Insulation Monitor
PGR-3200
PGR-3200 MANUAL
INSULATION MONITOR
REVISION 3-D-111915
NITOR
INSULATION MO
Copyright © 2015 by Littelfuse, Inc.
All rights reserved.
Document Number: PM-1025-EN
Printed in Canada
PGR-3200 Insulation Monitor
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Page i
Rev. 3-D-111915
PGR-3200 Insulation Monitor
TABLE OF CONTENTS
PAGE
SECTION
General....................................................................... 1
Operation................................................................... 1
2.1 Relay Operating Mode ............................................... 1
2.2 Front-Panel Controls .................................................. 1
2.2.1 Reset................................................................ 1
2.2.2 Test.................................................................. 1
2.3 Front-Panel Indication ................................................ 1
2.3.1 Power .............................................................. 1
2.3.2 Insulation Warning ......................................... 1
2.3.3 Active .............................................................. 1
2.3.4 Insulation Alarm ............................................. 1
2.4 Analog Output ............................................................ 1
2.5 Remote Reset .............................................................. 1
2.6 Remote Test ................................................................ 1
3
Installation................................................................. 3
3.1 PGH-5000 and PGH-6000 ......................................... 4
4
Technical Specifications .......................................... 6
4.1 PGR-3200 ................................................................... 6
4.2 PGH High-Tension Couplers..................................... 7
5
Ordering Information.............................................. 7
6
Performance Test ..................................................... 7
6.1 Insulation Test ............................................................ 7
Appendix A PGR-3200 Revision History .......................... 8
1
2
LIST OF FIGURES
FIGURE
1
2
3
4
5
6
PAGE
PGR-3200 Outline and Mounting Details ................. 2
Connection Diagram for Ungrounded Systems
Under 1.3 kV .............................................................. 3
Connection Diagram for Ungrounded
5-kV Systems.............................................................. 3
PGH-5000 Outline and Mounting
Details ......................................................................... 4
PGH-6000 Outline and Mounting
Details ......................................................................... 5
PGA-0510 Analog Ohm Meter ................................. 5
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.
Page ii
Rev. 3-D-111915
PGR-3200 Insulation Monitor
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Page iii
Rev. 3-D-111915
PGR-3200 Insulation Monitor
1. GENERAL
The PGR-3200 Insulation Monitor measures phase-toground resistance to detect electrical-insulation failure in
an ungrounded power utilization system. It provides
three levels of detection with a 50-k warning with an
LED and output contact indication, a 30-k warning with
LED indication, and a 10-k alarm with LED and output
contact indication. An analog output is provided for
predictive maintenance trending.
The PGR-3200 can be used to detect faults in
ungrounded systems up to 6 kV. It can be directly
connected to a system up to 1.3 kV, single or three phase,
50 or 60 Hz. A PGH-series high-tension coupler is
required for 5- and 6-kV systems.
2. OPERATION
The PGR-3200 actively monitors insulation resistance
when it is connected to the supply voltage. All
conductors connected to the monitored circuit are
included in the insulation measurement. See Fig. 2.
2.1 RELAY OPERATING MODE
The PGR-3200 output relays operate in the non-failsafe mode; they energize when an insulation warning or
alarm occurs.
2.2 FRONT-PANEL CONTROLS
2.2.1 RESET
The front-panel RESET switch is used to reset latching
trips. Cycling the supply voltage will also reset the PGR3200. See Section 2.5.
2.2.2 TEST
All LED’s will light and output relays will energize when
the TEST button is pressed for at least 8 s.
2.3 FRONT-PANEL INDICATION
2.3.1 POWER
The green LED’s labelled PWR indicates presence of
supply voltage.
2.3.2 INSULATION WARNING
The red LED’s labelled 50 k and 30 k will light when
those respective insulation resistance values, or lower are
measured.
2.3.3 ACTIVE
The red LED labelled ACTIVE indicates the monitor is
enabled.
Page 1
Rev. 3-D-111915
2.3.4 INSULATION ALARM
When insulation resistance measures 10 k or less, the
red LED labelled <10 k will light.
2.4 ANALOG OUTPUT
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 using
optional meter PGA-0510. See Figs. 2, 3, and 6.
2.5 REMOTE RESET
When remote-reset terminals 18 and 19 (alarm) or 21 and
22 (warning) are connected, a warning or alarm remains
latched until the RESET switch is pressed or the remotereset terminals are momentarily opened.
If the remote-reset terminals are not connected, the
PGR-3200 operates in non-latching mode; a warning or
alarm will reset when the fault is removed.
2.6 REMOTE TEST
When terminal 29 is connected to ground the monitor will
alarm. See Figs. 2 and 3. Response to a test input can take
several seconds.
Page 2
Rev. 3-D-111915
PGR-3200 Insulation Monitor
NOTES:
INSULATION
MONITOR
1. DIMENSIONS IN MILLIMETRES (INCHES).
2. MOUNTING SCREWS: M4 x 13 OR 8-32 x 0.50.
3. OVERALL DIMENSION WHEN MOUNTED ON
DIN EN50022 35 mm x 7.5 mm TOP-HAT RAIL.
4. 24 V INPUT IS AVAILABLE ONLY FOR THE
PGR-3200-120 ORDERING OPTION.
L2/N L1
PHASE
<1.3 KV
1
2
3
4
5
6
24 V
7
8
9
10 k
INSULATION
10
11
12
50 k
INSULATION
13
14 15
TOP
99.80
113.0 (NOTE 3)
(3.93)
(4.45)
POWR-GARD
TEST
PGR-3200
SERIES
RESET
PWR
INSULATION WARNING
75.0
PUSH 8 s
INSULATION ALARM
50 K
(2.95)
INSULATION MONITOR
ACTIVE
30 K
<10 K
SIDE
FRONT
7.4
17
18
19
50 k
REMOTE
RESET
20
21
22
10 k
REMOTE
RESET
23
24
25
26
ANALOG
OUTPUT
27
28
ENABLE
29 30
PGH
>1.3 KV
61.2
(2.41)
75.0
(2.95)
16
(0.29)
99.80
(3.93)
85.0
(3.35)
FIGURE 1. PGR-3200 Outline and Mounting Details.
6.9
MOUNTING DETAIL
(0.27)
BOTTOM
Page 3
Rev. 3-D-111915
PGR-3200 Insulation Monitor
3. INSTALLATION
NOTE: Mounting, terminal-block connections, and
wiring must conform to applicable local electrical codes.
Check all applicable codes prior to installation.
24 Vac
SUPPLY (SEE NOTE)
The PGR-3200 can be surface or DIN-rail mounted.
See Fig. 1.
Use terminal 6 (L1) as the line terminal and terminal 5
(L2/N) as the neutral terminal. Connect terminal 30 to
ground.
For systems up to 1.3 kV, connect terminal 2 to one
phase on the load side of the starter.
Connect terminals for latching operation, remote reset,
and remote test as required. See Sections 2.5 and 2.6 and
Figs. 2 and 3.
Connect an optional PGA-0510 Analog Ohm Meter to
terminals 25 and 26. Meter outline, dimensions, and cutout
size are shown in Fig. 6.
24 Vac
SUPPLY (SEE NOTE)
1
3
2
PHASE
<1.3 KV
4
5
6
L2/N L1
7
8
9
11
10
12
10 k
INSULATION
(Alarm)
INSULATION
MONITOR
13
14
15
50 k
INSULATION
(Warning)
PGR-3200
SERIES
Remote Reset
or Latching Mode
10 K
REMOTE
RESET
50 K
REMOTE
RESET
16
17
18
19
20
21
22
23
Optional links to latch
fault condition.
18
21
Optional
Remote
Reset
ANALOG
OUTPUT
24
25
26
PGH
>1.3 KV
ENABLE
27
28
29
30
Optional
External
Test
M
PGA-0510
19 NOTE: 120/24 OR 240 VAC 50/60 HZ
ARE ORDERING OPTIONS.
22
USE SPECIFIED SUPPLY
VOLTAGE.
FIGURE 2. Connection Diagram for Ungrounded
Systems Under 1.3 kV.
A
1
3
2
PHASE
<1.3 KV
7
5
6
L2/N L1 24 V
4
8
9
11
10
12
10 k
INSULATION
(Alarm)
INSULATION
MONITOR
13
14
PGH-5000
15
M
50 k
INSULATION
(Warning)
PGR-3200
SERIES
Remote Reset
or Latching Mode
10 K
REMOTE
RESET
50 K
REMOTE
RESET
16
17
18
19
20
21
22
23
Optional links to latch
fault condition.
18
21
Optional
Remote
Reset
ANALOG
OUTPUT
24
25
26
PGH
>1.3 KV
ENABLE
27
28
29
30
Optional
External
Test
M
PGA-0510
19 NOTE: 120/24 OR 240 VAC 50/60 HZ
ARE ORDERING OPTIONS.
22
USE SPECIFIED SUPPLY
VOLTAGE.
FIGURE 3. Connection Diagram for Ungrounded
5-kV Systems.
E
Page 4
Rev. 3-D-111915
PGR-3200 Insulation Monitor
95.2
(3.75)
44.5
(1.75)
9.5
(0.38)
NOTE 2
POWR-GARD
PGH-5000
PGH-5000
Æ
5 KV HIGH TENSION
COUPLER
Æ
HT
Coupling Voltage:
5,000 Vac Max.
Current to Ground:
2.5 mA Max.
A
DANGER
HIGH VOLTAGE
Impedance to Ground:
E
>2M
M
RELAY
Revision:
Serial No:
1-800-TEC-FUSE (1-800-832-3873)
Made in Saskatoon, Canada
Formerly HTC 5000
165.1
(6.50)
PGH-5000
E
ATTENTION!
150.0
(5.91)
E E M
5kV HIGHTENSION COUPLER
BOTH GROUND CONNECTIONS
MUST BE MADE AND SECURED
BEFORE CONNECTIONS TO
THE RELAY AND THE
HIGH VOLTAGE LINE
MAXIMUM
VOLTAGE
AC 5000V
A
A
915.0
(36.00)
FRONT
SIDE
MOUNTING DETAIL
NOTES:
1. DIMENSIONS IN MILLIMETRES (INCHES).
2. MOUNTING HOLES: 5.00 (0.20).
3. ALL GROUND CONNECTIONS MUST BE
MADE AND SECURED BEFORE CONNECTION
TO RELAY AND HIGH VOLTAGE LINE.
4. CORD PROVIDED IS APPROXIMATELY
915.0 (36.00) LONG.
FIGURE 4. PGH-5000 Outline and Mounting Details.
3.1 PGH-5000 AND PGH-6000
For 5-kV and 6-kV systems, connect the PGR-3200 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-3200 terminal
30, which must be grounded. Connect terminal M to
PGR-3200 terminal 29. (PGR-3200 terminal 2 is not
used.) For PGR-3200 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. 3.
The
PGH-5000/PHG-6000 includes 915 mm (36”) of highvoltage conductor.
Page 5
Rev. 3-D-111915
PGR-3200 Insulation Monitor
145.0
(5.71)
120.0
(4.72)
98.5
(3.88)
12.50
(0.49)
12.50
(0.49)
POWR-GARD
POWR-GARD
A
E E M
6kV HIGHTENSION COUPLER
PGH-6000
6kV HIGHTENSION COUPLER
PGH-6000
PGH-6000
Æ
6 KV HIGH TENSION
COUPLER
Æ
Coupling Voltage:
6,000 Vac Max.
Current to Ground:
2.5 mA Max.
HT
A
DANGER
DANGER
HIGH VOLTAGE
ATTENTION!
175.0
(6.89)
200.0
(7.87)
HIGH VOLTAGE
Impedance to Ground:
ATTENTION!
BOTH GROUND CONNECTIONS
MUST BE MADE AND SECURED
BEFORE CONNECTIONS TO
THE RELAY AND THE
HIGH VOLTAGE LINE
>2M
PGH-6000
E
E
M
RELAY
Revision:
Serial No:
Formerly HTC 6000
1-800-TEC-FUSE (1-800-832-3873)
Made in Saskatoon, Canada
BOTH GROUND CONNECTIONS
MUST BE MADE AND SECURED
BEFORE CONNECTIONS TO
THE RELAY AND THE
HIGH VOLTAGE LINE
MAXIMUM
VOLTAGE
MAXIMUM
VOLTAGE
(0.49)
AC 6000V
12.50
AC 6000V
915.0 (36.00) LONG
SIDE
FRONT
NOTES:
1. DIMENSIONS IN MILLIMETRES (INCHES).
2. MOUNTING HOLES: 6.35 (0.25).
3. ALL GROUND CONNECTIONS MUST BE
MADE AND SECURED BEFORE
CONNECTION TO RELAY AND HIGH
VOLTAGE LINE.
4. CORD PROVIDED IS APPROXIMATELY
915.0 (36.00) LONG.
FIGURE 5. PGH-6000 Outline and Mounting Details.
67.5
(2.657)
67.5
(2.657)
48.0
(1.890)
66.0
(2.598)
R1.25(0.049)
MAXIMUM
NOTES:
1. DIMENSIONS IN MILLIMETRES (INCHES).
TOP
FRONT
65.0
(2.559)
71.0
(2.795)
MOUNTING CUTOUT
SIDE
FIGURE 6. PGA-0510 Analog Ohm Meter.
REAR
Page 6
Rev. 3-D-111915
PGR-3200 Insulation Monitor
4. TECHNICAL SPECIFICATIONS
4.1 PGR-3200
Supply
120 V option ............................... 5 VA, 120 Vac, 24 Vac
(+10, -15%) 50/60 Hz
240 V option ..........................5 VA, 240 Vac,
(+10, -15%) 50/60 Hz
Maximum System Voltage:
Direct Connection:
UL Rating ........................600 Vac
Maximum.........................1,300 Vac
With PGH-5000.....................5,000 Vac
With PGH-6000.....................6,000 Vac
Measuring Voltage ......................12 Vdc
Measuring Current.......................20 A maximum
DC Resistance..............................600 k
AC impedance at 50-60 Hz .........> 1 M
Frequency Range .........................50 – 20,000 Hz
Response-Level Settings .............10, 30, and 50 k (fixed)
Response Delay:
Warning, 10 k relay output:
Insulation Resistance
< 5 k ................................4 s
Insulation Resistance
= 10 k ...............................5 s
Alarm, 50 k relay output:
Insulation Resistance
< 25 k ..............................2.5 s
Insulation Resistance
= 50 k ..............................4.5 s
Analog Output:
Mode ......................................Self Powered
Range .....................................0 to 1 mA
Impedance ..............................6 k maximum
Parameter ...............................0 to ∞ Ω Insulation
Resistance
Output Relays; Warning and Alarm:
Configuration .........................N.O. and N.C. (Form C)
Operating Mode.....................Non-Fail-Safe
UL Contact Rating.................5 A, 240 Vac resistive,
0.28 A, 30 Vdc resistive
Switching Capacity................1,200 VA
Supplemental Contact Ratings:
Carry Continuous ...............5 A, maximum
Trip Mode ....................................Latching or Autoreset
Reset .............................................Front-Panel Button and
Remote N.C. Contacts
Test ...............................................Front-Panel Button and
Remote N.O. Contact
Terminals .....................................Wire Clamping,
22 to 12 AWG
(0.3 to 3.3 mm2)
conductors
Tightening Torque .............. 0.40 N·m (3.54 lbf·in)
Dimensions:
Height .....................................75 mm (3.0”)
Width......................................100 mm (3.9”)
Depth ......................................113 mm (4.4”)
Including DIN rail ..............115 mm (4.5”)
Shipping Weight ......................... 0.45 kg (1 lb)
Environment:
Operating Temperature..........-10 to 60°C (14 to 140°F)
Storage Temperature .............-40 to 80°C (-40 to 176°F)
Humidity ................................85% Non-Condensing
Certification .................................UL Listed
LISTED
SWITCHES, IND CONT
19PF
NRNT, NRNT7, E183688
UL508 Industrial Control
Equipment
FCC
PGR-3200 Insulation Monitor
4.2 PGH HIGH-TENSION COUPLERS
Maximum Line Voltage:
PGH-5000 ..............................5,000 Vac
PGH-6000 ........................... 6,000 Vac
Current to Ground .................... 2.5 mA maximum
Terminal M Maximum
Voltage ..................................... 50 Vac
Terminals:
E, E, and M ......................... Wire Clamping,
26 to 12 AWG
(0.13 to 3.3 mm2)
conductors
Tightening Torque ........... 0.50 N·m (4.43 lbf·in)
...................................... Wire Clamping,
10 AWG (5.3 mm2)
maximum
High Tension Lead A ............... 8 AWG (8.4 mm2),
40 kVdc, 915 mm (36”)
5. ORDERING INFORMATION
PGR-3200-
Supply:
Blank – 240 V Supply(1)
120 – 120- or 24- Vac Supply
PGA-0510 ....................................Analog Ohm Meter
PGH-5000 ....................................5 kV High Tension
Coupler
PGH-6000 ....................................6 kV High Tension
Coupler
NOTES:
(1)
UL not available for this supply option.
Page 7
Rev. 3-D-111915
6. PERFORMANCE TEST
6.1 INSULATION TEST
Perform this test with the starter open and appropriate
lock-out procedures.
Connect a 20 k resistor between one phase and
ground at the line side of the starter or motor terminal
box. Select a phase that is not connected to PGR-3200
terminal 2 (or the PGH-5000 or PGH-6000). The
PGR-3200 will indicate a warning by lighting the 50 k
and 30 k LED’s and energizing the 50 k insulation
relay.
Replace the 20-k resistor with an 8 k resistor.
The PGR-3200 will indicate an alarm by lighting the
< 10 k LED and energizing the 10 k insulation relay.
Page 8
Rev. 3-D-111915
PGR-3200 Insulation Monitor
MANUAL
RELEASE DATE
APPENDIX A
PGR-3200 REVISION HISTORY
MANUAL
PRODUCT REVISION
REVISION
(REVISION NUMBER ON PRODUCT LABEL)
November 19, 2015
3-D-111915
August 4, 2015
3-C-080415
MANUAL REVISION HISTORY
REVISION 3-D-111915
SECTION 4
Terminal torque specifications added.
SECTION 5
Ordering information updated.
REVISION 3-C-080415
Model name changed to Insulation Monitor.
SECTION 3
Figs. 4, 5, and 6 updated.
SECTION 4
Output relay, dimension, and environment specifications updated.
Certifications updated.
Section 4.2 added.
SECTION 5
Ordering information updated.
APPENDIX A
Revision history added.
PRODUCT REVISION HISTORY
PRODUCT REVISION 01
UL Certification.
01