User Manual
Original Instructions
E100 Electronic Overload
Relay
Bulletins 193, 592
2 Rockwell Automation Publication 193-UM013C-EN-P - November 2022
E100 Electronic Overload Relay User Manual
Important User Information
Read this document and the documents listed in the additional resources section about installation, configuration, and operation of this equipment before
you install, configure, operate, or maintain this product. Users are required to familiarize themselves with installation and wiring instructions in addition to
requirements of all applicable codes, laws, and standards.
Activities including installation, adjustments, putting into service, use, assembly, disassembly, and maintenance are required to be carried out by suitably
trained personnel in accordance with applicable code of practice.
If this equipment is used in a manner not specified by the manufacturer, the protection provided by the equipment may be impaired.
In no event will Rockwell Automation, Inc. be responsible or liable for indirect or consequential damages resulting from the use or application of this
equipment.
The examples and diagrams in this manual are included solely for illustrative purposes. Because of the many variables and requirements associated with
any particular installation, Rockwell Automation, Inc. cannot assume responsibility or liability for actual use based on the examples and diagrams.
No patent liability is assumed by Rockwell Automation, Inc. with respect to use of information, circuits, equipment, or software described in this manual.
Reproduction of the contents of this manual, in whole or in part, without written permission of Rockwell Automation, Inc., is prohibited.
Throughout this manual, when necessary, we use notes to make you aware of safety considerations.
These labels may also be on or inside the equipment to provide specific precautions.
The following icon may appear in the text of this document.
WARNING: Identifies information about practices or circumstances that can cause an explosion in a hazardous environment,
which may lead to personal injury or death, property damage, or economic loss.
ATTENTION: Identifies information about practices or circumstances that can lead to personal injury or death, property
damage, or economic loss. Attentions help you identify a hazard, avoid a hazard, and recognize the consequence.
IMPORTANT Identifies information that is critical for successful application and understanding of the product.
SHOCK HAZARD: Labels may be on or inside the equipment, for example, a drive or motor, to alert people that dangerous
voltage may be present.
BURN HAZARD: Labels may be on or inside the equipment, for example, a drive or motor, to alert people that surfaces may
reach dangerous temperatures.
ARC FLASH HAZARD: Labels may be on or inside the equipment, for example, a motor control center, to alert people to
potential Arc Flash. Arc Flash will cause severe injury or death. Wear proper Personal Protective Equipment (PPE). Follow ALL
Regulatory requirements for safe work practices and for Personal Protective Equipment (PPE).
Identifies information that is useful and can help to make a process easier to do or easier to understand.
Rockwell Automation Publication 193-UM013C-EN-P - November 2022 3
Table of Contents
About This Publication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Summary of Changes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Terminology. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Additional Resources . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Chapter 1
Product Overview Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Chapter 2
System Operation and
Configuration
Before You Begin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Configure the Device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Configure Accessory Modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Chapter 3
Troubleshooting E100 Electronic Overload Relay. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Accessory Modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Appendix A
Wiring Diagrams E100 Wiring Configurations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
4 Rockwell Automation Publication 193-UM013C-EN-P - November 2022
Table of Contents
Notes:
Rockwell Automation Publication 193-UM013C-EN-P - November 2022 5
Preface
About This Publication
This manual describes how to install, configure, operate, and troubleshoot the E100™
Electronic Overload Relay.
Summary of Changes This publication contains the following new or updated information. This list includes
substantive updates only and is not intended to reflect all changes.
Terminology Throughout this publication, we also refer to the E100 Electronic Overload Relay as the E100
overload relay and E100 relay. These terms are interchangeable.
Additional Resources These documents contain additional information concerning related products from Rockwell
Automation. You can view or download publications at rok.auto/literature.
Topic Page
Added information for use with Bulletin 100-E contactors throughout
Resource Description
E100 Electronic Overload Relay Specifications, publication 193-TD013 Provides complete specifications for the E100 Electronic Overload Relay.
Bulletin 193 Core Balanced Ground Fault Sensor Application and Installation
Instructions, publication 193-IN047
Provides instruction about how to install and apply 193-CBCT core balanced ground fault
sensors.
E100 Overload Relay Application and Installation Instructions (IEC),
publication 193-IN081
Provides instruction about how to install the E100 Overload Relay onto IEC contactors.
E100 Ground Fault/Jam and Remote Reset Module Application and
Installation, publication 193-IN082
Provides instruction about how to install and apply the ground fault/jam and remote reset
module.
E100 Overload Relay with Pass-thru Wiring Application and Installation
Instructions, publication 193-IN083
Provides instruction about how to install the E100 Overload Relay with the pass-thru wiring
option.
E100 External Current Transformer Overload Relay Application and
Installation Instructions, publication 193-IN084
Provides instruction about how to install the Advanced E100 Overload Relay.
E100 Overload Relay Remote Reset Installation, publication 193-IN085 Provides instruction about how to install and set up the remote reset module.
E100 DIN Rail or Panel Adapter Installation, publication 193-IN086
Provides instruction about how to install the E100 relay onto DIN Rail or the panel adapter.
E100 Remote Indication Display Application and Installation,
publication 193-IN087
Provides instruction about how to install and set up the remote status indication module.
E100 Overload Relay Application and Installation Instructions (NEMA),
publication 592-IN021
Provides instruction about how to install the E100 Overload Relay onto 500 line contactors.
EtherNet/IP Network Devices User Manual, ENET-UM006
Describes how to configure and use EtherNet/IP devices to communicate on the EtherNet/IP
network.
Ethernet Reference Manual, ENET-RM002
Describes basic Ethernet concepts, infrastructure components, and infrastructure features.
System Security Design Guidelines Reference Manual, SECURE-RM001
Provides guidance on how to conduct security assessments, implement Rockwell
Automation products in a secure system, harden the control system, manage user access,
and dispose of equipment.
UL Standards Listing for Industrial Control Products,
publication CMPNTS-SR002
Assists original equipment manufacturers (OEMs) with construction of panels, to help ensure
that they conform to the requirements of Underwriters Laboratories.
American Standards, Configurations, and Ratings: Introduction to
Motor Circuit Design, publication IC-AT001
Provides an overview of American motor circuit design based on methods that are outlined
in the NEC.
Industrial Components Preventive Maintenance, Enclosures, and Contact
Ratings Specifications, publication IC-TD002
Provides a quick reference tool for Allen-Bradley industrial automation controls and
assemblies.
Safety Guidelines for the Application, Installation, and Maintenance of
Solid-state Control, publication SGI-1.1
Designed to harmonize with NEMA Standards Publication No. ICS 1.1-1987 and provides
general guidelines for the application, installation, and maintenance of solid-state control in
the form of individual devices or packaged assemblies incorporating solid-state
components.
Industrial Automation Wiring and Grounding Guidelines, publication 1770-4.1
Provides general guidelines for installing a Rockwell Automation industrial system.
Product Certifications website, rok.auto/certifications. Provides declarations of conformity, certificates, and other certification details.
EtherNet/IP Network Devices User Manual, ENET-UM006
Describes how to configure and use EtherNet/IP devices to communicate on the EtherNet/IP
network.
6 Rockwell Automation Publication 193-UM013C-EN-P - November 2022
Notes:
Rockwell Automation Publication 193-UM013C-EN-P - November 2022 7
Chapter 1
Product Overview
This chapter provides an overview of the E100™ Electronic Overload Relay.
Description The E100 Electronic Overload Relay is the newest technology for overload protection, and
supports both single- and three-phase operation in a single component.
The device is available in two versions: a Basic (Cat. No. 193-1EE) and Advanced (Cat. No. 193-
1EF, 592-1EF) version. The Basic offering allows adjustable trip current, manual trip reset, and
limited trip class selection. The Advanced version offers the same adjustable trip current,
manual or automatic trip reset, a larger selection of trip classes, and the ability to add
additional accessory modules.
The E100 relay provides the following benefits:
• Electronic overload detection
• Simple configuration
• Selectable trip class
• Adjustable trip current
• Integration with both IEC and NEMA contactors
• Test and Reset buttons
• Auto/Manual reset selection
• RMS Current sensing (50/60 Hz)
•External current transformers
• Direct and Pass-thru mounting
The advanced version of the E100 relay (193/592-EF only) lets you add the following accessory
modules through the front-mounted communication port. Accessories include:
• Ground Fault/Jam Protection Module
• Remote Indication Display, with or without Reset
• Remote Reset Module
Other accessories for both versions include:
• Remote Reset Solenoid
• Anti-Tamper Shield
•Reset Adapter
• Panel Adapter
8 Rockwell Automation Publication 193-UM013C-EN-P - November 2022
Chapter 1 Product Overview
Notes:
Rockwell Automation Publication 193-UM013C-EN-P - November 2022 9
Chapter 2
System Operation and Configuration
This chapter provides instructions about how to operate and configure an E100™ Electronic
Overload Relay system. It includes instructions about how to set the Trip Current and Trip
Class. This chapter also describes the accessory modules that are available for the Advanced
(193/592-1EF) E100 relay.
Before You Begin Before you configure the E100 relay, you must install it onto a contactor or DIN Rail, or mount it
on a panel. See page 5 for a list of related installation instructions. You can search for and
download literature at rok.auto/literature
.
Configure the Device Use the rotary dials on the front of the unit to select the trip class and adjust the trip current.
Figure 1 - E100 Overload Relay Settings
Basic Unit, 193-1EE… Advanced Unit, 193/592-1EF…
Trip Current Selection
(1)
Trip Current
Selection
(1)
Trip Class Selection
(2)
Trip Class/Reset Selection
(2)
Reset
Reset
Push to Stop
Push to Stop
Push to Test
Push to Test
Trip Indicator Window
(3)
Trip Indicator
Window
(3)
Communication Port
Note Number Feature Information
1 Trip Current Selection
To adjust the trip current, turn the dial until the desired current is aligned with the pointer. Trip rating is 120% of dial setting value.
Minimum setting is 0.1 FLA.
2 Trip Class Selection
Use this setting to select the desired trip class. Basic units only support manual reset operations. Manual DIP switch position is
independent of relay function and trip class. On Advanced units, use this setting to select between automatic and manual reset
modes.
3 Trip Indicator Window The red status indicator is visible when the unit has tripped.
10 Rockwell Automation Publication 193-UM013C-EN-P - November 2022
Chapter 2 System Operation and Configuration
Set the Trip Current
When you set the trip current, you must consider the motor service factor and FLA. You can
find this information on the motor nameplate, as shown in Table 1 and Table .
Table 1 - Service Factor/Motor FLA Dial Settings
Service Factor Trip Current Setting
<1.15 0.9 x FLA
≥ 1.15 1 x FLA
Y (Star-Delta) FLA/1.73
Table 2 - Service Factor/Motor FLA Dial Settings
Service Factor Trip Current Setting
Y (Star-Delta) FLA/1.73
Direct-on-line 1 x FLA
Service Factor
FLA
FLA
Rockwell Automation Publication 193-UM013C-EN-P - November 2022 11
Chapter 2 System Operation and Configuration
Configure Accessory
Modules
This section describes how to configure the accessory modules for the Advanced version (193/
592-1EF) of the E100 relay. You must correctly install the accessories before you configure
them. See page 5
for a list of related installation instructions.
Cat. No. 193-1EGJ Universal Protection Expansion Module
The Cat. No. 193-1EGJ Universal Protection module adds ground fault and jam protection to the
Advanced version (193/592-1EF) of the E100 relay. The add-on module lets you select the jam
current level, jam trip delay, and ground fault level.
Figure 2 - Cat. No. 193-1EGJ Universal Protection Expansion Module Settings
Note Number Feature Information
1 Jam Level Selection Set the FLA percentage for Jam Protection. Selectable from 125…600% FLA.
2 Jam Delay Selection Set the time delay for a Jam Trip to occur. Customizable from 0.1…10 s
3
Ground Fault Level
Selection
Set the current level for a Ground Fault Trip to occur. Customizable from
0.02…5 A.
4
Accessory
Diagnostic LED
For more information about the diagnostic LED codes, see page 16
.
Jam Level
(1)
Jam Delay
(2)
Ground Fault Level
(3)
Accessory Diagnostic LED
(4)
12 Rockwell Automation Publication 193-UM013C-EN-P - November 2022
Chapter 2 System Operation and Configuration
Wiring
Figure 3 shows the basic wiring for the 193-1EGJ Module.
Figure 3 - Cat. No. 193-1EGJ Universal Protection Expansion Module Wiring
Cat. No. 193-1ERR Electronic Reset and Indication Display Module
The Cat. No. 193-1ERR Electronic Reset and Indication Display Module lets you use the Cat. No.
193-ERID and 193-ERIDN Remote Indication and Display module with the Advanced version (193/
592-1EF) of the E100 relay.
Figure 4 - Cat. No. 193-1ERR Electronic Reset and Indication Display Module
Note Number Information
1 Terminals R1 and R2 are used with 193-ERID and 193-1ERIDN modules.
2 External power must be user supplied. 24…240V, 47…63 Hz or DC.
3 Reserved for 193-CBCT external ground fault current sensor.
Note Number Feature Information
1 Accessory Diagnostic LED For more information about the diagnostic LED codes, see Chapter 3
.
R1
R2
S1
S2
A1
A2
(1)
(2)
(3)
Accessory Diagnostic LED
(1)
Rockwell Automation Publication 193-UM013C-EN-P - November 2022 13
Chapter 2 System Operation and Configuration
Wiring
Figure 5 shows the basic wiring for the 193-1ERR Module.
Figure 5 - Cat. No. 193-1ERR Electronic Reset and Indication Display Module Wiring
Cat. No. 193-ERID or 193-1ERIDN Remote Indication and Display Module
The remote indication and display modules let you view the status of the E100 relay from the
front of a panel. Cat. No. 193-ERID also features a reset button. The light-emitting diode (LED)
status indicators show the status of the overload relay.
Figure 6 - Cat. No. 193-ERID and 193-1ERIDN Remote Indication and Display Module Features
See page 17 for information about the fault and status codes for the remote indication and
display modules.
Figure 3
and Figure 5 show the basic wiring for the 193-ERID and 193-1ERIDN Modules.
Note Number Information
1 Cat. No. 193-ERID or 193-1ERIDN Remote Indication and Display module.
2 External power must be user supplied. 24…240V, 47…63 Hz or DC.
R2
R1
A1
A2
(1)
(2)
Reset (193-ERID only)
Module Power/Status
Fault Status
Phase Loss
Overload
14 Rockwell Automation Publication 193-UM013C-EN-P - November 2022
Chapter 2 System Operation and Configuration
Notes:
Rockwell Automation Publication 193-UM013C-EN-P - November 2022 15
Chapter 3
Troubleshooting
This chapter helps you troubleshoot the E100™ Electronic Overload Relay by using the
diagnostic LED status indicators. It also guides you through troubleshooting associated
accessory modules.
E100 Electronic Overload
Relay
All E100 relay units include a trip indicator window on the front of the unit labeled “Status”. If
the red indicator is not visible, the overload relay is not tripped. If the red indicator is visible,
the overload relay is tripped.
Accessory Modules Universal Protection Module and Remote Reset Module
The Universal Protection Module and the Remote Reset Module both include an LED status
indicator that shows the state of the E100 relay. The modules are supplied with external power,
so in the event of a fault event, the status LEDs still operate.
ATTENTION: Servicing energized industrial control equipment can be
hazardous. Electrical shock, burns, or unintentional actuation of controlled
industrial equipment may cause death or serious injury. For safety of
maintenance personnel and others who may be exposed to electrical hazards
associated with the maintenance activities, follow the local safety-related
work practices (for example, the NFPA 70E, Part II, Electrical Safety for
Employee Workplaces, in the United States) when working on or near
energized equipment. Maintenance personnel must be trained in the safety
practices, procedures, and requirements that pertain to their respective job
assignments. Do not work alone on energized equipment.
ATTENTION: Do not attempt to defeat or override fault circuits. The cause of
a fault indication must be determined and corrected before attempting
operation. Failure to correct a control system or mechanical malfunction may
result in personal injury and/or equipment damage due to uncontrolled
machine system operation.
16 Rockwell Automation Publication 193-UM013C-EN-P - November 2022
Chapter 3 Troubleshooting
The status LED indicates the cause of a trip by flashing a red trip code. The number of flashes
followed by a pause identifies the specific trip code as shown in Table 4.
Remote Indication Display
There are four LED status indicators on the front of the Cat. No. 193-ERID and 193-1ERIDN
modules. These status indicators show Module Power/Status, Overload, Phase Loss, and Fault
Status. See Figure 7
Figure 7 - Cat. No. 193-ERID and 193-E1ERIDN Remote Indication and Display Module Features
Table 5 lists the status, warning, and fault codes for the remote indication and display
modules.
Table 3 - 193-1EGJ and 193-1ERR Remote Indication and Display Module Fault/Status Codes
Status
Indicator Color
Solid/Flashing Description Solution
Green
Flashing Module powered —
Solid
Module powered and motor
current present
—
Amber Flashing Warning
Red
Flashing
Fault detected and overload
relay tripped
Use Table 4
to identify the specific trip code
Solid
Hardware fault; internal
hardware fault detected and
overload relay trip attempted
• Recover fault by cycling overload relay
accessory supply voltage
• Verify that the supply voltage is within limits
• Verify the wiring to the terminals is correct
• Verify that the pins that connected the
accessory to the overload relay are not
damaged or misaligned
• Verify the operating temperature of the
devices is within specification limits
Table 4 - Trip Code Identification
No. of Flashes Trip Type
1Overload Trip
2Phase Loss
3Ground Fault
5Jam
8 Short Circuit
10
COM Loss
(1)
(1) If you experience repeated COM Loss trips, this may be due to a damaged
communication interface cable. To test whether this is the case, unplug the
communication interface cable from the communication port and wait at least 3
seconds before re-connecting. If the issue persists, consider replacing the
communication interface cable.
11 Test Trip
Reset (193-ERID only)
Module Power/Status
Fault Status
Phase Loss
Overload
Rockwell Automation Publication 193-UM013C-EN-P - November 2022 17
Chapter 3 Troubleshooting
Table 5 - 193-ERID and 193-E1ERIDN Remote Indication and Display Module Fault/Status Codes
Status Indicator Symbol Status Indicator Color
Solid/
Flashing
Description
Module Power/
Status
Green
Flashing Module powered
Solid
Module powered and motor current
present
Red Solid Hardware fault
Overload
Red Solid Overload trip
Amber Flashing
Overload warning
(1)
(1) An Overload warning occurs when the E100 overload reaches 90% thermal capacity utilization (TCU ). The overload trips at
100% TCU.
Phase Loss
Red
Solid Short Circuit Trip
Flashing Phase Loss Trip
Amber Flashing
Phase Loss Warning
(2)
(2) Phase Loss warning is active if the overload detects a Phase Loss condition. The warning is maintained for 3 seconds before
a Phase Loss Trip occurs.
Fault Status
Red 3 Flashing
Ground Fault Trip
(3)
(3) A Ground Fault trip occurs if the configured Ground Fault Level is reached for 100 ms.
Amber 3 Flashing Ground Fault Warning
Red 5 Flashing Jam Trip
Amber 5 Flashing
Jam Warning
(4)
(4) A Jam warning is active if the measured FLA is greater than the set Jam Level. The warning is active until the Jam Delay time
is reached and the overload relay trips.
Red 9 Flashing
Welded Contact
(5)
(5) Does not apply to the E100 relay.
Red 10 Flashing Comm Loss
Amber 10 Flashing Comm Warning
Red 11 Flashing Test Trip
18 Rockwell Automation Publication 193-UM013C-EN-P - November 2022
Chapter 3 Troubleshooting
Notes:
Rockwell Automation Publication 193-UM013C-EN-P - November 2022 19
Appendix A
Wiring Diagrams
E100 Wiring Configurations The following pages illustrate various wiring configurations for the E100™ Electronic Overload
Relay.
Figure 8 - 3-Phase, Full-voltage Direct-on-line Starter, NEMA Symbology
Figure 9 - 3-Phase, Full-voltage Direct-on-line Starter, IEC Symbology
95
L2 L3 13L1
14
A1
A2
T2 T3T1
96 97 98
T1 T3
T2
Connection must be
fitted by the user
Short-circuit
Protection Device
95
3
13
1
14
A1
A2
462
96
U
V
5
97 98
W
Connection must be
fitted by the user
Short-circuit
Protection Device
20 Rockwell Automation Publication 193-UM013C-EN-P - November 2022
Appendix A Wiring Diagrams
Figure 10 - 1-Phase, Full-voltage Direct-on-line Starter, NEMA Symbology
Figure 11 - 1-Phase, Full-voltage Direct-on-line Starter, IEC Symbology
Figure 12 - E100 Overload Relay with External Current Transformer
For more information about how to install an external Current Transformer, see
Bulletin 193 Core Balanced Ground Fault Sensor Application and Installation
Instructions, publication 193-IN047
.
95
L2 L3 13L1
14
A1
A2
T2 T3T1
96 97 98
T1 T2
Connection must be
fitted by the user
Short-circuit
Protection Device
Connection must be
fitted by the user
95
35
13
1
14
A1
A2
462
96 97 98
U1 U2
Connection must be
fitted by the user
Short-circuit
Protection Device
Connection must be
fitted by the user
M
L1/1
L1/1
T1/2
T2/4 T3/6
L2/3
L3/5
L2/3 L3/5
H1(Dot) H1(Dot) H1(Dot)
H2 H2 H2
X1
X1 X1
X2X2X2
CT1
T1/2
T2/4
T3/6
CT2 CT3
Overload Relay
Rockwell Automation Publication 193-UM013C-EN-P - November 2022 21
E100 Electronic Overload Relay User Manual
Notes:
Publication 193-UM013C-EN-P - November 2022
Supersedes Publication 193-UM013B-EN-P - December 2019 Copyright © 2022 Rockwell Automation, Inc. All rights reserved. Printed in the U.S.A.
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