Littelfuse PGR-6101 User manual
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PGR-6101 MANUAL
GROUND-FAULT & INSULATION MONITOR
Revision 0-C-041918
Copyright © 2018 by Littelfuse, Inc.
All rights reserved.
Document Number: PM-1101-EN
PGR-6101 Ground-Fault & Insulation Monitor Page i
Rev. 0-C-041918
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PGR-6101 Ground-Fault & Insulation Monitor Page ii
Rev. 0-C-041918
TABLE OF CONTENTS
SECTION PAGE
1 General..........................................................................1
2 Operation......................................................................1
2.1 Output Relay Operating Mode....................................1
2.2 PGR-6101 Operating Mode.........................................1
2.2.1 Online Operation...........................................1
2.2.2 Offline 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...................1
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 RemoteReset ................................................................2
2.8 CT Verification .............................................................2
3 Installation....................................................................2
3.1 PGH-5000 and PGH-6000...........................................4
4 Technical Specifications.............................................8
4.1 PGR-6101......................................................................8
4.1.1 PGR-6101 Online Operation.......................8
4.1.2 PGR-6101 Offline Operation.......................8
4.2 PGH High Tension Couplers.......................................9
5 Ordering Information................................................9
6 Performance Tests ....................................................10
6.1 Ground-Fault Test.......................................................10
6.2 Insulation Test.............................................................11
Appendix A PGR-6101 Revision History.........................12
LIST OF FIGURES
FIGURE PAGE
1 PGR-6101 Outline and Mounting Details..................3
2 Typical Connection Diagram.......................................4
3 PGC-5000-Series Current Sensors..............................5
4 PGH-5000 Outlineand Mounting Details..................6
5 PGH-6000 Outlineand Mounting Details..................7
6 PGA-0500 Analog Percent Current Meter.................9
7 PGA-0510 Analog Ohm Meter .................................10
8 Ground-Fault-Test Circuit..........................................11
LIST OF TABLES
TABLE PAGE
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 a result of incorrect
application, incorrect adjustment, or a malfunction.
PGR-6101 Ground-Fault & Insulation Monitor Page iii
Rev. 0-C-041918
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PGR-6101 Ground-Fault & Insulation Monitor Page 1
Rev. 0-C-041918
1. GENERAL
The PGR-6101 Ground-Fault & Insulation Monitor can
detect a motor ground fault whether the motor is running
(Online mode) or stopped (Offline mode), and can be used
to protect a motor supplied by a solidly grounded,
resistance-grounded, or ungrounded system. On an
ungrounded system, use only the Offline mode.
On grounded systems, a current transformer(CT) is used
to detect ground-fault current as low as 30 mA when the
motor is running, and 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 30 to 200 mA. Trip
time is selectable from <50 to 250 ms. 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, power, and 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 60- to 600-kalarm-setting
range. Additional insulation-monitoring features include a
relay output that can operatein the fail-safe ornon-fail-safe
mode, LED active and low-resistance indication, and a 0-
to 1-mA-analog output.
The PGR-6101 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 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-6101 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 (insulation monitoring off) is selected
and when terminals 27 and 28 are connected, Offline mode
(insulation monitoring active) is selected.
2.2.1 ONLINE OPERATION
When the monitor is running, the PGR-6101 in
conjunction with a PGC-5000-series zero-sequence current
sensor operates as a sensitive ground-fault relay.
2.2.2 OFFLINE OPERATION
The PGR-6101 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 I selector switch is used to set the
ground-fault trip level from 30 to 200 mA. 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-6101 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 250 ms. 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-6101 insulation resistance function has an
adjustable alarm range of 60 to 600 k.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-6101.
To usethePGR-6101 inautoresetmode, connect terminals
18-19 and 21-22. See Fig. 2.
The reset function is not instantaneous. Press the RESET
button for several seconds.
PGR-6101 Ground-Fault & Insulation Monitor Page 2
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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 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 push button.
2.4 FRONT-PANEL INDICATION
2.4.1 POWER
The green LED labelled PWR indicates presence ofsupply
voltage.
2.4.2 >I
The red LED labelled >Iindicates a ground-fault trip.
2.4.3 CT
The red LED labelled CT indicates that a
PGC-5000-series current sensor is not connected. See
Section 2.8.
2.4.4 ACTIVE
The green LED labelled 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 labelled<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-faulttrip setting is 30 mA, then 1 mA
outputwill be indicated when themeasured current is 30mA.
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 pushbutton 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-6101.
2.8 CT VERIFICATION
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-
6101-series Ground-Fault & Insulation Relay, a PGC-
5000-series CT, and for systems over 1.3 kV, a PGH-5000
or PGH-6000 High Tension Coupler connected as shown
in Fig. 2.
A PGR-6101 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 centre 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- 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 normally closed contact on themotor starter.
For systems up to 1.3 kV connect terminal 2 to one phase
of the load side of the starter.
Connect optional PGA-0500 Analog Current Meter and
PGA-0510 Analog Ohm Meter as shown in Fig. 2. Meter
outline, dimensions, and cutout size are shown in Figs. 6
and 7.
PGR-6101 Ground-Fault & Insulation Monitor Page 3
Rev. 0-C-041918
FIGURE 1. PGR-6101 Outline and Mounting Details.
PGR-6101 Ground-Fault & Insulation Monitor Page 4
Rev. 0-C-041918
3.1 PGH-5000 AND PGH-6000
For 5-kV and 6-kV systems, connect the
PGR-6101 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-6101 terminal 30, which must be grounded.
Connect terminal M to PGR-6101 terminal 29.
(PGR-6101 terminal 2 is not used.) For PGR-6101 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.
Connect terminal A to one phase on the load side of the
motor starter. See Fig. 2. The PGH-5000/PHG-6000
includes 915 mm (36”) of high-voltage conductor.
FIGURE 2. Typical Connection Diagram.
PGR-6101 Ground-Fault & Insulation Monitor Page 5
Rev. 0-C-041918
FIGURE 3. PGC-5000-Series Current Sensors.
PGR-6101 Ground-Fault & Insulation Monitor Page 6
Rev. 0-C-041918
FIGURE 4. PGH-5000 Outline and Mounting Details.
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