Procedure: Migrating Rockwell Bulletin 592 Overload Relays to E100

Procedure: Migrating Rockwell Bulletin 592 Overload Relays to E100 1. Purpose and scope

This procedure replaces an existing Allen-Bradley Bulletin 592 overload relay on a NEMA Bulletin 500-series starter with an E100 electronic overload relay, one starter at a time, with the motor de-energized.

It covers bimetallic (heater-element) 592 relays and 592-EE solid-state relays mounted on Bulletin 500 contactors, sizes 00 through 2. Larger sizes, CT-fed overloads, and starters inside listed MCC buckets need an engineering review before using this procedure, because bucket modifications can affect the MCC's UL listing.

Always confirm catalog numbers, current ranges, and mounting compatibility against the current Rockwell Automation selection guide and the E100 installation instructions shipped with the relay. Where this procedure and the manufacturer's instructions differ, the manufacturer's instructions govern.

2. Safety requirements

All work is done de-energized under the site's lockout/tagout program by a qualified electrical worker per NFPA 70E (or the local equivalent).

☐ Work permit and job briefing completed; arc flash and shock boundaries reviewed from the equipment label.
☐ Motor stopped and process placed in a safe state; operations notified.
☐ Disconnect opened, locked, and tagged. Separately lock out any external control power (control transformer fed from another source, interposing relays, PLC outputs).
☐ Absence of voltage verified on line, load, and control terminals with a meter tested on a known live source before and after.
☐ Stored energy checked: power-factor capacitors, VFD bypass paths, motor heaters, and back-feed from other circuits.
☐ PPE worn as required until absence of voltage is confirmed.
Lockout/tagout kit and voltage-rated PPE for the task
CAT III/IV multimeter with proving unit; clamp-on ammeter (true RMS)
Insulated screwdrivers (flat and Phillips/Pozidriv) and calibrated torque screwdriver
Wire strippers, crimpers, ferrules, and spare conductor of matching size and insulation rating
Wire markers and labels
Insulation resistance tester (megger) for the motor circuit check
Replacement E100 relay and accessories from Section 4, with the installation instructions shipped in the box
Current schematic and panel layout drawings, red-lined copy for as-builts
Camera or phone for before/after photos of wiring
- N.C. 95-96 in series with the contactor coil (the overload trip circuit)
- N.O. 97-98 to any trip alarm, pilot light, or PLC input that used it before
☐ Schematic and panel layout red-lined with the new E100 catalog number, settings, and any accessory wiring
☐ Motor/starter record updated: E100 catalog no., FLA setting, trip class, reset mode, date installed
☐ Test results recorded: megger values, running current per phase, trip test result
☐ Before/after photos filed with the work order
☐ Heater elements and 592 relays removed from the spares list for this starter; E100 spare added if required
☐ Discrepancies noted for engineering (mis-sized heaters, damaged conductors, missing nameplates)
☐ LOTO removed and operations notified the motor is back in service

Do not defeat, jumper, or bypass the overload at any point during the swap. The motor must not run without overload protection.

3. Pre-migration survey

Record the following for every starter before ordering parts. The motor FLA and the starter size drive the E100 selection; the control wiring drives the auxiliary contact and reset choices.

Item	Where to find it	Record
Starter catalog no. and NEMA size	Contactor nameplate (e.g., 500-xxx)
Existing overload catalog no.	592 relay nameplate
Heater element catalog no. (bimetallic only)	Stamped on each heater
Motor FLA, service factor, voltage, HP	Motor nameplate (not the heater chart)
Ambient compensation / trip class in use	592 nameplate or 592-EE settings
Reset mode in use (manual / automatic)	Relay reset mechanism or setting
Overload aux contacts: N.C. 95-96, N.O. 97-98, other	Relay terminals and schematic
Control voltage and source	Control transformer / schematic
Remote reset, trip indication, or PLC monitoring	Schematic and I/O list
Enclosure free space above/below the starter	Measure
Conductor size and material, motor leads	Inspect / drawings

If the motor nameplate is missing or illegible, measure running current under normal load and get engineering sign-off on the FLA value before proceeding. Do not size from the old heater element alone, since heaters are often mis-sized over a plant's life.

4. Selecting the E100 replacement

Pick the 592-1EF (E100 Advanced, NEMA 500 direct-mount) relay whose adjustable range brackets the motor FLA, ideally with the FLA near the middle of the range, and whose mounting matches the starter size.

The 592-EE solid-state relays being replaced are the older E1 Plus family. They mount to NEMA size 0–2 Bulletin 500 contactors and offer trip class 10/15/20/30, manual or auto reset, and 1 N.O. + 1 N.C. contacts (592-EEDC listing). The E100 Advanced keeps those functions and adds optional accessory modules (592-1EFDC listing).

E100 catalog no.	Adjustable range (A)	NEMA 500 size	Trip class
592-1EFBC	0.2–1.0	0–2	10/15/20/30
592-1EFDC	3.2–16	0–2	10/15/20/30
592-1EFEC	5.4–27	0–2	10/15/20/30
592-1EFFC	11–55	0–2	10/15/20/30
592-1EFGD	20–100	3	10/15/20/30
592-1EFKF	60–300	5	10/15/20/30

Other ranges (for example 1–5 A for size 0–2, and size 4) are in the Rockwell product configurator; confirm the exact catalog number there before ordering.

Selection rules:

Match the mounting suffix to the contactor size. A size 0–2 relay will not fit a size 3 contactor.
Choose the range so motor FLA falls inside it with margin on both ends. E100 relays are self-powered from motor current, so a range set near its bottom limit is not recommended.
Copy the trip class from the existing 592-EE setting. For bimetallic 592 relays, use class 20 unless the motor or process documentation calls for class 10 (e.g., submersible pumps, hermetic compressors) or class 30 (high-inertia loads).
Order any accessories needed to replicate existing functions: remote reset, extra auxiliary contacts, or trip indication.
Where no direct-mount version suits the starter, the E100 Basic integrated panel-mount pass-through relays (193-1EE..P, e.g. 193-1EEDP) work with all contactors but need panel space and rewiring.
Photograph the starter, relay, and all wiring from at least two angles.
Label every conductor on the overload: motor leads T1, T2, T3 and each control wire at 95, 96, 97, 98 (or other aux terminals). Note which wire landed where on the schematic.
For a 592-EE relay, record the FLA dial, trip class, and reset setting. For a bimetallic 592, record the heater catalog numbers and reset mode.
Disconnect the motor leads from the overload load terminals. Tape and secure the ends clear of the work area.
Disconnect the control wires from the overload auxiliary contacts.
Loosen the screws connecting the overload line-side terminals (or straps) to the contactor load terminals.
Remove any mounting screws or bracket securing the overload to the contactor or backplate, and lift the relay off.
Inspect the contactor load terminals and the motor lead ends for heat damage, discoloration, or loose strands. Re-terminate or replace damaged conductors before proceeding.
Tag the removed relay and heaters with the starter ID and store or dispose of them per site practice. Do not return used heaters to stores stock.
Confirm the catalog number on the E100 nameplate matches the survey record and that the range brackets motor FLA.
Align the E100 line-side connection tabs with the contactor load terminals (T1/T2/T3) and seat the relay fully. Use any mounting hardware supplied in the kit.
Torque the contactor load terminal screws to the value printed on the contactor or in the E100 instructions. Do not guess torque values.
Land motor leads T1, T2, T3 on the E100 load terminals in the same phase order as before, so motor rotation does not change. Torque to the E100 instruction value.
Land the control wires on the E100 auxiliary contacts:
Install and wire any accessory modules (remote reset, extra contacts) per their instructions.
Tug-test every conductor, confirm no strands are outside a terminal, and confirm the relay clears adjacent devices and the enclosure door.
Mark the new relay with the starter ID and motor FLA.
Verify point-to-point wiring against the schematic.
Megger the motor and load conductors phase-to-ground at the voltage appropriate for the motor rating; record values.
With the meter on continuity, confirm 95-96 is closed and 97-98 is open in the reset state. Press the test/trip function and confirm they change state, then reset.
Apply control power only (motor disconnected or isolated where the design allows). Trip the E100 with its test function and confirm the contactor drops out or will not pull in. Confirm any trip alarm or PLC input responds.
Reset the relay and confirm the starter can be started normally.
Bump the motor and confirm correct rotation.
Run the motor under normal load. Measure each phase with a clamp-on ammeter and record. Current should be at or below the FLA setting and roughly balanced; investigate imbalance above a few percent.
Observe for 15–30 minutes or one full process cycle for nuisance trips.

5. Tools and materials 6. Removing the existing 592 overload

Remove the old relay only after Section 2 is complete and absence of voltage is verified.

7. Installing and wiring the E100

Mount the E100 directly to the contactor load side, then land the motor leads and control wires to match the original schematic.

8. Configuring the E100

Set the FLA dial from the motor nameplate, not from the old heater table. Bimetallic heaters were chosen from charts with built-in factors; the E100 dial is set in amps directly.

Setting	How to set	Notes
FLA	Motor nameplate FLA, adjusted for service factor per the E100 manual	Rockwell's usual guidance for electronic overloads is nameplate FLA for SF ≥ 1.15 and about 90% of FLA for SF 1.0; confirm in the shipped instructions. Check against NEC 430.32 limits.
Trip class	Same as the old 592-EE setting, or per Section 4 rule 3	Record the reason for any change
Reset mode	Manual unless the old starter was intentionally automatic	Automatic reset can restart a motor unexpectedly in 2-wire control; use it only where safe and documented
Accessory settings	Per accessory instructions	e.g., remote reset source

If the old relay's settings looked wrong (heater sized well above FLA, trip class higher than the motor allows), set the E100 correctly and note the discrepancy for engineering.

9. Testing and commissioning

The starter returns to service only after the overload is proven to trip the coil circuit and the motor runs with balanced current below the FLA setting.

De-energized checks:

Energized checks (remove locks per LOTO procedure, all personnel clear):

If the relay trips during startup on a high-inertia load, check that the trip class is appropriate before changing the FLA setting. Never raise the FLA above the value set in Section 8 to stop nuisance trips.

10. Documentation and sign-off

The migration is complete when drawings, records, and spares reflect the new relay.

Role	Name	Signature	Date
Electrician performing work
Verifier / lead
Engineering (if settings changed)

Sources: Rockwell product configurator: E100 cut sheets; distributor listings linked in Section 4.