BLUE JAY BJ-PR200 Series Electronic Motor Protection Relay User Manual

BLUE JAY BJ-PR200 Series Electronic Motor Protection Relay User Manual

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When you use BJ-PR200 series electronic motor protection relay, be sure to read this user manual carefully, and be able to fully understand the implications, the correct guidance of operations in accordance with user manual, which will help you make better use of BJPR200 series motor protector, and help to solve the various problems at the scene.

1. Before the meter turning on the power supply, be sure that the power supply within the provisions of the instrument;
2. When installation, the current input terminal must non-open, voltage input terminals must Nonshort circuit;
3. Communication terminal (RS232/RS485 or Ethernet) is strictly prohibited to impose on high pressure;
4. Be sure the instrument wiring consistent with the internal system settings;
5. When communicating with the PC, instrument communication parameters must be consistent with the PC.

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1. – SUMMARIZE

PR200 motor protection relay is an all-in-one solution designed to continuously monitor 3-phase power lines for abnormal conditions. It can use with motors less than 690V/820A. Packed inside a small and economic package you’ll find a solution designed to save you time and money.

The series of products through the real-time monitoring of the scene signal, provide various protection trip to avoid motor failure. When the PR200 sense the motor operating parameters to achieve the preset alarm value, will trig the DO port to warning the abnormal status; abnormal parameters continue to accumulate to a dangerous value, will automatically trigger the release switch to shut down the circuit.

Option RS485 communication port can upload the monitor data and alarm status to remote control system.

Protection function (Details please refer to chapter 7)

Start Overtime,
Over Load,
Phase Failure,
Stall,
Current imbalance,
Under load,
Jam,
Ground fault

2. – FEATURES

-. High accuracy sample calculation, class 0.5 for 2% -120% measurement range; class 1 for 120% -1000% measurement range.
-. Built-in 2-channel relay, free to user set protected trip mode, alarm mode and trig mode. In protection mode, channel 1 relay can use for alarm, channel 2 for trig operation.
-. User free to set each protection function act off, alarm or trip.
-. Build in Sequence of Event function, can logger last 10 trip records.
-. With programmable analog output function, user option RS-485 communication interface.
-. Can provide basic electrical parameter for user SCADA system.
-. Wide range of power supply AC85-265V or AC80-450V.

3. – SPECIFICATIONS

Working environment:
Motor rated voltage: AC380V / AC660V
Motor rated current: 0.5-820A
Working temperature: -20C ~ +60C
Storage temperature: -40C ~ +80C
Relative humidity: < 93% RH
Elevation: not more than 3000 m
Atmospheric conditions: installation site does not allow the explosive medium, containing gas to corrode metal and damage the insulation and conductive medium.

Measuring accuracy:
Current: ± 0.5% (2% to 120% of Ie)
± 1% (120% to 10% of Ie)
Voltage: ± 0.5%
Leakage current: ± 1% (10% to 100% of Ir)
Analog Output: ± 1% (4 ~ 20mA)

Electrical parameters:
Auxiliary Power: AC80-450V (DC110V-500V)
Power consumption: <4 VA
Insulation resistance: > 100MΩ
Relay: Trip relay @ 10A / AC250V, 10A / 30VDC (NC node) Alarm relay @ 5A / 250VAC, 5A / 30VDC (NO node)

Electrical test:

IEC 61000-4-2 level III
IEC 61000-4-4 level III
IEC 61000-4-5 level III
IEC 61010-1 AC2kV/1min Between power / input / output

Product standards

Protection CT selection guide

Residual current CT
If PR200 choose ground fault protection, need external LCT05/30 series CT for detect leakage current.
LCT05 rated current of 500mA, the current range (50 ~ 500mA) LCT30 rated current of 30A, the current range of (3 ~ 30A)
Each PR200 need 1pcs, please contact sales team for purchase issue.

4.- INSTALLATION AND START-UP

⚠ The manual you hold in your hand contains information and warnings that the user should respect in order to guarantee a proper operation of all the instrument functions and keep it in safety conditions. The instrument must not be powered on and used until its definitive assembly is on the cabinet’s door.
If the instrument is not used as manufacturer’s specifications, the protection of the instrument will be damaged.
When any protection failure is suspected to exist (for example, it presents external visible damages), the instrument must be immediately powered off. In this case contact a qualified service representative.

4.1.- Installation

Mounting
PR200 series motor protector have two version installation mode, one for CT separate installation, another is CT integrated installation. Each instrument is to be mounted on panel (cut-out a mounting hole). Keep all connections into the cabinet.
Note that with the instrument powered on, the terminals could be dangerous to touch and cover opening actions or elements removal may allow accessing dangerous parts. Therefore, the instrument must not be used until this is completely installed.
Note: This connection drawing is for reference only; the actual connecting terminal please refer to the label on the rear part.

4.2.- Typical Wiring

4.2.1.- Connection with residual protection CT

4.2.2.- Connection with analog output

5. OPERATION MODE

5.1- Panel key operation

5.1.1- Key operation

← → In Monitor screen for move to next / previous page
In configuration menu for value increase/decrease
Menu Configuration menu enters or exit & roll back to up layer menu
 Enter next layer menu or confirm the change

5.1.2- Enter configuration menu

In normal monitor status, press key MENU, the main screen will show “CodE” press key into password screen, use key and to enter password (default user password is 0001), then press key to confirm enter, in password correct can into the menu screen, or still ask password.

5.1.3- Exit configuration menu

After parameter set, press key MENU, protector screen show “SAVE”, then press key for save the change and exit, press key MENU for exit without save.

5.2- Motor protector start

When the PR200 is powered up, the screen show “Stop”, mean the motor without work, user can press key and to check basic electrical parameter.
In the motor start period will show “- – – -“, after the start successful, the protector in normal working status, will automatic show three phase electrical parameter in turn. Then press key can choose page rolling manually or page rolling automatically, use key or for manually switch to next or previous display page.

5.3- Real-time fault detection

When a motor failure is detected, PR200 will act different logic:

Act for alarm -. Indicator lights in the front panel will ON; -. Alarm relay be trigged
After the failure be removed: -. Indicator will automatically turn off; -. Alarm relay automatic reset to NO status

Act for trip -. Indicator lights in the front panel will flicker -. Alarm relay be trigged -. Trip replay be trigged
After the failure be removed: -. Must press key to reset protector to normal status;
Notes: If overload protection trip, must waiting enough time for cool down then can success release.

5.4- Sequence of Event (SOE)

5.5- Configuration menu structure introduction

Note: Not all PR200 series have above complete configuration menus, please confirm your purchased PR200 sub-code, if do not have the corresponding extension module. In configuration menu corresponding part is invalid.

5.6- Example of programming menu operation

5.6.1- Set sampling input value

Step1: Press Menu enter configuration menu; device ask password;
Step2: Press  for entry password, use key ← & → to input password 0012, will move to Level-1 configuration menu;
Step3: Press  to enter level-2 of “Signal Input” menu, to set Input current range “InPt”;
Step4: Press  enter level-3 value range selecting, you can see default current range “5A”;
Step5: Press← or → to select input current range, in example use “10A”;
Step6: Press  to confirm the modify and return to the previous level menu;
Step7: Press Menu for roll back to the level-1 menu;
Step8: Press Menu for exit configuration to the monitor screen;
Step9: Main screen show “SAVE”, press  for save the change and exit configuration; press Menu for exit without save.

5.6.2- Overload protection setting

Step1: Press Menu enter configuration menu; device ask password;
Step2: Press for entry password, use key ← & → to input password 0001, will move to Level-1 configuration menu;
Step3: Press ← or → to choose Protection function setting menu “Pro.t”;
Setp4: Press  to enter level-2 of “Pro.t”, you can see Start timeout set menu “S.LnG”;
Step5: Press ← or → to choose Overload protection submenu “L.our”;
Step6: Press  to entry level-3, device ask set Protection mode menu “ModE”,
Then press  again entry selection, Press ← or → to choose “ALRM”, ”TRIP”, ”OFF”;
After select, press  to confirm the modify return to the previous level menu
Step7: In protection mode level-2, press → can set the overload K-factor;
Step8: In protection mode level-2, press → can set the overload cool down time;
Step9: In protection mode level-2, press → can set the overload reset mode;
Step10: Press Menu for exit configuration to the monitor screen;
Main screen show “SAVE”, press  for save the change and exit configuration; press Menu for exit without save.

6. – RS485 COMMUNICATION PORTOCOL

6.1.- MODBUS © protocol

The composition of the RS-485 cabling must be carried out with a meshed screen cable (minimum 3 wire), diameter of not less than 0.5mm2, with a maximum distance of 1,200 m between the motor protector and the master unit. This Bus may connect a maximum of 32unit.
Notes:

1. For communication with the master unit, customers can choose the RS-232 to RS-485 converter to use.
2. Not all the PR200 with RS485 port, please check your ordered product to confirm if the meter has remote communication function.

Due to product modifications or custom requirements, the interface pin place may be change. For details, please refer to product label on the rear board

6.1.1- Modbus RTU Frame Format:

6.1.2.- Modbus function code

6.2.- Register Map-I (Only Read, use code 04)

6.3.- Register map (II.- Read and write parts)

Cautions!

1. This chapter register map in default products the write function is disable in standard PR200, that to avoid unexpected damage due to frequent write operations, only opened for customer requirement!!
2. Registers support maximum 100,000 times writes, wrong write registers may cause device irreparable damage! Please ensure that host software engineer proficient in RS485 MODBUS protocol.
3. When the customer request valid the register write function, Blue Jay Technology Co., Ltd. will not responsible for any damage caused by the register write operation!!

7.- PORTECTION FUNCTION INTRODUCTION

7.1- Start Overtime protection

After the starting timer, if the three-phase average current 1.1 times the motor rated current (Ie) or 10% of the motor rated current (Ie) or three-phase average current, start timeout protection action.

Protection mode Alarm / Trip
Start timer 1.0 ~ 300.0s
Trip delay 0

7.2- Overload protection

Protector can track thermal capacity of the motor to avoid motor from overheating or damage. Controllers to simulate the thermal capacity of the motor in a variety of operating conditions, can real-time monitoring of motor heating conditions. Ensure effective protection of the repeated starting of the motor overheating condition continuous run.

Device provide 12 inverse time protection curves; user can select suitable curve for different motor working condition.

Typical trip time in different K factor and protection class

Overload inverse time curve quick select chart ( t unit: sec)

Cool down timer:
After motor stop, the cool down timer countdown to simulated the motor cools to a safe state process; the definition of the cooling time is to reach steady state of ambient temperature (the maximum allowable temperature) when motor overload trip. Typically, cool timer can set to 30 minutes as heat capacity values decreased from 100% to 15%.

7.3- Phase failure protection

When motor meet phase failure (Any of two phase over 25% of the rated current, another phase less than 12.5% of the rated current), will trip the phase failure protection.

Protection mode OFF / Alarm / Trip
Trip delay 0.1 ~ 50.0 s

7.4- Stall protection

Stall protection to prevent motor-driven equipment in serious operation block or motor overload operation and heat damage to the motor,
Note: Stall protection only be act after the motor starter is complete.

Protection mode OFF / Alarm / Trip
Threshold 100 ~ 1000%Ie
Trip delay 0.5 ~ 50.0 s

7.5- Current imbalance protection

Current imbalance protection based on the maximum phase current imbalance to determine whether to start phase unbalance protection function. Current unbalance is calculated as follows:

7.6- Under load protection

If motor load occurs abnormal mutations, such as belt break or pump idling, define this situation is under load. Typically set under load protection in alarm mode, to let site worker pay attention.

Protection mode OFF / Alarm / Trip
Threshold 20 ~ 100 %Ie
Trip delay 0.5 ~ 50.0 s

7.7- Rotor Jam protection

Compare the motor maximum measured current value and motor rated current in the starting process, to determine whether to act the protection.
Note: Jam protection only be act in the starting process, after motor normal working will be automatic locked.

Protection mode OFF/Alarm/Trip
Threshold 100 ~ 1000% Ie
Trip delay 0.5 ~ 50.0 s

7.8- Ground Fault Protection(Optional)

If any part of winding comes in contact with the ground, then we can say the motor is earthed. Device use external CT to detect residual current, ideal state to set the low residual current failure action values to protect as much stator coil and prevent the motor casing with electricity and dangerous.

In direct grounding system should be set short delay time to avoid damage; In resistance grounding system, the value of the residual current is limited within the safe range, user can choose a longer delay time.

Protection mode OFF / Alarm / Trip residual current threshold 10 ~ 100%IΔn
Trip delay 0.1 ~ 5.0 s

7.9.- tE Protection

The tE protection function used for increased safety(IEC-60079-7) type motor, it provides 8 extra inverse time protection curves, to avoid unexpected overheat status.

Note:

-. The setting value of tE trip delay will transfer to actually trip time refer above chart
-. To ensure that the regular overload protection act before tE trap time, we suggest choose lower inverse time curve in overload protection, typically less 15%.

Protection mode OFF / Alarm / Trip
Trip delay 0.1 ~ 5.0 s

8- I/O Output (Optional)

8.1.- Analog output port

PR200 can provide 1 channel analog output port, can provide 4 ~ 20mA signal to PLC or other device, user can free to select the transmit electrical parameters: Ia, Ib, Ic, Iavg
Note: Analog output port cannot be choosing with the ground fault protection function.

8.2.- Digital output port

PR200 can choose extra 2 channels digital output, the physical DO relay standard is 5A 250VAC / 5A 30VDC.

*Remote mode operation
In “Remote” mode, user can use function code 05 to trig single relay, device RS-485 port follow MODBUS-RTU protocol, command as following:

Detail operation please refer to chart 5.5- Programming menu structure introduction

9. – SAFETY CONSIDERATIONS

All installation specification described at the previous chapters named: INSTALLATION AND STARTUP, INSTALLATION MODES and SPECIFICATIONS.
Note that with the instrument powered on, the terminals could be dangerous to touching and cover opening actions or elements removal may allow accessing dangerous parts. This instrument is factory-shipped at proper operation condition.

10. – MAINTENANCE

The PR200 series not require any special maintenance. No adjustment, maintenance or repairing action should be done when the instrument is open and powered on, should those actions are essential, high-qualified operators must perform them.
Before any adjustment, replacement, maintenance or repairing operation is carried out; the instrument must be disconnected from any power supply source.
When any protection failure is suspected to exist, the instrument must be immediately put out of service. The instrument’s design allows a quick replacement in case of any failure.

For any inquiry about the instrument performance or whether any failure happens, contact to Blue Jay’s technical service.
Blue Jay – After-sales service
E-mail: tech@cqbluejay.com

Tel: +0086-023-67628702 www.cqbluejay.com Add: 1802,Building 2,No.88,Jianxin East Road,Chongqing,400020,China

Email:tech@cqbluejay.com 

References

• Blue Jay - Industrial Electric Automation Manufacturer - Power & Energy Meters, Automatic protection relay etc.

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