Bulletin 825 SMM Smart Motor Manager

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1 Bulletin 825 SMM Smart Motor Manager Your order must include: Cat. no. of the Smart Motor Manager selected with supply Voltage Suffix Code, Cat. no. of Converter Module selected, and, If required, Cat. no. of any option cards or accessories. Description Basic Unit Programmable electronic motor overload protection relay with communication capability Thermal Overload Phase Imbalance Jam (High Overload) Underload Ground (Earth) Fault Starting Time Monitor Limited Starts per Hour Cat. No. 825-M Control Voltage Suffix Code The cat. no. as listed is incomplete. Select a control Voltage Suffix Code from the table below to complete the cat. no. Example: Cat. No. 825-M for 120V power supply becomes Cat. No. 825-MD. Voltage AC 24V V V V 440V Voltage DC 24 48V 50/60 Hz KD D AJ N GB Code Z48 Converter Module Description Current Range Cat. No. Converter Module A 825-MCM2 Connection to the Smart Motor Manager is made by a A 825-MCM20 Cat. No. 825-MCM180 cable wire plug provided as standard with the converter module A 825-MCM A 825-MCM630 Cat. No. 825-MCM A 825-MCM630N Up to 2000 A when using primary current transformers. Core Balance Current Transformer Description Current Ratio Cat. No. Measure from earth current A 100:1 825-CBCT Up to 2000 A when using primary current transformers.

Description MST option Features Short Circuit Ground (Earth) Fault (Core Balance CT) Stalling During Start Thermistor Input (PTC) Analog Output Two-speed Motor Protection MLV option Features

Temperature) DeviceNet Communication Card DeviceNet Conformance Tested (Passed) M8 connections Set of three 4 x 16 x 102 mm (1/8 x 5/8 x 4-1/64 in.) (125 A max.

2 Description MST option Features Short Circuit Ground (Earth) Fault (Core Balance CT) Stalling During Start Thermistor Input (PTC) Analog Output Two-speed Motor Protection MLV option Features Wye-Delta (Star-Delta) Starting Phase Reversal (Sequence) Phase Failure (Motor Supply) MMV option Features 100 Platinum RTD Inputs #1 #6 (Stator/Bearings) 100 Platinum RTD Input #7 (Ambient Temperature) DeviceNet Communication Card DeviceNet Conformance Tested (Passed) M8 connections Set of three 4 x 16 x 102 mm (1/8 x 5/8 x 4-1/64 in.) (125 A max.) Universally applicable Weight: 230 g Thermal Utilization Meter Cat. No. 825-MST 825-MLV 825-MMV 825-MDN 825-MVM 825-MTUM Option cards include a connector set. Cat. Nos. 825-MLV and 825-MMV occupy the same slot, therefore only one of the option cards may be used at one time. Description Cat. No. Cat. No. 825-FPM Panel Mounting Frame 825-FPM Connector Sets Provided as Standard with option card For use with Cat. No. 825-M 825-CSB Cat. No. 825-PTS Cat. No. 825-MST 825-CSST Cat. No. 825-MMV Cat. No. 825-MLV 825-CSMV 825-CSLV Cat. No. 825-MPS Connection Cable (Replacement) Cat. No. 150-SM2 to Bul. 825-MCM Connection 825-MCA Power Supply Module (replacement) 825-MPS Control Voltage Suffix Code The cat. no. as listed is incomplete. Select a control Voltage Suffix Code from the table below to complete the Cat. No. Example: Cat. No. 825-MPS for 120V power supply becomes Cat. No. 825-MPSD. Voltage AC 24V V V V 440V Voltage DC 24 48V 50/60 Hz KD D AJ N GB Code Z48 Maximum Cable Lengths for Various Transmission Rates Controls 1 Values Actual Set Recorded Mode Selection Display current operating data Setting mode (set, change, save, and store parameters) Display recorded data 5 Reset Reset trips 2 Select Select functions and enter/change operating parameters 6 LCD Single Line (two lines of text are displayed alternately) 3 Settings Change Enter Entry Enable entry Save entry 7 Fault Indicator Blinking Continuous LED Warning Trip 4 Test Test functions (Alarm, trip, trip time)

3 Settings The following parameters must be programmed for every application. The other parameters (e.g., high overload, asymmetry) have factory-set values, which are correct for most applications. Main Settings Setting Range Factory Setting Rated motor current or operating current I e Use of a primary current transformer Current ratio of primary current transformer Locked-rotor current Locked-rotor time A No/Yes I e s 20 A No 1 6 I e 10 s If, instead of the permissible locked-rotor time, the maximum starting time is known, the approximate locked-rotor time is calculated as follows: Locked rotor time = Starting time 1.4 Special Settings Setting Range Factory Setting Connection of main relay () Connection of alarm relay (AL) Reset of thermal trip Reset at...% thermal utilization Reset PTC trip Cooling constant motor ON/OFF ratio Motor insulation class Electrically held/non-fail-safe Non-fail-safe/electrically held Manual/automatic % Manual/automatic B/E/F Electrically held Non-fail-safe Manual 50% Manual 2.5 B Function Overview Protective Functions Function Setting Tripping Delay Relays Factory Setting Range Factory Setting Range Factory Setting Selection Factory Setting Bulletin 825-M basic unit Thermal overload Asymmetry/Phase loss High overload/stalling Underload Underload delay Earth fault (Holmgreen) Start time monitoring Limited number of starts per hour % I e % % % 2.4 I e 75% 50% s s s s s s 2.5 s 0.5 s 10 s 0 s 0.5 s 10 s Option 825-MST Short circuit Earth fault (core balance transformer) Stalling during start PTC Thermistor input I e 5 ma...50 A 10 I e 1 A ms s 50 ms 0.5 s 800 ms #1 #1 Option 825-MLV Phase sequence (motor supply) Phase loss (motor supply) 1 s 2 s Option 825-MMV 100 Platinum RTD inputs #1...#6 (stator, bearings) 100 Platinum RTD input # C 50 C <8 s, AL#1...3 Alarm Functions Bulletin 825-M basic unit Thermal utilisation (% load) Asymmetry (% I e ) High overload (% II e ) % % I e % 75% 20% 2 I e 75% AL,#1...5 AL,#1...5 AL,#1...5 AL,#1...5 AL AL AL AL Underload Option 825-MST Earth fault (core balance transformer) Option 825-MMV 100 Platinum RTD inputs #1...#6 (stator, bearings) 5 ma...50 A 500 ma AL,#1...5 AL C 50 C AL,#1...5 AL Via external speed switch (control input #1); output relays and time delay as with high overload. Includes ambient temperature in the thermal image. ly one relay can be selected per function; = main relay, AL = alarm relay, auxiliary relays #1...#5. Function Overview, Continued

4 Function Setting Tripping Delay Relays Factory Setting Range Factory Setting Range Factory Setting Selection Factory Setting Control Functions Bulletin 825-M basic unit Warm start (% of cold trip) Emergency start % Jumper Terminals 70% Y11- Y min. 60 min. Option 825-MST Analog output assigned to: - Thermal utilisation - PT100 max. Temperature - I Motor ma % C I e % Control Auxiliary Relays #2, #3 via communication Control Input #1: (24V AC/DC; 8 ma) Alternatively, one of two functions may be selected: Pick-up delay, relay #2 Drop-out delay, relay #2 Disabling of protective functions: - Asymmetry/phase loss - High overload/stalling - Earth fault - Short circuit - Underload - Limited starts per hour - Thermistor PTC Platinum RTD s s 1 s 2 s #2 #2 Control Input #2: (24V AC/DC; 8 ma) Alternatively, one of three functions can be selected: Pick-up delay, relay #3 Drop-out delay, relay #3 Set 2nd rated current Disabling protective functions: - Asymmetry/phase loss - High overload/stalling - Earth fault - Short circuit - Underload - Limited starts per hour - Thermistor PTC Platinum RTD A 20 A s s 1 s 2 s #3 #3 Option 825-MLV Star-Delta starting Y- : 1.1 I e Y- : s 10 s Y: #4 : #5 ly one relay can be selected per function; = main relay, AL = alarm relay, relays #1...#5 Bulletin 825-M Basic Unit and Bulletin 825-M Converter Module Ambient Conditions Temperature Operation Storage Transport Climatic Withstand Damp heat IEC Climatic cycling IEC C C C 40 C, 92% relative humidity, 56 days 25/40 C, 21 Cycles Protection Class Bulletin 825, enclosed in panel Terminals IP65 IP20 Vibration Resistance per IEC Shock Resistance per IEC Hz, 3 G 30 G, shock duration 18 ms, half of a sin wave in x, y, z directions Bulletin 825-M Basic Unit and Bulletin 825-M Converter Module, Continued

5 Rated Voltage U e Primary Control Circuit 825-MCM2 825-MCM MCM MCM630N 825-MCM180 Motor Circuit per IEC, SEV, VDE 0660 per CSA, UL 400V AC 240V AC 660V AC 600V AC 1,000V AC 600V AC Control Circuit Main relay () , supply A1, A2 Phase-sequence protection L1, L2, L3 per IEC 947 per SEV per CSA, UL Alarm relay (AL) 13/14, Auxiliary Relays #1, #4, #5 per IEC 947 per SEV per CSA, UL Auxiliary Relays #2, #3 Control Inputs #1, #2 400V AC 380V AC 240V AC 400V AC 250V AC 240V AC 120V AC/30V DC 24V AC/DC Electrical Ratings Test Voltage 825-MCM2 825-MCM MCM MCM630N 825-MCM1808 Motor Circuit per IEC Control Circuit Control circuits against each other and against all other sets Main relay () , supply A1, A2 Phase sequence protection L1, L2, L3 Alarm relay (AL) 13/14, Auxiliary relays #1, #4, #5 per IEC Core-balance transformer k, I Auxiliary relays #2, #3 Control inputs #1, #2 per IEC U imp 2.5 kv U imp 6 kv U imp 8 kv U imp 4 kv U imp 2.5 kv EMC Standard Noise emission Noise proof per EN and EN per EN and EN Standards IEC 947-4, CSA C22.2 No. 14, UL 508 Approvals CE, UL-Listed, CSA Supply Nominal supply voltage U s Permissible voltage fluctuation Power consumption Short-circuit protection 50/60 Hz: , , , , , , 440V AC , V DC AC Us, DC U s AC 13 VA, DC 10 W max. With the appropriate supply cable rating, the supply module is short-circuit proof Terminals Bulletin 825-M Plug-in Terminals per UL per VDE Range of gauges: Nominal gauge: [mm2] [mm2] [AWG No.] [mm2] , single-wire , double-wire Main circuit 825-MCM2, 825-MCM20 Terminals: [mm2] [AWG No.] 2 x 2.5/1 x 4 2 x /1 x MCM MCM630(N) Aperture: or bus bars: Bus bars [mm] [mm] [mm] max /16 x 4 25 x 8 The measuring inputs PT100 and PTC, ma analog output and the RS 485 communication interface are not isolated from one another. Bulletin 825-M Basic Unit and Bulletin 825-MCM Converter Module, Continued

6 Relays Contact Data of Output Relays, Main Relay () Contacts 1 N.O. and 1 N.C. contact, electrically insulated Nominal operating voltage per UL, CSA: pilot duty 240V [V] Continuous thermal current 4 Rated operating current AC Maximum permissible switching current (cos = 0.3) AC Rated operating current DC (L/R = 300 ms), no protection network necessary Max. rated current of back-up fuse fast (D) 16; slow (DT) 10, 500V Type gg Alarm relay (AL), Auxiliary relays #1, #4, #5 Contacts 1 N.O. contact each Continuous thermal current 4 Maximum permissible switching voltage [V] 400 AC, 125 DC Nominal operating current cos = 1 cos = 0.4, L/R = 7 ms 4 at 250V AC or 30V DC 2 at 250V AC or 30V DC Maximum switching power cos = 1 cos = 0.4, L/R = 7 ms - per UL/CSA [VA/W] [VA/W] [V] 1250/ /60 240; 1 A pilot duty Auxiliary relays #2, #3 Contacts 1 N.O. contact each Continuous thermal current 4 Maximum permissible switching voltage [V] 48 AC, 30 DC Maximum switching power cos = 1 cos = 0.4, L/R = 7 ms [W] [W] Main Current Transformers for the Motor Circuit When Bulletin 825-M is used as a secondary relay with Cat. Nos. 825-MCM2, 825-MCM20 Min. rated operating voltage Min. rated primary current I 1n Rated secondary current Class and nominal overcurrent factor Power rating Rated frequency [V] [Hz] Nominal operating voltage of motors Nominal operating current of motor 1 or 5 5 P 10 ext. 120% According to power consumption in leads and measuring circuits 50/60 Burden Power consumption at maximum rated current Continuous thermal current Thermal current during 1 s Rated frequency General Notes on 825-MCM [VA] [Hz] 825-M MCM2 0.1 per Phase / M MCM per Phase /60 No-load An open-circuit secondary is permitted, since the burden is installed in the detection module Current transformer (P = Protection): ±1% error at rated current (I e ) ±5% error at rated overcurrent (10 I e ) Rated thermal current = 120% I e For starting current 10 I e : Class 5 P 20 The current transformer error is added to the Bulletin 825-M error. 2.5 A with Cat. No. 825-MCM2, 20 A with Cat. No. 825-MCM20

7 Core Balance Current Transformer Recommended Core Balance Current Transformer (cable-type) Nominal ratio K n = Burden: Bulletin 825-M measuring circuit Power consumption at max. rated current 0.5 A[VA] Continuous thermal current[va] Thermal current during 1 sec Frequency[Hz] Minimum detectable earth fault Pick-up current of Bulletin 825 earth fault protection /60 Short-Circuit Protection Selection of circuit breaker or fuse and associated contactor Short-Circuit coordination of the starter must always be considered The line-side circuit breaker or fuse must ensure that the engine will start, while still switching off short-circuit currents fast enough. Because of the latter, the fuse selected should always be as small as possible. The lowest possible fuse rating depends on the starting current of the motor and the tripping time set on the Bulletin 825-M. The contactor receives its tripping signal when the Bulletin 825 trips and must interrupt all currents up to the point of intersection of the time/current characteristics of the Bulletin 825 and circuit breaker or fuse. When starting large motors, the main contacts on the contactor are subjected to high thermal loads so that if the motor starting time exceeds a certain limit, the maximum permissible current has to be reduced. The fuse or contactor rating must also allow for the prospective short-circuit current. The Bulletin 825-MCM converter modules are short-circuit proof. The contactor coordination diagrams are available upon request. Bulletin 825-M Basic Unit and Bulletin 825-MCM Converter Module Response During Supply Voltage Failure If the supply voltage fails, the setting data is retained Supply voltage failure > 30 ms attracted output relays drop out LED extinguishes The timer for duration of supply failure starts (max. 8 h) The current and recorded data are memorized LCD extinguishes Recovery of the supply voltage Start of initialization routine The time of occurrence and the duration of the supply voltage failure are recorded Thermal image is calculated and updated output relays return to the state they were in before the supply failure LCD and LED are active Automatic Recognition of the Converter Module In the event of a fault, the output relay trips and the type of fault appears on the LCD Bulletin 825-M devices regularly check The Bulletin 825-M <-> 825-MCM link Agreement between the rated current set and the current range of the Bulletin 825-MCM The supervisory circuits Bulletin 825-MTUM Device for Indicating Thermal Utilisation, PT 100 max., I motor Display range Utilisation[%] Wire[mm2] Front[mm] Panel cutout[mm] Mounting depth[mm] ( I e at rated current I e ) 2 x x x 91.5 ( 0/+ 0.5) 55 Power Supply Module Permissible voltage fluctuation[ U s ] Power consumption[va/w] Short-circuit protection AC , DC AC 13/DC 10 The power supply module is short-circuit proof

8 Weights Bulletin 825-M with power supply module [g] 1000 Bulletin 825-M without power supply module [g] 710 Power supply module 825-MPS [g] 290 Options 825-MPB [g] MST [g] MLV [g] MMV [g] 90 Converter modules 825-MCM2 [g] MCM20 [g] MCM180 [g] MCM630 [g] MCM630N [g] 5460 Core balance transformer 825-CBCT [g] 500 Thermal utilisation indicator 825-MTUM [g] 180 Mounting frame 825-FPM [g] 860 PC Option kit 825-VISU [g] 125 T connector 825-PTS [g] 75 Stub cable 825-PTL2 [g] PTL4 [g] 45 Bus cable segment 825-PCB1 [g] 95 Bus termination 825-PCE [g] 20 Bus cable 825-BC [g] 59/m Bus cable connector 825-CBC9 [g] 15 Bus bar for Cat. No. 825-MCM MVM [g] MVM2 [g] 230 Short-Circuit Protection of Medium- and High-Voltage Motors with Option 825-MST Main Circuit 3-phase current evaluation Cat. No. 825-M for short-circuit protection Converter Module U1 825-MCM2 825-MCM20 Main current transformer U2...A/5 A or...a/1 A See Specifications for selection

Core balance transformer U3 5 ma...50 A Output to Bulletin 825-M: 5.

9 Core balance transformer U3 5 ma...50 A Output to Bulletin 825-M: ma Control Circuit Impulse contact control QM QA K1 Circuit breaker Shunt trip coil Contactor F1 825-M S1 S0 Us H1 H2 ON button OFF button Control voltage Indicator: contact closed Indicator: Bulletin 825 tripped (except for short-circuit protection) H3 Indicator: short-circuit trip Main output relay #1 Auxiliary relay, short-circuit indicator Dimensions are shown in millimeters. Dimensions are not intended to be used for manufacturing purposes. Bulletin 825-M Mounting Bulletin 825-M devices are suitable for both flush- and surface mounting. Flush Mounting Surface Mounting

10 Bulletin 825-M devices can be installed on a mounting frame (Cat. No. 825-FPM). The terminals can then be easily accessed without unmounting the device. Mounting Depth Mounting Position Bulletin 825-MCM Converter Module Cat. No. 825-MCM MCM180 Cat. No. 825-MCM630

Cat. No. 825-MCM630N Dimensions Cat. No. a b c c1 ø d d1 d2 d3 ø e ø e1 e2 b1 b2 825-MCM2 120 85 102 66 5.3 5.3 100 55 2 x 2.5 mm 2 825-MCM20 120 85 102 66 5.3 5.3 100 55 2 x 2.5 mm 2 38.5 38.

11 Cat. No. 825-MCM630N Dimensions Cat. No. a b c c1 ø d d1 d2 d3 ø e ø e1 e2 b1 b2 825-MCM x 2.5 mm MCM x 2.5 mm MCM / 100/ MCM M MCM630N M10 48 For snapping on to DIN Rail (EN x 15 or 35 x 7.5). Cat. No. 825-MCM180; with bus bar or max. ø 19 mm aperture for looping the conductors. With Cat. No. 825-MVM. Cat. No. 825-MVM2 See below for bus bars for Cat. No. 825-MCM180. Bus Bars Terminal Dimensions Cat. No. Bottom Top 825-MVM M8 M8 Core Balance Current Transformer Cat. No. 825-CBCT Rockwell Automation, Inc. Rights Reserved.

Smart Motor Manager. Bulletin 825. User Manual

Smart Motor Manager. Bulletin 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