Rockwell Automation 825 User Manual

Smart Motor Manager

Bulletin 825

User Manual

Important User Information

Because of the variety of uses for the products described in this publication, those responsible for the application and use of this control equipment must satisfy themselves that all necessary steps have been taken to assure that each application and use meets all performance and safety requirements, including any applicable laws, regulations, codes and standards.

The illustrations, charts, sample programs and layout examples shown in this guide are intended solely for purposes of example. Since there are many variables and requirements associated with any particular installation, Allen-Bradley does not assume responsibility or liability (to include intellectual property liability) for actual use based upon the examples shown in this publication.

Allen-Bradley publication SGI-1.1, Safety Guidelines for the Application, Installation and Maintenance of Solid-State Control (available from your local Allen-Bradley office), describes some important differences between solid-state equipment and electromechanical devices that should be taken into consideration when applying products such as those described in this publication.

Reproduction of the contents of this copyrighted publication, in whole or part, without written permission of Rockwell Automation, is prohibited.

Throughout this manual we use notes to make you aware of safety considerations:

ATTENTION

Identifies information about practices or circumstances that can lead to personal injury or death, property damage or economic loss

Attention statements help you to:

• identify a hazard

• avoid a hazard

• recognize the consequences

IMPORTANT

Allen-Bradley is a trademark of Rockwell Automation

European Communities (EC) Directive Compliance

If this product has the CE mark it is approved for installation within the European Union and EEA regions. It has been designed and tested to meet the following directives.

EMC Directive

Identifies information that is critical for successful application and understanding of the product.

This product is tested to meet the Council Directive 89/336/EC Electromagnetic Compatibility (EMC) by applying the following standards, in whole or in part, documented in a technical construction file:

• EN 50081-2 EMC — Generic Emission Standard, Part 2 — Industrial Environment

• EN 50082-2 EMC — Generic Immunity Standard, Part 2 — Industrial Environment

This product is intended for use in an industrial environment.

Low Voltage Directive

This product is tested to meet Council Directive 73/23/EEC Low Voltage, by applying the safety requirements of EN 61131-2 Programmable Controllers, Part 2 - Equipment Requirements and Tests. For specific information required by EN 61131-2, refer to the appropriate sections in this publication, as well as the Allen-Bradley publication Industrial Automation Wiring and Grounding Guidelines For Noise Immunity, publication 1770-4.1.

This equipment is classified as open equipment and must be mounted in an enclosure during operation to provide safety protection.

ATTENTION

In order to achieve maximum performance from this product, correct transport, proper and competent storage and installation, and careful operation and maintenance must be observed.

• The power supply must be switched off prior to any intervention

in the electrical or mechanical part of the equipment!

• In accordance with applicable rules, work on electrical equipment

or means of production may only be carried out by competent electricians or suitably trained persons guided and supervised by a competent electrician.

• The electrical equipment of a machine/plant must be inspected/

tested. Deficiencies, such as loose connections or scorched cables, must be eliminated immediately.

• The Bulletin 825 Smart Motor Manager features supervision and

protection functions that can automatically switch devices off, bringing motors to a standstill. Motors can also be stopped by mechanical blockage, as well as mains failures and voltage fluctuations.

• In case of functional disturbances, the machine/plant must be

switched off and protected and the disturbance eliminated immediately.

• The elimination of a disturbance may cause the motor to restart.

This may endanger persons or damage equipment. The user must take the necessary safety measures to avoid this type of occurrence.

• Sufficient safety distance must be maintained where wireless

equipment (walkie-talkies, cordless and mobile phones) is used.

Chapter 1 —

Why Have an Electronic Control and Protection System? . . . . . . . . . . . . 1-1

Operational Demands of the Motor/Drive . . . . . . . . . . . . . . . . . . . . . . . . 1-2

Temperature Rise . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

Motor Operating Characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

Current and Temperature Curves. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3

Limiting Temperatures, Insulation Classes . . . . . . . . . . . . . . . . . . . . . 1-4

Operational Requirements for Installation. . . . . . . . . . . . . . . . . . . . . . . . . 1-5

Personnel and Installation Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6

Bulletin 825 Smart Motor Manager

as an Automation Component . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6

Chapter 2 —

System Structure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

System Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

Modular Design. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2

Block Diagram. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3

Operating Elements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4

Specifications— Basic Unit and Converter Module . . . . . . . . . . . . . . . . . 2-5

Standards. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7

Main Current Transformers for the Motor Circuit. . . . . . . . . . . . . . 2-10

Core Balance Current Transformer . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11

Short-Circuit Protection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11

Response Supply Voltage Failure. . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12

Automatic Recognition of Converter Module . . . . . . . . . . . . . . . . . . . . . 2-13

Introduction

Equipment Description

Chapter 3 —

Menu Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

Actual Values. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

Set Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2

Recorded Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3

Functions

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Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4

Selecting the Setting/Display Mode. . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4

Setting the Operation Parameters (Set Values) . . . . . . . . . . . . . . . . . . 3-5

Indications of Actual Values. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7

Indications of Recorded Values (Statistics) . . . . . . . . . . . . . . . . . . . . . 3-8

Test Button. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9

Function Summary. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13

Functions of the Basic Unit (Cat. No. 825-M…). . . . . . . . . . . . . . . . . . . 3-16

Thermal Overload. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16

Adjustable Ratio of Cooling Constants . . . . . . . . . . . . . . . . . . . . . . . 3-17

Indication of the Time to Tripping . . . . . . . . . . . . . . . . . . . . . . . . . . 3-18

Indication of the Time until the Thermal Trip can be Reset . . . . . . 3-18

Adjustable Setting Characteristic . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-18

Asymmetry (Phase Unbalance) and Phase Failure . . . . . . . . . . . . . . 3-22

High Overload and Jam . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-23

Underload . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-25

Earth (Ground) Fault . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-27

Limiting the Number of Starts per Hour (Start Lockout). . . . . . . . . 3-33

Monitoring the Starting Time. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-34

Warm Start. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-35

Emergency Override of Thermal Trip (Emergency Start) . . . . . . . . 3-38

LED Alarm and Trip Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-39

Connection of the Main Relay (MR) . . . . . . . . . . . . . . . . . . . . . . . . . 3-40

Connection of the Alarm Relay (AL). . . . . . . . . . . . . . . . . . . . . . . . . 3-40

Alarm Relay AL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-41

Reset. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-42

Function of the Cat. No. 825-MST Option Card. . . . . . . . . . . . . . . . . . . 3-42

Short-Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-42

Earth (Ground) Fault Protection with a Core Balance Current

Transformer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-44

Stalling During Start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-44

PTC Thermistor Input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-46

Analog Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-48

Analog Output for Thermal Load or

Motor Temperature (PT100 Max.). . . . . . . . . . . . . . . . . . . . . . . . . . . 3-48

Analog Output for Motor Current. . . . . . . . . . . . . . . . . . . . . . . . . . . 3-50

Control Inputs #1 and #2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-51

Switching to a Second Rated Current . . . . . . . . . . . . . . . . . . . . . . . . 3-53

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Functions of the Cat. No. 825-MLV Option Card . . . . . . . . . . . . . . . . . 3-53

Phase Sequence. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-53

Phase Failure (Based on Voltage Measurement). . . . . . . . . . . . . . . . 3-54

Star-Delta (Wye-Delta) Starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-55

Functions of the Cat. No. 825-MMV Option Card. . . . . . . . . . . . . . . . . 3-56

PT100 (100Ω Platinum) Temperature Sensor (RTD) . . . . . . . . . . . 3-56

PT100 #7 Temperature Sensor (RTD) . . . . . . . . . . . . . . . . . . . . . . . 3-57

Chapter 4 —

Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

Flush Mounting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

Mounting Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2

Surface Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2

Converter Modules. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3

Thermal Utilization Indicator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4

Installation and Wiring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5

Main Circuits. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6

Control Circuits. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8

Chapter 5 —

Menu Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1

Main Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1

Special Settings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2

Operating Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4

Chapter 6 —

Checking the Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1

Checking the Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2

Checking the Installation with the Control Voltage Applied. . . . . . . . . . . 6-2

Switching on the Control Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2

Checking the Set Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2

Motor Current. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3

Locked Rotor or Starting Current . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4

Locked Rotor Time. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4

Assembly and Installation

Setting the Operational Parameters

Commissioning and Operation

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Programming, Setup, and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5

Starting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5

Operating. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6

Chapter 7 —

General. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1

Checking without Test Equipment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1

Functional Check with the Test Button . . . . . . . . . . . . . . . . . . . . . . . . 7-1

Indication of Recorded Values. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2

Checking with Test Equipment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5

Test Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5

Chapter 8 —

Alarm, Warning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1

Procedure when Alarm/Warning Picks Up. . . . . . . . . . . . . . . . . . . . . 8-1

Trip . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2

Fault Codes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3

Procedure if “ALARM” does not Reset . . . . . . . . . . . . . . . . . . . . . . . 8-8

Procedure if “TRIP” cannot be Reset . . . . . . . . . . . . . . . . . . . . . . . . . 8-8

Chapter 9 —

Bulletin 825 Smart Motor Manager with Contactors. . . . . . . . . . . . . . . . . 9-1

Main Circuit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1

Control Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-2

Star-Delta Starter with Bulletin 825 Smart Motor Manager. . . . . . . . . . . . 9-3

Main Circuit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-3

Control Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-3

Short-Circuit Protection of Medium/High-Voltage Motors. . . . . . . . . . . 9-4

Main Circuit (with Cat. No. 825-MST Option Card) . . . . . . . . . . . . . 9-4

Control Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-5

Two-Speed Motors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-5

Main Circuit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-6

Two-Speed Motor: 0.5 A < Speed I < 20 A < Speed II < 180 A. . . . . . . 9-7

Main Circuit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-7

Two-Speed Motors with Primary Current Transformer . . . . . . . . . . . . . . 9-8

Primary Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-8

Separately Ventilated Motors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-8

Testing and Maintenance

Error Diagnosis and Troubleshooting

Applications/Wiring

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Basic Unit and Converter Module with Primary Current Transformer

and Core Balance Current Transformer. . . . . . . . . . . . . . . . . . . . . . . . . . . 9-9

Main Circuit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-9

Basic Unit and Converter Module with Core Balance Current

Transformer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-10

Main Circuit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-10

Motors with Low Idling Current (< 20% 

Main Circuit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-11

Connecting the PT100 Temperature Sensors Using the

2/3/4-Conductor Technique. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-12

Basic Unit and Converter Module with Primary Current Transformer,

2-Phase Current Evaluation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-13

Time/Current Characteristic of Bulletin825 Smart Motor Manager . . . 9-14

) . . . . . . . . . . . . . . . . . . . . . . 9-11

Chapter 10 —

References

Figures

Figure 1.1Bulletin 825 Smart Motor Manager. . . . . . . . . . . . . . . . . 1-1

Figure 1.2Operating Characteristics of an AC Motor. . . . . . . . . . . 1-3

Figure 1.3 AC Current Profile of a Motor Starting

Direct-on-Line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4

Figure 1.4 Temperature Rise Characteristics

of Motor Windings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4

Figure 1.5 Reduction in Average Life (EM) of a Motor

when Winding is Continuously Overheated. . . . . . . . . . 1-5

Figure 2.1 Modular Design of the Bulletin 825

Smart Motor Manager . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2

Figure 2.2Block Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3

Figure 2.3Front View with Operating Elements. . . . . . . . . . . . . . . 2-4

Figure3.1Setting Mode. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5

Figure3.2Menu Selection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5

Figure3.3Entering a Data Value . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6

Figure3.4Selecting the Actual Values . . . . . . . . . . . . . . . . . . . . . . . 3-7

Figure3.5Selecting Recorded Data . . . . . . . . . . . . . . . . . . . . . . . . . 3-8

Figure3.6Basic Unit Test Button . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9

Figure 3.7 Two-Body Simulation of the Heating Up

of a Motor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17

Figure3.8Trip Characteristic (10…30s). . . . . . . . . . . . . . . . . . . . 3-19

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Figure3.9Trip Characteristics (40…100 s) . . . . . . . . . . . . . . . . . . 3-20

Figure 3.10 Reduction in Permissible Motor Output

Due to Voltage Asymmetry per IEC and NEMA . . . . 3-23

Figure3.11Function of High Overload and Jam Protection . . . . . 3-24

Figure3.12Function of Underload Protection . . . . . . . . . . . . . . . . 3-26

Figure3.133-Phase Current Detection . . . . . . . . . . . . . . . . . . . . . . 3-27

Figure3.14Example of 2-Phase Current Sensing . . . . . . . . . . . . . . 3-28

Figure 3.15 Isolated Network: Earth Fault

on the Network Side . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-31

Figure 3.16 Network Earthed through a High Impedance

Earth Fault on the Network Side . . . . . . . . . . . . . . . . . 3-31

Figure 3.17 Isolated network: Earth (Ground) Fault on the Leads

on the Motor Side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-32

Figure 3.18 Network Earthed through a High Impedance:

Earth (Ground) Fault on the Motor Leads. . . . . . . . . . 3-32

Figure 3.19 Isolated Network: Earth (Ground) Fault

in the Motor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-32

Figure 3.20 Network Earthed through a High Impedance:

Earth (Ground) Fault on the Motor. . . . . . . . . . . . . . . 3-32

Figure3.21Limiting the Number of Starts per Hour . . . . . . . . . . . 3-33

Figure3.22Monitoring Starting Time . . . . . . . . . . . . . . . . . . . . . . . 3-34

Figure 3.23 Current and Temperature Curves for Warm and

Cold Motor Starts and the Smart Motor Manager

Tripping Limits. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-36

Figure 3.24 Example for t6x

= 10 s and

Warm Trip Time= 70% . . . . . . . . . . . . . . . . . . . . . . . . 3-37

Figure3.25Interruption of a Short-Circuit . . . . . . . . . . . . . . . . . . . 3-43

Figure3.26Stalling During Starting . . . . . . . . . . . . . . . . . . . . . . . . . 3-45

Figure3.27Characteristic of PTC Sensors as per IEC 34-11-2 . . . 3-48

Figure3.28Analog Output for Motor Temperature Rise. . . . . . . . 3-49

Figure3.29Analog Output for Motor Temperature. . . . . . . . . . . . 3-50

Figure3.30Analog Output for Motor Current . . . . . . . . . . . . . . . . 3-50

Figure3.31Operating Diagram for Timer Functions . . . . . . . . . . . 3-52

Figure3.32Diagram of Star-Delta (Wye-Delta) Starting. . . . . . . . . 3-55

Figure 4.1Basic Unit Mounted in an Enclosure . . . . . . . . . . . . . . . 4-1

Figure 4.2Mounting Position. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2

Figure 4.3 Basic Unit Mounted into Panel Mounting Frame

(Cat. No. 825-FPM). . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2

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Table of Contents vii

Figure 4.4Cat. Nos. 825 MCM2, 825-MCM-20, 825-MCM180. . . 4-3

Figure 4.5Cat. Nos. 825-MCM630, 825-MCM630N . . . . . . . . . . . 4-3

Figure 4.6Cat. No. 825-MTUM Thermal Utilization Indicator . . . 4-4

Figure 4.7Basic Unit Housing with Option Cards . . . . . . . . . . . . . 4-5

Figure 4.8Basic Unit with Converter Module . . . . . . . . . . . . . . . . . 4-6

Figure 4.93-Phase Current Evaluation. . . . . . . . . . . . . . . . . . . . . . . 4-6

Figure 4.102-Phase Current Evaluation. . . . . . . . . . . . . . . . . . . . . . . 4-7

Figure 4.11Smart Motor Manager Basic Unit . . . . . . . . . . . . . . . . . . 4-8

Figure 4.12Cat. No. 825-MST Option Card . . . . . . . . . . . . . . . . . . . 4-9

Figure 4.13Cat. No. 825-MLV Option Card. . . . . . . . . . . . . . . . . . 4-10

Figure 4.14Cat. No. 825-MMV Option Card . . . . . . . . . . . . . . . . . 4-11

Figure 6.1 Range of Starting Currents of Standard Motors

Expressed as Multiple of the Rated Service

Current . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4

Figure 7.1Test with a 3-Phase Current Source . . . . . . . . . . . . . . . . 7-5

Figure 7.2Test with a Single-Phase Current Source . . . . . . . . . . . . 7-6

Figure 9.1Basic Unit and Converter Module. . . . . . . . . . . . . . . . . . 9-1

Figure 9.2Control by Momentary Contact . . . . . . . . . . . . . . . . . . . 9-2

Figure 9.3Basic Unit and Converter Module. . . . . . . . . . . . . . . . . . 9-3

Figure 9.4Control by Momentary Contact . . . . . . . . . . . . . . . . . . . 9-3

Figure 9.5Basic Unit for Short-Circuit Protection . . . . . . . . . . . . . 9-4

Figure 9.6Control by Momentary Contact . . . . . . . . . . . . . . . . . . . 9-5

Figure 9.7Two-Speed Application Utilizing One 825-MCM* . . . . 9-6

Figure 9.8Two-Speed Application Utilizing 825-MCM180 . . . . . . 9-7

Figure 9.9 Two-Speed Application Utilizing Primary Current

Transformer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-8

Figure 9.10 Typical Application Utilizing Primary Current

Transformers and Core Balance Current

Transformer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-9

Figure 9.11 Typical Application Utilizing Core Balance Current

Transformer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-10

Figure 9.12Application with Low Idling Current . . . . . . . . . . . . . . 9-11

Figure 9.132/3/4 Conductor Technique for PT100 Wiring . . . . . 9-12

Figure 9.14 Typical Application Utilizing 2-Phase Current

Evaluation with Primary Current Transformers. . . . . . 9-13

Figure 9.15Trip Characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-14

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viii Table of Contents

Tables

Table 2.AEnvironmental Ratings . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5

Table 2.B Nominal Rated Voltages Ue . . . . . . . . . . . . . . . . . . . . . . 2-6

Table 2.CElectrical Ratings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6

Table 2.DSupply Ratings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7

Table 2.ERelay Ratings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8

Table 2.FTerminals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9

Table 2.GMain Current Transformer Ratings. . . . . . . . . . . . . . . . 2-10

Table 2.H Recommended Data for Core Balance Current

Transformer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11

Table 2.IConverter Module — Related Error Messages. . . . . . . 2-13

Table 3.AActual Values Overview. . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

Table 3.BSet Values Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2

Table 3.CRecorded Values Overview. . . . . . . . . . . . . . . . . . . . . . . 3-3

Table 3.DDisplay Example of Set Values Menu. . . . . . . . . . . . . . . 3-6

Table 3.EDisplay Example of Actual Values Menu. . . . . . . . . . . . 3-7

Table 3.FDisplay Example of Recorded Values. . . . . . . . . . . . . . . 3-9

Table 3.GProtective Functions Summary. . . . . . . . . . . . . . . . . . . 3-13

Table 3.HWarning Functions Summary . . . . . . . . . . . . . . . . . . . . 3-14

Table 3.IControl Functions Summary. . . . . . . . . . . . . . . . . . . . . 3-15

Table 3.JThermal Overload Setting Parameters . . . . . . . . . . . . . 3-21

Table 3.KProtection Against Thermal Overload . . . . . . . . . . . . . 3-22

Table 3.L Asymmetry (Phase Unbalance)

Setting Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-23

Table 3.MHigh Overload and Jam Setting Parameters. . . . . . . . . 3-24

Table 3.NUnderload Setting Parameters. . . . . . . . . . . . . . . . . . . . 3-26

Table 3.O Earth (Ground) Fault — Holmgreen/Residual

Setting Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-28

Table 3.P Core Balance Current Transformer

Setting Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-29

Table 3.Q Earth (Ground) Fault Core Balance

Setting Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-29

Table 3.RStarts per Hour Setting Parameters. . . . . . . . . . . . . . . . 3-33

Table 3.SMonitoring Start Time Setting Parameters. . . . . . . . . . 3-35

Table 3.TWarm Start Setting Parameters . . . . . . . . . . . . . . . . . . . 3-38

Table 3.UAlarm Examples. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-41

Table 3.VReset Setting Parameters . . . . . . . . . . . . . . . . . . . . . . . . 3-42

Table 3.WShort Circuit Setting Parameters. . . . . . . . . . . . . . . . . . 3-44

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Table of Contents ix

Table 3.XStalling during Start Setting Parameters . . . . . . . . . . . . 3-45

Table 3.YPTC Setting Parameters. . . . . . . . . . . . . . . . . . . . . . . . . 3-46

Table 3.ZSensor Measuring Circuit Specifications. . . . . . . . . . . . 3-47

Table 3.AAPhase Sequence Setting Parameters. . . . . . . . . . . . . . . . 3-54

Table 3.ABPhase Failure Setting Parameters. . . . . . . . . . . . . . . . . . 3-54

Table 3.AC Star-Delta (Wye-Delta) Starting

Setting Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-55

Table 3.AD PT100 Temperature Detector Resistance

per IEC 751 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-56

Table 3.AEPT100 (RTD) Setting Parameters . . . . . . . . . . . . . . . . . 3-57

Table 3.AFMotor Insulation Class Setting Parameters. . . . . . . . . . 3-58

Table 4.ACat. Nos. 825 MCM2, 825-MCM-20, 825-MCM180. . . 4-3

Table 4.BCat. Nos. 825-MCM630, 825-MCM630N . . . . . . . . . . . 4-4

Table 4.CSpecifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7

Table 5.AMain Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1

Table 5.BSpecial Settings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2

Table 5.CCommunication Settings . . . . . . . . . . . . . . . . . . . . . . . . . 5-3

Table 5.DCat. No. 825-M… Operating Parameters. . . . . . . . . . . . 5-4

Table 6.AChecking the Actual Values. . . . . . . . . . . . . . . . . . . . . . . 6-6

Table 7.AList of Recorded Values. . . . . . . . . . . . . . . . . . . . . . . . . . 7-2

Table 8.APossible Causes and Actions. . . . . . . . . . . . . . . . . . . . . . 8-3

Publication 825-UM001B-EN-P January 2001

x Table of Contents

Notes:

Publication 825-UM001B-EN-P January 2001

Chapter



Introduction

Why Have an Electronic Control and Protection System?

The need to optimize production facilities requires enhanced control, monitoring, and protection systems.

Motor and installation use must be maximized while minimizing both the downtime required for maintenance and that caused by motor failures; these requirements are easily met by the microprocessor-based Bulletin 825 Smart Motor Manager.

The Bulletin 825 Smart Motor Manager has a modular design and is easily programmed. Its attributes enable an optimum fit to a wide variety of motor and installation requirements.

The Bulletin 825 Smart Motor Manager provides continuous monitoring of motor operating data in one of two ways. The data can be viewed directly on the unit or it can be monitored remotely via a network by using a PC or process computer. The main statistical data can also be accessed at any time.

Figure 1.1 Bulletin 825 Smart Motor Manager

Publication 825-UM001B-EN-P January 2001

1-2 Introduction

Operational Demands of the Motor/Drive

Temperature Rise

Motor designs and applicable standards require that, when a motor is operated under specified loads and ambient conditions, the critical parts of the motor will remain within an allowable temperature range and short-term overloads will not harm the motor.

The device protecting the motor must permit full use of the motor and its economical operation. At the same time, the protective device must switch off rapidly if an overload occurs.

Motor Operating Characteristics

Electric motors absorb electrical energy and supply mechanical energy. During this energy conversion, losses are produced in the form of heat. The total loss consists of the following separate losses:

• Losses independent of the current (these losses are virtually constant i.e., they also

occur at no load)

• Iron losses caused by remagnetization and eddy currents

• Mechanical losses caused by friction and ventilation

• Losses dependent on the current (these losses increase with load i.e., with the current

consumed by the motor)

• Heat losses caused by the current in the stator

• Heat losses caused by the current in the rotor

• Increased temperature rise caused by poor cooling (e.g., cooling fins are dusty or

damaged, coolant temperature is too high)

Publication 825-UM001B-EN-P January 2001

Figure 1.2 Operating Characteristics of an AC Motor

Introduction 1-3

1.5



1.4



1.3



1.2

1.1

1.0

cos ϕ, η,

0.9

0.8

0.7

0.5

Operating characteristics of an AC motor as a function of load. Between no load and half load, the losses increase only slightly with rising load. Between half load and rated load, the change in efficiency is minimal, and the power factor approaches its maximum. The losses increase approximately proportional to the load. Above rated load, the losses increase more rapidly than the load.

cos ϕ

25 50 75 100 125

P Power Pe Rated operational power Pv Power losses Pve Power losses under rated condition

 Operational current 

Rated service current

n Speed n

Rated operational speed

Synchronous speed

cos ϕ Power factor η Efficiency

[%]



Current and Temperature Curves

Power loss is approximately proportional to the square of the motor current. The potential for motor hazards exists mainly during starting and in a locked rotor condition. When a locked rotor condition exists, the maximum value of the starting current flows (approximately 4…8 times the rated service current I

As the motor speed increases, the power converted into heat decreases. But if the rotor remains locked, the temperature of the stator and rotor windings rises considerably, caused by the high losses and the short time that heat can flow into the laminated core. If the motor is not switched off quickly, the stator or rotor winding can burn out.

After startup, the temperature of the winding rises according to the load and cooling of the motor. In time, the winding reaches its steady-state value.

A high current results in a correspondingly high operating temperature.

), and all of the power absorbed is converted into heat.

Publication 825-UM001B-EN-P January 2001

1-4 Introduction

Figure 1.3 AC Current Profile of a Motor Starting Direct-on-Line

Starting current



Starting time

Rated service



current

t Time

Oscillogram of switching on a squirrel-cage induction motor by direct-on-line starting. The high motor starting current A flows during the starting time (t cause an excessive temperature rise. The brief, asymmetrical peak when switching on can be ignored.

). If this is less than the limit specified by the manufacturer (usually 10 s), the starting current does not

1.6 2 I

2 2 I

Motors are not thermally homogeneous. The winding, stator iron, and rotor have different heat capacities and conductivities. Following unduly heavy loads, e.g., during starting, temperature equalization occurs between the various parts of the machine (heat flows from the warmer winding into the cooler iron until the temperature difference is minimal).

Figure 1.4 Temperature Rise Characteristics of Motor Windings

Temperature limit of the insulation

Coolant temperature

Temperature rise at start

Temperature rise when operated

continuously at rated current

Starting time

Permitted stalling time

Temperature rise in a motor winding. During the starting time (tA), the temperature of the winding rises very rapidly; at the end of startup, the temperature drops temporarily because heat is transferred to the laminated core.

Limiting Temperatures, Insulation Classes

The permissible temperature limit for a winding — and thus the load-bearing capacity — of the motor is primarily a function of the motor's insulation. Applicable standards (UL, CSA, IEC, and NEMA) distinguish between different classes of insulation and corresponding temperature limits.

Publication 825-UM001B-EN-P January 2001

Introduction 1-5

Insulation Aging

The aging of insulation material is a chemical process that is accelerated by continuous overtemperature. It may be assumed that a winding temperature that is constantly 10 K higher than the temperature limit reduces the motor life by half. This “life law” shows that particular attention must be paid to adhering to the permitted operating temperature for long periods of time. (Note that overtemperatures of short duration and infrequent occurrence do not seriously affect the life of the machine.)

The Bulletin 825 Smart Motor Manager's ability to accurately limit excessive current conditions greatly aids in extending motor life. In practice, it may be expected that there will be reduced loads and pauses, so that when the temperature limit is reached, the motor life will not be impaired.

Figure 1.5 Reduction in Average Life (EM) of a Motor when Winding is Continuously Overheated

Average motor life

Temperature limit of the insulation

100

+5K +10K +15K +20K

Rotor Temperature

The rotors of squirrel-cage induction motors with simple construction (no insulation) may continuously attain higher temperatures than rotors in motors with insulated windings. However, in larger motors, the concentration of the rotor losses during starting is higher than the concentrations of losses in other parts of the motor. The starting time of such motors is therefore limited by the thermal capacity of the rotor. These types of motors are commonly referred to as “rotor-critical” motors. Critical to the rotor are the mechanical stresses caused by the temperature rise, unsoldering of the rotor bars, and, for EExe motors (motors for use in the chemical industry), the high temperature as a source of ignition.

Operational Requirements for Installation

Monitoring the application parameters and process data of an installation can be very important. Even a slight change in the starting and operating behavior of the motor can indicate an impending fault. The Smart Motor Manager helps eliminate potential trouble before major repairs are necessary and loss of production occurs.

Publication 825-UM001B-EN-P January 2001

1-6 Introduction

The Smart Motor Manager fulfils these requirements by providing protection against the following:

• high overload, stalling and jam

• underload

• phase sequence

Personnel and Installation Safety

Personnel protection in the vicinity of control equipment is of primary importance. The corresponding requirements of regulatory agencies are therefore becoming increasingly severe. The Smart Motor Manager reflects this by providing the following protection:

• equipment construction

• touch protection

• insulated housing

• motor protective functions:

• Earth (ground) fault

• High overload, stalling and jam

• Wrong direction of rotation

Bulletin 825 Smart Motor Manager as an Automation Component

The Bulletin 825 Smart Motor Manager detects abnormal operating conditions and faults in motor branch circuits. The data made available by the Smart Motor Manager can be used for operational control and optimization of the installation.

A large number of supervisory, protective, and control functions improve operational control and avoid unnecessary downtime. This maximizes your motor investment, making the Smart Motor Manager a valuable component in modern automation systems.

Publication 825-UM001B-EN-P January 2001

Chapter



Equipment Description

System Structure

The Bulletin 825 Smart Motor Manager is a microprocessor-based protection and control system for motors. For the AC motor and the operated installation this means:

• Maximum utilization

• Continuous supervision

• Reliable protection

The modular structure of the system and all of its possible functions enable the Bulletin 825 Smart Motor Manager to be economically and optimally adapted to any installation.

System Components

The motor protection system consists of:

• The basic control and protection unit

• Current converter modules for 0.5…630 A

• Cable for connecting between the basic unit and the current converter module

• Optional plug-in printed circuit boards

• Thermal utilization meter to indicate the thermal load

Installation

The Smart Motor Manager can be either flush mounted in an enclosure door, or surface mounted to the enclosure mounting plate using a panel mounting frame.

Current converter modules can be surface mounted.

Publication 825-UM001B-EN-P January 2001

2-2 Equipment Description

Modular Design

The Cat. No. 825-M basic unit can be fitted with additional option (function) cards to suit the requirements.

Figure 2.1 Modular Design of the Bulletin 825 Smart Motor Manager

Basic unit, Cat. No. 825-M…

Option: Cat. No. 825-MLV Cat. No. 825-MMV

Communication

Communication Network

Cat. No. 825-MST

Thermal utilization module

Core Balance Current Transformer

PT100

4...20 mA

Converter module

Available Communications Cards

Cat. No. 825-MDN: DeviceNet

Cat. No. 3600-RIO: Remote I/O ➊ Cat. No. 3600-MBS: Modbus ➊

Cat. No. 825-MPB: PROFIBUS FMS

➊ Available from Prosoft Technology, Inc. (not an Allen-Bradley product). References to third-part products are

provided for informational purposes only. Prosoft Technology, Inc., is solely responsible for the accuracy of information, supply, and support of this product. For further information regarding this particular referenced product, please contact Prosoft Technology, Inc., in the U.S. at (661) 664-7208 or your local Prosoft Technology, Inc. distributor.

Publication 825-UM001B-EN-P January 2001

Block Diagram

Figure 2.2 Block Diagram

Equipment Description 2-3

PLC

LCD

Operation

Supply

Y11

A1 (-)

A2 (+)

Warning/Trip

Main relay MR

Alarm relay AL

95/96

97/98

13/14

825-M

Basic unit

Controller

Y13

Remote reset

Y22

Y21

Disable settings

Emergency start

Y12

Auxiliary relay #1

23/24

825-M

k, l

Auxiliary relay #2

Auxiliary relay #3

Analog output

33/34

43/44

I+ / I-

4…20 mA

825-MST

overload

Earth fault

Thermistor

T1, T2

Y31

24 V AC/DC

Control

Y32

inputs

Y41

Y42

24 V AC/DC

Auxiliary relay #4

Auxiliary relay #5

53/54

63/64

825-MLV

Phase

sequence

Phase failure

L1L3L2

Choice

825-MLV or 825-MMV

825-MMV

Stator /

Ambient temperature

bearing temperature

PT100 #7

(RTD)

PT100 #1…#6

(RTD)

1T1/1T2/1T3

7T1/7T2/7T3

…6T1/6T2/6T3

Network

825-MPB

3600-MBS

3600-RIO

825-MDN

Communication Interface

825-

L1 L2 L3

MCM

∑

3 ~

amb

Publication 825-UM001B-EN-P January 2001

2-4 Equipment Description

Operating Elements

The Smart Motor Manager is very easy to operate. All functions, data, and tests can be entered, executed, or displayed using the six membrane keys and the single-line LCD, which displays all available data and functions.

Figure 2.3 Front View with Operating Elements

➊

➋

➏

➎

➍

➌

➊ Fault indicator (LED)

Flashing: warning Steady state: trip

➋ LCD: Single line (two lines of text are displayed alternately) ➌ Values: Selection of mode

Actual: Indication of actual operational data

Set: Setting mode (set/modify, store parameters)

Recorded: Indication of statistical data

➍ Select: Select function and enter/change operating parameter ➎ Settings: Enable entry (Change) and memorize (Enter) ➏ Test: Verifies operation of Smart Motor Manager. ➐ Reset: Enables the Smart Motor Manager after a trip.

Publication 825-UM001B-EN-P January 2001

➐

Equipment Description 2-5

Specifications — Basic Unit and Converter Module

Table 2.A Environmental Ratings

Temperature

Operation -5…+ 60 °C (23…140 °F) Storage -40…+ 60 °C (-40…140 °F) Transport -40…+ 85 °C (-40…185 °F)

Climatic Withstand

Damp heat IEC 68-2-3 Climatic cycling IEC 68-2-30 25/40 °C (77/104 °F), 21 cycles

Enclosure Protection Class

825-M, enclosed in panel IP65

Terminals IP20

as per IEC 68-2-6 10…150 Hz, 3 G

as per IEC 68-2-27

40 °C (104 °F), 92% relative humidity, 56 days

Resistance to Vibration

Resistance to Shock

30 G, shock duration 18 ms, half a sine wave in x, y, z directions

Publication 825-UM001B-EN-P January 2001

2-6 Equipment Description

Table 2.B Nominal Rated Voltages U

Primary Detection Circuit

as per IEC, SEV, VDE 0660 400V AC 660V AC 1 000V AC as per CSA, UL 240V AC 600V AC 600V AC

Main relay (MR) 95…98, supply A1, A2 Phase sequence protection L1, L2, L3

as per IEC 947 400V AC as per SEV 380V AC as per UL, CSA 240V AC

Alarm relay (AL) 13/14 Auxiliary relay #1, #4, #5

as per IEC 947 400V AC as per SEV 250V AC

as per UL, CSA 240V AC Auxiliary relays #2, #3 50V AC/30V AC Control inputs #1, #2 24V AC/DC

Motor Circuit

Control Circuit

825-

MCM2

825-

MCM20

825MCM180 MCM630

MCM630N

Table 2.C Electrical Ratings

Test V olt age

as per IEC 947-1

Control Circuit

Between control circuits and to all other circuits ➊ Main relay (MR) 95…98, supply A1, A2 Phase sequence protection L1, L2, L3 Alarm relay (AL), auxiliary relay #1, #4, #5 as per IEC 947-4

Core balance current transformer k, I Control inputs #1, #2 Auxiliary relays #2, #3 as per IEC 947-4

825-

MCM2

Motor Circuit

imp

2.5 kV

825-

MCM20

imp

6 kV

MCM180 MCM630

imp

4 kV

imp

2.5 kV

825-

imp

8 kV

825-MCM630N

12 kV

imp

➊ The measuring inputs for PT100 and PTC, the 4…20 mA output, and the communication interface are not

isolated from one another.

Publication 825-UM001B-EN-P January 2001

Equipment Description 2-7

Standards

EMC

Noise emission as per EN 50 081-1 and as per EN 50 081-2

Noise proof as per EN 50 082-1 and as per EN 50 082-2

Standards: IEC 947-4, CSA C22.2 No. 14, UL 508

Approvals: CE, UL-Listed, CSA, PTB: Physkalisch-Technische Bundesanstalt (Germany): Certification required for motor protection in explosion hazard area (e.g., Chemical, Petrochemical Installations).

Table 2.D Supply Ratings

50/60 Hz, 22…24, 33…36, 44…48, 110…120, 220…240,

Nominal supply voltage U

Permissible voltage fluctuation

Power consumption AC 13 VA, DC 10 W max.

Short-circuit protection

380…415, 440V AC 24…48, 72…120, 220V DC AC 0.85…1.10 U

DC 0.80…1.10 US for 24…48V DC

DC 0.80…1.20 U

DC 0.80…1.15 U

With the appropriate supply cable rating, the supply module is short-circuit proof.

for 72…120V DC

for 220V DC

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2-8 Equipment Description

Table 2.E Relay Ratings

Contact Data of Output Relays

Main Relay (MR) 95…96

Contacts fitted 1 N/C and 1 N/O contact, galvanically separated Nominal operating voltage

as per UL, CSA: pilot duty 240 V Continuous thermal current [A] 4 Rated operating current for AC-15 [A] 3 3 1.2 Max. permissible switching current

(cos ϕ = 0.3) AC-15 Rated operating current for DC-13 without prot. network,

L/R = 300 ms Max. rated current of back-up fuse: [A] 10 A, 500V AC, Type gG

Contacts fitted 1 N/O contact each Continuous thermal current 4 A Max. permissible switching voltage 400V AC, 125 VDC

cos ϕ = 1 4 A at 250V AC or 30V DC cos ϕ = 0.4, L/R = 7 ms 2 A at 250 VAC or 30V DC

cos ϕ = 1 1 250 VA, 150 W cos ϕ = 0.4, L/R = 7 ms 500 VA, 60 W as per UL/CSA 240 V, 1 A pilot duty

Contacts fitted 1 N/O contact each Continuous thermal current 4 A Max. permissible switching voltage 48 VAC, 30 VDC

cos ϕ = 1 150 W cos ϕ = 0.4, L/R = 7 ms 60 W

[V] 24 110…125 220…250 380…440

[A] 30 30 12

[A] 2 0.3 0.2 –

Alarm Relay (AL), Auxiliary Relays #1, #4, #5

Nominal Operating Current

Max. Switching Power

Auxiliary Relays #2, #3

Max. Switching Power

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Equipment Description 2-9

Table 2.F Terminals

Range of gauges:

Cat. No. 825-M plug-in terminals

as per UL AWG No. 22…14

as per VDE

Main circuit

825-MCM2/ 825-MCM20

825-MCM180

825-MCM630(N) Bus bars: 25 x 8 mm

0.5…2.5 m2, single wire (AWG No. 20…14)

0.5…1.5 m

double wire (AWG No. 20…16)

nominal gauge 1.5 mm

Terminals: 2 x 2.5 mm

(2 x 0.0039 in

2 x AWG No. 20…14/1 x AWG No. 20…12

Aperture or busbars:

Wire ∅ 19 mm max. 20/16 x 4 mm

/1 x 4 mm2

/1 x 0.006 in2)

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2-10 Equipment Description

Main Current Transformers for the Motor Circuit

When the Cat. No. 825-M Control and Protection Unit is used as a secondary relay with Cat. Nos. 825-MCM2 and 825-MCM20, the following specifications apply:

Table 2.G Main Current Transformer Ratings

Minimum nominal operating voltage Nominal operating voltage of motor Minimum rated primary current 

Rated secondary current 1 A or 5 A Class and nominal

overcurrent factor

Power rating

Rated frequency 50/60 Hz

Burden:

Power consumption at max. rated current Continuous thermal current 3 A 24 A Thermal current, 1 s duration 250 A 600A Frequency of input current 50/60 Hz 50/60 Hz

No-load

➊ Designation according to IEC 60044 part 2:

5 Total measurement error (percentage):

±5% within range up to rated nominal overcurrent (10X) ±1% at rated nominal primary current

P For protection purposes

10 Rated nominal overcurrent factor: 10X rated nominal primary current

ext.

Extended rated thermal current: 120% of rated nominal primary current (if 

120%

rated nominal transformer current)

With starting current 10  The current transformer error in addition to the basic unit error

➋ 2.5 A with Cat. No. 825-MCM2, 20 A with Cat. No. 825-MCM20

➋

General Notes on 825-MCM…

: class 5 P 20

Nominal operating current of motor

5 P 10 ext. 120% ➊

According to power consumption in leads

and measuring circuits

825-M +

825-MCM2

0.1 VA/phase 0.4 VA/phase

An open-circuit secondary is permitted, as the burden is

installed in the detection module

825-M +

825-MCM20

motor > 87% of

Publication 825-UM001B-EN-P January 2001

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