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:

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

!

Attention statements help you to:

•identify a hazard

•avoid a hazard

•recognize the consequences

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

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.

Table of Contents

Chapter 1 — Introduction

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 — Equipment Description

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

Chapter 3 — Functions

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

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

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

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

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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 (100 Ω Platinum) Temperature Sensor (RTD) . . . . . . . . . . . 3-56 PT100 #7 Temperature Sensor (RTD) . . . . . . . . . . . . . . . . . . . . . . . 3-57

Chapter 4 — Assembly and Installation

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 — Setting the Operational Parameters

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

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

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

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

Chapter 6 — Commissioning and Operation

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

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

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

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

Chapter 7 — Testing and Maintenance

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 — Error Diagnosis and Troubleshooting

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 — Applications/Wiring

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

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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% ,e) . . . . . . . . . . . . . . . . . . . . . . 9-11 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 Bulletin 825 Smart Motor Manager . . . 9-14

Chapter 10 — References

Figures

Figure 1.1 Bulletin 825 Smart Motor Manager. . . . . . . . . . . . . . . . . 1-1 Figure 1.2 Operating 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 2.2 Block Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3 Figure 2.3 Front View with Operating Elements. . . . . . . . . . . . . . . 2-4 Figure 3.1 Setting Mode. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5 Figure 3.2 Menu Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5 Figure 3.3 Entering a Data Value . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6 Figure 3.4 Selecting the Actual Values . . . . . . . . . . . . . . . . . . . . . . . 3-7 Figure 3.5 Selecting Recorded Data . . . . . . . . . . . . . . . . . . . . . . . . . 3-8 Figure 3.6 Basic Unit Test Button . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9 Figure 3.7 Two-Body Simulation of the Heating Up

of a Motor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17 Figure 3.8 Trip Characteristic (10…30 s) . . . . . . . . . . . . . . . . . . . . 3-19

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Figure 3.9 Trip Characteristics (40…100 s) . . . . . . . . . . . . . . . . . . 3-20 Figure 3.10 Reduction in Permissible Motor Output

Due to Voltage Asymmetry per IEC and NEMA . . . . 3-23 Figure 3.11 Function of High Overload and Jam Protection . . . . . 3-24 Figure 3.12 Function of Underload Protection . . . . . . . . . . . . . . . . 3-26 Figure 3.13 3-Phase Current Detection . . . . . . . . . . . . . . . . . . . . . . 3-27 Figure 3.14 Example 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 Figure 3.21 Limiting the Number of Starts per Hour . . . . . . . . . . . 3-33 Figure 3.22 Monitoring 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,e = 10 s and

Warm Trip Time = 70% . . . . . . . . . . . . . . . . . . . . . . . . 3-37 Figure 3.25 Interruption of a Short-Circuit . . . . . . . . . . . . . . . . . . . 3-43 Figure 3.26 Stalling During Starting . . . . . . . . . . . . . . . . . . . . . . . . . 3-45 Figure 3.27 Characteristic of PTC Sensors as per IEC 34-11-2 . . . 3-48 Figure 3.28 Analog Output for Motor Temperature Rise . . . . . . . . 3-49 Figure 3.29 Analog Output for Motor Temperature . . . . . . . . . . . . 3-50 Figure 3.30 Analog Output for Motor Current . . . . . . . . . . . . . . . . 3-50 Figure 3.31 Operating Diagram for Timer Functions . . . . . . . . . . . 3-52 Figure 3.32 Diagram of Star-Delta (Wye-Delta) Starting. . . . . . . . . 3-55 Figure 4.1 Basic Unit Mounted in an Enclosure . . . . . . . . . . . . . . . 4-1 Figure 4.2 Mounting Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2 Figure 4.3 Basic Unit Mounted into Panel Mounting Frame

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

Publication 825-UM001B-EN-P January 2001

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vii

Figure 4.4 Cat. Nos. 825 MCM2, 825-MCM-20, 825-MCM180 . . . 4-3 Figure 4.5 Cat. Nos. 825-MCM630, 825-MCM630N . . . . . . . . . . . 4-3 Figure 4.6 Cat. No. 825-MTUM Thermal Utilization Indicator . . . 4-4 Figure 4.7 Basic Unit Housing with Option Cards . . . . . . . . . . . . . 4-5 Figure 4.8 Basic Unit with Converter Module . . . . . . . . . . . . . . . . . 4-6 Figure 4.9 3-Phase Current Evaluation. . . . . . . . . . . . . . . . . . . . . . . 4-6 Figure 4.10 2-Phase Current Evaluation. . . . . . . . . . . . . . . . . . . . . . . 4-7 Figure 4.11 Smart Motor Manager Basic Unit . . . . . . . . . . . . . . . . . . 4-8 Figure 4.12 Cat. No. 825-MST Option Card . . . . . . . . . . . . . . . . . . . 4-9 Figure 4.13 Cat. No. 825-MLV Option Card . . . . . . . . . . . . . . . . . . 4-10 Figure 4.14 Cat. 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 7.1 Test with a 3-Phase Current Source . . . . . . . . . . . . . . . . 7-5 Figure 7.2 Test with a Single-Phase Current Source . . . . . . . . . . . . 7-6 Figure 9.1 Basic Unit and Converter Module. . . . . . . . . . . . . . . . . . 9-1 Figure 9.2 Control by Momentary Contact . . . . . . . . . . . . . . . . . . . 9-2 Figure 9.3 Basic Unit and Converter Module. . . . . . . . . . . . . . . . . . 9-3 Figure 9.4 Control by Momentary Contact . . . . . . . . . . . . . . . . . . . 9-3 Figure 9.5 Basic Unit for Short-Circuit Protection . . . . . . . . . . . . . 9-4 Figure 9.6 Control by Momentary Contact . . . . . . . . . . . . . . . . . . . 9-5 Figure 9.7 Two-Speed Application Utilizing One 825-MCM* . . . . 9-6 Figure 9.8 Two-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 9.12 Application with Low Idling Current . . . . . . . . . . . . . . 9-11 Figure 9.13 2/3/4 Conductor Technique for PT100 Wiring . . . . . 9-12 Figure 9.14 Typical Application Utilizing 2-Phase Current

Evaluation with Primary Current Transformers. . . . . . 9-13 Figure 9.15 Trip Characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-14

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viii Table of Contents

Tables

Table 2.A Environmental Ratings . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5

Table 2.B Nominal Rated Voltages Ue . . . . . . . . . . . . . . . . . . . . . . 2-6 Table 2.C Electrical Ratings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6

Table 2.D Supply Ratings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7 Table 2.E Relay Ratings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8 Table 2.F Terminals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9 Table 2.G Main Current Transformer Ratings. . . . . . . . . . . . . . . . 2-10 Table 2.H Recommended Data for Core Balance Current

Transformer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11 Table 2.I Converter Module — Related Error Messages. . . . . . . 2-13 Table 3.A Actual Values Overview. . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 Table 3.B Set Values Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2 Table 3.C Recorded Values Overview . . . . . . . . . . . . . . . . . . . . . . . 3-3 Table 3.D Display Example of Set Values Menu. . . . . . . . . . . . . . . 3-6 Table 3.E Display Example of Actual Values Menu . . . . . . . . . . . . 3-7 Table 3.F Display Example of Recorded Values. . . . . . . . . . . . . . . 3-9 Table 3.G Protective Functions Summary . . . . . . . . . . . . . . . . . . . 3-13 Table 3.H Warning Functions Summary . . . . . . . . . . . . . . . . . . . . 3-14 Table 3.I Control Functions Summary . . . . . . . . . . . . . . . . . . . . . 3-15 Table 3.J Thermal Overload Setting Parameters . . . . . . . . . . . . . 3-21 Table 3.K Protection Against Thermal Overload . . . . . . . . . . . . . 3-22 Table 3.L Asymmetry (Phase Unbalance)

Setting Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-23 Table 3.M High Overload and Jam Setting Parameters . . . . . . . . . 3-24 Table 3.N Underload 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.R Starts per Hour Setting Parameters . . . . . . . . . . . . . . . . 3-33 Table 3.S Monitoring Start Time Setting Parameters . . . . . . . . . . 3-35 Table 3.T Warm Start Setting Parameters . . . . . . . . . . . . . . . . . . . 3-38 Table 3.U Alarm Examples. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-41 Table 3.V Reset Setting Parameters . . . . . . . . . . . . . . . . . . . . . . . . 3-42 Table 3.W Short Circuit Setting Parameters . . . . . . . . . . . . . . . . . . 3-44

Publication 825-UM001B-EN-P January 2001

Table of Contents ix

Table 3.X	Stalling during Start Setting Parameters . . . . . . . . . . . .	3-45
Table 3.Y	PTC Setting Parameters . . . . . . . . . . . . . . . . . . . . . . . . .	3-46
Table 3.Z	Sensor Measuring Circuit Specifications . . . . . . . . . . . .	3-47
Table 3.AA	Phase Sequence Setting Parameters. . . . . . . . . . . . . . . .	3-54
Table 3.AB	Phase 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.AE	PT100 (RTD) Setting Parameters . . . . . . . . . . . . . . . . .	3-57
Table 3.AF	Motor Insulation Class Setting Parameters. . . . . . . . . .	3-58
Table 4.A	Cat. Nos. 825 MCM2, 825-MCM-20, 825-MCM180 . .	. 4-3
Table 4.B	Cat. Nos. 825-MCM630, 825-MCM630N . . . . . . . . . .	. 4-4
Table 4.C	Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	. 4-7
Table 5.A	Main Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	5-1
Table 5.B	Special Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	5-2
Table 5.C	Communication Settings . . . . . . . . . . . . . . . . . . . . . . . . .	5-3
Table 5.D	Cat. No. 825-M… Operating Parameters . . . . . . . . . . . .	5-4
Table 6.A	Checking the Actual Values . . . . . . . . . . . . . . . . . . . . . . .	6-6
Table 7.A	List of Recorded Values. . . . . . . . . . . . . . . . . . . . . . . . . .	7-2
Table 8.A	Possible 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 1

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

Introduction 1-3

Figure 1.2 Operating Characteristics of an AC Motor

cos ϕ, η, n I Pv ne, Ie, Pve

1.5

1.4

1.3

1.2

1.1

1.0

0.9

0.8

0.7

0.5

			P	Power
			Pe	Rated operational power
			Pv	Power losses
			Pve	Power losses under rated conditions
	Ie	ns	,	Operational current
			,e	Rated service current
η	n
			n	Speed
cos ϕ			ne	Rated operational speed
	I		ns	Synchronous speed
			cos ϕ	Power factor
	Pv
			η	Efficiency

25	50	75	100	125
			P	[%]
			Pe

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.

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

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.

Publication 825-UM001B-EN-P January 2001

1-4 Introduction

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

,A Starting current tA Starting time

,e Rated service current

t Time

		I
A		e
I
2		2 I
1.6	A	2
	2 I
	2
		tA

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 (tA). If this is less than the limit specified by the manufacturer (usually 10 s), the starting current does not cause an excessive temperature rise. The brief, asymmetrical peak when switching on can be ignored.

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

ϑ

ϑ G

ϑ e

ϑs

ϑK

0 tA tB

ϑ	G	Temperature limit of the insulation
ϑ	K	Coolant temperature
ϑ	s	Temperature rise at start
ϑ	e	Temperature rise when operated
		continuously at rated current
tA		Starting time
t tB		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

%

E M

EM

Average motor life

ϑ G

Temperature limit of the insulation

100

70

50

25

ϑ G

0

+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 2

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

Cat. No. 3600-MBS: Modbus

Cat. No. 825-MPB: PROFIBUS FMS

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 [phone] or your local Prosoft Technology, Inc. distributor.

Publication 825-UM001B-EN-P January 2001

2001 January P-EN-BUM001-825 Publication

L1 L2 L3

Figure

Block

A1 (-) -

Supply

Operation

LCD

95/96

Block2.2

Diagram

Y13

A2 (+) +

Y11

Emergency start

Warning/Trip

Y12

Disable settings

825-M

825-

Controller

97/98

Main relay MR

Diagram

MCM

Y21

Basic unit

Y22

Remote reset

13/14

Alarm relay AL

825-M

∑

k, l

Earth fault

23/24

Auxiliary relay #1

33/34

Auxiliary relay #2

825-MST

T1, T2

Thermistor

43/44

Auxiliary relay #3

overload

4…20 mA

I+ / I-

Analog output

M

Y31

3 ~

24 V AC/DC Y32

#1

Control

24 V AC/DC Y41

#2

inputs

ϑ amb

Y42

L1

F

L1

Phase

53/54

Auxiliary relay #4

L2

L2

sequence

825-MLV

L3

L3

63/64

Auxiliary relay #5

Phase failure

Equipment

Choice

1T1/1T2/1T3

PT100 #1…#6

825-MMV

825-MLV or 825-MMV

Stator /

…6T1/6T2/6T3

(RTD)

bearing temperature

PC

7T1/7T2/7T3

PT100 #7

Ambient temperature

Network

Description

(RTD)

825-MDN 3600-RIO

3600-MBS 825-MPB

PLC

Communication Interface

3-2

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

Fault indicator (LED) Flashing: warning Steady state: trip

LCD: Single line (two lines of text are displayed alternately)

Values: Selection of mode

Actual: Indication of actual operational data

Set: Setting mode (set/modify, store parameters) Recorded: Indication of statistical data

Select: Select function and enter/change operating parameterSettings: Enable entry (Change) and memorize (Enter)

Test: Verifies operation of Smart Motor Manager.

Reset: Enables the Smart Motor Manager after a trip.

Publication 825-UM001B-EN-P January 2001

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		40 ° C (104 ° F), 92%
		relative humidity, 56 days
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
	Resistance to Vibration
as per IEC 68-2-6		10…150 Hz, 3 G
	Resistance to Shock
as per IEC 68-2-27		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 Ue

				825-
Primary Detection Circuit		825-	825-	MCM180
		MCM2	MCM20	MCM630
				MCM630N
	Motor Circuit
as per IEC, SEV, VDE 0660		400V AC	660V AC	1 000V AC
as per CSA, UL		240V AC	600V AC	600V AC
	Control Circuit
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

Table 2.C Electrical Ratings

		825-	825-	825-
Test Voltage				MCM180	825-MCM630N
		MCM2	MCM20
				MCM630
	Motor Circuit
as per IEC 947-1		Uimp	Uimp	Uimp	Uimp
		2.5 kV	6 kV	8 kV	12 kV
	Control Circuit
Between control circuits and to all other circuits
Main relay (MR) 95…98,
supply A1, A2				Uimp
Phase sequence protection
L1, L2, L3				4 kV
Alarm relay (AL), auxiliary relay
#1, #4, #5 as per IEC 947-4
Core balance current transformer k, I				Uimp
Control inputs #1, #2
Auxiliary relays #2, #3				2.5 kV
as per IEC 947-4

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 Us	380…415, 440V AC
		24…48, 72…120, 220V DC
		AC 0.85…1.10 US
	Permissible voltage fluctuation	DC 0.80…1.10 US for 24…48V DC
		DC 0.80…1.20 US for 72…120V DC
		DC 0.80…1.15 US for 220V DC
	Power consumption	AC 13 VA, DC 10 W max.
	Short-circuit protection	With the appropriate supply cable rating, the supply module is
		short-circuit proof.

Publication 825-UM001B-EN-P January 2001

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	[V]	24		110…125	220…250	380…440
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	[A]	30			30	12
(cos ϕ = 0.3) AC-15
Rated operating current for DC-13
without prot. network,	[A]	2		0.3	0.2	–
L/R = 300 ms
Max. rated current of back-up fuse:	[A]	10 A, 500V AC,		Type gG
Alarm Relay (AL), Auxiliary Relays #1, #4, #5
Contacts fitted			1 N/O contact each
Continuous thermal current			4 A
Max. permissible switching voltage			400V AC, 125 VDC
	Nominal Operating		Current
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
	Max. Switching		Power
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
	Auxiliary Relays		#2, #3
Contacts fitted			1 N/O contact each
Continuous thermal current			4 A
Max. permissible switching voltage			48 VAC, 30 VDC
	Max. Switching		Power
cos ϕ = 1			150 W
cos ϕ = 0.4, L/R = 7 ms			60 W

Publication 825-UM001B-EN-P January 2001

Equipment Description	2-9

Table 2.F Terminals

		Range of gauges:
	Cat. No. 825-M plug-in terminals	0.5…2.5 m2, single wire (AWG No. 20…14)
		0.5…1.5 m2 double wire (AWG No. 20…16)
	as per UL	AWG No. 22…14
	as per VDE	nominal gauge 1.5 mm2
	Main circuit
	825-MCM2/	Terminals: 2 x 2.5 mm2/1 x 4 mm2
		(2 x 0.0039 in2/1 x 0.006 in2)
	825-MCM20
		2 x AWG No. 20…14/1 x AWG No. 20…12
	825-MCM180	Aperture or busbars:
		Wire 19 mm max. 20/16 x 4 mm
	825-MCM630(N)	Bus bars: 25 x 8 mm

Publication 825-UM001B-EN-P January 2001

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 ,1n	Nominal operating current of motor
	Rated secondary current		1 A or 5 A
	Class and nominal	5 P 10 ext. 120%
	overcurrent factor
	Power rating	According to power consumption in leads
		and measuring circuits
	Rated frequency		50/60 Hz
	Burden:	825-M +		825-M +
		825-MCM2		825-MCM20
	Power consumption at max. rated current	0.1 VA/phase		0.4 VA/phase
	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
	General Notes on 825-MCM…
	No-load	An open-circuit secondary is permitted, as the burden is
		installed in the detection module
	Designation according to IEC 60044 part 2:

5Total 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 ,e motor > 87% of
120%	rated nominal transformer current)

With starting current 10 ,e: class 5 P 20

The current transformer error in addition to the basic unit error2.5 A with Cat. No. 825-MCM2, 20 A with Cat. No. 825-MCM20

Publication 825-UM001B-EN-P January 2001