857 Programming - Motor Protection v1.12.6

Bulletin 857 Motor Protection
Programming Basics
V 1.12.6
John A. Kay, C.E.T., IEEE Fellow
Principal Engineer
Rockwell Automation Canada
857/865 Product Manager
1500 MV Motor Control Product Manager
PUBLIC
Copyright © 2018 Rockwell Automation, Inc. All Rights Reserved. 1

What you need to know!
 Only trained personnel should attempt complete programming of 857 products for
user applications!!!
 Always check for the latest version of the SetPointPS software
(http://compatibility.rockwellautomation.com/Pages/MultiProductDownload.aspx?crumb=112&keyword=SetPointPS )
 You should ALWAYS use a programming cable (857-VX003-3) or you can program via an
ethernet port (if the relay is equipped)
 YOU CANNOT do firmware flash via ethernet
 The use of a Null Modem cable will cause firmware upload failures!
 If you computer does not have a serial port, you will need to obtain a USB to Serial
Converter such as the Bulletin 9300-USBS or an equivalent (download latest drivers)
 You will need to obtain all of the motor/feeder data as well as obtain the expectation
for control and protection requirements before you begin!
PUBLIC V1.12.6 Copyright © 2018 Rockwell Automation, Inc. All Rights Reserved. 2
SetPointPS Programming Software
 Download from
 http://compatibility.rockwellautomation.com/Pages/MultiProductDownload.aspx?crumb=112&keyword=SetPointPS
 Encourage customers to also download (free)
SetPointPS Initial Program Set Up
 A –Select Settings| Program Settings
 B – Enable Continuous Updating from device
 C – Enable Online Measurements
 D – Enable Folder View
 E –Create a file folder (if it is not already on
you HDD) and Enable Events & Change Logs
 F – Make sure Root Directory (and alternative
backup directory is addressed here)
 G – Pre-define passwords for ease of use
Communications Set Up
 A – Setting | Communications
Setup
 B – Select Network for ethernet
connection
 C – Enter IP address of relay
OR
 D – For serial connection select
Port used for USB to Serial
converter
 E – Default speed is 38400 baud
SetPointPS- Tips and Tricks
 Special settings which can provide enhanced troubleshooting capabilities
SetPointPS Setup Tips- Folder View
 Filters parameters/data under
functional Tabs or Folders
 Must be configured before
connecting to a relay
SetPointPS- Online Measurements
 Displays analog Online Measurements
data in real time

 Very useful when
using the Virtual
Measurements
Tool
 Must be selected
before connecting
to the relay
SetPointPS-Visualization of Trips/Alarms
 If the user wishes to see Alarms and Trip information displayed on the HMI
immediately…
 Insure that the Enable Alarm Screen box is checked
SetPointPS Setup Tips
 PU versus Primary Units for faults
 In Local Panel Conf selections
 Selectable based on preference
 Format for fault values
Per Unit Based Primary Units Based
 Reduce the complexity of the Output Matrix
 Typical output matrix will include all status
indictors in the left hand side
 This could be several screen long
 Many of those status indictors may not be
being used
 Utilize the ‘Show only used matrix signals’ option
 Will remove all of the unused status signals in the output matrix display
 Generally reduces the number of screens down to two or three
 Easy to visualize all of the connected and utilized status and commands
 Make sure you disable this feature if you want to see all of the status
elements…
WebSet
 Ethernet I/P based setting and interrogation tool
 Access any relay over ethernet I/P (if permitted by firewalls)
 Perform a remote device restart
 Similar to SetPointPS
 Does not include Virtual Measurement tool
 Does not include Disturbance Recorder Tool
 Cannot perform a firmware update
WebSet-
Ethernet based programming tool
 Similar functionality to SetPointPS-
different graphical interface
 Ethernet I/P based
 IP address required to access
 Two levels of security/access
 User-view only mode (user)
 Configurator mode (conf)
 Passwords same as in
SetPointPS
WebSet-
Ethernet based programming tool
 Includes full graphic capabilities
 Metering and data shown
 Monthly minimums and maximums
 Real time data measurements
What you need to know before you start!
 You need to understand the application requirements, e.g. what is the
switching device: a fused contactor or a circuit breaker?
 How is the I/O used in the control circuit…
 DO NOT ASSUME!!!. Large motors are expensive and the protection values
you set could make the difference between full or inadequate protection
 This presentation covers only a very small portion of the relay’s capabilities
 If you don’t know, don’t guess!
Product Support (857/865)
 Utilize the on-line knowledgebase tools
https://rockwellautomation.custhelp.com/app/home
 Utilize the local distributor as a first contact for product support!!!
 Or, utilize our support line 440-646-3434 or 888-382-1583 (North America)
select Option 3 (Technical Support), then select Option 5 (More Options)
then, when prompted, enter code 513 for 857/865 support
Supporting resources…
 The 857 has a very wide scope of control and protection capability, as well as world class levels of functionality and
configurability
 This is a product designed for global applications, it utilizes both IEC and ANSI symbology and terminology
 Refer to the product documentation for additional assistance
 857-PP001 Product Profile
 857-UM001 857 User manual
 857-UM002 RTD User Manual
 857-UM003 857-VPA3CG Profibus DP Option Module
 857-UM004 857/865 IEC 61850 Configuration Instructions
 857-PM001 SetPointPS User Manual
 857-QS001 857 Quick Start Guide
 http://ab.rockwellautomation.com/Circuit-and-Load-Protection/Medium-Voltage/857-Medium-Voltage-
Protection#documentation
Protection#software
The Basics- Section #1
 Basic Navigation on the front panel
 What Protection Elements are really needed?
 Protection differences between Fuse Contactors versus Circuit Breakers
 Protection element selection
 Difference of terminologies used
 ANSI versus IEC
 857 uses both terminologies where possible
IEC versus ANSI
 857 is a global product - installed in many parts of the world
 Sold in RA finished goods and to global OEMs
 It has been designed to work in the global community
 It has features optimized for both IEC and ANSI protection
 Unlike competitive products, it can control and protect a multitude
of varying applications and switching devices
 You may be exposed to either ANSI or IEC symbology depending on
the project, where it originated from, where it is applied or where it is
installed
Local panel user interface of 857 and
865
LOCAL PANEL PUSH BUTTONS
UP
CANCEL/ ENTER INFO
RESET
LEFT RIGHT
• Change Contrast*
• Enter Password
DOWN *after password entered
• Press once to acknowledge each
event in the alarm list
• Press and hold for approximately 3s to
reset all latched indicators
Local panel menu structure
When moving up or down the next
screen is always one of the leftmost
screen (Main menu).
Pressing the CANCEL button

for three seconds puts you back to
the first screen of the main menu
Set up like a Windows file tree

Local panel user interface
Display provides clues on where addition information can be found in these
display rung
Scroll left and right

Scroll bar indicates
you can scroll up and
down
Protection Element Condition/Status
 The way the status of a protective element is given varies different regional
standard. The variances are shown below between ANSI and IEC
IEC ANSI
Condition of the element is that it has detected a level
within the setting range programmed and it is still
Start Alarm within the programmed delay time of the protection
Protection
element setting
condition Condition of the element is that it has detected a level
Trip Trip within the setting range programmed and the delay
time has expired
Allen-Bradley 857
Hardware Configurations - Overview
One communication
channel used for
optional RTD
scanners
Ethernet,
RS 232/RS485,
Serial Fiber,
SPA-Bus,
Profibus
DNP 3
Hardware Interfaces &
Supported Protocols
External I/O: RTDinput

External I/O: Modbus
Interface Supported
ModBus TCP
Protocols
Profibus DP
Ethernet IP
IEC-61850
ANSI 85
DNP 3.0
IEC-101
IEC-103
ModBus
SpaBus
GetSet
None
RS-232
Physical Interface
RS-485
Serial fiber Tx&Rx
Copper Ethernet
RTD fiber (Rx)
Profibus
Dual Fiber Ethernet
What Protection Elements are Needed
 Ultimately the user must choose the protection based on the size of the
motor, the current switching device, the application and other process
related controls
 Many users have no

idea what they need or
want!!!
IEC & ANSI Terminology
Both methods are

shown where possible.
Not all locations show
both!
Minimum Suggested Protection for
Fused Contactor Control
Current stages Earth-fault stages
Recommended Recommended
Enable for I> (50/51) OFF* Enable for Io> (50N/51N) ON
Enable for Io>> (50N/51N) ON*
Enable for I>> (50/51) OFF*
Enable for Ioφ> (67N) OFF
Enable for I>>> (50/51) OFF*
Enable for Ioφ>> (67N) OFF
Enable for Iφ> (67) OFF
Enable for Io>>> (50N/51N) OFF
Enable for Iφ>> (67) OFF
Enable for Io>>>> (50N/51N) OFF
Enable for Iφ>>> (67) OFF Enable for Uo> (59N) OFF
Enable for Iφ>>>> (67) OFF Enable for Uo>> (59N) OFF
Enable for I2> (46) ON
Voltage stages:
(unless 3 phase reference
Enable for I2>> (47) ON voltages are applied)
Enable for Ist> (48) ON Enable for U> (27) OFF
Enable for N> (66) ON Enable for U>> (27) OFF
Enable for U>>> (27) OFF
MOTOR STATUS ON
Enable for U< (27) OFF
Enable for I< (37) OFF Enable for U<< (27) OFF
Enable for If2> (51F2) OFF Enable for U<<< (27) OFF
Enable for If5> (51F5) OFF
*- May be used for other protective functions, details to follow

Fused Contactor Control
Other functions:
Frequency stages:
Recommended
Recommended
Enable for P< (32) OFF
Enable for f >< (81) OFF
Enable for P<< (32) OFF
Enable for f><>< (81) OFF
Enable for T> (49) ON
Enable for f< (81L) OFF
Enable for CBFP (50BF) OFF
Enable for f<< (81L) OFF
Enable for Prg1 (99) OFF
Enable for df/dt (81R) OFF
Configuration for RTD Protection Enable for Prg4 (99) OFF
Configurations for detecting Enable for Prg6 (99) OFF
Communication Enable for Prg7 (99) OFF
Errors Enable for Prg8 (99) OFF
Protective Function Selection is based on the hardware

configuration, the users needs and the hardware configuration
Breaker Control- Motors
Enable for Io> (50N/51N) ON
Enable for I> (50/51) ON
Enable for Io>> (50N/51N) ON*
Enable for I>> (50/51) ON* Enable for Ioφ> (67N) OFF
Enable for I>>> (50/51) ON*
Enable for Ioφ>> (67N) OFF
Enable for Iφ> (67) OFF
Enable for Iφ>> (67) OFF Enable for Io>>> (50N/51N) OFF
Enable for Iφ>>> (67) OFF Enable for Io>>>> (50N/51N) OFF
Enable for Iφ>>>> (67) OFF
Enable for Uo> (59N) OFF
Enable for I2> (46) ON Enable for Uo>> (59N) OFF
Enable for I2>> (47) ON
Voltage stages:
(unless 3 phase reference
Enable for Ist> (48) ON voltages are applied*)
Enable for N> (66) ON Enable for U> (27) OFF

MOTOR STATUS ON Enable for U>> (27) OFF
Enable for I< (37) OFF*
Enable for If2> (51F2) OFF Enable for U<< (27) OFF
Breaker Control- Motors
Frequency stages: Other functions: Other Protection stages:
Recommended Recommended Recommended
Enable for f >< (81) OFF Enable for P< (32) OFF CT Supervision ON
Enable for f><>< (81) OFF Enable for P<< (32) OFF VT Supervision ON
Enable for f< (81L) OFF Enable for T> (49) ON CB Wear ON
Enable for f<< (81L) OFF Enable for CBFP (50BF) ON
Enable for df/dt (81R) OFF Enable for Prg1 (99) OFF
Enable for Prg3 (99) OFF Configuration for RTD
Enable for Prg4 (99) OFF Protection
Enable for Prg6 (99) OFF Configurations for detecting
Enable for Prg7 (99) OFF Communication
Errors
Breaker Control- Feeder
Enable for Io> (50N/51N) ON
Enable for I> (50/51) ON
Enable for Io>> (50N/51N) ON
Enable for I>> (50/51) ON* Enable for Ioφ> (67N) OFF*
Enable for I>>> (50/51) ON*
Enable for Ioφ>> (67N) OFF*
Enable for Iφ> (67) OFF*
Enable for Iφ>> (67) OFF* Enable for Io>>> (50N/51N) OFF
Enable for Iφ>>> (67) OFF Enable for Io>>>> (50N/51N) OFF
Enable for Iφ>>>> (67) OFF
Enable for Uo> (59N) OFF
Enable for I2> (46) ON Enable for Uo>> (59N) OFF
Enable for I2>> (47) ON
Voltage stages:
(unless 3 phase reference voltages
Enable for Ist> (48) ON applied*)
Enable for N> (66) OFF Enable for U> (27) OFF
MOTOR STATUS OFF Enable for U>> (27) OFF
Enable for I< (37) ON*
Enable for If2> (51F2) OFF Enable for U<< (27) OFF
Breaker Control- Feeder
Frequency stages: Other functions: Other Protection stages:
Recommended Recommended Recommended
Enable for f >< (81) OFF Enable for P< (32) ON CT Supervision ON
Enable for f><>< (81) OFF Enable for P<< (32) ON VT Supervision ON
Enable for f< (81L) OFF Enable for T> (49) OFF CB Wear ON
Enable for f<< (81L) OFF Enable for CBFP (50BF) ON
Enable for df/dt (81R) OFF Enable for Prg1 (99) OFF
Enable for Prg6 (99) OFF Configurations for detecting
Enable for Prg7 (99) OFF Communication
Errors
Summary
 Download the latest version of SetPointPS
 Configure program settings in SetPointPS – usually only the first use is
required
 Configure communications: Either via Serial or Ethernet, based on the
connection used at the time
 Understand the Protective Element Status Conditions
 Understand the basic protection requirements for Motor or feeder : Fused
contactors versus circuit breakers
Section #2
Motor Protection Fundamentals
 Basic Relay set up
 Protection Elements, Section A
 Setting up the external analog devices, i.e., CTs, VTs etc.
Motor Electrical Protection
 Thermal Overload
 Process Caused (Excessive load)
 High Ambient Conditions (Hot environment, Blocked Ventilation)
 Power Supply Issues (Voltage/Current Unbalance, Harmonics)
 Phase Faults
 Single phasing or incorrect phase relationships
 Ground Faults
 Abnormal Operating Conditions
 Over & Under Voltage
 Under frequency
 Voltage and Current Unbalance
 Load Loss
 Jamming
 Jogging
Overload Protection - Thermal Model
 A motor can be run overloaded without a fault in motor or supply
 The primary protective element in a motor protection relay is the thermal
overload element - T> (49)
 This element is provided through a motor thermal image modeling
 The thermal models must account for thermal process in the motor while
motor is starting, running at normal load, running overloaded and stopped.
 Algorithm of the thermal model integrates both stator and rotor heating into
a single model.
Overload Protection - Thermal Model
 Main Factors and Elements Comprising the Thermal Model are:
 Overload Pickup Level
 Overload Curve
 Running & Stopped Cooling Time Constants
 Hot/Cold Stall Time Ratio
 Motor State Machine
 Unbalance Biasing
857 Detects Various Motor States
 Motor Stopped:
 Current is < threshold & contactor/breaker is open
 Motor Starting:
 Previous state is “Stopped” & Current > threshold.
 Motor current must increase to the level higher than overload pickup within a given
time
 Motor Running:
 Previous state is “Starting” or “Overloading” & Current drops below overload pickup
level
 Motor Overloading:
 Previous state is “Running” & Current raises above overload pickup level
 Thermal Capacity Used (TCU) begins to accumulate during overload
857 configuration and setting steps
The configuration and setting of a 857 can be divided into six parts:
1) Obtain information regarding the load and the application

2) How is the relay connected to the load and the measurment devices?
3) Enter the scaling parameters. CT, VT (i.e. PT), motor’s name plate values etc.
4) Select which protection stages and other features are to be used
5) Configure the setting values for each protection stage based on the application.
6) Map the trip and Start (Alarm) signals from the used protection stages to the output
relays, virtual ouputs and LEDS using the output matrix
7) Configure the communication protocols being used
PUBLIC V1.12.6 Rockwell Automation, Inc. Copyright © 2018 Rockwell Automation, Inc. All Rights Reserved. 41
857 application example
Application example #1
• Motor feeder, contactor controlled- (BREAKER control is different)
• Direct On Line (DOL) starting
• Duty cycle S1 (continuous running, constant load)
Name Plate Values
Induction motor 710 kW (952 hp)
Rated current (FLA) 152 A
Start current (LRA) 5.3 pu (530% FLA)
Max. start time 15 s
Service factor 1.15
Max. # of starts/hr 2
Induction motor protection example
 Motor/Application data
 Max. Motor voltage = 4160 V
 Full Load Current = 152 A
 Locked Rotor = 5.3 x FLC @100%V
 Service Factor = 1.15
 Load Start time = < 30 sec @100%V
 Starts/Hr. = 2
 Class F insulation system
 Class B temperature Rise
 Starter Info
 Fused contactor
 Primary CTs = 200:5
 Ground Fault CT = 100:1
 PT/VT = 4160V:120V
 Open Delta
General Settings- Step 1
Information about the relay location

Purpose of these descriptors is to help in the
Identification, commissioning, later
maintenance of the relay and connected load
and to provide a descriptor for archiving of the
setting files using with the SetPointPS program
Sublocation only appears on the front panel of

the device -[Maximum of 9 characters
visibale on display]
Information to show on the relay front panel
Device name
Displayed in the HMI display at upper row
when the ” Title screen” is selected.
Device type:
Displayed in the HMI display at middle row
when the ” Title screen” is selected.
Information regarding the installed

firmware, serail number & date
Serial number:
Serial Number of the relay- maybe shown in VID
section depending on firmware version
Order Code: Not used
Program version:
Firmware version
FLASH memory size: Size of EEPROM
Information regarding SetPointPS

compatibility
Minimum setting tool version:
Lowest applicable version of SetPointPS software
that will function properly with this version of
firmware
Current setting tool version:
Version of SetPointPS software currently
connected to the relay
Information regarding the Date and

Time in the relay
Date and time: Date and time on board the
relay
Time and date of the relay can be set manually

from the front panel HMI or using the SetPointPS
software
SetPointPS also provides a single click function to
sync relay’s clock to your PC’s clock
Settings for the front panel display contrast

Display contrast:
The display contrast may be set up by values
from 50 to 210, where the value 210 is maximum
dark and 50 the minimum
Display backlight ctrl: This selection sets the
trigger for engaging the display backlight to a
digital or virtual input (Local Panel Conf setting)
The input may be one of the digital or virtual
inputs or from any on board logic functions
Backlight is turned on when ever a front panel

button is depressed and remains on for the
programmed timeout (range 0 – 2000 min.
Settings for the relay access levels

Panel access level: Displays which level the
current user has been logged in to the relay from
the HMI
There are 3 acess levels (default passwords
shown)
No password: User, Viewing of the logs and
measurements only
0001: Operator = Setting changes allowed
0002: Configurator = Unrestricted access
PC access level: SetPointPS user access level
Tested by and Calibration date: Information from

the relay calibration and the initials of calibrator
Change password(s): The currently logged in
user, with this selection, can add a new
password replacing the default password(s) in
the relay
Application mode
 Set the application mode to “Motor”.
 If the mode was ”Feeder” before,
let the device automatically restart and
re-read all data from the relay to the
SetPointPS This makes the MOTOR protection
functions available
Note: If working offline using a template,

the template must be a MOTOR template!
857 Scaling Configuration- Step 2
Scaling
 Motor FLA (rated current)
 CT Primary
 CT Secondary
 VT (PT) Primary
 VT (PT) Secondary
 ZSCT#1 Primary
 ZSCT#1 Secondary
 ZSCT#2 Primary
 ZSCT#2 Secondary
(earth/ground fault CTs)
 Do not change!
 Voltage measurement mode
Wye-Wye = 3LN
Open-Delta = 2LL+Uo
(other settings for special applications)
 Freq. Adapatation mode
(Auto = Uses 1st two voltage inputs as reference, at least one must be active)
Section #2 Summary
 The basic set up of the relay
 Customer variables (ID)
 Display basics
 Setting up the basic configuration
 Current and potential transformer ratios
 PT/VT connection method
Section #3
Selection of Protection Elements
 Selection of protective elements
 How to select the protection elements needed for the application
 Basic configuration of those elements
Select and Validate Protection Stages-
Step 3
Select the protection stages to be used
 51 overload, low setting*
 51 Jam*
 50* used to block other
stages to let the fuses do the breaking
in case of high fault currents
 46 current unbalance
 47 Incorrect Phase Sequence
 48 stall
 66 prevent too frequent starting
 51N low set earth fault

 50N high set earth fault
 49 Thermal Protection
*- 50/51 elements are not used for general S.C. protection on

fused contactors (fuses provide S.C. protection)
Select and Validate Protection Stages-
Step 3
Thermal overload stage

The stages circled are the recommended
settings for most motor applications. For
motors controlled via a CB, other selections
will be required. Other selections will be based
on user preference.
857 Protection settings- Step 4
I> 51 for Sensitive Overload, low setting
Use this element for applications where the
motor can be driven into overload
Stage must be blocked (Block Matrix) by the
”Motor start” status signal to avoid tripping
during start!
Pick-up = S.F.of the motor
Delay curve family

[DT, IEC, IEEE, IEEE2 or RI]
Delay Curve Type
[DT, NI, VI, EI, LTI]
Operational Delay Time
(just longer than the longest allowed O/L time)
NOTE: Screen options change if

Definite time (DT) is NOT used
I>> 51 (Used for Jam or Locked Rotor Protection)
Note: coordination with the main power fuses needs to be
considered
Pick-up (pu of Motor FLC)

- Set well below the LRA (~2.5 pu)
- Set well below the interrupting capacity
of the switching device (contactor)
Operation Delay Time

- Set 10-25% faster than the max. allowed start time (shorter time)
Use a high set 50 (I>>>) to block this stage to let the fuses break any high fault
currents.
I>>> 50 (High Setting)
Used to detect locked rotor or short circuit
This stage is not used to trip the contactor*!
Instead it’s used to block other protection
stages in case of short circuit fault.
Short circuit faults are then handled by the fuses.
*-May be used with CB control
Pick-Up Setting
(at least 2 pu HIGHER than the LRC pu current BUT
well below the breaking capacity of the contactor.
400A contactor = 6kA interrupting

800A contactor =12.5kA interrupting
NOTE
LRA = 5.3 pu. in this example
When the motor is started, the current
will exceed the pick-up values of both
51 stages I> and I>>.
These stages must be blocked by the
”Motor start” status signal to avoid tripping during start!
PUBLIC V1.12.6 . Copyright © 2018 Rockwell Automation, Inc. All Rights Reserved. 60
48 Stall Protection
The breaking capacity of the contactor must
exceed the start current. Otherwise this stage must be used for alarm only.
Start Detection Level (1.5 pu nom)

LRA (pu of name plate FLA)
Delay Curve Type
Operation time
(set 10% below the allowed maximum start
time as a rule of thumb)
Note:
This stage is active only when the motor is starting. This stage will not
detect rotor stalling during normal running.
The 2nd 51 stage (I>>) is used for jam protection during normal running.
Overcurrent
Coordination
Interrupting device
opening time
Interrupting capacity of
interrupting device
which must be > than I>>>
46 Current Unbalance
 Induction motors won’t withstand
much current unbalance
 Motor manufacturers traditionally
don’t specify the allowed limits for unbalance
 Thus a sensitive setting is preferred (5-15%)
Pick-up (% x FLA)
Delay Curve Type
Delay time
66 Maximum Starts/Hour
Note:
This stage is not used to trip the interrupting device.
It used to prevent subsequence starts of the motor.
Starts in the last 1 hour period

Elapsed time since last start
Status of the element (see below)
Starts counted by relay
Status
Motor name plate values Enabled = Starts are permitted
Note: Disabled = No Starts are permitted
Most large MV motors are rated for only 2 start/hour. OneLeft = One start left - >66 alarm activated
Always refer to the motor manufacturers information.
Refer to Technical Advisory 026-2013.1 for implementation details within for 1500 products
Frequent Start Protection N> 66
This stage is not tripping, but used

to disable too frequent starting.
Let’s limit the motor to

2 starts per hour
Minimum time NC contacts of output relay A3 is

used to inhibit starting
between starts to 30
minutes
OneLeft initiates the N> Alarm signal (not shown active below)
Disable initiates the > motor start inhibition signal in O/P Matrix
(stays active for as long as the Min time between starts setting)
Enable disengages both the N> Alarm and the N> motor start
inhibition
Refer to Technical Advisory 026-2013.x for

implementation details within Bulletinn 1500 products
N> (66) Maximum Starts/Hour MVMCC
• Default setup for the n> motor start
inhibition signal in the OP matrix is a
latched connection to T1 (N.C.)
• This is NOT the condition that should be
used for fused contactor style control
• Utilize an alternative output relay in
combinations with a modified control rung
(A2 used in this example)
• Setting the minimum time between motor
starts to zero will disable the > motor start
inhibition signal and permit immediate
OneLeft initiates the N> Alarm signal (not shown active here)
restarts!!!
> motor start inhibition signal activated with Disable status in 66 element
(stays active for as long as the Min time between starts setting)
Enable disengages both the N> Alarm and the N> motor start inhibition
Trip circuit for 3 wire Contactor Control
Trip and 66 (N>) circuitry used in fuse contactor configurations
This control scheme should be used for electrically held contactors to prevent a start/trip
based on #starts in an hour and time between starts
O/P A2 should be mapped to N> Motor Start Inhibition
If this method is not used, the motor will be permitted to start then is immediately tripped
offline due to # starts. (CB protection is NOT done this way)
N> (66) - Maximum Starts/Hour
Start #1 Start #2
Motor Starting
Motor Running
Disabled Disabled
One
Enable Left Enable
Motor Start Status (N>/66)
N> Alarm
N> Motor Start Inhibition
Min. Time between starts (customer setting)
60 minute count down timer (starts/hr)
N> (66) Maximum Starts/Hour (CBs)
• Factory default setup for the n> motor start
inhibition signal, in the OP matrix, is a latched
connection to T1
• Used with CBs, T1 set to Non-failsafe (N.O.)
 OneLeft initiates the N> Alarm signal in the Output Matrix

 > motor start inhibition signal activated with Disable status in 66
element & Mot Str Dis in event buffer (stays active for as long as the
Min time between starts setting)
 Enable disengages both the N> Alarm and the N> motor start
inhibition in the Output Matrix
 In Event Buffer Mot Str Ena= Time between starts has expired >
motor start inhibition signal deactivated
51N, G or GS Ground Fault Protection
51N, G or GS Ground Fault Protection
(low setting)
(N= residual , G= Neutral point via CT, GS= core-balance via CT)
Input for measurement of sensitive 51 protection.

(Options are Io1, Io2, IoCalc = solidly grd’d system)
Any local requirements must be fulfilled when

calculating the setting values.
Pu value of Primary ratio of ZSCT

(Std ZSCT ratio = 100:1 on MV MCC)
Delay curve family
Delay Curve Type
If you are connected to a relay, this value will be calculated
[DT, NI, VI, EI, LTI] and displayed by the relay– if you’re not connected this
Delay Time value will not change if you change the setting
51N or G Ground Fault Protection
51N or G Ground Fault Protection- For Solid
Grounds
(High Setting Io>>)
50N or G protection in solidly grounded systems

[Any local requirements must be fulfilled when
calculating the setting values]
Pick Up Setting
(pu of Primary CTs primary ratio- in this example
Primary CTs are 200:5)
Delay Time
The high setting for the 50 element is used to block
this stage to let the fuses break any high fault currents
Session #3 Summary
 Selection of protective elements
 How to select the protection elements needed for the application
 Basic configuration of those elements
Section #4
Protection Settings, continued
 Stall Protection
 Alternative uses of 50/51 elements
 Jam
 Low level over current
 Thermal protection (T>, 49)
 Ambient RTD input modifier
Stall/prolonged start protection, (stator critical motors)
Stator critical motors have equal limit for

locked rotor time (stall time) and the
maximum start time.
In = 420A
Un = 11 kV
M Pn = 6800kW
Istart = 530%
Start Time = <30 s
Start/hr = 2 A 10 % safety margin
”Inv. time coefficient k” is the delay parameter for

inverse i.e. ”INV” type delay.
Stall/prolonged start protection
Delay type ”INV” allows more time for starting if the start current is less than specified. This can happen
when the supply voltage drops during starting.
Stall protection of a rotor critical motor
Rotor critical motors have a shorter locked rotor time than the maximum allowed start time. However, the start current can be
equal to the current of a locked rotor situation (i.e. stalled) during long acceleration times
In such a case, a speed switch may be used or needed for stall protection
NC speed Digital
switch input 6
In this case,
The speed switch opens when rpm exceeds
e.g. 80 % of the synchronous speed and the
Istall> stage will be blocked.
Thus the stall protection is enabled only
during starting.
Overcurrent protection I> 51 (alt. 1)
Case 1 allowing repeated cyclic overloading
Use the thermal limit curves for the motor to determine the
withstand current (PU) and the delay time.
NOTE: When using any 50/51 protection elements, in combination with fused contactor
controllers, insure the coordination with power fuses and the current switching device.
Insure the contactors interrupting capabilities are not compromised.
Overcurrent protection I> 51 (alt. 2)
Case 2, no cyclic overload
With these settings the load current must

never exceed 1.25 PU for longer than 2 s.
This low set and relative fast stage must be

blocked with ”Motor starting” signal to avoid
tripping during start.
Short circuit protection I>> 50 (CBs)
In = 420A
Un = 11 kV
M Pn = 6800kW
Istart = 530%
Start Time = <30 s
Start/hr = 2
More coarse settings can be used as long as

the selectivity of the whole network is
maintained and the cable is also protected.
5.3 + 10% = 5.83
From the motor’s point of view, 5.83 x Imot is enough to allow starting
Risks for an Overheated Motor
 Stator Windings Insulation Degradation (for stator limited motors)
 Insulation lifetime decreases by half if motor operating temperature
exceeds thermal limit by 10ºC for any period of time
 Rotor conductors deforming or even worse, melting
 For rotor limited motors - thermal limit is defined by motor stall time
 i.e. incorrect programmed stall times could = motor damage
 Proper RTD temperature settings are important!!!
 Proper thermal element settings are equally as important!
Risks for an Overheated Motor
For class F insulation,
a stator temperature
of 165C causes the
motor lifetime to
decrease by 50%
Thermal overload protection T> 49
The thermal overload stage is
protecting against prolonged and
cyclic overloads.
 
( )
t
−
Θ(t ) = I − I2 2
P ⋅ 1 − e τ  + I P2

 
In this example the motor manufacturer did not specify overload factor k (i.e. service factor) or time constant t.
We can approximate the overload factor using the motor’s insulation classes.
From a motor specs:
Class F insulation system:
Maximum allowed temperature rise Θmax = 105 K + 10 Khot spot margin @ TAmb = +40 °C
Class B temperature rise

Maximum allowed temperature rise Θmax = 80 K + 10 Khot spot margin @ TAmb = +40 °C
Overload factor i.e. service factor can be estimated as follows:
105 + 10
k= = 1.13
80 + 10
Estimating the thermal time constant
The equation 1 is based on the
IEC 60255-8, appendix B thermal model:
single time constant model
I 2 − I P2
t = τ ⋅ ln 2 (eq. 1)  −
t

I −k2 Θ(t ) = cI 2 1 − e τ 

(eq. 2)
t = operation time  
τ = thermal time constant
I = measured current
IP = precurrent corresponding the temperature rise so far. This is the memory of the model.
k = overload factor i.e. service factor
Solving τ from equation 1 and setting IP = 0, i.e. cold curve, we get

t
τ= (eq. 3)
I2
ln 2
I − k2
Estimating thermal time constant
I = 1.6 PU
We approximate the thermal time constant using the first t = 400 s
point of the thermal limit cold curve and equation 3.
400
τ= = 579.1s
1.6 2
ln 2
1.6 − 1.13 2
Let’s use a 10 % safety margin

τ = 0.9 ⋅ 579.1s = 521.2 = 8.7 min
Check the estimated parameters k and τ against the thermal limit curves
Protection
The matching is not perfect. characteristics for a
cold motor
Especially a hot motor will be Thermal limit curve
overprotected. for a cold motor
A user programmed I2t curve for

a 51 stage would have a perfect
Thermal limit curve
match, but no memory. for a hot motor
Protection characteristics
for a hot motor
Example of an other motor with better match to the thermal model
t6x value gives thermal constant τ=13 minutes.
This leads to a small over protection. τ=12 minutes gives exact fit.
Standard overcurrent (extremely inverse) curve is used for acceleration protection.
Overload factor i.e. service factor
Thermal time constant t (cooling time!)
Ambient temperature compensation
Ambient temperature measurement via

RTD to control the overload factor
In this example RTD 1 (ExtAl1)
If no input selected manually enter Ambient
temperature above
Relative Cooling Time Constant
• The default value = 1
• Forced/water cooled motors = <1
• Motor heated by abnormal additional

heating - i.e. solar radiation = >1
• Some trial and error may be required to
fine tune this setting
(I can provide some direction if you have the
motor cooling (thermal) data sheet)
Using the external RTD Scanner modules for ambient temperature measurement
scaling
ExtAI1
ExtAI2
ExtAI3
ExtAI4
.......
Ambient temperature input selected in T>
Value to relay’s data base

overload stage
ExtAI1 = RTD channel #1

ExtAI2 = RTD channel #2 Scaling
Etc.
[x2, y2] = [100,1]
Scaling is done
automatically for RTD
selections [x1, y1] = [0,0] Value from Modbus module
Overload correction factor Setting according the motor
Ambient temperature
Total overcurrent and thermal protection
I> (alt. 1)
Motor
withstand
(cold)
T>
(cold)
Stall protection
(enabled only during
starting)
Cold running motor

I>>
Total overcurrent and thermal protection
I> (alt. 1)
Motor
withstand
(hot)
T> (hot)
Stall protection
(enabled only during
starting)
Hot running motor

I>>
Stator temperature protection
Stator temperature is measured with an external RTD module
scaling
ExtAI2
ExtAI2
Stator temperature channel

Alarm limit = 102 °C
Trip limit = 110 °C
Dead band = 4 °C
Sensitive alarm stage for earth fault I0>
51N
Input signal for the stage.
The choices are:
Io input X1-7&8
Io2 input X1-9&10
IoCalc calculated IL1+ IL2+ IL3
This stage is set very

sensitive. It will not be used
for tripping, only for earth-
fault alarm.
The network is unearthed. Thus very sensitive

settings are possible. No dot ==> no trip!
Earth fault protection I0>> 51N
Input signal for the stage.
The choices are:
Io input X1-7&8
Io2 input X1-9&10
IoCalc calculated IL1+ IL2+ IL3
This stage is tripping the CB
The actual settings must comply

with the prospective earth fault
current of the network, local
safety and other requirements!
A dot ==> do trip!
Current unbalance protection I2> 46
Induction motors don’t withstand much unbalance. Let’s use the most
sensitive pick-up setting.
Unbalance current heats mostly the rotor.
1/6 of the stator’s time constant should be

safe for rotor.
8.7 min/6 = 87 s
50 s gives a good margin.
Protection against reverse
rotation I2>> 47
Just enable the stage.
All settings are fixed.
Total Load Running Time/Starts Counter
Running time-Hr & sec.
Total starts counter
Present Status
Trigger Input (mandatory!)
Last start date/time
Last Stop date/time
Freeform Label
• Running time, total starts and status of the triggering input
YOU MUST engaged via a selectable input; DI, VI, VO or via Logic
Suggest a VO be used
Total Load Running Time/Starts Counter
• Will not ‘count’ unless it is

triggered by a link source
• If an contactor aux. has not been
wired into the 857, connect
“Motor Running” to VO6*
• Set up Run Hour DI Link in
Running Hour Counter to be
triggered by VO6
*-any virtual output (VO) can be used. Confirm

that the virtual output you select is not mapped
elsewhere in the Output Matrix!
There are other ways to trigger the counter
including a Digital input or via on-board Logic.
Creating Custom Protection Stages
 Protection stages and configuration Task priority  How often
scheduler checks the “Coupler”
value. Priority is used only when
Time base for input value is
selected as “Instant”
How often the “Coupling” value is
checked.
List of measured/calculated
values which can be added to
programmable stage (Coupling).
Compare condition for over or

under pick-up.
User selectable hysteresis for pick-up value.
Low limit (status blocked when value goes under

setting)
Summary of Session #4
 Stall Protection
 Alternative uses of 50/51 elements
 Jam
 Low level over current
Section #5
Outputs, Inputs & Matrix
 Output relay Polarity
 Output Matrix
 Blocking Matrix
Output Relays (Trip and Alarm)
For Fused Contactor based controllers, relay used to
trip the contactor must be set for Fail safe (N.C.)
In this example, T1 is normal closed (N.C. fail safe)
T1 opens when there is a trip command or when the 857 looses control
voltage
For Circuit Breaker applications the relay used to trip

the contactor should be set for Non-Fail safe (N.O.)
Output Matrix
 Connects the output signals of the various protection stages to digital inputs
and logic outputs
 Also connects output signals to other internal signals to the output relays,
front-panel status indicators, virtual outputs, and so on
 Very flexible and easy to use
Output Matrix
 Two methods to
open
 MATRIX tab
 ICON
Output Matrix
With this icon you can clear all connections in the output matrix
Click on the
intersection =
Connects a status to
an output
T1 Main Trip relay 1- typically to Ct breaker trip coil or Vacuum contactor control rung
A1 & LA Alarm contact - Overcurrent, overload and overtemperature alarms & LA=’A’ LED on front of relay
A2 & LB Alarm contact - Current unbalance alarm & LB=’B’ LED on front of relay
A3 Alarm contact - Restart inhibit relay (NC contact)
A4 & LC Alarm contact - Earth fault alarm - & LC=’C’ LED on front of relay
If it’s RED, then you haven’t downloaded the changes to the relay
857 Protection settings- Step 5,
Output Matrix
Disturbance
OUTPUT RELAYS LED INDICATORS recorder
trigger
lockout 86
For fuse contactor control, these may need to be “Connected & latched”. Refer to control circuit.
857 Protection settings- Step 5,
Output Matrix
There are several ways to reset
latched indicators and output relays
lockout 86
 From the alarm list, move back to the initial
display by pushing/holding the CANCEL key for
approx. 3 sec. Release manual via software
By pushing the ENTER key the latched
indicators and output relays are reset.
 Acknowledge each event in the alarm list

one by one by pushing the ENTER key  Release using a Digital Input
equivalent times. Then, in the initial display,
reset the latched indicators and output relays
by pushing the ENTER key.
Output matrix
• Activating ”Show only used matrix signals” makes the matrix easier to read
• Removes lines in the Output matrix that are not being utilized in the settings
Block Matrix
 Any protection function, (except arc protection), can be blocked with internal
controls and/or status signals or via external control signals
 When a protection stage is blocked, it does not pick up if a fault condition is
detected (Start [Alarm] or Trip)
 If the blocking is activated during the operation delay, the delay counting is
frozen until the blocking goes off or the pick-up reason
 If the stage is already in a tripped condition, the blocking has no effect.
Block Matrix
 Lock symbol means a connection is made

 Only a connected status
Summary of Session #5 –Output Matrix
Front Panel Disturbance Virtual
Connected = follows lockout 86 OUTPUT RELAYS LED INDICATORS Recorder trigger Outputs
the state of the
element
Connected &
Latched =
Follows the FIRST T1 through T4- Main Trip relays
A1 through A5 – Main Alarm or Signal relays
change of state and
Al – Alarm LED on front of relay (Amber)
is locked to that Tr – Trip LED on front of relay (Red)
status LA – Programmable LED labelled ’A’ on front of relay (Amber)
LB – Programmable LED labelled ’B’ on front of relay (Amber)
LC – Programmable LED labelled ’C’ on front of relay (Amber)
DR – Disturbance Recorder Activation
VO1 through VO6 – Virtual Outputs (connected via Logic Elements in relay – see L O G I C in SetpointPS
Summary of Session #5 –Block Matrix
Summary of Session #5
 Output relay Polarity (Fail Safe, Non-Failsafe)
 Use Fail safe (NC) on Trip contact for fused contactor applications
 Use non-Failsafe (NO) for circuit breaker applications
 Output Matrix
 Blocking Matrix
Section #6
RTD Protection
 Types of RTD scanners available
 How to configure the two styles of RTD scanners to the base relay
 How to configure the individual channels
 Setting High and low level temperature alarms
857 Protection Set Up
RTD Protection
 We have seen a lot of setting files where the RTD scanner was wired but
the settings were not completed to provide any protection!!!
 Several Customer Dissatisfaction alerts
 Easy to set up
 Refer to the equipment electrical diagram to determine if an RTD is
physically connected
 Refer to SetPointPS Manual and 857-RAA/RAD Users Manual
Typical 857 with 857-RAD application
example
Application example
External RTD Modules
857-RAA or 857-RAD RTD Scanners
Two different communication EXTENSION
configurations depending on scanner type PORT & External
I/O
Optical Fibre
857-RAA RTD module

OR • 12 Channels
857-RAD RTD module

REMOTE PORT & select •
•
12 Channels +
4- Analogue Ins
External IO • 4- Analogue Outs
• 1- PTC Input
Protocol Configuration
 RTD scanners are attached to a communications channel

 Channel has to be configured
Protocol Configuration for
857-RAA
Comm. Option must be VCM RTD
(in either of the two comm. option
ports)
Select ”ExternalI/O” from the drop down list in

the Extension Port area, please reload all
setting from the relay.
This will bring out new screens to configure and
use the external I/O.
External I/O Configuration for
857-RAA
Configure the EXTERNAL I/O CONFIGURATION

tab enter these defaults for 857-RAA
• Device type= 857-RAA
• Protocol = RTDinput
• Rate = 9600 Bps
• Parity = Even
Remote I/O module 857-RAD
Comm. Option must be VCM
FIBER (in either of the two comm.
option ports)
Use REMOTE PORT and select
External IO from the drop down
list
Configure the EXTERNAL I/O CONFIGURATION

Settings for 857-RAD
• External I/O Device = 857-RAD
• External I/O Protocol= Modbus
• External Bit rate=9600 Baud
• Parity= Even
External I/O Configuration for
857-RAD
Configure the EXTERNAL I/O

CONFIGURATION Settings for 857-RAD
• External I/O Device = 857-RAD
• External I/O Protocol= Modbus
• External Bit rate=9600 Baud
• Parity= Even
RTD Channel Configuration
 Easy way to set up
each RTD channel
 Enable the
channels used
 Set RTD type
 Set RTD function
 Set 1st and 2nd
level temperatures
Enabling RTD Channels
Enable Channels needed
Select RTD Type
Select Sensor Function
Select Alarm and Trip temperature
 First 12 channels
used for RTD
protection
 Last four used for
specific purposes
RTD Trip and Alarm Levels
 Settings should be based on motor insulation class
 For example, a motor with class F insulation (temperature rating of 155°C)
 Stator RTD Trip level should be set between 140°C to 145°C, with 145° C being the
maximum (155°C - 10°C hot spot= 145 maximum)
 The stator RTD alarm level should be set to a level to provide a warning that the
motor temperature is rising to near the trip level (for example, 140°C- 10°C= 130°C)
 You have to Map the Alarm and Trip signals appropriately in the Output
Matrix
RTD Trip and Alarm Levels
 You must map each RTD channel (Ext. Analog Input) in the Output Matrix
if you want Alarms and Trips levels to perform a control function
 Alarm 1 is the Alarm level setting for each AI (RTD) and Alarm 2 is the Trip
level setting
 Map accordingly to an Alarm Relay or Trip Relay
RTD Scanner Communication Errors
 Connection to 857-RAA operating Normally
 Connection Broken to 857-RAA
“Extension comm. inactive” activates (In this case Trip relay 1 is activated)
Usually you should map this to an Alarm out – user defines!
RTD Scanner Communication Errors
 Connection to 857-RAD operating Normally
 Connection Broken connection to 857-RAD
“Remote comm. inactive” activates (In this case Alarm relay 3 is activated)
857-RAD Analog Inputs/Outputs
 Provides for external analog inputs and outputs to the base relay
 Four channels for both inputs and outputs. Normally only O/Ps used
857-RAD Analog Inputs 13-16
 Rarely used
857-RAD Analog Output Configurations
 A & B, min. & max. current for the output channel

 B, analog measurand linked to this channel, e.g. IL , Uline, T
 C, Min & Max limits for the linked measurand
 D, Modbus equivalent value for the mA min and max values
 (modbus value = mA value X 1000)
Analog Output- Example
 Output range- min. & max. current= 0
& 20mA
 Linked to IL (average current, all 3
phases)
 Linked Min & Max limits = 0 & 1000A
 Modbus range value mA min and
max values, 0 & 20,000
Identifying RTD Channel Errors
 Disconnected RTD channel (open circuited) - Value measured = -200ºC
 Shorted/Mis-wired RTD channel, Value measured = -250ºC
 Power lost to 857-RAA or communication to base lost (broken fiber)
 All enabled channels displays a value of -250ºC
 Timeout Counter increases in the Protocol menu/Extension port
 Power lost to 857-RAD or communications to base relay lost (broken fiber
or swapped fibers)
 Timeout counter increases in the Protocol menu/Remote Port
 Channel values frozen at last reported temperature
Identifying Communication Errors
857-RAA 857-RAD
Message Counter- Number of Words (sent from) and received by the base relay
Error Counter - Number of Corrupt Words received by the base relay with data
Timeout Counter* – Words the Base relay expected from the RTD scanner
*-indication of broken fiber optics, malfunctioning RTD scanner, loss of power to scanner or improper setup
Section #6 -Summary
RTD Protection
 How to configure the two styles of RTD scanners to the base relay
 How to configure the individual channels
 Setting High and low level temperature alarms
 Setting Analog outputs (857-RAD only)
 Detecting connection or configuration issues on individual channels
 Detecting and annunciating communication loss
Section #7
 Virtual Measurement Tool
 Overview
 Set Up
 Use
 Validation of settings
Virtual Measurement Tool
Checking your Settings
 Provides complete offline testing of the protection and measurement
capabilities- no load required!
 Injection of simulated current and voltage profiles
 Ideal for validating protective settings before commissioning
 Widely variable configurations
 Run one or multiple profiles
 Run multiple cycles of a given profile
 Provides for simulation of real load profiles not just a static test
Checking your Settings
 The SetPointPS contains an embedded test set emulator (Virtual
Measurements Tool) which digitally injects;
 Three phase currents with varying phase angles
 Three phase voltages with varying phase angles
 2- Ground fault currents with varying phase angles
 2nd, 3rd and 5th harmonic injection with varying phase angles
 Run up to five (5) different profiles can be configured
 Run various profiles through multiple sequences
 Relay must be connected to the SetPointPS software to test
Enabling the Virtual Tool in SetPointPS
Virtual Measurement
tool is like having an
Omicron type tester
• Inject Currents
• Inject Voltages
• Inject Harmonics
• Change phase angles
• Run up to 5 variations of profiles
Version 2.2.185 and lower • Run a single event
Tool may be hidden on the right
side of the screen
Virtual Measurement Simulation Tool
 Real time measurement values
displayed
 Multiple load profiles can be loaded
and run in sequence
 Energy management data displayed
 Adjustable phase angles displayed
 YOU MUST ENTER THE NUMBER
OF POWER CYCLES TO ENABLE
THE SELECTION OF VARIABLES
Virtual Measurement Simulation Tool
 In Program Settings…
 Enable Online Measurements
if you want to see real time
measurand data
 PQ diagram style can be modified
PQ Diagram Settings
Real time Virtual Measurement
Simulation Tool
 Validate protective settings
 Valid output contact states
 Validate Trip and Alarm settings
 Capture live data using Disturbance Recorder
Section #7- Summary
 Virtual Measurement Tool
 Basic Overview and Set Up
 Basic use, single event, Running Sequences
 Tool used to validate settings before you turn a motor/load
 Very useful to fine tune settings
Section #8
Disturbance Recorder
 How to enable
 How to set up
 Event Buffer
Bulletin 857 – Disturbance Recorder
• Up to 12 selectable channels
• Waveform or Trend Data
• Easy to configure
• Supports COMTRADE format
Records all I/O’s and Analog inputs (5 x I and 3 x U)

Sampling length Max. Record
32/cycle 6.66 s
16/cycle 13.33 s
8/cycle 26.66 s
1/10 ms 80 s
1/20 ms 2 min
1/200 ms 27 min
1/1 s 133 min
1/5 s 11 h
1/1 min 5.5 days!
PUBLIC V1.12.6 149
Built in Disturbance Recorder
Disturbance recorder can help to find the reasons behind possible abnormalities
related to the function of the load, the communication network or the process
• Can activated manually or be triggered based on

a specific protective element(s) or conditon from
the output matrix
• Variable Sample Rate
• Variable recording length
• Variable pre-event data length
Event Buffer
• Event Buffer is a recorded log for
every change of state event in the
relay
• Usefull for diagnostic of process
issues
• Details of alarms, trips and
protective element status prior to
events
• Can be configured for Old >New
or New >Old
• Size is variable from 50-2000
entries: default is 200
Event Buffer
 Change buffer size only if
necessary
 Change from FIFO to LIFO
(Old-New, New-Old)
Section #8- Disturbance Recorder/ Event
Buffer- Summary
 Very useful and powerful troubleshooting tools
Section #9- Applications
 How to apply Remote Starting/Stopping/Status
 Motor status condition monitoring
 Starting
 Running
 Stopped
Remote Start-Stop Functionality
 There are a multitude of ways to control the load remotely via a communication channel,
one method is briefly outlined below
 The 857 includes 4-Virtual Inputs (VI) and 6 Virtual Outputs (VO)
 Use the VI to trigger one of the output relays to energize a breaker or contactor.
Map a VI to any output relay, which would be used to energize the contactor or
breaker
 Use any VO to monitor the open or closed status of the switching device by wiring
in an aux contact to a DI and mapping that DI to one of the VO- or use motor
status info from the 857, for example
 Virtual I/O are inputs and outputs that are accessible via the communication network
(Enet)
Typical Remote Control/Monitoring
Utilize Virtual Inputs and Virtual Outputs for control and monitoring
Motor Status reported
Motor
The average current for the motor is less than 10% of the nominal current, IMot
Stopped
To achieve this status condition, the motor must be in the Motor Stopped status for at least
500ms before starting.
Motor
The motor average current must increase above the setting for start detection current within
Starting
200ms (Set in the Ist, Device #48 parameter).
This status continues to be reported until the conditions for the running state are reached.
The running status is achieved from the stop or start condition.
Motor
The low limit for Motor Running is 20% of the motor nominal current, IMot
Running
The high limit for Motor Running is 120% of the motor nominal current, IMot
Imot= Motor Nominal Current (FLC) set in the Scaling Section of SetPointPS
Motor Status
Section #9- Applications Summary
 857 can control the starting and stopping of the load, over ethernet, using
virtual inputs
 Status conditions can be fed back via communications using Virtual Outputs
 857 provides status conditions of the load based on current profiles
What you need to arm yourself with…
 The 857 has a very wide scope of control and protection capability - as well as world class levels of functionality and
configurability
 This slide show provides only a very small portion of the products capabilities
 For further information or a full product demonstration, please contact your local Rockwell Automation distributor or sales
partner.
 Refer to the product documentation for additional assistance
 857-PP001 Product Profile
 857-UM001 857 User manual
 857-UM002 RTD User Manual
 857-PM001 SetPointPS User Manual
 857-QS001 857 Quick Start Guide
Protection#documentation
 http://ab.rockwellautomation.com/Circuit-and-Load-Protection/Medium-Voltage/857-Medium-Voltage-Protection#software
Circuit Breaker Applications
 Many of the protective settings are used differently for circuit breaker control
and protection versus fused contactor applications
 50/51 elements are programmed to provide various levels of over
current protection to the load, the load cables or the dist. system
 The output trip contacts will typically be configured differently than with
electrically held MV contactor (Typically N.O. versus N.C.)
 Circuit breaker and CT/VT circuit monitoring is typically critical
 Circuit breaker condition monitoring is very important
Differences in Analog Transformation
Devices
 For CB applications, the selection of the CT characteristics is very important
 Output of the CT must be much greater than the connected secondary load (burden)
 The CTs must not saturate when associated with the overcurrent protection
 CTs must only saturate at very high currents to preserve the protection within the relay
 Generally saturation should only begin at double the setting value - with a minimum of
20 X nominal current
 CTs used for differential, distance relaying, etc. must be selected case by case
 Typically overcurrent relays have a minimum tolerance of 100 X secondary current for
1 second
Differences in Analog Transformation
Devices
 For voltage transformers the precision class is generally only guaranteed if the
secondary load on the VT is at least 25% or higher than the rated performance
 The use of ballast loads (resistances) may need to be inserted on the secondary of the
VT to guarantee the precision class (when necessary)
 Neutral resistor current measurements may also be required for a main transformer
versus a typical zero sequence method for an individual load
Faults in a three-phase system
 The 50/51 elements must be configured to open the breaker appropriately
 Three-phase short-circuit (phases are short circuited with each other)
 Two-phase short-circuit (only two phases are short circuited with each
other)
 Two-phase short-circuit to ground (two phases and ground are short-
circuited with each other)
 Single-phase short-circuit to ground (short-circuited between one
phase and ground)
Application dependent O/C settings
 Time and current selectivity is important
 Differential protection and distance protection selectivity may be required
 Zone selectivity has to be considered by the protection engineer
Transformer Protection- Typical
Selections
 46 negative sequence overcurrent protection;
 49 thermal overload protection;
 51 overcurrent protection with inverse time;
 51 or 50t secondary side short-circuit overcurrent protection;
 50 primary side overcurrent short-circuit protection;
 51G primary side and/or secondary overcurrent ground fault protection;
 68F2/F5 magnetizing inrush/over excitation protection;
Optional
 63 overpressure protection (only for oil transformers- use a device 99 tied to a DI).
 87N restricted differential ground fault protection (for one or both windings); (use bulletin 865)
 87T differential transformer protection; (use bulletin 865)
 25 Sync-check
PUBLIC V1.12.6 25 Sync-check
Motor Protection- Typical Selections
 49 thermal image protection against overload;
 50 overcurrent short-circuit protection (provided by power fuses- use for other functions: low level OC
or Jam)
 51G overcurrent ground fault protection;
 47 Phase Sequence Protection
 48 overcurrent protection against prolonged starting;
 46 negative sequence overcurrent protection;
 66 number of starts control protection
Optional
 27 undervoltage phase loss protection against motor disconnection (Must have 3ph voltage inputs)
 37 undercurrent protection (phase/load loss)
857 Protection settings- Breakers
I> 51 Sensitive overload, low setting
Use this element for applications where
the motor can be driven into overload
Pick-up = S.F.of the motor
Delay curve family

Delay Curve Type
Operational Delay Time
(just longer than the longest allowed O/L time)
NOTE: Screen options change if

Definite time (DT) is NOT used
I>> 51 (Used for Jam or Locked Rotor Protection)
Pick-up (pu of Motor FLC)

- Set well below the LRA (~2.5 pu)
- Set well below the interrupting capacity
of the switching device (contactor)
Operation Delay Time

- Set 10-25% faster than the max. allowed start time (shorter time)
I>>> 50 (High Setting)
Used to detect locked rotor or short circuit
This stage is used to trip the breaker!
Pick-Up Setting
(at least 2 pu HIGHER than the LRC pu current up to the breaking
capacity of the breaker
Output Matrix
 The heart of connecting the protection and status provided by the 857 to
the external control systems
 Easily configurable and customizable
 Factory default setting
 All protective function Trips connected and latched to T1 & TR
 All protective functions Starts (alarms) connected to A1 and AL
Blocking Matrix
 Used to Block protective stages under certain conditions
 Factory Default is NO protective elements are blocked
 Blocked elements shown with a Padlock symbol
Steps to configuration an 857
The configuration and setting of a 857 can be divided into six/seven parts:
1) Obtain information regarding the load and the application

2) How is the relay connected to the load and the measurment devices?
3) Enter the scaling parameters. CT, VT (i.e. PT), motor’s name plate values etc.
4) Select which protection stages and other features are to be used
5) Configure the setting values for each protection stage based on the application.
6) Map the trip and Start (Alarm) signals from the used protection stages to the output
relays, virtual ouputs and LEDS using the output matrix
7) Configure the communication protocols for optional RTD scanners and/or customer
communication network
Be prepared
 Download latest SetPointPS software from product page
 Obtain the correct programming cable, 857-VX003-3
 USB to Serial converter (almost any one will work)
 Make sure you have the most up to date drivers installed!!!
Additional Support Materials
Some tidbits from feedback
 The next few slides cover some basic topics which have caused some
service engineers issues
 There are differences in symbology between IEEE/ANSI and IEC
 Some of these provide key pieces of information for setting the relay
 If your not sure, don’t guess!
IEC versus ANSI
 857 is a global product - installed in many parts of the world
 Sold in RA finished goods and to global OEMs
 It has been designed to work in the global community
 It has features optimized for both IEC and ANSI protection
 Unlike competitive products, it can control and protect a multitude of
varying applications and switching devices
 You may be exposed to either ANSI or IEC symbology depending on the
project, where it originated from or where it is applied or where it is installed
IEC versus ANSI drawing symbols
IEC ANSI
 Circuit breaker
 Alternative circuit breaker
 Normal open contact
 Normal closed contact
 Indicating Lamp*
• 857 is a global product - includes both IEC and ANSI symbology

• *-Some other features in 857 Matrix’ shown with this symbol
IEC ANSI
Measurement transformers and
their polarity
 IEC marks P1 and P2 for primary and

marks s1 and s2 for secondary
are used in detailed wiring diagrams
but the polarity is unambiguous also
without any markings.
 CT in single wire diagrams
(no polarity indication)
 Core Balance (ZSCT)
IEC ANSI
Measurement transformers and
their polarity
 VT = voltage transformer
PT = potential transformer
 IEC: (fuses included)

Marks A and B (or N) for primary and
marks a and b (or n) for secondary
are used in detailed wiring diagrams
for each winding but the polarity is
unambiguous also without any markings.
 VTs (=PT) in single wire diagrams

(no polarity indication)
Connection group of IEC transformers
UPPER case letter = primary D = delta For example
Y = wye (star)
Z = zig zag D y n 11
lower case letter = secondary d = delta

y = wye (star)
z = zig zag
Neutral point:
 N = Neutral point is available in primary
 n = neutral point is available in secondary
The number is a clock hour i.e. h*30°. For example 11 means that the primary is leading secondary by 11*30° = 330°(ie.
lagging 30°).
Similarly in a YNd5 transformer the primary is leading 5x30° = 150°.
IEC versus ANSI transformer phase shift
Connectiong group/vector group/phase shift
IEC ANSI
 Wye-Delta with primary leading Yd1 Standard
by 30° Wye-Delta
 Wye-Delta with primary lagging by 30° Yd11
 Delta-Wye with primary leading Standard

Dy1
by 30° Delta-Wye
 Delta-Wye with primary lagging by 30°

Dy11
CT definitions
ANSI
500/5 C100 class (used on CB applications)
100 V to 1 Ω @ 20 pu = 100 Asec
Error of the secondary current @ 20 pu and with a 1 Ω rated burden is not more than 10 %.
Approximation of the rated power:Sn = 52 A2 x 1 Ω = 25 VA
IEC
500/5 10P20 25VA
Accuracy limit factor kALF = 20
At 20 pu = 100 Asec the error of the secondary current is not more than 10 % for a rated burden.
Rated burden at 5 A is 25 VA => RN = 25 VA/52 A2 = 1 Ω
(5P10 and 5P20 are also widely used)
CT knee point voltage approximation
Knee point voltage can be read from the excitation curve of the CT.
If such a graph is not available, the knee point voltage can be approximated using the CT’s nameplate
values.
ANSI
500/5 C100
A rough knee point voltage approximation: Vkp = 0.8 x 100 V = 80 V
IEC
500/5 10P20 25VA
A rough knee points voltage approximation: Vkp = 0.8 x kALF x SN/INsec V = 80 V
kALF = 20, accuracy limit factor
INsec = 5 A
SN = 25 VA
IEC versus ANSI logic gate symbols
IEC ANSI
AND-gate
(& = et = and)
OR-gate
(one or more)
Exclusive OR-gate
(exactly one)
The letter denoting voltage
IEC ANSI
Letter for voltage U V
For example: U12 => Vab, UL2 => Vb.
In IEC applications there are strict rules how to use UPPER and lower case letters. For example
kV = kilovolt not KV = kelvinvolt??
ms = millisecond not vmS = millisiemens (= kilo-ohm)
mA = milliampere not MA = mega-ampere
uF = microfarad not mF = millifarad nor MF = megafarad
Open delta voltage and broken delta
voltage
IEC ANSI
V-connection open delta
open delta broken delta
Contact your local Rockwell Automation
distributor for further assistance
Thank You!
PUBLIC
www.rockwellautomation.com

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Bulletin 857 Motor Protection

Copyright © 2018 Rockwell Automation, Inc. All Rights Reserved. 1

 Encourage customers to also download (free)

data in real time

Pressing the CANCEL button

Set up like a Windows file tree

Scroll left and right

External I/O: RTDinput

 Many users have no

Both methods are

*- May be used for other protective functions, details to follow

Protective Function Selection is based on the hardware

Enable for N> (66) ON Enable for U> (27) OFF

1) Obtain information regarding the load and the application

Information about the relay location

Sublocation only appears on the front panel of

Information regarding the installed

Information regarding SetPointPS

Information regarding the Date and

Time and date of the relay can be set manually

Settings for the front panel display contrast

Backlight is turned on when ever a front panel

Settings for the relay access levels

Tested by and Calibration date: Information from

Note: If working offline using a template,

 51N low set earth fault

*- 50/51 elements are not used for general S.C. protection on

Thermal overload stage

Delay curve family

NOTE: Screen options change if

Pick-up (pu of Motor FLC)

Operation Delay Time

400A contactor = 6kA interrupting

Start Detection Level (1.5 pu nom)

Starts in the last 1 hour period

This stage is not tripping, but used

Let’s limit the motor to

Minimum time NC contacts of output relay A3 is

Refer to Technical Advisory 026-2013.x for

N> Motor Start Inhibition

Min. Time between starts (customer setting)

60 minute count down timer (starts/hr)

 OneLeft initiates the N> Alarm signal in the Output Matrix

Input for measurement of sensitive 51 protection.

Any local requirements must be fulfilled when

Pu value of Primary ratio of ZSCT

50N or G protection in solidly grounded systems

Stator critical motors have equal limit for

”Inv. time coefficient k” is the delay parameter for

With these settings the load current must

This low set and relative fast stage must be

More coarse settings can be used as long as

Class B temperature rise

Overload factor i.e. service factor can be estimated as follows:

Solving τ from equation 1 and setting IP = 0, i.e. cold curve, we get

Let’s use a 10 % safety margin

A user programmed I2t curve for

Overload factor i.e. service factor

Thermal time constant t (cooling time!)