Section 11 - Testing; General; What To Test; Tests On A Running Motor - Eaton MP-4000 Instruction Bulletin For Installing, Operating, And Maintaining

SECTION 11 - TESTING

11.0 General

The MP-4000 requires no maintenance. Do not remove its rear cover.
In most applications, normal cycles of use demonstrate that the relay
is functioning properly. Use the procedures in this section for bench
checkout, and for verification of inputs and outputs that have not been
observed to function for one year or more. Users with normally trou-
ble-free applications should check the alarm relay and the annunciator
to which it is connected, at least annually.
11.1 What to Test
The MP-4000 microprocessor routinely checks most of its own elec-
tronics, program memory, and the writable, nonvolatile data storage
memory. If it detects malfunctions, the microprocessor reports specific
messages, and has settings to alarm the User and/or trip the motor as
desired. Refer to Setting P12L16 in Table 4.3 and Subsection 5.12.16.
It is neither necessary nor beneficial to test individual functions of a
multifunction microprocessor relay for maintenance purposes. All
functions are performed by the same microprocessor electronics. It
is important only to make sure the settings are correct (use the View
Setting mode any time), and to confirm that the inputs and outputs are
working with the application wiring.
To test the MP-4000 inputs and outputs, use the SP TEST page in the
Program mode. Refer to Subsections 5.0 and 5.13 and to Table 4.3 for
details on using the Program mode to activate test settings P13L1 to
P13L8.
11.2 Tests on a Running Motor
To use any of the test settings on a running motor, the MP-4000 must
be set to allow programming while running. Refer to STOP PGM ver-
sus RUN PGM in Subsection 5.12.6 and Setting P12L6.
To test the trip output relay, the motor must be stopped in any case. An
attempt to test this while the motor runs causes an ILLEGAL message
to be displayed.
All other inputs and outputs can be tested while the motor runs.
DaNGER
USING ThE TEST SETTINGS ChaNGES ThE STaTE OF ThE OUT-
PUTS, REGaRDlESS OF ThE FUNCTIONS NORMally
OPERaTING ThOSE OUTPUTS. UNlESS TESTING IS URGENT,
WaIT UNTIl ThE MOTOR IS STOPPED TO RUN TESTS. IF ThE
MOTOR IS RUNNING, MaKE SURE ThaT ChaNGING ThE OUT-
PUT STaTE WIll NOT CREaTE a DaNGEROUS SITUaTION IN
ThE MOTOR, STaRTER, OR PROCESS.
11.3 Verifying Current Inputs
If the motor current readings were checked at the time of commis-
sioning as described in Section 7, it is often adequate just to periodi-
cally observe the motor load current readings during normal motor
operation. Use the phase current values on the MONT I page of the
Monitor mode, or check values by remote communications. If a clip-on
ammeter is used, allow tolerance for errors in the clip-on CT and in the
main CTs of the motor starter.
11.4 Bench Test of Current Inputs
Use a three-phase source or relay test set to simulate motor load cur-
rent. Check the correctness of all readings, considering the scaling of
the PCT and GCT CT ratio settings P1L5 and P1L6.
MP-4000
If a three-phase source is not available, use the single-phase test
mode of the MP-4000. Set P13L1 to 1 PHASE. A single current
around 3.5 A to 4 A can be applied to all four CT inputs, daisy-chained
in series. Observe the metered values, considering PCT and GCT.
BE SURE TO RETURN SETTING P13l1 TO ThREE-PhaSE BE-
FORE RETURNING ThE RElay TO SERVICE. all PROTECTION
FUNCTIONS ThaT ChECK PhaSE BalaNCE OR SEQUENCE
aRE DISaBlED IN SINGlE-PhaSE TEST MODE. SEEING ThE
DISPlay REaDy - 1 IN ThE MOTOR STaTE MODE WhEN ThE
MOTOR IS STOPPED IS a WaRNING ThaT ThE SETTING IS aT
SINGlE- PhaSE. ThE CORRECT DISPlay IS REaDy - 3.
11.5 Testing the Trip Relay
Stop the motor—this test is blocked if the motor is running. Enter the
Program mode and go to test setting P13L2. The trip relay contacts
(terminals 11 through 13) can be monitored for proper operation, or
observe the controlled-circuit operation. See Figure 6.6 for the rear
panel terminal layout.
To use this function:
Determine whether the MP-4000 trip relay is configured for
•
MODE 1 or MODE 2 operation. Refer to SYSTEM Page
Setting P12L1.
In MODE 1, the trip relay is normally de-energized. Set up
•
for the test by selecting TRP ENER in P13L2.
In MODE 2, the trip relay is normally energized. Set up for
•
the test by selecting TRP DENR in P13L2.
Press the Reset pushbutton to test the relay. The Trip LED
•
also lights. Release the pushbutton to revert to the prior
output state.
11.6 Testing the alarm Relay
Use setting P13L3 to test the alarm relay. The procedure is the same
as for the trip relay test. Press the Reset pushbutton to light the Alarm
LED and activate the alarm contacts (terminals 17 through 19). If
the MP-4000 is set for RUN PGM, this output can be tested while the
motor runs.
11.7 Testing the aUX1 Relay
Use setting P13L4 to test the AUX1 relay. The procedure is the same
as for the trip relay test. Press the Reset pushbutton to light the
Aux 1 LED and activate the AUX1 contacts (terminals 14 through 16).
If the MP-4000 is set for RUN PGM, this output can be tested while
the motor runs.
11.8 Testing the aUX2 Relay
Use setting P13L5 to test the AUX2 relay. The procedure is the same
as for the trip relay test. Press the Reset pushbutton to light the
Aux 2 LED and activate the AUX2 contacts (terminals 1 through 3). If
the MP-4000 is set for RUN PGM, this output can be tested while the
motor runs.
11.9 Testing the analog Output
To test the 4-20 mA analog transducer output at terminals 24 and 25,
use P13L6. Set the test output current level to be 4, 12, or 20 mA.
Press the Reset pushbutton to force the selected test output current.
Release the pushbutton to return to the normal measurement-driven
output. Note that the MP-4000 analog output must drive an isolated
external circuit.
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WaRNING
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