Littelfuse PGR-6100 User manual

Tel: +1-800-832-3873

E-mail: techline@littelfuse.com

www.littelfuse.com/PGR-6100

Document Number: PM-1100-EN

PGR-6100 MANUAL

GROUND-FAULT & INSULATION MONITOR

Revision 2-C-050818

Page i

REV. 2-C-050818

PGR-6100 Ground-Fault & Insulation Monitor

This page intentionally left blank.

Page ii

REV. 2-C-050818

PGR-6100 Ground-Fault & Insulation Monitor

TABLE OF CONTENTS

1 GENERAL ................................................................1

2 OPERATION............................................................1

2.1 Output Relay Operating Mode ................1

2.2 PGR-6100 Operating Mode .....................1

2.2.1 Online Operation .....................................1

2.2.2 Ofine Operation .....................................1

2.3 Front-Panel Controls................................1

2.3.1 Ground-Fault Trip Level ...........................1

2.3.2 Ground-Fault Trip Time ............................1

2.3.3 Insulation Resistance Response................

2.3.4 Reset........................................................1

2.3.5 Test ..........................................................2

2.4 Front-Panel Indication .............................2

2.4.1 Power.......................................................2

2.4.2 >∆I...........................................................2

2.4.3 CT ............................................................2

2.4.4 Active.......................................................2

2.4.5 <R.............................................................2

2.5 Analog Outputs........................................2

2.5.1 Out I ...........................................................2

2.5.2 Out R ..........................................................2

2.6 Remote Test...............................................2

2.7 Remote Reset ............................................2

2.8 CT Verication............................................2

3 INSTALLATION ......................................................2

3.1 PGH-5000 and PGH-6000...........................4

4 TECHNICAL SPECIFICATIONS

..............................8

4.1 PGR-6100 ...................................................8

4.1.1 PGR-6100 Online Operation.......................8

4.1.2 PGR-6100 Ofine Operation ......................8

4.2 PGH High Tension Couplers.......................9

5 ORDERING INFORMATION..................................9

6 TESTS....................................................................10

6.1 Ground-Fault Test ....................................10

6.2 Insulation Test .........................................11

APPENDIX A PGR-6100 REVISION HISTORY

.......12

LIST OF FIGURES

1 PGR-6100 Outline and Mounting Details ....................3

2 Typical Connection Diagram ........................................4

3 PGC-5000-Series Current Sensors...............................5

4 PGH-5000 Outline and Mounting Details ....................6

5 PGH-6000 Outline and Mounting Details ....................7

6 PGA-0500 Analog Percent Current Meter ...................9

7 PGA-0510 Analog Ohm Meter ...................................10

8 Ground-Fault-Test Circuit..............................................

LIST OF TABLES

1 Ground-Fault-Test Record ..........................................11

DISCLAIMER

Speciﬁcations are subject to change without notice.

Littelfuse, Inc. is not liable for contingent or consequential

damages or for expenses sustained as result of incorrect

application, incorrect adjustment, or malfunction.

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REV. 2-C-050818

PGR-6100 Ground-Fault & Insulation Monitor

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Page 1

REV. 2-C-050818

PGR-6100 Ground-Fault & Insulation Monitor

1. GENERAL

The PGR-6100 Ground-Fault & Insulation Monitor can

detect a motor ground fault whether the motor is running

(Online mode) or stopped (Ofﬂine mode). The PGR-6100 can

also be used to protect a motor that is supplied by a solidly

grounded, resistance-grounded or ungrounded system. For

ungrounded systems, use only the Ofﬂine mode.

Grounded systems use a current transformer (CT) to detect

ground-fault currents as low as 10 mA when the motor is

running. Insulation resistance is measured to detect a fault

when the motor is stopped. Online or Ofﬂine mode is selected

with a digital input connected to a starter auxiliary contact.

In the Online mode, ground-fault current is sensed by

a PGC-5000-series zero-sequence CT. The trip level of the

ground-fault circuit is selectable from 10 mA to 3 A. Trip

time is selectable from <50 ms to 1.0 s. Additional current-

detection features include harmonic ﬁltering, a relay output

that can operate in the fail-safe or non-fail-safe mode, CT-

connection detection, LED trip, LED power and LED open-CT

indication, autoreset or latching trips with front-panel and

remote reset, a test button, and a 0-to-1-mA analog output.

In the Ofﬂine mode, insulation-resistance monitoring is

enabled with a selectable 250-k to 2-M alarm-setting

range. Additional insulation-monitoring features include

a relay output that can operate in the fail-safe or non-fail-

safe mode, LED active and low-resistance indication, and a

0-to-1-mA analog output.

The PGR-6100 can be directly connected to a supply up to

1.3 kV. For systems from 1.3 to 5 kV, use a PGH-5000 High

Tension Coupler. For systems from 5 kV to 6 kV, use a PGH-

6000 High Tension Coupler.

2. OPERATION

2.1 Output Relay Operating Mode

In the fail-safe mode the output relays energize when power

is applied and the ground-fault and insulation-resistance

circuits are not tripped. Fail-safe mode is the factory setting.

For a non-fail-safe operation, connect terminals 19-20 and

22-23. The respective output relay will energize when a fault

occurs. See Fig. 2.

2.2 PGR-6100 Operating Mode

Connect terminals 27 and 28 to a normally closed (Form B)

auxiliary starter contact. When terminals 27 and 28 are open,

Online mode is selected (insulation monitoring off). When

terminals 27 and 28 are connected, Ofﬂine mode is selected

(insulation monitoring active).

2.2.1 Online Operation

In Online mode, the PGR-6100 in conjunction with a

PGC-5000-series zero-sequence current sensor operates

as a ground-fault relay.

2.2.2 Ofine Operation

The PGR-6100 changes mode by means of an auxiliary

contact on the main contactor when the motor is off. It

becomes an insulation-resistance monitor and imposes a

small dc voltage to the motor windings and supply cable from

the motor starter. Leakage to ground is detected.

2.3 Front-Panel Controls

2.3.1 Ground-Fault Trip Level

The Leakage Current ∆Iselector switch is used to set the

ground-fault trip level from 10 mA to 3 A. For ground-fault

detection, the switch setting must be set substantially below

the prospective ground-fault current. To avoid sympathetic

tripping, the switch setting must be above the charging

current of the protected feeder.

2.3.2 Ground-Fault Trip Time

The PGR-6100 has a deﬁnite-time trip characteristic. In

tripping systems, the TIME DELAY selector is used to set the

ground-fault trip time for coordination with upstream and

downstream ground-fault devices. Trip time is selectable

from < 50 ms to 1.0 s. Coordination requires the same trip

level for all ground-fault devices in a system and the trip

time to progressively increase upstream. The amount of

equipment removed from the system will be a minimum if the

ﬁrst ground-fault device to operate is the one immediately

upstream from the fault.

2.3.3 Insulation Resistance Response

The PGR-6100 insulation resistance function has an

adjustable alarm range of 250 k to 2 M . There is no

selectable time delay. The unit will operate in less than three

seconds.

2.3.4 Reset

The front-panel RESET button is used to reset latching trips.

After a fault has been cleared, cycling the supply voltage will

also reset the PGR-6100.

To use the PGR-6100 in autoreset mode, connect terminals

18-19 and 21-22. See Fig. 2.

Press the RESET button for several seconds. The reset

function is not instantaneous.

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REV. 2-C-050818

PGR-6100 Ground-Fault & Insulation Monitor

2.3.5 Test

The TEST button will test both leakage-current and

insulation-resistance circuits regardless of the selected

operating mode. Press the TEST button for at least eight

seconds to complete the test. All LED’s will light and relay

contacts will change to fault/alarm state. In the default mode

(latching), the tripped state will remain until reset. Allow

eight seconds before operating the RESET button.

2.4 Front-Panel Indication

2.4.1 Power

The green LED labeled “PWR’’ indicates presence of supply

voltage.

2.4.2 > ∆I

The red LED labeled > I indicates a ground-fault trip.

2.4.3 CT

The red LED labeled “CT’’ indicates that a PGC-5000-series

current sensor is not connected. See Section 2.8.

2.4.4 Active

The green LED labeled ACTIVE indicates that the Ofﬂine

monitoring function is active. The insulation monitoring

or lockout function is active when terminals 27 and 28 are

connected. See Section 2.2.

2.4.5 <R

The red LED labeled “<R’’ indicates a low resistance.

2.5 Analog Outputs

2.5.1 Out I

A non-isolated, 0- to 1-mA output (terminals 24 and 25)

indicates ground-fault current sensed by the CT. The full-

scale value corresponds to the ground-fault trip setting. For

example, if the ground-fault trip setting is 30 mA, then 1 mA

output will be indicated when the measured current is 30 mA.

The output is linear between zero and full scale. See Figs. 2

and 6.

2.5.2 Out R

A non-isolated, 0- to 1-mA output (terminals 25 and 26)

indicates insulation resistance. The metering output relates

to an insulation-resistance range of 0 to inﬁnity. See Figs. 2

and 7.

2.6 Remote Test

Use external switches to test the current-sensor detection,

insulation-monitoring activation, and insulation-monitoring

functions. See Fig. 2. Response to a test input can take several

seconds.

2.7 Remote Reset

For remote reset, connect a switch or button with a normally

closed contact between the neutral side of the supply voltage

and terminal 5. See Fig. 2.

For an alternate conﬁguration, connect a normally open,

double-pole, single-throw switch across terminals 18 and

19, and terminals 21 and 22. A momentary connection across

these terminals will reset the PGR-6100.

2.8 CT Verication

A ground-fault trip will occur and the red CT LED will light

when a PGC-5000-series CT is not connected to terminals 16

and 17.

3. INSTALLATION

NOTE: Mounting, terminal block connections and wiring

must conform to applicable local electrical codes. Check all

applicable codes prior to installation.

This ground-fault monitoring system consists of a PGR-

6100-series Ground-Fault & Insulation Monitor, a PGC-5000-

series CT, and for systems over 1.3 kV, a PGH-5000 or PGH-

6000 High Tension Coupler connection, as shown in Fig. 2.

A PGR-6100 can be surface- or DIN-rail mounted. See Fig. 1.

Use terminal 6 (L1) as the line terminal for a 120 or 240

Vac supply. Use terminal 7 as the line terminal for a 24 Vac

supply. Use terminal 5 (L2/N) as the neutral terminal. Connect

terminal 30 to ground.

Pass the phase conductors through the CT window and

position them in the center of the opening (for four-wire and

single-phase systems, also pass the neutral conductor through

the CT window). Do not pass ground conductors through the

CT window. In applications that require shields or drain wires

to pass through the CT window, return them through the

CT window before connecting them to ground. CT connections

are not polarity sensitive. Applications in electrically noisy

environments require twisted-pair or shielded twisted-pair

CT-secondary conductors. Connect the CT secondary leads to

terminals 16 and 17, and connect the shield to terminal 17.

See Fig. 3 for PGC-5000-series CT dimensional drawings.

If insulation monitoring is required, connect terminals 27

and 28 to a contact on the motor starter that is normally

closed.

For systems up to 1.3 kV, connect terminal 2 to one phase of

the load side of the starter.

Connect an optional PGA-0500 Analog Current Meter and

PGA-0510 Analog Ohm Meter as shown in Fig. 2. Meter

outlines, dimensions, and cutout sizes are shown in Figs. 6

and 7.

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REV. 2-C-050818

PGR-6100 Ground-Fault & Insulation Monitor

123456 78 9101112131415

L2/N 24 V

INSULATION

LEAKAGE

PHASE

<1.3 KV

16 17 18 19 20 21 22 23 24 25 26 27 28 29 30

ANALOG

OUT I OUT R

AUTO

RESET

AUTO

RESET

NON

FAIL

SAFE

NON

FAIL

SAFE INSULATION

K2 K1

PGH

>1.3KV

NOTES:

1. DIMENSIONS IN MILLIMETRES (INCHES).

2. MOUNTING SCREWS: M4 x 13 OR 8-32 x 0.50.

3. OVERALL DIMENSION WHEN MOUNTED ON DIN

EN 50022 35.0 x 7. 5 (1.38 x 0.30)TOP- HAT RAIL.

4. 24 V INPUT IS AVAILABLE ONLY FOR THE

PGR-6100-120 ORDERING OPTION.

TOP

BOTTOM

FRONT

99.80

(3.93)

99.80

(3.93)

85.0

(3.35)

7. 4

(0.29)

61.2

(2.41)

75.0

(2.95)

6.9

(0.27)

MOUNTING DETAIL

SIDE

11 5.0 (NOTE 3)

(4.53)

PWR

TEST RESET

PUSH 8 s

POWR-GARD

GROUND-FAULT & INSULATION MONITOR

PGR-6100

SERIES

LEAKAGE CURRENT TIME DELAY

INSULATION RESISTANCE

FAULT ∆I

>∆I

RESPONSE

ACTIVE

75.0

(2.95)

0 = <50 ms

1 = 250 ms

2 = 500 ms

3 = 1. 0 s

500 kΩ1. 0 MΩ

250 kΩ

2.0 MΩ

0= 10 mA

1= 30 mA

2= 60 mA

3= 80 mA

4= 10 0 mA

5= 0.3 A

6= 0.6 A

7= 0.8 A

8= 1. 0 A

9= 3.0 A

110.0

(4.33)

FIGURE 1. PGR-6100 Outline and Mounting Details.

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REV. 2-C-050818

PGR-6100 Ground-Fault & Insulation Monitor

3.1 PGH-5000 and PGH-6000

For 5-kV and 6-kV systems, connect the PGR-6100 to the

monitored circuit with a PGH-5000 and PGH-6000 respectively.

See Fig. 4 for PGH-5000 outline and mounting details. See

Fig. 5 for PGH-6000 outline and mounting details.

Connect protective-ground terminal ( ) to ground. Connect

terminal E to ground or to PGR-6100 terminal 30, which must

be grounded. Connect terminal M to PGR-6100 terminal 29.

For PGR-6100 to PGH-5000/PGH-6000 distances greater

than 10 m (30’), use shielded cable, and connect the cable

shield to the second PGH-5000/PGH-6000 terminal E

(PGR-6100 terminal 2 is not used). Connect terminal A to one

phase on the load side of the motor starter. See Fig. 2. The

PGH-5000/PH-6000 includes 915 mm (36”) of high-voltage

conductor.

L2/N

6L1

L2/N 5

LOW INSULATION

PGR-6100

REMOTE RESET

CURRENT

SENSOR

24 V

LEAKAGE CURRENT

MΩ

PGH-5000 / PGH-6000

EEM

NOTE 2

PGC-5000-SERIES

CURRENT SENSOR

STARTER

NOTE 3

HIGH TENSION COUPLER

FOR CONNECTIONS ABOVE

1,300 VAC

NOTE 3

STARTER

CONTACT

REMOTE TEST

120 VAC OR

240 VAC

NOTE 4

24 VAC

PGA-0500

0-100%

PGA-0510

0Ω - INFINITY

CONNECT 18 & 19 FOR AUTORESET

OPERATION OF K2

CONNECT 19 & 20 FOR NON-FAIL-SAFE

OPERATION OF K2

CONNECT 21 & 22 FOR AUTORESET

OPERATION OF K1

CONNECT 22 & 23 FOR NON-FAIL-SAFE

OPERATION OF K1

WARNING:

BEFORE CARRYING OUT MEGGER OR

DIELECTRIC-STRENGTHTESTS ONTHE

SYSTEM, DISCONNECTTHE PGR-6100.

NOTES:

1. RELAY CONTACTS SHOWN WITH

PGR-6100 DE-ENERGIZED.

2. INSULATION MONITORING IS

ONLY ACTIVE WHENTERMINALS

TERMINALS 27 AND 28 ARE

CONNECTED. JUMPERTHESE

TERMINALS FOR EXTERNAL

TESTING.

3. WHEN PGH-5000 OR PGH-6000 IS

USED, DO NOT CONNECT

TERMINAL 2.

4. 120 OR 240 VAC ARE ORDERING

OPTIONS. USE SPECIFIED

SUPPLY VOLTAGE.

5. ALTERNATE REMOTE-RESET

CONFIGURATION.

6. 24 VAC NOT AVAILABLE WITH THE

PGR-6100-240 ORDERING OPTION.

NOTE 5

LOAD

NOTE 6

FIGURE 2. Typical Connection Diagram.

Page 5

REV. 2-C-050818

PGR-6100 Ground-Fault & Insulation Monitor

FIGURE 3. PGC-5000-Series Current Sensors.

Page 6

REV. 2-C-050818

PGR-6100 Ground-Fault & Insulation Monitor

Revision:

Coupling Voltage:

PGH-5000

5 KV HIGH TENSION

COUPLER

Serial No:

1-800-TEC-FUSE (1-800-832-3873)

Made in Saskatoon, Canada

Impedance to Ground:

Current to Ground: 2.5 mA Max.

Formerly HTC 5000

E M

RELAY

PGH-5000

5,000 Vac Max.

> 2 M

POWR-GAR D

E E M

44.5

(1.75)

165.1

(6.50)

95.2

(3.75) 9.5

(0.38)

NOTE 2

150.0

(5.91)

FRONT SIDE MOUNTING DETAIL

NOTES:

1. DIMENSIONS IN MILLIMETRES (INCHES).

2. MOUNTING HOLES: 5.00 mm (0.20).

3. ALL GROUND CONNECTIONS MUST BE

MADE AND SECURED BEFORE CONNECTIONS

TO RELAY AND HIGH VOLTAGE LINE.

4. CORD PROVIDED IS APPROXIMATELY

915.0 (36.00) LONG.

915.0

(36.00)

5kV HIGHTENSION COUPLER

PGH-5000

DANGER

HIGH VOLTAGE

ATTENTION!

BOTH GROUND CONNECTIONS

MUST BE MADE AND SECURED

BEFORE CONNECTIONS TO

THE RELAY AND THE

HIGH VOLTAGE LINE

MAXIMUM

V O LTAG E

AC 5000V

FIGURE 4. PGH-5000 Outline and Mounting Details.

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