL OR KEY SWITCH
THERMISTOR
[0.1K-30K]
PT100
[100-2400]
MAIN CONTACTOR
CONTROL
VOLTAGE
STOP B
STOP A
CONTACT SHOWN IN
DE-ENERGISED STATE
NOTE TERMINALS 74,70,
66 & 21 MUST BE CONNECTED
TO THE EARTH STUD
TERMINAL 63