IB7.2.1.7-4D 49 50 51 (Issue D)
IB7.2.1.7-4D 49 50 51 (Issue D)
IB7.2.1.7-4D 49 50 51 (Issue D)
7-4
Jl 1111 Issue D
,.,1,1,
INSTRUCTIONS
Overcurrent Relay for Motor Protection
CIRCUIT 9 SHIELD en
TYPES 49/50/51, 49/50, 49
Catalog Series 214 Standard Case
TABLE OF CONTENTS
Introduction......................... Page 2
Precautions............... ............Page 2
Placing Relay into Service.... Page 3
Application Data..................Page 4
Specifications.......................Page 6
Testing.................................Page 11
Obsolete Units......................Page 14
INTRODUCTION
These instructions contain the information required to properly install, operate, and test the ABB Circuit-Shield™ Type
49/50/51, Type 49/50, and Type 49 Motor Overcurrent Relays.
The relay is housed in a case suitable for conventional semiflush panel mounting. All connections to the relay are made at the
rear of the case and are clearly numbered. The 414 series relay provides totally drawout construction with integral test
facilities. Current transformer shorting is accomplished by a direct-acting spring and blade assembly upon removal of the
relay from its case. Sequenced disconnects prevent nuisance tripping during withdrawal or insertion of the relay if the
normally-open contact is used in the application. The 214 series relay is of partial drawout construction with the input
transformers remaining in the case upon withdrawal of the lower circuit board.
All settings are made on the front panel of the relay behind a removable clear plastic cover. The targets are reset by means
of a push-button extending through the relay cover.
PRECAUTIONS
I. Incorrect wiring may result in damage. Be sure wiring agrees with the connection diagram for the particular relay before
energizing.
2. Apply only the rated voltage marked on the relay front panel. For units rated for de control power, the proper polarity must be
observed.
3. A tripping circuit must be interrupted by an "a" contact to remove high current from the output circuit. Do not exceed contact
ratings.
4. When applying high input currents during testing, interrupt the current immediately after the relay operates to prevent thermal
stress.
5. High voltage insulation tests are not recommended. See section on testing for additional information.
6. The entire circuit assembly of the relay is removable. The unit should insert smoothly. Do not use excessive force.
7. Follow test instructions to verify that the relay is in proper working order.
8. When handling this relay, take all the necessary precautions to prevent damage from static electricity. This relay contains
static sensitive components which could be damaged without proper grounding .
.A ATTENTION
~ OBSERVE PRECAUTIONS
~ ._ .&. FOR HANDLING
.&f.a...' ELECTROSTATIC
SENSITIVE DEVICES
CAUTION: since troubleshooting entails working with energized equipment, care should be taken to avoid personal shock.
Only competent technicians familiar with good safety practices should service these devices.
Motor Overcurrent Relay IB 7.2.1.7-4
Page3
Upon receipt of the relay (when not included as part of a switchboard) examine for shipping damage. If damage or loss is evident file a claim at
once and promptly notify the nearest Asea Brown Boveri office. Use normal care in handling to avoid mechanical damage. Keep clean and dry.
2. INSTALLATION
Mounting- The outline dimensions and panel drilling and cutout information is given in Fig. 3.
Connections Internal connections are shown in Figure 2. Note that the external connections will be different for the 214 series and 414 series
units. Typical external connections are shown in Figure 1.
These relays have metal front panels which are connected through printed circuit board runs and connector wiring to a terminal at the rear
of the relay case. The terminal is marked "G". In all applications this terminal should be wired to ground.
FAST-RESET terminals 15 and 16 are provided for use during testing or for special applications. A momentary contact closure will fully
reset the relay overload memory. CAUTION: the overload (49) unit will be inoperative when1..'Ver terminals 15 and 16 are connected;
therefore, if a contact is used, it must provide only a momentary closure.
Control power polarity must be observed for relays rated for use on de control. For relays rated for ac control voltage, it is preferred (but not
required) that the grounded end of the supply be connected to terminal 8 and the hot side to tenninal 7.
All units are supplied with an external power resistor mounted on the back of the relay and wired to tenninals 9 and 10. Tilis resistor must be
connected for proper operation.
3. SETTINGS
CURRENT PICKUP TAPS
The tap block, located on the upper part of the front panel, is the "pickup" or "ultimate trip setting" for the OVERLOAD (49) unit. The
settings are marked in ct secondary amperes.
By means of the screwdriver VERNIER adjustment next to the tap block, the relay effectively has a continuous range. With the vernier turned
fully counterclockwise, pickup corresponds to the tap setting. As the vernier is turned clockwise, pickup increases, until at the fully clockwise
position, pickup corresponds to the next highest tap value. With the tap pin in the highest position, the vernier also gives additional range
equivalent to one tap position.
The tap pin may be moved with the relay in service. When the pin is pulled out, pickup switches to the maximum tap setting.
4. INDICATORS
TARGETS
For the Type 49/50/51, operation targets are provided for the 49 and 50/51 functions. For the Type 49/50, targets are
provided for the 49 and 50 functions; and for the Type 49, a target is provided for the 49 function. Control power must be
present to reset the targets, and the overload unit must be in a "thermally-reset" condition.
PICKUP INDICATOR
A light-emitting-diode is provided to indicate when the input current is above the pickup setting. The led will flash on and
off at a rate that is related to the current value: the higher above pickup, the faster the rate of flashing. With the OVERLOAD
dial set at 1 minute, approximately 40 flashes will occur prior to a trip operation (assuming the relay was fully reset when the
overload was applied). For a 5 minute setting approximately 200 flashes will occur.
IMPORTANT: the pickup indicating led is not an operation target. Once a trip occurs the state of the indicating led is
indeterminate. It may go out or it may remain continuously lighted. The led will remain in that state until secondary current
is re-established into the input of the relay. The relay is "timing-out" only when the Jed is flashing.
APPLICATION DATA
The ABB Circuit-Shield™ Type 49/50/51 three-phase Overcurrent Relay provides three important functions for the protection
of motors: overload, locked rotor, and fault detection. Although packaged in one case, the three functions are individually
adjustable, allowing optimum protection without compromise among the various elements. Settings are easily made with
all adjustments on the front panel of the relay.
Unlike bi-metals or other thermal type relays, the Type 49 element has memory of previous overloads with long
reset time; long enough to ensure proper protection in applications involving repetitive overloads and hard
starts. If a second overload occurs before the full reset of the memory, the relay will trip in a time shorter
than shown by the current curves. This relationship may be expressed by the equation below, which is a rough
approximation.
T12
T1 = l -T1 + (Valid when Ti less than I)
where TR is the time in minutes required for a specific time dial setting:
Time Dial 1 2 3 4 5
T2 is the time required for the second overload to cause the relay to trip, as a fraction of the value read
from the time current curve.
TI is the time for which the first overload lasted, expressed as a fraction of the time allowed by the time-current
curve. For example, with the relay set on time dial #1, if the first overload was 2 times pickup and lasted 20 seconds:
20 l
T1 = ········ · - .......
(for time dial # 1)
60 3
TI2 is the time between removal of first overload and application of the second, in minutes.
Motor Overcurrent Relay IB 7.2.1.7-4
Page 5
Solutions to the equation yielding values greater than 1 are not valid, and should be set equal to 1.
Note that the solution is in terms of the time required for a trip. There is no requirement that the second overload be the
same magnitude as the first. For example if the second overload is 2X pickup, and T2 was calculated as 100%, then the
second overload can last as long as 60 sec. (using time dial #1), before a trip occurs. However, if the second overload
happens to be 4X pickup, it can only last 16 seconds or a trip will occur. The minimum interval between overloads may be
calculated by setting T2= 1 ; then T12 = T1 TR. Another example is shown graphically in Fig. 5 for a repetitive overload of
200% tap value, with the 49 unit time dial set at 2 minutes.
This element is designed to provide stalled rotor and high-overload protection. The shape of this curve accommodates both
full and reduced voltage starts. The time delay is adjustable from 5 to 30 seconds at 6 times the overload setting, allowing its
use even with motors having very long starting times.
This instantaneous element is adjustable from 4 to 16 multiples of the overload unit setting. The operating time of this unit
is such that on fused motor starters the relay will trip before the fuse opens on low grade faults, thus saving fuses, but the fuse
will be faster than the relay for faults above the interrupting capability of the starter.
COMPOSITE CHARACTERISTIC
An example of the composite Time-Current Tripping Characteristic for a relay equipped with the 49, 50, and 51 elements is
given in Figure 6. For this example the relay settings are: pickup tap at 120% of motor full load current; time dial (49) set
at 2 minutes; time dial for stall unit at 5 seconds; and instantaneous pickup at 7.2 times full load amperes.
SPECIFICATIONS
INPUT CIRCUIT
Rating: 3 multiples of tap setting- continuous
200 amperes - 1 second (5 amp unit)
40 amperes - 1 second (1 amp unit)
Pickup Taps: 2.5, 2.8, 3.1, 3.5, 4.0, 4.5 (5 amp unit)
0.5, .56, .62, 0.7, 0.8, 0.9 (1 amp unit)
TOLERANCES
Pickup: +/- 10% of setting. Note: tolerances shown are with
Operating Time (49/51): +/- 10% of setting. respect to printed dial markings
on the relay. Final operating values may be
set by test using pickup vernier and time
dials.
TEMPERATURE RANGE
Nominal: 25 degrees C ambient
Additional +/ - 5% tolerance: -15 to +55 degrees C
Must operate: -30 to +70 degrees C
OUTPUT CONT ACTS (Link Selectable For Hand Reset Or Self Reset)
Each contact at 120 vac: at 125 vdc: at 250 vdc:
Tripping: 30 amperes 30 amperes 30 amperes
Continuous: 5 5 5
Break: 2 0.3 0.1
For units with selector link in the hand-reset position, the contacts are reset by pressing the TARGET RESET
pushbutton. If the contacts do not reset at that time, additional time must be allowed for motor cooling.
CONTROL VOLTAGE
DC Reliable Bus ( +) a
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Fivure -4 Figure 6
Example
Type 49 Type 49/50/51 Composite Motor Protection
Allowable Time Between Overloads
for a 2 Minute Curve Overload Unit Set at 1.2 times full load amps.
Locked Rotor Unit set at 5 second curve.
Trip Times in Percent of Times Instantaneous Unit Set at 7.2 times full load amps
from Time-Current Curves
1000
1000
100
.a Locked Rotor
8
• 10
Ill
...
c:
0%.._~~~~~.....----------~
0 2.4 4.8 ...I
f4
1
Minutes Between Successive 0Verl0&d• Locked Rotor Unit '511
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0 l :z l 4 5
' 7
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Figure 5
Example
Type 49
Typical Operation of Thermal Memory Unit
2 Minute Time Dial
Motor current IA
in \ Of ,.,,
Relay Tap Setting
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RELAY TRIPS
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Contents
of Thermal Me1110ry ~
in \ of Total
0
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Time in Minutes
Motor Overcurrent Relay IB 7.2.1.7-4
Page9
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TIME.CURRENT CHARACTERISTICS
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CURRElllT 1111 MULTIPLES OF SETTllllG
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TESTING
No routine maintenance is required on the Type 49/50/51 relays. Follow test instructions to verify that the relay is in proper
working order. We recommend that an inoperative relay be returned to the factory for repair; however, a schematic
diagram will be provided on request. Renewal parts will be quoted by the factory on request.
Drawout circuit boards of the same catalog number are interchangeable. Also units with catalog numbers of the form
214xxxx2 may replace units with catalog numbers the same except of the form 214xxxxl (hand-reset units),where all digits
except the last are identical. Similarly, units of the form 214xxxx3 may replace units of the form 214xxxx0 (self-reset units).
A unit is identified by the catalog number stamped on the front panel and the serial number stamped on the bottom side of the
drawout circuit board.
The board is removed by using the metal pull knobs on the front panel. Removing the board in service does not open circuit
the CT' s; however, in applications using the normally closed contact, a trip will result.
Metal handles provide leverage to withdraw the relay assembly from the case. Removing the unit in an application that
uses the normally closed contact will cause a trip. The assembly is identified by a catalog number stamped on the
front of the unit and a serial number stamped on the bottom of the board.
Test connections are readily made to the Drawout relay unit by means of standard banana plugs. Current connections are
made to the vertical posts at the blade assemblies. Control power and output connections are made at the rear
vertical circuit board. This rear board is marked for easier identification of the connection points.
Should separation of the upper and lower circuit boards be needed, remove (2) screws that attach the left and right handle
assemblies to the upper printed circuit board. The lower board may then be withdrawn forward from the printed circuit
connector. An 18 point extender board (cat. 200X0018) is available from the factory if access to the lower circuit board is
required for troubleshooting.
A test plug assembly, catalog 400X0001 is available for use with the 414 series units. This device plugs into the relay
case on the switchboard and allows access to all external circuits wired to the case. See Instruction Book m 7.7.1.7-8 for
details on the use of this device.
High potential tests are not recommended. A hi-pot test was performed at the factory before shipping. If a control wiring
insulation test is required, partially withdraw the relay unit from the case sufficient to break the rear connections before
applying the test voltage.
A built-in trip test feature is provided as a convenient means of testing the operation of the relay and the associated
trip circuit. Be sure to record or mark the relay settings before proceeding, so you can easily return to the proper settings at
the end of the procedure.
To check the FAULT (50) function, set the Fault dial at 4 multiples. Press the TRIP test button. The relay should trip
instantaneously and display the (50) target.
Motor Overcurrent Relay IB 7.2.1.7-4
Page 12
To check the STALL (51) function, set the Fault dial at 8 multiples (or higher) to avoid instantaneous operation. Set the
Overload dial at 5 to avoid overload operation. Depress and hold the TRIP button. The relay should operate in
approximately the time in seconds set on the Stall dial and a target should be displayed for the 51 function. (The pickup led
should flash during this test, indicating proper operation of the overload unit.)
The above tests are quick functional checks that can be performed without test equipment. High accuracy should not be
expected.
4. ACCEPTANCE TESTS
A typical test circuit for use with a single-phase test current source is shown in Figure 7. The test current connections must
be as shown. Also, since the relay is designed for three-phase applications and responds to the average of the 3 phase
currents, a test current correction must be made for single-phase testing: the test current source must be set to 1.5 times
the desired test currenc to obtain the correct response. (If a three-phase test source is available, no correction would be
required). Apply proper control power per the nameplate rating of the relay.
Thermal memory considerations: when control power is initially applied to the relay, the thermal memory is set at
approximately half-way to the trip point. Therefore, during testing it is preferable that the control power be applied
continuously. Also, terminals 15 and 16 should be momentarily shorted prior to any timing test of the overload (49)
element, to insure that the thermal memory is fully reset.
Interaction Between Elements: some settings and test currents may cause the relay to trip on a function other than that
expected. Check the time-current curves for the planned test current level and time-dial settings prior to running a test.
Usually one or more dials can be set temporarily higher to avoid such interaction.
Pickup test: set the desired tap (use 2.5 if none specified). The vernier should be fully counterclockwise. Increase the test
current slowly until the pickup lamp begins flashing. Note the test current (Remember the l .5x factor when testing with a
single-phase source). Pickup should be within +/-10% of the tap setting (3.37 - 4.13 amperes ifthe 2.5 ampere tap is used
with single-phase testing). Pickup may then be set exactly to the desired value using the vernier adjustment.
Fault Unit (50): set the Stall dial to maximum. Set the Fault dial to the desired setting (use 8x it none specified). Increase
the current quickly to determine the instantaneous unit pickup current. Do not apply high currents more than a few
seconds due to the thermal stress. If the unit does not trip immediately remove the test current and review your procedures.
(Remember the l .5x factor when testing with a single-phase source). The setting may be trimmed as necessary to obtain
the required operating value. (If a setting of less than 6x is to be used, the final adjustment must be deferred until the stall
function is checked). Timing tests of the Fault element are not recommended due to the difficulties in controlling and
measuring very short times. If a timing test must be run, preset the test current for 2 times the fault element pickup setting.
Operating time of0.03 seconds or less is acceptable.
Stall Unit (51): set the Fault dial at 8x or higher. Set the Overload dial at 5. Set the Stall dial to the desired delay. (Use 10
seconds if none specified). Momentarily short terminals 15-16 to reset the overload unit. Apply a test current of6x the
overload pickup setting. (Remember the l.5x factor when testing with a single-phase source). The relay should trip on the
51 function within +/-lOX of the setting. (9-11 seconds if set at IO). If the required setting is known the final timing
adjustment may be made using the time-dial and repeating the test.
Overload Unit (49): set the test current to 2x the pickup value. (Remember the 1.5x factor when testing with a single-phase
source). Set the overload time-dial to the desired setting. (Use #1 dial if none specified). Reset the thermal memory. Apply
the test current. The relay should time out within +/-10% of the value shown on the overload curve 605838 (54 - 66 seconds
if dial # I used). If the required setting is known, the final timing adjustment may be made using the time-dial and retesting.
m 1.2.1.1-4 Motor Overcurrent Relay
Page 13
TEST
IAMPSf fTIME:Rf
SET
i
CONTROL
I STDP
VDLTAliE
PER REL"Y
AflllTINli.
l
0
G
'f
8
RESET
'f
+
1
tr •
3 1
l l
iii; iis
Notes:
1. For single-phase testing as shown, adjust current to 1.5 times desired test current level.
2. Momentary current closure across terminals 15 to 16 fully resets memory circuit of the (49) overload function.
Motor Overcurrent Relay m 7.2.1.7-4
Page 14
The relays referenced here are obsolete and no longer in production. They have been superseded by the improved series 414A,
414B and 414C units covered by this instruction book. The information that follows is a guide to these older units, especially
in the event you are replacing one with the newer relay.
Drawout circuit boards of the same catalog number are interchangeable. Also units with catalog numbers of the form
214xxxx2 may replace units with the same catalog number of the form 214xxxxl (hand-reset units), where all digits except
the last are identical. Similarly, units of the form 214xxxx3 may replace units of the form 214xxxx0 (self-reset units). A unit
is identified by the catalog number stamped on the front panel and the serial number stamped on the bottom side of the
drawout circuit board. The major difference between the 214xxxx0, 214xxxxl series and the 214xxxx3, 214xxxx2 series unit
is that the latter models use hermetically sealed output trip contacts.
The 414A, 414B and 414C series units with catalog numbers ending with the digit "6" have been designed to provide a field
selectable link for changing the output contacts to either "self-reset" or "manually reset". Earlier models had to be purchased
with preselected output contact modes.
Drawout circuit boards are not interchangeable between the 414xxxx2,3 or the 414xxxx6 series. However, the rear terminal
connections are the same for all three series, therefore, the entire relay including the case assembly may be replaced with no
change in the external wiring.
The following is a list of recommended replacement units for the older models:
Note: To complete the catalog number for the above relay list, the "x" must be replaced by a control voltage digit.
Control voltage: x = 0 for 110 Vdc x = 5 for 250 Vdc
= 3 for 48 Vdc = 6 for 120 Vac
= 4 for 125 Vdc
+ Std, + T•st
16D214A C&s•
16D414A
c-•
c
tJS td.l t-Jt
IHllET IHl'UT 1'11111 Tt:IT UIE DNLV.
01& 015 u
01~ 111 f:~~~
lllEllT INl'UT ,.Diii TIEIT UI[ DNl.V.
Note: Units rated for 250 Vdc control are supplied with a 8200 ohm, 25 watt resistor connected to terminals
14 and 15. This resistor must be connected to these rear terminals for proper relay operation.