BLUE JAY BJ-PR240 Series Motor Protect Relay User Manual

BJ-PR240 series
Motor Protect Relay
User Manual
Version 3.7

BJ-PR240 Series Motor Protect Relay

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When you use BJ-PR240 series intelligent 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 Non short 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.

• Please read this user manual carefully
• Please save this document

SUMMARIZE

PR240 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. It can realize a variety of control operation, as well as measurement, self-diagnosis, maintenance management, field bus communication and other functions.
The series of products through the real-time monitoring of the scene signal, provide various protection trip to avoid motor failure. Option RS485 communication port can upload the monitor data and alarm status to remote control system.

(Details please refer to chapter 7)
Start Overtime (Max. Start time),
Over Load,
Phase Failure (Phase loss),
Jam in starting(Stall),
Current imbalance,
Under power,
Jam in running,
Ground fault,
Over temperature,
Short circuit,
Over voltage,
Under voltage,
Abnormal frequency,
Abnormal power factor,
tE protection (Increased safety motor overload)
Automatic restart,| Three-phase current,
Three-phase line voltage,
Frequency,
Active power,
Reactive power,
Apparent power,
Power factor,
Electrical energy,
Ground residential current

FEATURES

• Various electrical parameter real-time detect, Dot matrix LCD display.
• Built-in 4-channels relay, provide various start methods: Direct start, positive & negative start, star – delta start, auto transformer start, 2-speed motor start, circuit breaker direct start and protection trip logic.
• User free to set each protection function act off, alarm or trip.
• Build in Sequence of Event function, can logger last 100 trip records.
• With programmable analog output function, user option RS-485 communication interface.

SPECIFICATIONS

Working environment:

medium, containing gas to corrode metal and damage the insulation and conductive medium.

Measuring accuracy:

Electrical parameters:

Electrical test:

Product standards

GB / T 14048.1 (IEC 60947-1)| Low-voltage switch gear and control equipment General Provisions
---|---
GB / T 14048.4 (IEC 60947-4)| Low voltage electromagnetically contractors and motor starters requirements
JB / T 10613-2006| General specification for digital motor combined protection equipment
JB / T 10736-2007| Low voltage motor protection

Product selection guide

Chart 3.1

Notes : Standard type without additional function, If need multiple additional functions the coded arranged in sequence after main code.

Chart 3.2

Chart 3.3
External protection CT selection guide, typical in 380V grid:

External CT
---|---|---|---
75| 135| 10A| 500/5
90| 165
110| 200
132| 240
160| 285
200| 352
220| 420
250| 480

Notes: If motor rated current over 100A, need to connect an external CT, Blue Jay suggest use 500/5A CT. In Configuration menu-[CT ratio] set to 100.(See chapter 5.6.2)
Residual current sensor
If PR240 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 PR240 need 1pcs, please contact sales team for purchase issue.
Wiring core for cable type

Wiring core for cooper bar type

Notes: Protection function please refer Chapter 7.7

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
PR240 series motor protection relay designed as separate 2 parts, one for din-rail mounting body, another is panel mounting HMI.
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.

4.1.- Terminal Definition

LED indicator Introduction
Run/Stop:
Always ON when motor stopped;
Flicker when motor running.
COMM:
Flicker when RX/TX.
Alarm/Failure
Always ON when device have failure;
Flicker when motor in alarm threshold rigged.
Notes:

1. PR240 provide 7 digital input terminals, external signal sampling interval >= 100ms. 15Vdc internal feeder, external can be controlled by passive contacts.
2. DI status can be set in NO or NC.
3. PR240 provide 4 relay outputs, DO status can be set in NO or NC, support Level output or Pulse output.

Caution:

1. Forbidden to connect external feed voltage to DI terminals!
2. Do not wire the DI terminal in the same tube or twist it with high voltage cable!
3. If distance more than 2 meters must use shielded cable! The maximum distance of the DI pinout should not exceed 300 meters!

Terminal defecation

OPERATION MODE

PR240 have a HMI, wired to relay body by DB9 cable; It used for parameter display and configuration, also can use operation button to control motor working or stop.
LED indicator show motor status.
5.1- LCD display screen
Screen area adopts a large size dot-matrix LCD, backlight is gray. The backlight time free to configuration. When there is a key operation, the backlight will be re-lit, and will go out after the set interval.
After device be powered, HMI default screen is measurement interface. In this interface, pressing  the ” ” button can enter password and switch to configuration interface.
In this configuration menu, user can set the protection mode, system parameter, view fault alarm record, operation information etc.
5.2- Panel LED Indicator

Motor stopped
Start| Motor in non-start status
Motor in starting period
Runs| Motor in non-runs status
Motor in running
Alarm| Motor in normal status
Alarm threshold rigged
Failure| DO in non-trip status
DO tripped

5.3- Motor Control Buttons
There have 4 key buttons for motor operation:

| Local direct control| Under remote control mode
---|---|---
In “Protect only” mode| Invalid
In “Panel control start/stop” mode| Motor start| Invalid
In “Forward and reverse start” mode| Motor start in forward rotation| Invalid
In “Two-Winding start” mode| Motor start in low winding-1(low speed)| Invalid
In “Wye-Delta Transition” mode| Motor start| Invalid
In “Auto transformer Closed Transition” mode| Motor start| Invalid
| Local direct control| Under remote control mode
---|---|---
In “Protect only” mode| Invalid
In “Panel control start/stop” mode| Motor start| Invalid
In “Forward and reverse start” mode| Motor start in reverse rotation| Invalid
In “Two-Winding start” mode| Motor start in low winding-2(high speed)| Invalid
In “Wye-Delta Transition” mode| Invalid| Invalid
In “Auto transformer Closed Transition” mode| Invalid| Invalid
| Local direct control| Under remote control mode
---|---|---
In “Protect only” mode| Invalid
In “Panel control start/stop” mode| Stop motor immediately| Invalid
In “Forward and reverse start” mode| Stop motor immediately| Invalid
In “Two-Winding start” mode| Stop motor immediately| Invalid
In “Wye-Delta Transition” mode| Stop motor immediately| Invalid
In “Auto transformer Closed Transition” mode| Stop motor immediately| Invalid
| Press to release alarm and reset DO port to non-tripped status when motor in Stopped status.
---|---

5.4- Configuration Buttons
In HMI right are have 4 buttons for configuration operations

| Under measurement interface: Switch to former parameter displayed. Under configuration interface: Move cursor to left and increase value.
---|---
| Under measurement interface: Switch to next parameter displayed. Under configuration interface: Move cursor to right and decrease value.
| Under measurement interface: Switch to configuration interface (password requested). Under configuration interface: Exit or switch to measurement interface.
| Confirmed the enter value or setting changes.

5.4.1- Enter configuration menu
In normal monitor status, press , screen will ask Password,
Press into password screen, use  and  to enter password
Notes: Default user password is 0001),
Then press key to confirm enter, in password correct can into the menu screen,
Notes: If password changed and enter error, screen still ask password again.
5.4.2- Exit configuration menu
After parameter set, press , protector screen show “SAVE”, then press for save the  change and exit, press key for exit without save.
5.5- Measurement Interface

Notes:

1. Thermal resistance parameter is only valid when access temperature probe;

2. Symbol of DI/DO status:
   Hollow circle means no digital input or no relay rigged;
   Solid circle means digital signal looped in or relay be rigged;

3. When the measured current > 1.3 * Protect CT, the display value of measurement error will be increasing.

4. Press Enter button can switch to Motor status screen:

5.6- Configuration Menu

5.6.1- Protection mode configuration
There have 15 different protection mode can configuration, detail function descriptions please refer to Chapter 7:

5.6.2- System parameter- configuration

RS485 COMMUNICATION PROTOCOL

6.1.- MOD BUS © 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 0.5mm , 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 PR240 series have RS485 full operation function, please check your ordered product to confirm whether has related function. If products no response when read/write some register, mostly not equipped that functions.

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- Mod bus RTU Frame Format:

Starting address, low byte
Number of registers, high byte
Number of registers, low byte
Error Check code| 2 BYTE| Cyclical Redundancy Check ( CRC )

6.1.2.- Mod bus function code

or Physical Coils
FUNCTION 02| Read signal Coils| This function permits to read Physical Discrete Inputs
FUNCTION 03| Reading of n Words of holding register| Read protection setting, system parameters, starting parameters, etc.
Read the I/O port status
FUNCTION 04| Reading of n Words of input register| Read measurement values (voltage, current, power, etc.); Read SOE record
FUNCTION 05| Force Single Coil| This function permits to write Internal Bits or Physical Coils
FUNCTION 06| Write single register| This function permits to write

Example_1: Read A, B, C phase current value
Host to Slave

MOD BUS ID| Func.| Data Address (high)| Data Address (low)| Data Number (high)| Data number (low)| CRC16 (low)| CRC16 (high)
---|---|---|---|---|---|---|---
01H| 04H| 00H| 00H| 00H| 03H| BEG| F7H

Slave to Host

MO BUDS ID| Func.| Data length| A-phase current| B-phase current| C-phase current| CRC
---|---|---|---|---|---|---
01| 04| 06| 03| E8| 03| E8| 03| E7| C0| 7D

Example_2: Write motor rated current from 1A to 1.5A
Host to Slave

MOD BUS ID|

Func.

| Data Address

(high)

| Data Address

(low)

| Data Value

(high)

| Data Value

(low)

|

CRC

---|---|---|---|---|---|---
01| 06| 02| 05| 00| 0F| 80| 7E

Slave to Host

MOD BUS ID| Func.| Data Address (high)| Data Address (low)| Data Value (high)| Data Value (low)| CRC
---|---|---|---|---|---|---
01| 06| 02| 05| 00| 0F| 80| 7E

Example_3: MOD BUS command control relay to rigged

MOD BUS ID| Func.| Data Address (high)| Data Address (low)| Data Value (high)| Data Value (low)| CRC
---|---|---|---|---|---|---
01| 05| 00| 01| FF| 00| DD| DA

Host to Slave

MOD BUS ID| Func.| Data Address (high)| Data Address (low)| Data Value (high)| Data Value (low)| CRC
---|---|---|---|---|---|---
01| 05| 00| 01| FF| 00| DD| DA

6.2.- Motor Status Parameter (Read Only, code 04)

BIT1:DI2 BIT2:DI3 BIT3:DI4 BIT4:DI5 BIT5:DI6
BIT6:DI7
0x13| Digital output status| 0: Opened
1: Closed BIT0:DO1 BIT1:DO2 BIT2:DO3
BIT3:DO4
0x14| A-Phase current percentage| Unit: 0.1%
0x15| B-Phase current percentage| Unit: 0.1%
0x16| C-Phase current percentage| Unit: 0.1%
0x17| AB line voltage percentage| Unit: 0.1%
0x18| BC line voltage percentage| Unit: 0.1%
0x19| CA line voltage percentage| Unit: 0.1%
0x1A| Active power percentage| Unit: 0.1%
0x1B| Reactive power percentage| Unit: 0.1%
0x1C| Apparent power percentage| Unit: 0.1%
0x1D| Power factor percentage| Unit: 0.1%
0x1E| Frequency percentage| Unit: 0.1%
0x1F| Residual current percentage (External)| Unit: 0.1%
Sampling from external zero-sequence sensor
0x20| Residual current percentage (Internal)| Unit: 0.1%
Calculated from fundamental frequency
0x23| Average voltage percentage| Unit: 0.1%
---|---|---
0x24| Average current percentage| Unit: 0.1%
0x25| Peak voltage percentage| Unit: 0.1%
0x26| Peak current percentage| Unit: 0.1%
0x28| A-phase current imbalance| Unit: 0.1%
0x29| B-phase current imbalance| Unit: 0.1%
0x2A| C-phase current imbalance| Unit: 0.1%
0x32-0x35| Active energy (Ep)| Unit: 1WH
0x36-0x39| Reactive energy (Eq)| Unit: 1varH
0x48| Device present state| 0: Waiting for delay timer 1: Start standby

2: Starting

3: Running

4: Stopped

5: Stopped by failure trip

0x49| Device present alarm type| 0x0000: No alarm
0x0001: Start Overtime
0x0002: Over Load
0x0004: Phase Failure
0x0008: Jam in starting
0x0010: Current imbalance
0x0020: Under power
0x0040: Jam in running
0x0080: Ground fault
0x0100: tE protection
0x0200: Over voltage
0x0400: Under voltage
0x0800: Abnormal frequency
0x1000: Abnormal power factor
0x2000: Over temperature
0x4000: Short circuit
0x4A| Device present failure type| 0x0000: No alarm
0x0001: Start Overtime
0x0002: Over Load
0x0004: Phase Failure
0x0008: Jam in starting
0x0010: Current imbalance
0x0020: Under power
0x0040: Jam in running
0x0080: Ground fault
0x0100: tE protection
0x0200: Over voltage
0x0400: Under voltage
0x0800: Abnormal frequency
0x1000: Abnormal power factor
0x2000: Over temperature
0x4000: Short circuit
0x4B| Present run hours (Lower 16 bits)| Unit: Second
0x4C| Present run hours (High 16 bits)
0x4D| Present stopped hours (Lower 16 bits)| Unit: Second
0x4E| Present stopped hours (High 16 bits)
0x4F| Total run hours (Lower 16 bits)| Unit: Second
0x50| Total run hours (High 16 bits)
0x51| Total stopped hours (Lower 16 bits)| Unit: Second
0x52| Total stopped hours (High 16 bits)
0x53| Total operation times(Lower 16 bits)| Unit: times
---|---|---
0x54| Total operation times(High 16 bits)
0x55| Total tipped number(Low 16 bits)| Unit: times
0x56| Total tipped number(High 16 bits)
0x64| Year| RTC info
0x65| Month
0x66| Date
0x67| Hour
0x68| Minute
0x69| Second
0x6A| Week

6.3.- Motor Basic Configuration (Read and write)
Cautions!

1. This chapter register map in default products the write function is disable in standard PR240, 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!!

0.1-999.9 A)
0x204| Motor rated voltage| Range: 0-690
0x205| Motor rated current (Ie)| Range: 1-9999 (real value 0.1-999.9 A)
0x206| MODBUS ID| Range: 1~247
0x207| Baud ratio| 0:2400
1:4800
2:9600
3:19200
0x208| Data format| 0: n.8.1
1: o.8.1
2: e.8.1
3: n.8.2
0x209| Reserved| /
0x20A| Ground fault detect mode| 0: Internal
Calculated from fundamental frequency component
1: External
Sampling from external zero-sequence sensor
0x20B| Auto restart| 0: Disable
1: Enable
0x20C| Voltage loss threshold| Range: 50 ~100%Ue
0x20D| Voltage recovered threshold| Range: 50 ~100%Ue
0x20E| Voltage loss timer| Range: 0.1-60.0sec
0x20F| Restart delay timer| Range: 0.1-60.0sec
0x210| Motor rated power| unit KW

6.4.- Motor Protection Functions Configuration (Read and write)
Cautions!

1. This chapter register map in default products the write function is disable in standard PR240, 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!!

Chapter 7.2

| 0: Invalid
1: Alarm| 2: Trig DO
0x302| Over Load K factor| 0: K=10
1: K=25
2: K=60
3: K=75
4: K=100
5: K=125| 6: K=250
7: K=300
8: K=500
9: K=750
10: K=1000
11: K=1200
0x303| Over Load protection cool down timer| Range: 1-1200min
0x304| Over Load reset method| 0: Manual
1: Automatic
0x305| Jam in running protect action| Chapter 7.3| 0: Invalid
1: Alarm
2: Trig DO
0x306| Jam in running protect threshold| Range: 100-1000% Ie
0x307| Jam in running protect timer| Range: 0.5-50.0sec
0x308| Contractor breaking current| Range: 100-1000% Ie
0x309| Jam in starting protect action| Chapter 7.4| 0: Invalid
1: Alarm
2: Trig DO
0x30A| Jam in starting protect threshold| Range: 100-1000% Ie
0x30B| Jam in starting protect timer| Range: 0.5-50.0sec
0x30C| Phase failure protect action| Chapter 7.5| 0: Invalid
1: Alarm
2: Trig DO
0x30D| Reserved|
0x30E| Phase failure protect timer| Range: 0.1-50.0sec
0x30F| Current imbalance protect action| Chapter 7.6| 0: Invalid
1: Alarm
2: Trig DO
0x310| Current imbalance threshold| Range: 5-60%
0x311| Current imbalance protect timer| Range: 0.1-50.0sec
0x312| Ground fault protect action| Chapter 7.7| 0: Invalid
1: Alarm
2: Trig DO
0x313| Ground fault protect threshold| Range: 10-100% Ir
0x314| Ground fault protect timer| | Range: 0.1-50.0sec
---|---|---|---
0x315| Under power protect action|

Chapter 7.8

| 0: Invalid
1: Alarm
2: Trig DO
0x316| Under power protect threshold| 20-100% Ie
0x317| Under power protect timer| Range: 0.5-60.0sec
0x318| Over temperature protect action| Chapter 7.9| 0: Invalid
1: Alarm
2: Trig DO
0x319| Temperature probe type| 0: PTC
1: NTC
0x31A| Over temperature trig threshold| Range: 0.1 ~ 30.0KΩ
0x31B| Over temperature recover hysteresis| Range: 0.1 ~ 30.0KΩ
0x31C| Short circuit protect action| Chapter 7.10| 0: Invalid
1: Alarm
2: Trig DO
0x31D| Short circuit protect threshold| Range: 100-1000% Ie
0x31E| Short circuit protect timer| Range: 0.1-50.0sec
0x31F| Over voltage protect action| Chapter 7.11| 0: Invalid
1: Alarm
2: Trig DO
0x320| Over voltage protect threshold| Range: 105-150% Ue
0x321| Over voltage protect timer| Range: 0.1-50.0sec
0x322| Under voltage protect action|

Chapter 7.12

| 0: Invalid
1: Alarm
2: Trig DO
0x323| Under voltage protect threshold| Range: 50-95% Ue
0x324| Under voltage protect timer| Range: 0.1-50.0sec
0x325| Abnormal frequency protect action|

Chapter 7.13

| 0: Invalid
1: Alarm
2: Trig DO
0x326| Frequency protect upper threshold| Range: 50.00-55.00 Hz
0x327| Frequency protect lower threshold| Range: 45.00-50.00 Hz
0x328| Frequency protect timer| Range: 0.1-50.0sec
0x329| Abnormal power factor protect action|

Chapter 7.14

| 0: Invalid
1: Alarm
2: Trig DO
0x32A| Power factor protect threshold| Range: 20-95%
0x32B| Power factor protect timer| Range: 1.0-60.0sec
0x32C| Reserved| |
0x32D| tE protect action| Chapter 7.15| 0: Invalid
1: Alarm
2: Trig DO
0x32E| tE protect value| Range: 1.0~15.0sec

6.5.- Motor Start Mode Configuration (Read and write)
Cautions!

1. This chapter register map in default products the write function is disable in standard PR240, 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 MOD BUS 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!!

valid 1: Local/remote:
DI3 closed for HMI panel control;
DI3 opened for external control loop (DO or MODBUS command) control.
Notes : Factory default set “0”
0x333| Motor start mode| 0: Only protection
1: Full voltage
2: Forward / reverse 3: Two-Winding
4: Voltage loss restart 5: Wye-Delta Transition
6: Auto transformer Closed Transition 7: MCB direct start
0x334-0x335| Reserved|
0x336| Start Wiring Check Enable| 0: Disable
1: Enable
0x337-0x33F| Reserved|
0x340| AO output zero span(0mA)| Default 0.0%
0x341| AO output full span(20mA)| Default 100.0%
0x342| AO output selection| 0: 0-20mA
1: 4-20mA
0x343| AO transmit parameters| 0: I1
1: I2
2: I3
3: U1
4: U2
5: U3| 6: Ps
7: Qs
8: Ss
9: Pf
10: Fr
0x344-0x348| Reserved|
0x349| DO4| Trip Circuit Breaker when short circuit protection. Export pulse signal to MCB, refer to chapter 7.10
Range: 0-999.9Sec 0 for level control
Address| Contents| Description
---|---|---
0x500-0x504| SOE_001| SOE_001 is latest record Details see Notes
0x505-0x509| SOE_002
0x50A-0x50E| SOE_003
0x50F-0x513| SOE_004
0x514-0x518| SOE_005
0x519-0x51D| SOE_006
…| …
0x6EF-0x6F3| SOE_100

Notes: Each event is represented by 10 bytes.

BYTE 0-1 for failure type| 01: Start Overtime
02: Over Load
03: Phase Failure 04: Jam in starting
05: Current imbalance| 06: Under power 07: Jam in running 08: Ground fault
09: tE protection
10: Over voltage| 11: Under voltage
12: Abnormal frequency 13: Abnormal power factor 14: Over temperature
15: Short circuit
---|---|---|---
BYTE 2-3| Failure value| |
BYTE 4-9| Failure event timestamp| |
BYTE 4| Year| |
BYTE 5| Month| |
BYTE 6| Date| |
BYTE 7| Hour| |
BYTE 8| Minute| |
BYTE 9| Second| |

6.5.- Motor Advanced Control (Read and write)
Cautions!

1. This chapter register map in default products the write function is disable in standard PR240, 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!!

0x40 Start A 0x80
0xF00| Reset energy counter| Writ in code: 0A0A

PROTECTION FUNCTION INTRODUCTION

7.1- Start Overtime Protection
Start overtime protection provides protection of motor during starting period. After motor in regular running period, start overtime protection will automatically exit.
Protective action logic:
After Start timer countdown to 0, either of the following two condition will trig protect action.

1. Three-phase average current ≥ 1.1 times the motor rated current (Ie) OR
2. Three-phase average current ≤ 10% of the motor rated current (Ie)

1. Start time can be set in HMI configuration menu, or register 0x32FH

7.2- Overload Protection
Device can calculate used thermal capacity (UTC) of the motor to avoid motor from overheating damage. Internal program simulates the used 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.
Inverse-time formula

t Operating inverse time
I Motor working current value
Ie Motor rated current
K K factor curve need set

Typical trip time in different K factor and protection class

K factor| Class| I/Ie = 1.0| I/Ie 1.2| I/Ie 1.5| I/Ie 7.2
---|---|---|---|---|---
125| 10| Without trip in 2h| Trip in 1h| Tp≤2min| 2s<Tp≤10s
250, 300| 10| Tp≤4min| 4s<Tp≤10s
500| 20| Tp≤8min| 6s<Tp≤20s
750| 30| Tp≤12min| 9s<Tp≤30s

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

K I/Ie| 10| 25| 60| 75| 100| 125| 250| 300| 500| 750| 1000| 1200
---|---|---|---|---|---|---|---|---|---|---|---|---
1.1| 47.62| 119.05| 285.71| 357.14| 476.19| 595.24| 1190.48| 1428.57| 2380.95| 3571.43| 4761.90| 5714.28
1.2| 22.73| 56.82| 136.36| 170.45| 227.27| 284.09| 568.18| 681.82| 1136.36| 1704.55| 2272.73| 2727.27
1.3| 14.49| 36.23| 86.96| 108.70| 144.93| 181.16| 362.32| 434.78| 724.64| 1086.96| 1449.28| 1739.13
---|---|---|---|---|---|---|---|---|---|---|---|---
1.4| 10.42| 26.04| 62.50| 78.13| 104.17| 130.21| 260.42| 312.50| 520.83| 781.25| 1041.67| 1250.00
1.5| 8.00| 20.00| 48.00| 60.00| 80.00| 100.00| 200.00| 240.00| 400.00| 600.00| 800.00| 960.00
2.0| 3.33| 8.33| 20.00| 25.00| 33.33| 41.67| 83.33| 100.00| 166.67| 250.00| 333.33| 400.00
2.5| 1.90| 4.76| 11.43| 14.29| 19.05| 23.81| 47.62| 57.14| 95.24| 142.86| 190.48| 228.57
3.0| 1.25| 3.13| 7.50| 9.38| 12.50| 15.63| 31.25| 37.50| 62.50| 93.75| 125.00| 150.00
3.5| 0.89| 2.22| 5.33| 6.67| 8.89| 11.11| 22.22| 26.67| 44.44| 66.67| 88.89| 106.67
4.0| 0.67| 1.67| 4.00| 5.00| 6.67| 8.33| 16.67| 20.00| 33.33| 50.00| 66.67| 80.00
4.5| 0.52| 1.30| 3.12| 3.90| 5.19| 6.49| 12.99| 15.58| 25.97| 38.96| 51.95| 62.34
5.0| 0.42| 1.04| 2.50| 3.13| 4.17| 5.21| 10.42| 12.50| 20.83| 31.25| 41.67| 50.00
5.5| 0.34| 0.85| 2.05| 2.56| 3.42| 4.27| 8.55| 10.26| 17.09| 25.64| 34.19| 41.03
6.0| 0.29| 0.71| 1.71| 2.14| 2.86| 3.57| 7.14| 8.57| 14.29| 21.43| 28.57| 34.29
6.5| 0.24| 0.61| 1.45| 1.82| 2.42| 3.03| 6.06| 7.27| 12.12| 18.18| 24.24| 29.09
7.0| 0.21| 0.52| 1.25| 1.56| 2.08| 2.60| 5.21| 6.25| 10.42| 15.63| 20.83| 25.00
7.2| 0.20| 0.49| 1.18| 1.48| 1.97| 2.46| 4.92| 5.90| 9.83| 14.75| 19.67| 23.60
7.5| 0.18| 0.45| 1.09| 1.36| 1.81| 2.26| 4.52| 5.43| 9.05| 13.57| 18.10| 21.72
8.0| 0.16| 0.40| 0.95| 1.19| 1.59| 1.98| 3.97| 4.76| 7.94| 11.90| 15.87| 19.05
Protect action| OFF / Alarm / Trig DO
---|---
K factor value| 10 ~ 1200
Cool down timer(1)| 1 ~ 1200 min
Overload reset method(2)| Auto reset / Force cooling

1. 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, suggest cool down timer set “30 minutes” to let motor cooled completely.

2. Overload reset method:
   If protect action select [Trig DO], After relay tripped there have two ways reset motor to next working cycle (Standby status):

to reset status.

Notes:

1. If overload protection trigged after UTC > 15%, press Stop will invalid, HMI still show “Overload”; Must reset UTC to 0%, then press Stop to Standby status.
2. Press and hold seconds can reset UTC to 0%.
3. Used thermal capacity (UTC) displayed on HMI (See chapter 5.4), or read from register 0x0D.

7.3- Jam in Running Protection (Stall)
Protective action logic:
Motor measured current > Threshold set value

Note: Only valid in regular running period.
7.4- Jam in Starting Protection (Rotor locked)
Protective action logic:
Motor measured current > Threshold set value

Note: Only valid in starting period.
7.5- Phase Failure Protection
Protective action logic:
Any two phase current > 25% Rated current, AND third phase current < 12.5% Rated current,

Notes: This protection will valid in both starting and running period.
7.6- 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:

Iim Three-phase current imbalance
Imax Maximum phase current in the real-time measurement of three-phase
Imin Minimum phase current in the real-time measurement of three-phase
Iavg Three-phase average current
Notes: When the three-phase average current (Iavg) is less than the motor rated current (Ie), in formula Iavg = Ie
Protective action logic:
Iim > Threshold set value

7.7- Ground Fault Protection
Device have two ways for ground fault protection, Sampling from external zero-sequence CT (residential current sensor see chapter 3), or calculated from fundamental frequency component.
Please set detect mode in HMI or in register 0x20A.

1. Threshold related residential CT install position, ideal state to set the lower threshold values.
2. In directly grounding system, should set shorter delay timer to avoid damage or electrical shock;  In resistance grounding system, residual current be limited within a safe range, can set longer delay timer.

7.8- Under Power Protection
If motor load occurs abnormal mutations, such as belt break or pump idling, define this situation is under power.
Protective action logic:
Motor measured current < Threshold set value

Notes: Typically, under power protection set to alarm mode, to notice site staff to pay attention.
7.9- Over Temperature Protection
Device accept 1pcs NTC or PTC sensor for temperature measurement, provide original resistance parameters value.
Protective action logic:
Measured resistor > Threshold set value

1. Probe type can select in HMI or in register 0x319.

7.10- Short Circuit Protection
The protection is performed when motor occurred incorrectly wiring or line is damaged that caused short circuit.

Notes: Blue Jay suggest set threshold in large value, and short trip delay time. Set protect threshold = Contractor trip threshold (0x308). CB will trip priority than contractor.
7.11- Over Voltage Protection
Protective action logic:
Any of the three phase voltage > Threshold set value

Notes: This protection will valid in both starting and running period.
7.12- Under Voltage Protection
Protective action logic:
Any of the three phase voltage < Threshold set value

Notes: This protection will valid in both starting and running period. If enabled restart function (chapter 7.16), under voltage protection will automatically disable.
Enable under voltage protection can open Auto Restart function, this function used in some special application scenarios, by ignoring the under voltage protection caused by system voltage loss, let motor can be automatically restarted after the voltage recovered.

Voltage loss threshold| 50% ~ 100%Ue; Set “0” to disable this function Default 80%Ue| Register 0x20C
---|---|---
Voltage recovered threshold| 50% ~ 100%Ue; Set “0” to disable this function Default 80%Ue| Register 0x20D
Voltage loss timer| 0.1s ~ 60.0s Default 5.0s| Register 0x20E
---|---|---
Restart delay timer| 0.1 ~ 60.0s Default 0.1s| Register 0x20F

Notes: Motor start mode set [Only protection], Auto restart function is invalid.
7.13- Abnormal Frequency Protection
Protective action logic:
Frequency > Upper threshold set value OR Frequency < Lower threshold set value

7.14- Abnormal Power Factor Protection
Protective action logic:
Power factor < Threshold set value

7.15.- tE Protection
The tE protection function used for increased safety type motor(IEC-60079-7), it valid in both starting and running period. tE time protection fault must be reset manually. It cannot be valid with overload protection (chapter 7.1) at the same time.

Note: 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%.

1. Real trip delay value = Set tEp * tEp[1.0s] Example: Set tEp = 5, I/Ie=3.4
   Trip delay timer = 15.4sec tEp setting value quick select chart (time unit: sec)

tEp I/Ie| 1.0(s)| 4.0(s)| 4.3(s)| 4.6(s)| 5.0(s)| 5.5(s)| 6.0(s)| 15.0(s)
---|---|---|---|---|---|---|---|---
3.00| 4.00| 16.00| 17.20| 18.40| 20.00| 22.00| 24.00| 60.00
3.20| 3.48| 13.92| 14.96| 16.01| 17.40| 19.14| 20.88| 52.20
3.40| 3.08| 12.32| 13.24| 14.17| 15.40| 16.94| 18.48| 46.20
3.60| 2.76| 11.04| 11.87| 12.70| 13.80| 15.18| 16.56| 41.40
3.80| 2.50| 10.00| 10.75| 11.50| 12.50| 13.75| 15.00| 37.50
4.00| 2.29| 9.16| 9.85| 10.53| 11.45| 12.60| 13.74| 34.35
4.20| 2.11| 8.44| 9.07| 9.71| 10.55| 11.61| 12.66| 31.65
4.40| 1.95| 7.80| 8.39| 8.97| 9.75| 10.73| 11.70| 29.25
4.60| 1.82| 7.28| 7.83| 8.37| 9.10| 10.01| 10.92| 27.30
4.80| 1.70| 6.80| 7.31| 7.82| 8.50| 9.35| 10.20| 25.50
5.00| 1.60| 6.40| 6.88| 7.36| 8.00| 8.80| 9.60| 24.00
5.20| 1.51| 6.04| 6.49| 6.95| 7.55| 8.31| 9.06| 22.65
5.40| 1.43| 5.72| 6.15| 6.58| 7.15| 7.87| 8.58| 21.45
5.60| 1.36| 5.44| 5.85| 6.26| 6.80| 7.48| 8.16| 20.40
5.80| 1.29| 5.16| 5.55| 5.93| 6.45| 7.10| 7.74| 19.35
6.00| 1.23| 4.92| 5.29| 5.66| 6.15| 6.77| 7.38| 18.45
6.20| 1.18| 4.72| 5.07| 5.43| 5.90| 6.49| 7.08| 17.70
6.40| 1.13| 4.52| 4.86| 5.20| 5.65| 6.22| 6.78| 16.95
6.60| 1.08| 4.32| 4.64| 4.97| 5.40| 5.94| 6.48| 16.20
6.80| 1.04| 4.16| 4.47| 4.78| 5.20| 5.72| 6.24| 15.60
7.00| 1.00| 4.00| 4.30| 4.60| 5.00| 5.50| 6.00| 15.00
8.00| 1.00| 4.00| 4.30| 4.60| 5.00| 5.50| 6.00| 15.00

MOTOR START MODE INTRODUCTION

8.1.- Only protection mode

Terminal| Description| 1. After device powered ON, DO1 act, enters [ Standby ] state, HMI show “Full voltage”
If wiring is wrong, HMI show “Wring Error”, and failure alarm relay DO3 closed;
If wiring is correct, enters [ Standby ] state, HMI show “Full voltage”.
2. When press external start button (SW2), KM loops picks up and latched. Motor powered up enter [ Starting] period:
In [ Starting] period, “Start” light ON, HMI show “Starting”;
After Starting period, “Start” light OFF, “Runs” light ON, HMI show “Running”.
3. When press external stop button (SW1), OR there have protection tripping action:
DO1 released, KM opened, motor stopped and in [ Cooling ] period, used thermal capacity (UTC) drops.
4.  After UTC<15%, enters [ Standby ] state, HMI show “Full voltage”.
---|---|---
DI1| Universal signal input
DI2| Universal signal input
DI3| DI3 closed for HMI panel control;
DI3 opened for external control
DI4| External “Start” switch status
DI5| Universal signal input
DI6| Universal signal input
DI7| Universal signal input
|
DO1| To contractor (KM)
DO2| /
DO3| Motor failure alarm output
DO4| To trip CB (QF)

Notes:

1. Control unit build in protect CT, Sampling CT in drawing:
   Motor rated current < 100A, power line can directly cross through the sampling core on control unit body.
   Motor rated current > 100A, need external …/5A protect CT, external CT secondary wire cross through the sampling core on control unit body. (need configuration in HMI or register 0x201, 0x202)

2. If protector detect failure protect current > Contractor breaking current, there will judgment short circuit protection (See chapter 7.10). DO1 will keep closed until DO4 act and CB tripped (QF), after delay timer then can act DO1 to disconnect contractor (KM).

3. In failure tripping, must use “Reset” switch looped to DI4 or “Reset” button on HMI to erase failure alarm then DO1 can act again to enter [Standby] state.

Typical wiring

Notes: If enable auto restart function (See chapter 7.16), must connect DO2 for restart trip:

8.2.- Full voltage start mode

Terminal| Description| 1.  After device powered ON, detect contactor (KM) state:
If wiring is wrong, HMI show “Wring Error”, and failure alarm relay DO3 closed;
If wiring is correct, enters [ Standby ] state, HMI show “Full voltage”.
2. When device received “Motor Start” signal, DO1 will act, then trig KM closed, motor powered up enter [ Starting] period:
In [ Starting] period, “Start” light ON, HMI show “Starting”;
After Starting period, “Start” light OFF, “Runs” light ON, HMI show “Running”.
3. When device received “Motor Stop” signal, OR there have protection tripping action:
DO1 released, KM will open, motor stopped and in [ Cooling ] period, thermal capacity (UTC) drops.
4. After UTC<15%, enters [ Standby ] state, HMI show “Full voltage”.
Notes : In failure tripping, must use “Reset” switch looped to DI4 or “Reset” button on HMI to erase failure alarm.
---|---|---
DI1| Contactor (KM) status
DI2| Circuit Breaker (QF) status
DI3| DI3 closed for HMI panel control; DI3 opened for external control
DI4| External “Reset” switch status
DI5| External “Start” switch status
DI6| External “Stop” switch status
DI7| Universal signal input
DO1| To contractor (KM)
DO2| /
DO3| Motor failure alarm output
DO4| To trip CB (QF)

Typical wiring

8.3.- Forward and reverse start mode

Terminal| Description| 1.  After device powered ON, detect contactor (KM1) state:
If wiring is wrong, HMI show “Wring Error”, and failure alarm relay DO3 closed;
If wiring is correct, enters [ Standby ] state, HMI show “Forward / Reverse”.
2.A. When device received “Motor Start A” signal, DO1 will act, then trig KM1 closed. Motor powered up enter [ Starting] period, “Start” light ON, HMI show “Forward Starting”;
After Starting timer (0x32F) count down to 0, Motor enter normal runs status, “Start” light OFF, “Runs” light ON, HMI show “Running”.
2.B. When device received “Motor Start B” signal, DO2 will act, then trig KM2 closed. Motor powered up enter [ Starting] period, “Start” light ON, HMI show “Reverse Starting”;
After Starting timer (0x32F) count down to 0, Motor enter normal runs status, “Start” light OFF, “Runs” light ON, HMI show “Running”.
3. When device received “Motor Stop” signal, OR there have protection tripping action. DO1 or DO2 released, KM1 or KM3 will opened, motor stopped and in [ Cooling ] period, used thermal capacity (UTC) drops.
4. After UTC<15%, enters [ Standby ] state, HMI show “Forward / Reverse”.
---|---|---
DI1| Contactor (KM1) status
DI2| Circuit Breaker (QF) status
DI3| DI3 closed for HMI panel control;
DI3 opened for external control
DI4| External “Reset” switch status
DI5| External “Start A” switch status
DI6| External “Stop” switch status
DI7| External “Start B” switch status
|
DO1| To contractor (KM1)
DO2| To contractor (KM2)
DO3| Motor failure alarm output
DO4| To trip CB (QF)

Typical wiring

8.4.- Two-Winding start mode

Terminal| Description| 1.  After device powered ON, detect contractor (KM1) state:
If wiring is wrong, HMI show “Wring Error”, and failure alarm relay DO3 closed;
If wiring is correct, enters [ Standby ] state, HMI show ” Two- Winding”.
2.A. When device received “Motor Start A” signal, DO1 will act, then trig KM1 closed. Motor powered up enter [ Starting] period, “Start” light ON, HMI show “Low Starting”;
After Starting timer (0x32F) count down to 0, Motor enter normal runs status, “Start” light OFF, “Runs” light ON, HMI show “Running”.
2.B. When device received “Motor Start B” signal, DO2 will act, then trig KM2 closed. Motor powered up enter [ Starting] period, “Start” light ON, HMI show “High Starting”;
After Starting timer (0x32F) count down to 0, Motor enter normal runs status, “Start” light OFF, “Runs” light ON, HMI show “Running”.
3. When device received “Motor Stop” signal, OR there have protection tripping action. DO1 or DO2 released, KM1 or KM3 will opened, motor stopped and in [ Cooling ] period, used thermal capacity (UTC) drops.
4.  After UTC<15%, enters [ Standby ] state, HMI show “Two-Winding”.
---|---|---
DI1| Contractor (KM1) status
DI2| Circuit Breaker (QF) status
__

DI3

| DI3 closed for HMI panel control;

DI3 opened for external control

DI4| External “Reset” switch status
DI5| External “Start A” switch status
DI6| External “Stop” switch status
DI7| External “Start B” switch status
DO1| To contractor (KM1)
DO2| To contractor (KM2)
DO3| Motor failure alarm output
DO4| To trip CB (QF)

Typical wiring

8.5.- Wye-Delta Transition mode

Terminal| Description| 1.  After device powered ON, detect contractor (KM1) state:
If wiring is wrong, HMI show “Wring Error”, and failure alarm relay DO3 closed;
If wiring is correct, enters [ Standby ] state, HMI show ” Wye- Delta”.
2. When device received “Motor Start” signal, DO1 will act, then trig KM1, KM3 closed, motor powered up enter [ Starting] period, “Start” light ON, HMI show “Starting”;
3. After Starting timer (0x32F) count down to 0, DO1 released, DO2 act, trig KM2, KM3 closed. Motor in normal runs status.
“Start” light OFF, “Runs” light ON, HMI show “Running”.
4. When device received “Motor Stop” signal, OR there have protection tripping action:
DO2 released, KM2, KM3 will opened, motor stopped and in [ Cooling ] period, used thermal capacity (UTC) drops.
5.   After UTC<15%, enters [ Standby ] state, HMI show “Wye- Delta”.
---|---|---
DI1| Contactor (KM1) status
DI2| Circuit Breaker (QF) status
DI3| DI3 closed for HMI panel control; DI3 opened for external control
DI4| External “Reset” switch status
DI5| External “Start” switch status
DI6| External “Stop” switch status
DI7| Universal signal input
|
DO1| To protect contractor (Relay A)
DO2| To protect contractor (Relay B)
DO3| Motor failure alarm output
DO4| To trip CB (QF)

Typical wiring

8.6.- Auto transformer Closed Transition mode

Terminal| Description| 1.  After device powered ON, detect contractor (KM1) state:
If wiring is wrong, HMI show “Wring Error”, and failure alarm relay DO3 closed;
If wiring is correct, enters [ Standby ] state, HMI show ” Auto transformer”.
2. When device received “Motor Start” signal, DO1 will act, then trig KM1, KM3 closed, motor powered up enter [ Starting] period, “Start” light ON, HMI show “Starting”;
3. After Starting timer (0x32F) count down to 0, DO1 released, DO2 act, trig KM2 closed. Motor enter normal runs status.
“Start” light OFF, “Runs” light ON, HMI show “Running”.
4. When device received “Motor Stop” signal, OR there have protection tripping action:
DO2 released, KM2 will opened, motor stopped and in [ Cooling ] period, used thermal capacity (UTC) drops.
5. After UTC<15%, enters [ Standby ] state, HMI show ” Auto transformer”.
---|---|---
DI1| Contractor (KM1) status
DI2| Circuit Breaker (QF) status
DI3| DI3 closed for HMI panel control; DI3 opened for external control
DI4| External “Reset” switch status
DI5| External “Start” switch status
DI6| External “Stop” switch status
DI7| Universal signal input
DO1| To protect contractor (Relay A)
DO2| To protect contractor (Relay B)
DO3| Motor failure alarm output
DO4| To trip CB (QF)

Typical wiring

8.7- Circuit Breaker directly start mode

Terminal| Description| 1.  After device powered ON, detect circuit breaker(QF) state:
If wiring is wrong, HMI show “Wring Error”, and failure alarm relay DO3 closed;
If wiring is correct, enters [ Standby ] state, HMI show “CB Direct”.
2. When device received “Motor Start” signal, DO1 will act, then trig QF closed, motor powered up enter [ Starting] period:
In [ Starting] period, “Start” light ON, HMI show “Starting”;
After Starting period, “Start” light OFF, “Runs” light ON, HMI show “Running”.
3. When device received “Motor Stop” signal, OR there have protection tripping action:
DO1 will released, QF will opened, motor stopped and in [ Cooling ] period, used thermal capacity (UTC) drops.
4. After UTC<15%, enters [ Standby ] state, HMI show “CB Direct”.
Notes : In failure tripping, must use “Reset” switch looped to DI4 or “Reset” button on HMI to erase failure alarm.
---|---|---
DI1| Universal signal input
DI2| Circuit Breaker (QF) status
DI3| DI3 closed for HMI panel control; DI3 opened for external control
DI4| External “Reset” switch status
DI5| External “Start” switch status
DI6| External “Stop” switch status
DI7| Universal signal input
DO1| To contractor
DO2| /
DO3| Motor failure alarm output
DO4| /

Typical wiring

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.

MAINTENANCE

The PR240 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
Email: tech@cqbluejay.com
www.cqbluejay.com
Add: 1802,Building 2,No.88,Jiangxi East Road,Chongqing,400020,China

References

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

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