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Copyright © 2009 Rockwell Automation, Inc. All rights reserved.

Bulletin 193/592 – Model EC5 E3 Plus Electronic Overload Relay with Voltage Protection and Energy Monitoring

Customer Presentation

Copyright © 2009 Rockwell Automation, Inc. All rights reserved. 2

• The E3 Plus Electronic Overload Relay with Voltage Protection and Energy Monitoring provides you with enhanced motor protection and motor energy consumption information– Enhanced Protection

• Current Protection• Voltage Protection• Power Protection

– Advanced Diagnostics• Voltage Metering• Energy Metering

– Additional Features• Trip History• Warning History• Snapshot Record• 6 Digital Inputs• E3 Status Object (Object Class 0x375)

E3 Plus with Voltage Protection & Energy Monitoring


– Enhanced Protection• Current Protection• Voltage Protection• Power Protection





Current Protection

• The E3 Plus with Voltage Protection and Energy Monitoring helps protect your electric motor investment by preventing damage from the following events:– Thermal Overload– Phase Loss– Jam Warning– Stall– Under Load– Current Unbalance– Ground Fault Current– Ground Fault Current Filtering for

High Resistance Ground Systems


Thermal Overload

• The E3 Plus Model EC5 helps protect your electric motor from consuming more electric current than its nameplate rating which can be caused by:

– Excessive load– Incorrectly sized motor– Low incoming voltage– Damaged equipment

• The trip class of the motor is selectable between 5 and 30

– Trip class represents the maximum trip time in seconds when the motor consumes 720% of the Full Load Amperes (FLA) rating of the electric motor

• %Thermal Capacity Utilization (%TCU) can be monitored to continuously view the thermal status of the electric motor


Phase Loss

• The E3 Plus Model EC5 helps protect your electric motor when one phase of power is lost causing the remaining phases to consume more electric current

• Phase loss is typically caused by:– Blown fuse– Loose wire– Damaged contactor contacts

Phase loss is a leading cause of motor failure!Phase loss is a leading cause of motor failure!


Jam, Stall, & Underload

• The E3 Plus Model EC5 helps provide these protection functions to ensure the safe operation of your electric motor or machine: – Jam protection

• Prevents an electric motor from running when a sudden rise in electrical current consumption occurs during its normal running operation

– Stall protection• Prevents an electric motor from running when

an extended amount of electrical current is consumed during its starting sequence

– Underload protection• Disables an electric motor when a sudden

drop in electrical current occurs indicating a possible mechanical malfunction


Current Imbalance

• The E3 Plus Model EC5 can help protect against the unequal consumption of electrical current on each of the three phases for your electric motor

• Current imbalance protection can be used to prevent electric motor damage from: – Imbalance in the voltage supply– Unequal motor winding impedance– Long and varying cable lengths


Ground Fault

• The E3 Plus Model EC5 has the capability to monitor for short circuits or current leakage to ground and provide equipment level protection (20mA – 5A)

• Low levels of ground fault current can rise very quickly causing damage to the electric motor if not caught early

• The E3 Plus Model EC5 can monitor ground fault current for:

– Solidly grounded systems– High resistance grounded systems

• Ground Fault Current Filtering option for High Resistance Ground Systems to prevent nuisance trips

It is important to catch ground faults at the leakage stage!It is important to catch ground faults at the leakage stage!


Available External Ground Fault Current Transformers

Catalog Number

Inner Diameter

Max Wire Size

3-Phase Current Rating

NEMA Contactor

IEC Contactor

193-CBCT1 20 mm (1) #8 Awg 45A Size 00…1 C9…C37

193-CBCT2 40 mm (1) #2 Awg 90A Size 00…3 C9…C85

193-CBCT3 65 mm (1) 250MCM 180A Size 4 D180

193-CBCT4 85 mm (2) 350 MCM 420A Size 5 D420


Voltage Protection

• The E3 Plus with Voltage Protection and Energy Monitoring helps you to protect against the following voltage issues:– Under Voltage– Over Voltage– Phase Failure– Voltage Unbalance– Phase Rotation Mismatch– Under Frequency– Over Frequency

Protection on the Line Side of the ContactorProtection on the Line Side of the Contactor


Supported Voltage Systems

• The E3 Plus Model EC5 can be used on the following voltage systems:– Catalog Number 193-EC5ZZ

• Delta without Potential Transformers• Delta with Potential Transformers• Wye with or without Potential Transformers• Open Delta with Potential Transformers• Single Phase with or without Potential Transformers

– All Other Catalog Numbers• Delta without Potential Transformers• Wye with or without Potential Transformers• Single Phase with or without Potential Transformers

• Supports direct connections up to 600 VAC (690 VAC IEC)


Power Protection

• To address power quality issues that could occur due to a specific application, the E3 Plus Electronic Overload Relay with Voltage Protection and Energy Monitoring also provides you with the following power based protection :– Real Power (kW) – Reactive Power (kVAR) – Apparent Power (kVA) – Power Factor (PF)

• Leading• Lagging


Advanced Diagnostics

• The E3 Plus Electronic Overload Relay not only helps protect your electric motor investment, but it can proactively assist in maintaining the electric motor by limiting:– Number of starts– Operating hours

• The E3 Plus Electronic Overload Relay can also help provide diagnostic and metering information to help you understand the consumption patterns for the motor or process by providing: – RMS current– Percentage of full load current (%FLA)– Current imbalance– Thermal Capacity Utilization (%TCU)– Trip log– Warning log


Energy Diagnostics

• To address energy usage concerns, the E3 Plus Electronic Overload Relay with Voltage Protection and Energy Monitoring provides you with the following energy diagnostic information:– Real Energy (kWh)– Reactive Energy (kVARh) – Apparent Energy (kVAh)– kW Demand– kVAR Demand– kVA Demand


Energy Diagnostics

• The E3 Plus Model EC5 can be included in your energy management system– Helps identify which motors

contribute to the monthly peak demand and power factor line items on a utility bill

– Helps to verify energy reduction initiatives

Monitoring consumption patterns and adjusting manufacturing procedures helps to use electricity more efficiently!

Monitoring consumption patterns and adjusting manufacturing procedures helps to use electricity more efficiently!


Historical Logs

• The E3 Plus Model EC5 internally records the last five trips and last five warnings– Trip History - Selectively record trip events

– Warning History - Selectively record warning events

– Snapshot Record – Records 12 real-time parameters at the time of the trip event

• Your maintenance personnel can use the historical logs to minimize down time during an unplanned event

Trip HistoryWarning History

Snapshot Record


Inputs & Outputs

• The E3 Plus Model EC5 offers direct control capabilities by offering discreet inputs and outputs in addition to the overload trip relay – 6 Inputs– 2 Outputs

• The E3 Plus Model EC5 also provides discreet outputs that can be used for:– Remotely starting a motor– Indicating a fault or warning– Two speed motor control– Logical discreet control

• DeviceLogix enabled


New E3 Status Object

• The new E3 Status Object (Object Class 0x375) provides a more efficient means to read data from an E3 Plus Electronic Overload Relay


DeviceNet Configuration Terminal

• The DeviceNet Configuration Terminal (Cat. No. 193-DNCT) is an optional device that provides users the capability to configure and view data for any DeviceNet component including the E3 Plus Electronic Overload Relays

• You can perform these functions locally on a DeviceNet network:– Parameter monitoring– Parameter editing – Storage of device configuration data– Network who– Display network diagnostics– Editing DeviceLogix programs– Trend parameters


E3 Plus Model EC5 Catalog Number Scheme

Inputs Outputs PTC Dlogix HT Voltage193/592-EC1 2 1193/592-EC2 4 2 √ Internal 1…5A √193/592-EC3 4 2 √ External 20mA…5A * √

193-EC4 4 2 External 20mA…5A * √ √193/592-EC5 6 2 External 20mA…5A * √ √

Ground Fault


E3 Plus Accessories


E3 Plus Model EC5 Renewal Parts

E3 Plus Replacement Overload Relay 193-NREC5ZZ

E3 Plus Replacement Voltage input Module 193-NVEC5VIM

E3 Plus Replacement Connectors 193-NCEC5CNT



• The E3 Plus Electronic Overload Relay with Voltage Protection and Energy Monitoring provides your with enhanced motor protection and motor energy consumption information– Enhanced Protection

• Current Protection• Voltage Protection• Power Protection

