Eaton MP-4000 Instruction Bulletin For Installing, Operating, And Maintaining Download Page 1

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IB02602002E

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IB02602002E

Rev. F

MP-4000 Motor Protection Relay

Instruction Bulletin for Installing, Operating, and Maintaining the

Eaton MP-4000 Motor Protection Relay

Summary of Contents for MP-4000

Page 1: ...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...

Page 2: ...c and or Eaton Corporation s Eaton experience and judgment and may not cover all contingencies If further information is required an Eaton sales office should be consulted Sale of the product shown in...

Page 3: ...6 SP DI 1 5 7 5 7 Page 7 SP DI 2 5 8 5 8 Page 8 SP AREL Settings P8L1 to P8L22 5 8 5 9 Page 9 SP AUX1 Settings P9L1 to P9L25 5 8 5 10 Page 10 SP AUX2 Settings P10L1 to P10L23 5 9 5 11 Page 11 SP A OUT...

Page 4: ...S 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 Commu...

Page 5: ...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 1...

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Page 7: ...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 Cutl...

Page 8: ...000 Gives specific 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...

Page 9: ...out 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 wit...

Page 10: ...ower supply converter 100 150 Vdc 66C2462G01 MPFO 1 1 Meter precut optical fiber link for URTD with connectors 66D2037G01 MPFO 5 5 Meter precut optical fiber link for URTD with connectors 66D2037G02 M...

Page 11: ...I Trip overload measure ment and motor thermal protection model that uses the manufacturer s nameplate data to develop an overload protection curve specifically for the motor being protected When RTD...

Page 12: ...arting the motor while it is spinning in the reverse direction The relay displays the timer countdown from the moment a stop is declared by the relay 2 2 4 Load Shedding The MP 4000 provides a mechani...

Page 13: ...Current 85 to 150 FLA Phase CT Ratio 10 to 4 000 In Ground CT Ratio 10 to 4 000 In Timing Accuracy The greater of 2 5 or 100 ms for current 1 1 X UTC Trip Setting Ranges Ground Fault GF Off 2 to 55 of...

Page 14: ...pe HFBR ELS length precut low loss with connectors Type HBFR EUS length bulk low loss without connectors Type HBFR RLS length standard loss acceptable for 10m 32 8 ft Clock Accuracy Freerunning 1 min...

Page 15: ...t saving any entered settings 4 0 7 Operator Panel LEDs There are 10 LEDs on the operator panel The Protection LED is lit when the MP 4000 is in the Protection mode The MP 4000 provides protection whe...

Page 16: ...e User to change the settings Table 4 3 is a guide for programming it is also a setting record sheet Section 5 contains a description of the Program mode 4 4 History Mode Pressing the History mode pus...

Page 17: ...D Indicators Figure 4 1 MP 4000 Pushbuttons Trip Auxiliary 1 Alarm Auxiliary 2 Program Monitor View Setting Protection Log History Mode Reset Help Display Log Mode History Mode Value RS 232 Connector...

Page 18: ...s 1 IAV XXX AVERAGE CURRENT OF THE THREE PHASES Average RMS current of 3 phase currents in amps 2 IA XXX PHASE A CURRENT IN AMPS Actual ac line motor RMS current 3 IB XXX PHASE B CURRENT IN AMPS Actua...

Page 19: ...TIME Current date and time with display format as programmed 1 HH MM XM CURRENT TIME 12 hour format or or HH MM 24 hour format 2 MM DD YY CURRENT DATE Common format or or DD MM YY European military f...

Page 20: ...GLE Phase angle of negative sequence current 6 I0AG XXXX I0 PHASE ANGLE Phase angle of zero sequence current MONT VPH REAL TIME DATA FROM SEQUENCE VOLTAGE PHASOR MEAUREMENTS 1 VAMG XXXX VA PHASOR MAGN...

Page 21: ...T RATIO NUMERATOR 2 20 of phase CT ratio numerator in 1 increments 5 PAGE 2 SP RTD SETTINGS FOR RTD INPUTS 1 RTD IN C or RTD in F DISPLAYED IN DEGREES C OR F Toggles between RTD IN C and RTD IN F 2 WD...

Page 22: ...LARM EVENTS 1 GFA XXX GROUND FAULT ALARM LEVEL IN OF GROUND CT RATIO NUMERATOR 2 55 OF Ground CT ration numerator OFF 1 increments 2 I2TA XXX I2T ALARM LEVEL IN FULL OF I2T TRIP CAPACITY 60 99 OFF 1 i...

Page 23: ...P MOTOR STOP DETECTION RST DBL RESET DISABLE ZERO SW ZERO SPEED SWITCH TO GET ANY OTHER EMG OVR EMERGENCY OVERRIDE Choose from the seven selections for the function of Discrete Input 1 If ZERO SW is s...

Page 24: ...Toggles between TBS T ON and TBS OFF 12 RTDF ON or RTDF OFF ENABLE INDIVIDUAL RTD CHANNEL FAILURE TO ACTIVATE ALARM RELAY OUTPUT OR DISABLE Toggles between RTDF ON and RTDF OFF 13 RCOM ON or RCOM OFF...

Page 25: ...JAM OFF 7 Choose UL A ON UL T ON or UL OFF ENABLE UNDERLOAD ALARM OR TRIP TO ACTIVATE AUX1 RELAY OUTPUT OR DISABLE Toggles between UL A ON UL T ON and UL OFF 8 Choose UB A ON UB T ON or UB OFF ENABLE...

Page 26: ...T ON or ZSWT OFF ENABLE ZERO SPEED SWITCH TRIP TO ACTIVATE AUX1 RELAY OUTPUT OR DISABLE Toggles between ZSWT ON and ZSWT OFF 25 TBYP ON or TBYP OFF ENABLE TRIP BYPASS TO ACTIVATE AUX1 RELAY OUTPUT OR...

Page 27: ...een RCOM ON and RCOM OFF 15 IOC A ON IOC T ON or IOC OFF ENABLE INSTANTANEOUS TRIP TO ACTIVATE AUX2 RELAY OUTPUT OR DISABLE Toggles between IOCT ON and IOCT OFF 16 PH R ON or PH R OFF ENABLE PHASE REV...

Page 28: ...M and STOP PGM 7 EMRG EN or EMRG DIS EMERGENCY OVERRIDE ENABLE EMRG EN ENABLE EMERGENCY OVERRIDE EMRG DIS DISABLE EMERGENCY OVERRIDE Toggles between EMRG EN and EMRG DIS 8 12 HOUR or 24 HOUR SET MONIT...

Page 29: ...MTR RST PUSH RAISE TO ENABLE MOTOR HISTORY RESET PUSH RST PUSH RESET TO EXECUTE RESET OF MOTOR HISTORY OR PUSH RAISE TO NOT RESET Change to PUSH RST and press Reset button or return to MTR RST none 2...

Page 30: ...QUENCY TRIP AND ALARM START DELAY Under Frequency Trip Alarm Start delay 0 60 sec 0 1 sec increments 3 UFTR XXXX UNDERFREQUENCY TRIP RUN DELAY Under Frequency Time Delay 0 60 sec 0 1 sec increments 4...

Page 31: ...0 1 sec increments 7 UVSD XXXX UNDER VOLTAGE TRIP AND ALARM START DELAY Under voltage trip alarm start delay 0 60 sec 0 1 sec increments PAGE 20 SP UPTRP SETTINGS FOR UNDER POWER 1 UPT XXXX UNDERPOWER...

Page 32: ...T ON OFA ON OF OFF ENABLE OVERFREQUENCY ALARM OR TRIP TO ACTIVATE ALARM RELAY OUTPUT OR DISABLE Toggles between OF T ON OF A ON OF OFF 5 Choose UF T ON UF A ON UF OFF ENABLE UNDERFREQUENCY ALARM OR TR...

Page 33: ...RM OR TRIP TO ACTIVATE AUX2 RELAY OUTPUT OR DISABLE Toggles between UF T ON UF A ON UF OFF 6 Choose UP A ON UP T ON UP OFF ENABLE UNDERPOWER ALARM OR TRIP TO ACTIVATE AUX2 RELAY OUTPUT OR DISABLE Togg...

Page 34: ...E OF EVENT Time of highest WMX MBX XXXX MBX XXXX HIGHEST MOTOR BEARING TEMPERATURE IN DEGREES C F Maximum motor bearing temperature monitored since last reset MM DD YY DATE OF EVENT Date of highest MB...

Page 35: ...ING TEMPERATURE TRIPS SINCE LAST RESET Total number of motor bearing temperature trips that occurred since reset MM DD YY DATE OF RESET Date when motor bearing temperature trip function was reset HH M...

Page 36: ...X NUMBER OF VOLTAGE UNBALANCE TRIPS SINCE LAST RESET Total number of voltage unbalance trips that occurred since reset MM DD YY DATE OF RESET Date when voltage unbalance trips function was reset HH MM...

Page 37: ...nction was reset LBA XX LBA XX NUMBER OF LOAD BEARING TEMPERATURE ALARMS SINCE LAST RESET Total number of load bearing temperature alarms that occurred since last reset MM DD YY DATE OF RESET Date whe...

Page 38: ...HH MM SS TIME OF RESET Time when power factor alarms function was reset HIST TOT HISTORY TOTALS FOR MOTOR TRPS TOTAL NUMBER OF TRIPS SINCE RESET Total number of trips that occurred since last reset DA...

Page 39: ...te list of alarms with help messages refer to the alarm conditions in Table 12 2 and the internal diagnostics failure messages in Table 12 4 MM DD YY DATE OF LOGGED EVENT Date that event occurred HH M...

Page 40: ...ENT RTD temperatures at time of trip LT2 XXX LOAD BEARING TEMP 2 IN DEGREES F OR C AT TIME OF EVENT RTD temperatures at time of trip AXT XXX AUXILIARY TEMP IN DEGREES F OR C AT TIME OF EVENT RTD tempe...

Page 41: ...also refer to Subsection 5 1 5 for guidance on CT ratio selection The instantaneous overcurrent trip setting IOC P3L4 must be below 1 130 PCT FLA or 1 600 whichever is less See IOC OUT in Table 5 1 T...

Page 42: ...mage could result 5 1 5 Setting P1L5 Phase Current Transformer Ratio PCT PCT specifies the numerator of the turns ratio of the main phase current transformers Obtain the value from the current transfo...

Page 43: ...ime of a start and assigns the role of a positive sequence to the larger of the two sequence components When the motor runs in reverse any phase current unbalance is displayed with a negative sign Thi...

Page 44: ...ary RTD temperature limit above which the relay trips the motor This trip can also be set to OFF Trip temperature values are in degrees C or F depending on Setting P2L1 above There is one specifically...

Page 45: ...before the trip output occurs Use JMTR to block undesired jam trips for temporary large loads that are normal for the process An example of this would be a heavy load suddenly placed on a conveyor be...

Page 46: ...he oldest starts in the memory are deleted as they age beyond the time limit set in P5L2 If the maximum number of starts is reached within the set time window the relay raises an alarm with STEX A on...

Page 47: ...nction must be enabled ZSW ON Refer to setting P5L11 in the next subsection The MP 4000 requires the zero speed switch to open within LRT 2 one half of locked rotor time setting P1L3 after a start or...

Page 48: ...ngs control the following 22 alarm assignments Any or all can be turned OFF Ground fault alarm or trip I2T alarm or trip Jam alarm or trip Underload alarm or trip Phase unbalance alarm or trip Winding...

Page 49: ...12L18 Page 12 configures overall operation of the MP 4000 5 12 1 Setting P12L1 Configure Trip Relay Output TP MODE1 or TP MODE2 P12L1 selects Mode 1 or Mode 2 MODE 1 The trip relay is normally de ener...

Page 50: ...to be the 12 hour format with AM or PM or the 24 hour military time or international time format 5 12 9 Setting P12L9 Month MONTH P12L9 sets the real time clock month 1 to 12 5 12 10 Setting P12L10 Da...

Page 51: ...testing purposes To use this function 1 Stop the motor first The test is blocked if the motor is running 2 Determine whether the MP 4000 trip relay is configured for MODE 1 or MODE 2 operation Refer...

Page 52: ...cy must remain below the Under Frequency Trip Threshold UFT setpoint before a trip event occurs This timer does not begin until after the Under Fre quency Trip Alarm Start Delay UFSD has timed out 5 1...

Page 53: ...e relay trips 5 20 2 Setting P20L2 Underpower Trip Run Delay UPTR P20L2 sets the number of seconds that the power must be below the Under Power Trip Threshold UPT setpoint before a trip event occurs T...

Page 54: ...ing P22L7 Setting P22L7 allows the Power Factor Alarm or Trip to activate the alarm relay output This function can be disabled by setting this setpoint to OFF 5 23 Page 23 SP UPTRP Settings P23L1 to P...

Page 55: ...etting P25L3 Volt amps Display P25L3 sets the volt amps display to kilo mega or giga 5 25 4 Setting P25L4 3 Phase Watts Display P25L4 sets the 3 phase watts display to kilo or mega 5 25 5 Setting P25L...

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Page 57: ...tion 10 for a description of the various types of optional PONI communications modules that can be used with the MP 4000 Check the I L for the selected PONI to confirm dimensions and com munications n...

Page 58: ...or to terminals 17 and 18 With this connection an alarm is given if the relay or its power supply fails or when any other problems the MP 4000 can actively report arise However if the MP 4000 is de en...

Page 59: ...ctors of the URTD and MP 4000 When using 3 wire shielded cable wire according to the connection guidelines in Table III of the Universal RTD Module IL 17367 The 3 wire shielded cable should be 16 AWG...

Page 60: ...Page 6 www eaton com IB02602002E MP 4000 Figure 6 2 Panel Cutout Dimensions...

Page 61: ...602002E 6 72 17 07CM 10 25 26 04CM 0 50 1 27CM Protection Program Trip Alarm Aux 1 Aux 2 Reset Help Monitor View Setting History Log Page Line Value Prog Emrg Over ride MP 4000 Figure 6 3 Faceplate Di...

Page 62: ...Page 6 www eaton com IB02602002E MP 4000 Figure 6 4 MP 4000 Case Depth Dimensions DIMENSIONS IN INCHES CM...

Page 63: ...www eaton com Page 6 MP 4000 IB02602002E Figure 6 5 Universal RTD Module Mounting Dimensions DIMENSIONS IN INCHES CM...

Page 64: ...Page 6 www eaton com IB02602002E MP 4000 Figure 6 6 Rear Panel Terminals...

Page 65: ...6 MP 4000 IB02602002E Figure 6 7 MP 4000 Typical CT PT Circuits and Motor Control Wiring Note Voltage Inputs Are 120 Nominal Limited to 150 Vac Figure 6 8 MP 4000 Typical CT PT Circuits and Motor Cont...

Page 66: ...Page 6 10 www eaton com IB02602002E MP 4000 Figure 6 9 MP 4000 Typical CT and PT Circuits and Motor Control Wiring Open Delta Figure 6 10 Typical AC Supply and URTD Wiring...

Page 67: ...www eaton com Page 6 11 MP 4000 IB02602002E Figure 6 11 Alternatives for Discrete Input Wiring...

Page 68: ...HRINK TUBING OR ELECTRICAL TAPE TO INSULATE 2 RTD CONNECTIONS BETWEEN INDIVIDUAL RTD s SHOULD BE MADE AT THE MOTOR OR THE MP 4000 3 TERMINAL16 OR 32 ON THE RTD MODULE SHOULD BE CONNECTED TO AN EARTH G...

Page 69: ...to relay 1 2 3 4 5 1 2 3 4 Turn ac power on to the MP 4000 and to the separate remote contact wetting source if one is used Usually the contacts to be read by the discrete inputs are energized from te...

Page 70: ...dress conflicts on the network multiple devices set to the same address or incorrect setting of the address switches on the PONI 9 10 11 12 13 14 15 16 17 18 1 2 3 4 5 1 2 3 4 7 6 Entering Relay Setti...

Page 71: ...of the Monitor mode are within approximately 5 of the ammeter values If the current during this test is well below FLA or if the CTs are far from the optimum ratio errors may be larger This test is i...

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Page 73: ...umber of starts per set time maximum number of consecu tive cold starts and minimum time between stop and start anti backspin protection Many of these functions also have separate alarm thresholds to...

Page 74: ...e phase currents produce torques in the rotor just like positive and negative sequence currents In particular the 7th and 13th and certain higher harmonics act like positive sequence The 5th 11th and...

Page 75: ...www eaton com Page 8 MP 4000 IB02602002E Figure 8 3 Unbalanced Motor Current Example Figure 8 2 Torques from Sequence Currents Figure 8 1 Motor Phase Currents from Three Main Motor Phase CTs...

Page 76: ...Page 8 www eaton com IB02602002E MP 4000 Figure 8 4 Positive Sequence Component Calculation Figure 8 5 Negative Sequence Component Calculation...

Page 77: ...hes the User set level between 60 and 100 full Without manual process load reduction automatic process load shedding refer to Subsection 9 1 5 or other remedial action after an alarm the relay eventua...

Page 78: ...mate Trip The setting for the ultimate trip function is the value of current above which the motor can be damaged over time Figure 9 2 shows a setting of 100 reflecting a nameplate service factor of 1...

Page 79: ...ro speed switch to Discrete Input 1 and setting P5L11 ZSW ON The zero speed switch is a contact that is closed when the motor is at rest and opens as the mo tor begins to spin usually at 5 to 10 of ru...

Page 80: ...uits through the ground CT input requires a much higher GFT setting to avoid false tripping Thus sensitivity is not nearly as good as with a separate flux canceling CT If the MP 4000 relay is installe...

Page 81: ...ULTR P3L11 Phase unbalance alarm run delay UBTR P3L14 Jam alarm run delay JMAR P4L4 Underload alarm run delay ULAR P4L6 Unbalance alarm run delay UBAR P4L8 Load shed delay for pickup and dropout LSDL...

Page 82: ...has special mitigating features like multiple well separated sources or local paralleled generation Conventional motor contactors drop out in 3 to 5 cycles stopping the motor Special delayed dropout c...

Page 83: ...www eaton com Page 9 MP 4000 IB02602002E Figure 9 1 Rotor Temperature Tracking...

Page 84: ...Page 9 www eaton com IB02602002E MP 4000 Figure 9 2 Motor Protection Curve...

Page 85: ...www eaton com Page 9 MP 4000 IB02602002E Figure 9 3 Underload Jam Protection Curve...

Page 86: ...Page 9 10 www eaton com IB02602002E MP 4000 Figure 9 4 Motor Protection Curve Example without RTDs...

Page 87: ...www eaton com Page 9 11 MP 4000 IB02602002E Figure 9 5 Motor Protection Curve Example with RTDs...

Page 88: ...Page 9 12 www eaton com IB02602002E MP 4000 Figure 9 6 Motor Start and Run Cycles...

Page 89: ...Allows the MP 4000 to communicate via Modbus RTM over a standard RS 485 network D PONI Allows the MP 4000 to communicate over the DeviceNet at 125 250 or 500 kilobaud and E PONI Ethernet PONI with 10B...

Page 90: ...r further information PowerNet software is supplied with its own comprehensive instruc tions which explain how to access MP 4000 data and control capabili ties at the host client computer 10 5 PowerNe...

Page 91: ...st of Current Inputs Use a three phase source or relay test set to simulate motor load cur rent Check the correctness of all readings considering the scaling of the PCT and GCT CT ratio settings P1L5...

Page 92: ...es 11 11 Checking Discrete Input 2 Use P13L8 to determine if discrete input 2 is on or off Apply or re move 120 Vac to check both states 11 12 Verify Voltage Inputs A DVM can be used to verify reading...

Page 93: ...ushbutton Refer to Table 4 4 for the four pages of information available for review in the History mode including the numbers of each of the different types of trips and alarms and the highest current...

Page 94: ...arm setting A trip caused by a jogging function starts per time exceed ed anti backspin timing time between starts is not cleared by resetting and counts down with the remaining time vis ible on the d...

Page 95: ...Check the problem value in the Monitor mode and determine the cause Stator heat may be due to overload or to cooling air flow blockage Bearing heat usually indi cates impending failure or lack of lub...

Page 96: ...r power condition occurred PWR FCTR POWER FACTOR ALARM A power factor alarm condition occurred Trip Flags PH UNV B VOLTAGE PHASE UNBALANCE TRIP A voltage phase unbalance occurred OVR V OVER VOLTAGE TR...

Page 97: ...led Also check RTD integrity Sustained overloading of the motor or cooling air flow blockage has occurred If the RTD is OK the bearing probably needs replacement Check the airflow path Look for the ca...

Page 98: ...the motor has reached 5 to 10 of its normal running speed Use the DI 1 test to confirm that the relay sees the ex pected input voltage REMOTE REMOTE TRIP Either or both of discrete input 1 and or disc...

Page 99: ...urrent flowing to the motor for more than a second after the trip The contactor or breaker is stuck or jammed Or the trip contact has been bypassed so that the contac tor remained energized after the...

Page 100: ...r 240 Vac 15 exists between terminals 4 and 7 Remove ac power completely for 10 seconds and reapply it If the problem persists return the MP 4000 to the fac tory for repair OPTO ERR message An optocou...

Page 101: ...rts List Description Quantity MP 4000 Drawout Inner Chassis 1 MP 4000 Drawout Outer Case 1 Outer Flange 1 Mounting Hardware 10 32 nuts and lock washers 6 each MP 4000 Instruction Book 1 Section 13 Dra...

Page 102: ...terminals before the upper tier terminals 3 All contacts are shown in the de energized position NOTE Each output relay may be configured for Mode 1 or Mode 2 op eration In Mode 2 the relay is energiz...

Page 103: ...13 1 Panel Cutout Dimensions PANE L CUTOUT 062 R AD 1 59 4 PLACE S 0 203 DIA 5 16 10 PLACE S DIME NS IONS IN INCHE S MM 2 225 56 52 4 450 113 03 6 675 169 55 8 900 226 06 2 531 64 29 5 062 128 57 4 6...

Page 104: ...r IQ metering product CAUTION The MP 4000 inner chassis must be fully insert ed and fully latched into its Drawout Outer Case for proper operation of the device When the unit is seated properly the qu...

Page 105: ...www eaton com Page 13 MP 4000 IB02602002E Figure 13 2 MP 4000 Drawout Panel Mounting Figure 13 3 Rear View of MP 4000 Drawout Outer Case DIMENSIONS IN INCHES MM DIMENSIONS IN INCHES MM...

Page 106: ...2602002E Figure 13 4 MP 4000 Drawout Typical Circuits and Motor Control Wiring Direct Connect Note Voltage Inputs Are 120 Vac Nominal Limited to 150 Vac Figure 13 5 MP 4000 Drawout Typical CT Circuits...

Page 107: ...www eaton com Page 13 MP 4000 IB02602002E Figure 13 6 MP 4000 Drawout Typical CT Circuits and Motor Control Wiring Open Delta...

Page 108: ...Page 13 www eaton com MP 4000 IB02602002E Figure 13 7 MP 4000 Drawout Typical AC Supply and URTD Wiring Figure 13 8 MP 4000 Drawout Alternatives for Discrete Input Wiring...

Page 109: ...UT CONTACTS 120 Vac 120 Vac REMOTE CONTACT WETTING SUPPLY or 240 Vac ONLY 28 30 27 29 26 25 24 22 23 21 20 19 15 16 18 17 14 13 12 11 57 59 58 60 55 56 53 51 54 52 NON CURRENT CARRYING GND 49 50 46 45...

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Page 112: ...eaton com and follow the power management products link Eaton Corporation Electrical Group 1000 Cherrington Parkway Moon Township PA 15108 4312 United States 877 ETN CARE 877 386 2273 Eaton com 2012...

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