Rockwell Automation Allen-Bradley E3 User manual

E3 and E3 Plus Solid-State
Overload Relay
Quick Start Guide
(Bulletins 193 and 592)
QUICK ST
A

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Publication 193-QR003B-EN-P - October 2009
Important User Information
Because of the variety of uses for the products described in this publication, those responsible
for the application and use of this control equipment must satisfy themselves that all
necessary steps have been taken to assure that each application and use meets all performance
and safety requirements, including any applicable laws, regulations, codes, and standards.
The illustrations, charts, sample programs and layout examples shown in this guide are
intended solely for purposes of example. Since there are many variables and requirements
associated with any particular installation, Rockwell Automation does not assume
responsibility or liability (to include intellectual property liability) for actual use based upon
the examples shown in this publication.
Rockwell Automation publication SGI-1.1, Safety Guidelines for the Application, Installation
and Maintenance of Solid-State Control (available from your local Allen-Bradley distributor),
describes some important differences between solid-state equipment and electromechanical
devices that should be taken into consideration when applying products such as those
described in this publication.
Reproduction of the contents of this copyrighted publication, in whole or part, without
written permission of Rockwell Automation, is prohibited.
ATTENTION
!
This guide does not replace the User Manual, publication
193-UM002_-EN-P, and is intended for qualified service personnel
responsible for setting up and servicing these devices. You must have
previous experience with and a basic understanding of electrical
terminology, configuration procedures, required equipment, and safety
precautions. The user manual can be downloaded from http://
literature.rockwellautomation.com.

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Publication 193-QR003B-EN-P - October 2009
General Precautions
In addition to the specific precautions listed throughout this manual, the following general
statements must be observed.
IMPORTANT
The purpose of this publication is to serve as a guide for proper
installation. The National Electrical Code and any other governing
regional or local code overrules the information in this publication.A
hazard of personal injury/equipment damage exists if codes are
ignored during installation. Rockwell Automation cannot assume
responsibility for the compliance or proper installation of the E3
Overload Relay or associated equipment.
IMPORTANT
Only personnel familiar with the E3 Overload Relay and associated
machinery should plan to install, start up, and maintain the system.
Failure to comply may result in personal injury/equipment damage.
IMPORTANT
An incorrectly applied or installed E3 Overload Relay can result in
damage to the components or reduction in product life. Wiring or
application errors, such as incorrectly configuring the FLA Setting,
supplying incorrect or inadequate DeviceNet supply voltage,
connecting an external supply voltage to the input or thermistor
terminals, or operating/storing in excessive ambient temperatures may
result in malfunction of the E3 Overload Relay.
IMPORTANT
The E3 Overload Relay contains ESD (electrostatic discharge)
sensitive parts and assemblies. Static control precautions are required
when installing, testing, servicing, or repairing this assembly.
Component damage may result if ESD control procedures are not
followed. If you are not familiar with static control procedures, refer
to Allen-Bradley publication 8200-4.5.2, Guarding Against Electrostatic
Damage, or any other applicable ESD protection handbook.

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Introduction
Follow these steps to successfully commission the E3 Overload Relay:
Table 1: Commissioning Procedure
Step Description
1 Hardware Installation
2 Wiring Installation
– Typical Motor Connections
– External Current Transformer Applications (193-EC_ZZ or 592-EC_ZZ)
– External Ground Fault Sensor Applications (193-EC3_ _ , 592-EC3_ _ and
193-EC5_ _ , 592-EC5_ _)
3 DeviceNet Commissioning
4 Setup Requirements
Setup for Bulletin 193 or 592-EC1/EC2/EC3/EC5 Overload Relay
– Protective Trip and Warning Summaries
– Parameter Group Listing
Setup for Cat. No. 193-EC4 Current Monitor Relay
– Trip and Warning Summaries
– Parameter Group Listing

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Publication 193-QR003B-EN-P - October 2009
Hardware Installation
The following figures illustrate the starter assembly instructions.
Starter Assembly Instructions
Figure 1: 100-C09…C43 Starter Assembly Instructions (for use with Cat. Nos.
193-EC_ _B and -EC_ _D)
1
2
CLICK
3
/tN
22 lb-in.

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Publication 193-QR003B-EN-P - October 2009
Figure 2: 100-C60…C85 Starter Assembly Instructions (for use with Cat. No.
193-EC_ _E).
1
2
/tN
35 lb-in.

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Publication 193-QR003B-EN-P - October 2009
Figure 3: 100-D95...D860 Starter Assembly Instructions (for use with Cat. Nos.
193-EC_ _F, 193-EC_ _G, and 193-EC_ _H).

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Publication 193-QR003B-EN-P - October 2009
Wiring Installation
Typical Motor Connections
Refer to the product nameplate or user manual for power lug termination information
including:
•Terminal wire size and torque specifications
•Maximum wire lengths
•Lug kit catalog numbers (108…1250 A)
For reliable input signal processing, input wiring should be routed in raceways separate from
power cabling.
Terminal Designations
Figure 4: E3 and E3 Plus Feature Overview
E3 PLUS
LED Status Indicators
DeviceNet Port
Input Terminals
Test/Reset Button
Node Address Switches
(Series B and later)
Output and PTC Terminals
Ground Fault Sensor Input
Voltage Input Module
Connection
(193/592 EC5 only)

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Publication 193-QR003B-EN-P - October 2009
Control Terminals
The following table defines the E3 Overload Relay control terminal designations.
➊Features are available only with the E3 Plus Overload Relay (cat. nos. 193/592-EC2and 193/592-EC3).
➋Available only on cat. nos. 193/592-EC5_ _.
➌ An earth ground connection to this terminal will assist in obtaining compliance with electromagnetic
compatibility requirements.
➍ The use of shielded cable is recommended for the positive PTC thermistor circuit to assist in obtaining
compliance with electromagnetic compatibility requirements.
➎ Available only on cat. nos. 193/592-EC3_ _ and 193/592-EC4_ _.
DeviceNet Terminals
The following table defines the DeviceNet connector terminal designations.
Table 2: Control Terminal Designation
Terminal
Designation Reference Description
1 IN 1 General-purpose sinking input number 1
2 IN 2 General-purpose sinking input number 2
3 IN 3 General-purpose sinking input number 3 ➊➋
4 IN 4 General-purpose sinking input number 4 ➊➋
5V+ +24V DC supply for inputs
6V+
7 IN 5 General-purpose sinking input number 5 ➋
8 IN 6 General-purpose sinking input number 6 ➋
End Earth Ground ➌
13/14 OUT A Output A
23/24 OUT B Output B ➊➋
95/96 Trip Relay Trip Relay
IT1/IT2 PTC Thermistor (PTC) input ➊➍
S1/S2 — External ground fault sensor input ➋➎
Table 3: DeviceNet Terminal Designation
Terminal Signal Function Color
1 V- Common Black
2 CAN_L Signal Low Blue
3 Drain Shield Non-insulated
4 CAN_H Signal High White
5 V+ Power Supply Red

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Grounding
The following grounding recommendations are provided to ensure electromagnetic
compatibility compliance during installation:
•The earth ground terminal of the E3 Overload Relay shall be connected to a solid
earth ground via a low-impedance connection
•Installations employing an external ground fault sensor shall ground the cable shield
at the sensor with no connection made at the E3 Plus Overload Relay
•The PTC thermistor cable shield shall be grounded at the E3 Plus Overload Relay
with no connection made at the opposite end
Wiring Diagrams
Figure 5: Three-Phase D.O.L & Single-Phase Wiring Diagrams
ATTENTION
!
When working on energized circuits, do not rely on the voltage and
current information provided by the E3 and E3 Plus for personal
safety. Always use a portable voltage or current measurement device
and measure the signal locally.
E3/E3Plus
L1 L2 L3
2/T1 4/T2 6/T3
E3/E3Plus
L1 L2 L3
2/T1 4/T2 6/T3
L1
2/T1 4/T2 6/T32/T1 4/T2 6/T3
2/T1 4/T2 6/T3
M
T1
E3/E3Plus
L1
2/T1 4/T2 6/T3
M
T1 T2 T3
S.C.P.D.
Three-Phase Direct-On-Line
Wiring Diagram
Single-Phase Full-Voltage
Wiring Diagram
T2
L2 L3 L2
E3/E3Plus
L1 L2 L3
Voltage Input Module
(For 193/592-EC5 only)
L1 L2
Voltage Input Module
(For 193/592-EC5 only)

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External Current Transformer Application (Cat. No. 193-EC_ZZ)
E3 and E3 Plus Overload Relays (Cat. No. 193-EC_ZZ) are designed for use with separately
mounted, customer-supplied current transformers (CTs) as required in higher-current
applications. The FLA setting range is 9…5000 A for these units, with a legal setting range
per the user’s manual. Parameter 78, CT Ratio, is provided for setting the current transformer
ratio to be installed.
Current Transformer Specifications
The 193-EC_ZZ Overload Relays are intended for use with a CT having a secondary current
rating of 5 A. The installer shall provide one CT for each motor phase and shall connect the
CT secondary leads to the appropriate E3 Overload Relay power terminals as shown in Figure
7: on page 13. The CT shall have an appropriate ratio rating as detailed in the user’s manual.
Additionally, the CT shall be selected to be capable of providing the required VA to the
secondary load, which includes the E3 Overload Relay burden of 0.1 VA at the rated
secondary current and the wiring burden.
Finally, the CT shall be rated for protective relaying to accommodate the high inrush currents
associated with motor startup and shall have an accuracy of ≤±2% over its normal operating
range.
IMPORTANT
Parameter 27, Single/Three Ph, should be set to single-phase for
single-phase devices and three-phase for three-phase devices.
IMPORTANT
In single-phase devices, traditional single-phase wiring (connecting
T2 to L3) will result in a vector imbalance of current flowing through
the E3 Plus Overload Relay. This will result in inaccurate ground fault
reporting and protection.
ANSI (USA) Class C5 B0.1
CSA (Canada) Class 10L5
IEC (Europe) 5 VA Class 5P10
IMPORTANT
The improper selection of a current transformer can result in the E3
Overload Relay reporting inaccurate motor operational data and
possible motor damage. The selected current transformer must be
rated for protective relaying applications.

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Publication 193-QR003B-EN-P - October 2009
Installation Instructions
Cat. No. 193-EC_ZZ Overload Relays are designed to be installed in cat. no. 193-ECPM2
panel mount adapters and connected to separately mounted current transformers. For a panel
mount adapter assembly, refer to the instructions included with the panel mount adapter. The
E3 Overload Relay must be mounted a distance equal to, or greater than, six times the cable
diameter (including insulation) from the nearest current-carrying conductor or current
transformer. For applications employing multiple conductors per phase, the diameter of each
cable should be added and multiplied by six to determine the proper placement distance for
the E3 Overload Relay.
Figure 6: Cat. No. 193-EC_ZZ Overload Relay Mounting Placement
IMPORTANT
Placement of the E3 Overload Relay closer than the recommended
distance of six times the cable diameter may compromise its current
reporting and protection capabilities.
6x
6x
OR
Pr
i
mar
y
C
urren
t
Tr
a
n
s
f
o
rm
e
r
s
E3
O
verloa
d
Rela
y

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Publication 193-QR003B-EN-P - October 2009
Figure 7: External CT Connection Diagrams
External Potential (Voltage) Transformer Application
(Cat. No. 193/592-EC5_ _)
The E3 Plus Overload Relay Catalog Number 193/592-EC5_ _ can be used with external
step-down potential transformers (PTs). The PT ratio is programmed into the E3 Plus by
entering the primary winding rating into Parameter 289, PT Pri, and the secondary winding
rating into Parameter 290, PT Sec. The voltage mode is also programmed into the E3 Plus by
selecting the appropriate mode in Parameter 156, Volt Mode. The E3 Plus will support Wye,
Delta, and Open Delta voltage modes with potential transformers.
IE
C
NEMA
L1
L2
L
3
L1
L2
L
3
E
3
E
3
M
M
K1
T1
/2
T1
T2
T
3
T2
/4
T3/6
T
L1
/1
L2
/3
L3/5
L
T1
/2
T2
/4
T
3/6
L1
/1
L2
/3
L
3/5
Primar
y
C
urren
t
Tr
a
n
s
f
o
rm
e
r
s
Primar
y
C
urren
t
Tr
a
n
s
f
o
rm
e
r
s

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Publication 193-QR003B-EN-P - October 2009
Figure 8: External PT Connection Diagrams
Load
L1 L2 L3
Line
L1 L2 L3
Delta Connection with PTs
Load
L1 L2 L3
Line
N/GND
L1 L2 L3
Wye Connection with PTs
Load
L1 L2 L3
Line
L1 L2 L3
Open Delta Connection with PTs

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External Ground Fault Sensor Application
(Cat. Nos. 193/592-EC3_ _, 193/592-EC4_ _, and 193/592-EC5_ _)
Cat. Nos. 193/592-EC3_ _, 193/592-EC4_ _, and 193/592-EC5_ _ E3 Plus Overload Relays
are intended to provide ground fault protection when used with the cat. no. 193-CBCT_
external ground fault (core balance) sensor. The ground fault sensor mounts separately from
the E3 Plus Overload Relay and must be placed within three meters of the relay. The
customer-supplied cable for wiring the ground fault sensor to the E3 Plus Overload Relay
should meet the specifications outlined in Table 1.9 on page 15.
Power Cable Installation Instructions
1. All power cables (including the neutral when used) must pass through the sensor
window. The equipment ground conductor (the conductor used to carry the
non-current-carrying metal parts of equipment, as defined by Article 100 of the
NEC), must not pass through the sensor window.
2. The power cables through the sensor window should be straight, tightly bundled,
centered in the window, and perpendicular to the sensor for a length equal to, or
greater than, six times the cable diameter (including insulation) from the sensor.
3. All other conductors with available currents in excess of 1,000 A should be placed a
distance equal to, or greater than, six times the cable diameter (including insulation)
from the sensor.
4. The power cables of the branch circuit to be protected by the E3 Plus Overload Relay
must not be grounded on the load side of the ground fault sensor.
5. If the power cables are enclosed in a conducting jacket, the jacket must be grounded
on the line side of the sensor. The jacket must not pass through the sensor window,
but must be cut at the window and joined with a conductor that passes outside the
sensor window.
6. The power system may be solidly grounded or grounded through an impedance at its
source as long as the impedance allows a magnitude of fault current to flow that is
within the 1…5 A operational range of the E3 Plus Overload Relay (193/592-EC2_
_) or the 20 mA…5 A operational range of the E3 Plus Overload Relay (193/
592-EC3_ _, 193/592-EC4_ _, and 193/592-EC5_ _).
Table 1.9 Ground Fault Sensor Terminals (S1 and S2)
Wire type Shielded, twisted pair
Cross section 0.2…4.0 mm2(#24…12 AWG)
Torque 0.55 N•m (5 lb-in.)

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Publication 193-QR003B-EN-P - October 2009
Figure 10: Ground Fault Sensor Mounting Placement
Figure 11: Power Cable Configuration — Two Cables per Phase
Figure 12: Ground Fault Sensor Wiring to the E3 Plus Overload Relay
IMPORTANT
The shield of the twisted pair cable must be connected to earth
ground at the sensor, with no connection made at the E3 Plus
Overload Relay.
Power
Cables
GF Sensor
6x
6x
90˚
L1
L2 L2
L3
L3 L1
1
1
The spacer is a short (approximately 10 times
the cable diameter in length) piece of cable
with no connections to any terminal.
MOTOR
L1 L2 L3
S1
S2
S1
S2
193-CBCT_
Ground
Fault
Sensor
E3 Plus
Overload Relay

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DeviceNet Node Commissioning
Overview
E3 Overload Relays are shipped with a default software node address (MAC ID) setting of 63
and the data rate set to Autobaud. Each device on a DeviceNet network must have a unique
node address which can be set to a value from 0…63.
Keep in mind, most DeviceNet systems use address 0 for the master device (scanner) and
node address 63 should be left vacant for introduction of new slave devices. The node
address and data rate for series B or later, E3 Overload Relays can be changed using software
or by setting the hardware switches that reside on the front of each unit. While both methods
yield the same result, it is good practice to choose one method and deploy it throughout the
system.
IMPORTANT
The following recommendations are intended to ensure a trouble-free
startup and operation:
1. Use the node commissioning tool in RSNetWorx or the
DeviceNet configuration terminal (cat. no. 193-DNCT) when
modifying the E3 node address. Do not use the General tab found
in the product window in RSNetWorx. The node commissioning
tool ensures the device goes through a hard reset and requires
the user to upload the most current parameter information from
the device prior to making configuration changes.
2. Ensure you have the most current configuration information
prior to saving an RSNetWorx configuration file.
3. If you intend to employ the ADR function of the DeviceNet
scanner, ensure the device configuration is as you intend it
BEFORE saving it to memory.
4. Be aware the Restore Device Defaults button in RSNetWorx will
reset the E3 Overload Relay node address setting to 63. For
Series B or later devices, the hardware node address switches take
precedence over the software node address setting.

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Publication 193-QR003B-EN-P - October 2009
Figure 13: Node Address Switches
Note: For node address switch values in the range of 0…63, cycle power to the E3 Overload Relay to
initialize the new setting.
Setup Requirements
Setup for Cat. Nos. 193/592-EC1/EC2/EC3/EC5 Overload Relays
After the E3 Overload Relay is installed according to the guidelines specified in this manual,
apply power to the overload relay’s DeviceNet connector. After applying power, the following
sequence should occur:
1. The Trip relay should close 2.35 seconds later and the TRIP/WARN LED will not
flash (unless a Non-Volatile Fault previously existed or a fault condition is present).
2. At the same time, the NETWORK STATUS LED should flash green for
approximately two seconds, then red for a 1/4 second. If autobaud is enabled and the
E3 Overload Relay is connected to an active network, the green LED will continue to
flash once the baud rate has been determined. If the E3 Overload Relay is not
connected to an active network, the LED will not continue to flash.
3. Once the E3 Overload Relay has been allocated by a master, the NETWORK
STATUS LED will turn solid green.
After being powered up, use the DeviceNet Configuration Terminal (Cat. No. 193-DNCT) in
order to set up the parameters. There are five basic parameters that need to be established
before using the protective functions. These parameters are listed under the OVERLOAD
SETUP menu and include: Single/Three Phase, Full Load Current (FLA) Setting, Trip Class,
Overload/PTC Reset mode, and Overload Reset Level. (Note: You will need to program
additional parameters when customer-supplied CTs are used.)
Once these parameters are set, the E3 Overload Relay is functional. Use the ADVANCED
SETUP menu to set other parameters per the specific application requirements.
Table 2: Node Address Setting
Switch Settings Description
0…63 The node address setting is determined by the switch values when set in this range.
64…99 For switch settings in this range, the node address setting is determined by the software
setting using the RSNetWorx for DeviceNet configuration tool.
99 Factory default setting.

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Publication 193-QR003B-EN-P - October 2009
Protective Trip/Warning Summaries & Parameter Group Listing
(Cat. Nos. 193/592-EC1/EC2/EC3/EC5)
Table 3: Trip Summary
Trip
Function Trip Enable
Factory
Default
Trip Level Settings Trip Delay Settings Inhibit Time
Settings ➊
Range Default Range Default Range Default
Overload Enabled ➋➋Trip Class
5…30 Trip Class 10 ——
Phase Loss Enabled ➌➌0.1…25.0 s 1.0 s 0…250 s 0 s
Ground Fault
(193/592-EC2) Disabled Internal 1…5 A 2.5 A 0.0…25.0 s 0.5 s 0…250 s 10 s
Ground Fault
(193/592-EC3) Disabled External 0.02…5 A ➍2.5 A 0.0…25.0 s 0.5 s 0…250 s 10 s
Stall Disabled 100…600% ➎600% ➎0…250 s
➎10 s➎——
Jam Disabled 50…600% 250% 0.1…25.0 s 5.0 s 0…250 s 10 s
Underload Disabled 10…100% FLA
➏50% 0.1…25.0 s 5.0 s 0…250 s 10 s
PTC Disabled — — — — — —
Current
Imbalance Disabled 10…100% 35% 0.1…25.0 s 5.0 s 0…250 s 10 s
Comm Fault Enabled — — — — — —
Comm Idle Disabled — — — — — —
Remote Trip Disabled — — — — — —
Voltage Input
Module
Hardware Fault
➐
Disabled — — — — — —
Undervoltage
L-L ➐Disabled 0...65535 100 0.1…25.0s 1.0 s 0…250s 10 s
Overvoltage L-L
➐Disabled 0...65535 500 0.1…25.0s 1.0 s 0…250s 10 s
Voltage
Unbalance ➐Disabled 0…100 75 0.1…25.0s 1.0 s 0…250s 10 s
Phase Rotation
➐Disabled 1…2 1 — — 0…250s 10 s
Under
Frequency ➐Disabled 0…250 57 0.1…25.0s 1.0 s 0…250s 10 s
Over Frequency
➐Disabled 0…250 63 0.1…25.0s 1.0 s 0…250s 10 s
Under Real
Power ➐Disabled 0…32767 0.1…25.0s 1.0 s 0…250s 10 s
Over Real
Power ➐Disabled 0…32767 0.1…25.0s 1.0 s 0…250s 10 s

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Publication 193-QR003B-EN-P - October 2009
➊The inhibit time setting parameters are applicable to both the trip and warning functions.
➋FLA Setting range and default values are dependent upon the current rating of the product. See the user
manual for more information.
➌Phase loss trip level is factory-set at a current imbalance greater than or equal to 100% and is not
user-adjustable.
➍ Must use Ground Fault Sensors (Cat. No. 193-CBCT_).
➎Stall protection is only applicable during the motor starting sequence. If any phase of current falls below the
programmed Stall Trip Level, stall protection is disabled.
➏ 50…100% for devices with FRN 1.003 and earlier.
➐ Available on 193/592-EC5 only.
Under
Consumed
kVAR ➐
Disabled 0…32767 0.1…25.0s 1.0 s 0…250s 10 s
Over Consumed
kVAR ➐Disabled 0…32767 0.1…25.0s 1.0 s 0…250s 10 s
Under
Generated
kVAR ➐
Disabled -32767…0 0.1…25.0s 1.0 s 0…250s 10 s
Over Generated
kVAR ➐Disabled -32767…0 0.1…25.0s 1.0 s 0…250s 10 s
Under Power
kVA ➐Disabled 0…32767 0.1…25.0s 1.0 s 0…250s 10 s
Over Power kVA
➐Disabled 0…32767 0.1…25.0s 1.0 s 0…250s 10 s
Under Power
Factor Lagging
➐
Disabled -100…0 -90 0.1…25.0s 1.0 s 0…250s 10 s
Over Power
Factor Lagging
➐
Disabled -100…0 -95 0.1…25.0s 1.0 s 0…250s 10 s
Under Power
Factor Leading
➐
Disabled 0...100 90 0.1…25.0s 1.0 s 0…250s 10 s
Over Power
Factor Leading
➐
Disabled 0...100 95 0.1…25.0s 1.0 s 0…250s 10 s
Table 3: Trip Summary
Trip
Function Trip Enable
Factory
Default
Trip Level Settings Trip Delay Settings Inhibit Time
Settings ➊
Range Default Range Default Range Default