Cat. No. 825-MThe Cat. No. 825-MST option card provides input terminals for connection of a speed switch. This enables the Smart Motor Manager to detect a stalled motor during start

5

Bulletin 825SMM™ Smart Motor Manager

0

Bulletin 825• 0.5…2000 A Current

Range• Modular Construction• Built-in Keypad and LCD• Test and Reset Buttons• Alarm/Trip LED• NEMA 4 (IP65) Housing• Communication Options• Suitable for Low- and

Medium-Voltage Applications

TABLE OF CONTENTSDescription Page Description PageProduct Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6Product Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13Approximate Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

DescriptionThe Bulletin 825 SMM™ Smart Motor Manager provides the tools necessary to obtain optimal utilization of motors that operate critical processes. The Smart Motor Manager can minimize unplanned shutdowns with its comprehensive protective, monitoring, warning, and diagnostic capabilities. Protective features include: thermal overload, phase loss, phase reversal, phase imbalance, rapid trip/mechanical jam, ground (earth) fault, short circuit, over-temperature (thermistor input), underload, stator and bearing RTD monitoring, start time monitoring, stall during start, and multiple starts. Some of these features require the installation of an option card.

Conformity to Standards: Approvals: Your order must include:• Cat. no. of the Smart Motor Manager

selected with supply Voltage Suffix Code.

• Cat. no. of Converter Module selected.

• If required, Cat. no. of any option cards or accessories.

IEC 947-4 CECSA C22.2 No. 14 PTBUL 508 CSA Certified

UL Listed

Smart Motor ManagerCat. No. 825-M⊗


6

Product Overview

Thermal Overload

Two-Body SimulationMost thermal overload protective devices employ a one-body thermal simulation model. This model assumes that a motor’sthermal response is uniform throughout.

The Smart Motor Manager uses a two-body simulation to calculate a more precise representation of a motor’s thermal condition during all modes of operation. A two-body simulation incorporates the temperature rise characteristics of both the stator windings and the iron mass of the motor into the thermal image.Starting: In a two-body simulation, the fast rise in the winding temperature and the much slower conduction of heat to the iron during starting are correctly simulated.Running: While the motor is running, both the iron and current imbalance losses are entered into the model. The optional addition of the ambient temperature into the simulation improves the level of motor use, even in cases where the temperature is subject to considerable fluctuations.Stopped: The different cooling rates of a self-cooled motor while running and at rest are taken into account by two separate time constants. The simulation includes the faster cooling of the windings relative to the temperature of the iron mass after switching off the motor, as well as the slower cooling of the motor as a whole.

Thermal Capacity UtilizationThermal capacity utilization is the motor I2t value that the Smart Motor Manager calculates with the two-body simulation. This value can be accessed via the front panel keypad/LCD under the Actual Values menu. When the value reaches 100%, a thermal (overload) trip occurs.

Adjustable SettingsTo allow maximum utilization of a motor, the Smart Motor Manager provides the following adjustable settings that allow the installer to match the electronic thermal overload protection to the time-current response of the motor:• Full Load Current• Locked Rotor Current• Locked Rotor TimeThe thermal capacity of the iron is particularly important at low-level overloads; allowance for it in the thermal image enables the overload reserves of the motor to be used without risking a premature trip.

Adjustable Ratio of Cooling Time ConstantsThe ratio of the cooling time constant when the motor is stationary to the cooling time constant when the motor is running allows for the different cooling rates in each of these states. The factory-programmed default value is 2.5; this value is correct for the majority of self-cooled motors. For forced-cooled and special motors, especially those that respond either very quickly or slowly, it may be necessary to modify this value.

Tripping Time DisplayIn conditions when an overload is likely to occur, the time to trip is continuously displayed on the Smart Motor Manager’sfront-panel LCD. This allows corrective action to be taken so that production may continue uninterrupted.

Reset Time DisplayFollowing a thermal trip, the Smart Motor Manager cannot be reset until the temperature in the thermal image has fallen to the reset level, which has a factory-programmed default value of 50% of thermal utilization.

Thermal WarningThe Smart Motor Manager provides the capability to alert in the event of an impending overload trip. The thermal warning level has an adjustable range of 50…99% of thermal utilization, and the warning can be assigned to any of the available auxiliary relays.

Motor Temperature MonitoringDirect motor temperature monitoring can provide enhanced protection against influences that are independent of current, such as ambient temperature and obstructed motor ventilation. Doing so requires a motor with temperature sensors embedded in the windings. The Smart Motor Manager offers two options for direct temperature monitoring.Thermistor Input: The option card (Cat. No. 825-MST) allows connection of a maximum of six positive temperature coefficient (PTC) thermistors in series. The resistance of a thermistor increases immediately when its rated response temperature is exceeded. The Smart Motor Manager provides an instantaneous trip when the measures thermistor response resistance level is achieved.RTD Input: The option card (Cat. No. 825-MMV) allows connection of six 100 Ω platinum resistant temperature detectors (RTDs) for monitoring motor winding and bearing temperature. A seventh input for monitoring the ambient temperature is also available. User-adjustable settings are provided for programming separate warning and trip temperature values. The monitored temperatures are displayed through the Actual Values menu.

Product Selection — Page 10Accessories — Page 11Specifications — Page 13Approximate Dimensions — Page 21

7


Product Overview, Continued

Ground FaultMotor insulation breakdown usually results in a leakage current to the grounded parts of the machine or, in the case of a power cable, the protective conduit. In grounded power systems, the fault current that develops can rise rapidly to a very high value. The Smart Motor Manager offers the following ground fault sensing options.

Residual Method (Holmgreen)The Smart Motor Manager uses the Holmgreen method with the basic unit as standard. This method calculates the ground fault current by summing the individual phase currents. In a "healthy" motor where there is no residual current flowing to ground, the three-phase currents sums to zero. The Holmgreen method is best suited for use on either solidly grounded power systems or those grounded through a low impedance. The trip setting has an adjustable range of 10…100% of the motor’s full load current rating.

Zero Sequence Method (Core Balance)The option card (Cat. No. 825-MST) allows the user to connect a core balance transformer (Cat. No. 825-CBCT), which measures the ground fault current directly from the three-phase motor conductors passing through it. This method is best suited for use on high-impedance grounded power systems. It is also preferred when a sensitive measurement is required. Both trip and warning settings are available with adjustable ranges from 5 mA…50 A.

Imbalance/Phase LossThe Smart Motor Manager continuously monitors and calculates the current imbalance of an operational motor. The measured current imbalance is entered into the thermal image calculation to simulate the resulting increased motor heating.

User-adjustable trip and warning settings for current imbalance are available with a preset range of 5…80% of full-load current.

Phase loss, a severe form of imbalance, is one of the primary causes of motor failure. A phase loss can occur as a result of a blown fuse or a poor electrical connection. Under a phase loss condition, the current draw of the remaining two powered phases increases by as much as 1.73 times the normal operating current. The Smart Motor Manager offers two options for obtaining phase loss protection.Basic Unit: With the basic unit, phase loss protection is gained by using the current imbalance (asymmetry) settings.Cat. No. 825-MLV: This option card provides terminals for connection to the three-phase power system. With the connection made before the motor-starting contactor, a phase loss condition is recognized even while the motor is stopped. The Smart Motor Manager’s phase loss protection provides a preset delay of 2 s prior to a trip.

Rapid Trip/Mechanical JamWhen a driven load is jammed, causing the motor to stall, undue stress is applied to the transmission elements (gears, bearings, motor shaft, etc.). Additionally, as the motor stalls, its current draw begins to increase to the level of its locked rotor current rating.

The Smart Motor Manager provides the capability to quickly take a motor off line in the event of a mechanical jam, thereby reducing the potential for mechanical damage. It can also monitor and warn of impending jam situations.

User-adjustable trip and warning settings are available with a range of 1…6 times the motor full-load current.

UnderloadA sudden drop in motor current can signal conditions such as:• Pump cavitation• Tool breakage• Belt breakage

In these instances rapid fault detection can help minimize damage and aid in reducing production downtime.

Additionally, monitoring for underload can provide enhanced protection for motors that are cooled by the medium being handled (e.g., submersible water pumps). Such motors can become overheated despite being underloaded. This can result from an absence or insufficient amount of the medium (due to clogged filters, closed valves, etc.).

The adjustment range of the underload trip and warning settings is 25…100% of the motor’s full load current rating.

Short CircuitIn the event of a short circuit (phase-to-phase or phase-to-ground), excessive currents, typically much greater than a motor’s locked rotor current rating, are generated. Given the magnitude of this current, it is generally preferable or necessary to interrupt three-phase power to the motor through the branch-protecting circuit breaker rather than the motor-starting contactor due to the differences in the short-circuit withstand rating.

In the event of a short circuit, the Smart Motor Manager trips output relay #1 of the option card (Cat. No. 825-MST) regardless of other protective functions, actuating the circuit breaker with adequate breaking capacity. To prevent the contactor from opening under short-circuit conditions, its main relay is blocked from operating at currents greater than or equal to 12 times the motor’s full-load current rating. Tripping is delayed by 50 ms.



8


Start Time Monitoring

The Smart Motor Manager furnishes a setting for the installer to define the time that the motor should accelerate the load to full speed. The adjustment is 1…240 s.

Start time monitoring begins when the motor’s starting inrush current is recognized (current is greater than 110% of the motor’s full-load current rating). Acceleration to full speed is deemed to have been completed when the starting inrush current has fallen below 110% of the motor’s full-load current rating.

Start time monitoring is independent of thermal overload protection.

Speed Switch Input

The Cat. No. 825-MST option card provides input terminals for connection of a speed switch. This enables the Smart Motor Manager to detect a stalled motor during start and react immediately to take the motor off-line; this reduces the risk of damage to either the motor or the driven load.

Two-Speed Motor Protection

In the case of two-speed motors, the Smart Motor Manager provides a second motor current rating setting. Activating control input #2 of the option card signals the Smart Motor Manager to begin protection based on this second setting.

Control Functions

Contactor Operation

The Smart Motor Manager allows control relays #2 and #3 on the Cat. No. 825-MST option card to be operated over an automation network (e.g., DeviceNet via the Cat. No. 825-MDN communication card). The relays will actuate the motor-starting contactor(s).

Wye-Delta Control

With the Cat. No. 825-MLV option card installed, the Smart Motor Manager can control the transition from wye to delta. The command to transition is issued when the starting current has dropped to the motor’s full-load current rating, thus minimizing the associated current transients.

Emergency Restart

If a critical process requires the restart of the motor, the Smart Motor Manager provides two terminals that, when bridged, return the stored thermal capacity utilization to zero so that an emergency restart can be initiated.

Outputs

Output Relays

The basic unit provides a main relay and an alarm relay. The main relay can be operated either as electrically held or non-fail-safe. The Cat. No. 825-MST option card offers three additional auxiliary relays. Two additional auxiliary relays are available with the Cat. No. 825-MLV option card.

Isolated Analog Output

The Cat. No. 825-MST option card provides an isolated 4…20 mA analog output signal. This can be set to indicate one of the following:• Motor current (as a percentage of the motor’s full-load current

rating)• Maximum RTD temperature measured• Thermal capacity utilization

Monitoring and Diagnostic Display

The Smart Motor Manager provides the following useful operating motor data via the Actual Values and Recorded Values menus.

Actual Values• Operating current (average of three-phase)• Operating current (individual phase values)• Thermal capacity utilization• Tripping time (thermal overload)• Reset time (thermal overload)• Percent current imbalance• Ground fault current• RTD temperature measurements

Recorded Values• Running times• Number of starts• Cause of five most recent trips• Pre-trip Actual Value data• Number of trips by fault type• Time duration of a power failure

Communications

The Smart Motor Manager provides a dedicated communication expansion slot for connection to the following automation networks:• DeviceNet• Modbus• Remote I/O

This can enhance process operation by allowing the user to do the following via the network:• Control the motor starter• Modify settings• Access operational, diagnostic, and historical data


9



Basic and Optional Features

★ Available

Possible Combinations of Option Cards with Basic Unit

➊ The features and protective functions provided by each option card can be monitored through the communication network with any of the communication cards.

➋ A single communication card (DeviceNet, Modbus or Remote I/O) can be used with any combination of option cards.★ Available in shown combination.

Features ➊ BasicBulletin 825Option Cards

Cat. No. 825-MST Cat. No. 825-MLV Cat. No. 825-MMVThermal Overload ★ — — —Phase Imbalance (Asymmetry) ★ — — —Jam (High Overload/Stalling) ★ — — —Underload ★ — — —Ground (Earth) Fault (Holmgreen) ★ — — —Starting Time Monitor ★ — — —Limited Starts Per Hour ★ — — —Emergency Start ★ — — —Short Circuit — ★ — —Ground (Earth) Fault (Core Balance CT) — ★ — —Stalling During Start — ★ — —Thermistor Input (PTC) — ★ — —Analog Output for Thermal Utilization — ★ — —Two-Speed Motor Protection — ★ — —Wye-Delta (Star-Delta) Starting — — ★ —Phase Reversal (Sequence) — — ★ —Phase Failure — — ★ —100 Ω Platinum RTD Inputs #1…#6(Stator/Bearings) — — — ★100 Ω Platinum RTD Input #7(Ambient Temp.) — — — ★

BasicBulletin 825-M…

Option Cards ➋Cat. No. 825-MST Cat. No. 825-MLV Cat. No. 825-MMV

★ ★ ★ —

★ ★ — ★

★ ★ — —

★ — ★ —

★ — — ★

★ — — —



10

Product Selection

Smart Motor Manager Basic Unit

⊗ Control Voltage Suffix CodeThe 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.

Converter Module

➊ Up to 2000 A when using primary current transformers.

Core Balance Current Transformer

Description Cat. No.

Basic UnitProgrammable 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

825-M ⊗

Voltage AC 24V 120…220V 220…240V 380…415V 440V Voltage DC 24…48V50/60 Hz KD D AJ N GB Code Z48

Description Current Range (A) Cat. No.

Converter ModuleConnection to the Smart Motor Manager is made by a cable wire plug provided as standard with the converter module.

0.5…2.5 825-MCM2

2.5…20 ➊ 825-MCM20

20…180 825-MCM180

IEC:160…630UL/CSA: 160…434 825-MCM630

IEC:160…630UL/CSA: 160…630 825-MCM630N

Description Current Ratio Cat. No.

Measure from earth current 0.5...10 A 100:1 825-CBCT

Cat. No. 825-MCM180

Cat. No. 825-MCM630

Product Overview — Page 6Accessories — Page 11Specifications — Page 13Approximate Dimensions — Page 21

11


Option Cards ➊/Accessories

➊ Option cards include a connector set.➋ Cat. Nos. 825-MLV and 825-MMV occupy the same slot, therefore only one of the option cards may be used at one time.➌ Available from Prosoft Technology, Inc. (not an Allen-Bradley product). Cat. references to third-party 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., at (661) 664-7208 or your local PTI distributor.

➍ This terminal set can only be used for applications less than 420A and can only be installed on the load side of the converter module.

Description Cat. No.MST option — FeaturesShort CircuitGround (Earth) Fault (Core Balance CT)Stalling During StartThermistor Input (PTC)Analog OutputTwo-speed Motor Protection

825-MST

MLV option ➋ — FeaturesWye-Delta (Star-Delta) StartingPhase Reversal (Sequence)Phase Failure (Motor Supply)

825-MLV

MMV option ➋ — Features100 Ω Platinum RTD Inputs #1…#6 (Stator/Bearings)100 Ω Platinum RTD Input #7 (Ambient Temperature)

825-MMV

Communication Card — DeviceNet — DeviceNet Conformance Tested (Passed) 825-MDN

Modbus 3600-MB5 ➌

Remote I/O 3600-RIO ➌

Bus Bars for Cat. No. 825-MCM180 — Features• Terminals: M8• 4 x 16 x 100mm• Weight: 230 g

825-MVM

Terminal Cover — Provides touch protection for Cat. No. 825-MCM converter modules (two pieces per set)For use with Cat. Nos.• 825-MCM2• 825-MCM20• 825-MCM180• 825-MCM630N

CAB6-HA1CAB6-HA1CAB6-HA2CAB6-HA3

Main Terminal Set — Dual connection 3-pole terminal lug block providing touch protection (2 blocks, 6 lugs per set)For use with Cat. Nos. • 825-MCM180 (with Cat. No. 825-MVM bus bar kit)• 825-MCM630N

CAB6-HB2CAB6-HB3➍

Thermal Utilization Meter 825-MTUM

Product Overview — Page 6Specifications — Page 13Approximate Dimensions — Page 21


12

Accessories

⊗ Control Voltage Suffix CodeThe 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.

Description Cat. No.

Panel Mounting Frame 825-FPM

Connector SetsProvided as Standardwith option card

For use with Cat. No. 825-M ⊗MSTMMVMLV

825-CSB825-CSST825-CSMV825-CSLV

Connection cable (replacement)825M to 825-MCM connection 825-MCA

Power Supply Module (replacement) 825-MPS ⊗

Voltage AC 24V 120…220V 220…240V 380…415V 440V Voltage DC 24…48V50/60 Hz KD D AJ N GB Code Z48

Cat. No. 825-FPM

Cat. No. 825-MPS

13


Specifications

Controls

SettingsThe 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.

➊ 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

➀ Values Mode SelectionActual Display current operating dataSet Setting mode

(set, change, save, and store parameters)Recorded Display recorded data

➄ Reset Reset trips

➁ Select Select functions and enter/change operatingparameters

➅ LCD Single Line(two lines of text are displayed alternately)

➂ Settings EntryChange Enable entryEnter Save entry

➆ Fault Indicator LEDBlinking WarningContinuous Trip

➃ Test Test functions(Alarm, trip, trip time)

Main Settings Setting Range Factory SettingRated motor current or operating current IeUse of a primary current transformerCurrent ratio of primary current transformerLocked-rotor currentLocked-rotor time ➊

0.5...2000 ANo/Yes1...2000

2.5...12 Ie1...600 s

20 ANo1

6 Ie10 s

Special Settings Setting Range Factory SettingConnection of main relay (MR)Connection of alarm relay (AL)Reset of thermal tripReset at...% thermal utilizationReset PTC tripCooling constant motor ON/OFF ratioMotor insulation classCommunication

Electrically held/non-fail-safeNon-fail-safe/electrically held

Manual/automatic10...100%

Manual/automatic1...5

B/E/FDeviceNetRemote I/O

Modbus

Electrically heldNon-fail-safe

Manual50%

Manual2.5B——4

1 2 34

5

6

7

Product Overview — Page 6Product Selection — Page 10Accessories — Page 11Approximate Dimensions — Page 21


14

Specifications, Continued

Function Overview

➊ Via external speed switch (control input #1); output relays and time delay as with high overload.➋ Includes ambient temperature in the thermal image.➌ Only one relay can be selected per function; MR = main relay, AL = alarm relay, auxiliary relays #1...#5.

Function Setting Tripping Delay Relays ➌Factory Setting Range

Factory Setting Range

Factory Setting Selection

Factory Setting

Protective FunctionsBulletin 825-M basic unitThermal overloadAsymmetry/Phase lossHigh overload/StallingUnderloadUnderload delayEarth fault (Holmgreen)Start time monitoringLimited number of starts per hour

OnOnOnOffOnOnOffOff

—5...80%1...6 Ie

25...100%—

10...100%—

1...10

—35%2.4 Ie75%—

50%—2

—1...5 s

0.5...25 s1...60 s0...240 s0.1...5 s1...240 s

—

—2.5 s0.5 s10 s0 s

0.5 s10 s—

MRAllAllAll—AllAllAll

MRMRMRMR—MRMRMR

Option 825-MSTShort circuitEarth fault (core balance transformer)Stalling during start ➊PTC Thermistor input

OffOffOffOff

4...12 Ie5 mA...50 A

——

10 Ie1 A——

20...990 ms0.1...5 s

——

50 ms0.5 s

—800 ms

#1All

All ➊All

#1MR

MR ➊MR

Option 825-MLVPhase sequence (motor supply)Phase loss (motor supply)

OffOff

——

——

——

1 s2 s

AllAll

MRMR

Option 825-MMV100 Ω Platinum RTD inputs #1...#6 (stator, bearings) 100 Ω Platinum RTD input #7 ➋

OffOff

50...200°C—

50°C—

——

15



Function Overview

➊ Only one relay can be selected per function; MR = main relay, AL = alarm relay, relays #1...#5

Function Setting Range Tripping Delay Relays ➊



Factory Setting Selection

Factory Setting

Control Functions

Bulletin 825-M basic unitWarm start (% of cold trip)Emergency start

OffOff

50...100%Jumper

Terminals

70%Y11- Y12

4...60 min.—

60 min.—

——

——

Option 825-MSTAnalog outputassigned to:- Thermal utilisation- PT100 max. Temperature- I Motor

On 4...20 mA

0...100%5...200°C

0...200% Ie

— — — — —

Control Auxiliary Relays #2, #3via communication Off — — — — — —

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- 100 Ω Platinum RTD

OffOff

OffOffOffOffOffOffOffOff

——

————————

——

————————

0...240 s0...240 s

————————

1 s2 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- 100 Ω Platinum RTD

Off

Off

OffOffOffOffOffOffOffOff

——

0.5...2000 A

————————

——

20 A

————————

0...240 s0...240 s

—

————————

1 s2 s—

————————

———

————————

#3#3—

————————

Option 825-MLVStar-Delta starting Off Y-Δ:1.1 · Ie

Y-Δ:1...240 s

10 s Y: #4 Δ: #5



16


Bulletin 825-M Basic Unit and Bulletin 825-M Converter Module

➊ The measuring inputs PT100 and PTC, 4...20 mA analog output and the RS 485 communication interface are not isolated from one another.➋ Approved by the PTB (Physikalisch-Technische Bundesanstalt, Physical Testing Institute, Federal Republic of Germany) for the protection of

motors used in explosion hazard areas (EEx e).

Ambient ConditionsTemperatureOperationStorageTransport

–5...+60°C–40...+60°C–40...+60°C

Climatic WithstandDamp heat IEC 68-2-3Climatic cycling IEC 68-2-30

40oC, 92% relative humidity, 56 days25/40°C, 21 Cycles

Protection ClassBulletin 825, enclosed in panelTerminals

IP65IP20

Vibration Resistanceper IEC 68-2-6 10...150 Hz, 3 GShock Resistanceper IEC 68-2-27 30 G, shock duration 18 ms, half of a sin wave in x, y, z directions

Rated Voltage Ue

Primary Control Circuit 825-MCM2 825-MCM20825-MCM630

825-MCM630N825-MCM180

Motor Circuitper IEC, SEV, VDE 0660per CSA, UL

400V AC240V AC

660V AC600V AC

1,000V AC600V AC

Control CircuitMain relay (MR) 95...98, supply A1, A2Phase-sequence protection L1, L2, L3• per IEC 947• per SEV• per CSA, ULAlarm relay (AL) 13/14, Auxiliary Relays #1, #4, #5• per IEC 947• per SEV• per CSA, ULAuxiliary Relays #2, #3Control Inputs #1, #2

400V AC380V AC240V AC

400V AC250V AC240V AC

120V AC/30V DC24V AC/DC

Electrical Ratings

Test Voltage 825-MCM2 825-MCM20825-MCM630

825-MCM630N825-MCM180

Motor Circuitper IEC 947-4 Uimp 2.5 kV Uimp 6 kV Uimp 8 kVControl CircuitControl circuits against each other and against all other sets ➊Main relay (MR) 95...98, supply A1, A2Phase sequence protection L1, L2, L3Alarm relay (AL) 13/14, Auxiliary relays #1, #4, #5• per IEC 947-4Core-balance transformer k, IAuxiliary relays #2, #3Control inputs #1, #2• per IEC 947-4

Uimp 4 kV

Uimp 2.5 kVEMC Standard

Noise emissionNoise proof

per EN 50 081-1 and EN 50 081-2per EN 50 082-1 and EN 50 082-2

Standards IEC 947-4, CSA C22.2 No. 14, UL 508Approvals CE, UL-Listed, CSA, PTB ➋


17



Bulletin 825-M Basic Unit and Bulletin 825-MCM Converter Module

Supply

Nominal supply voltage Us

Permissible voltage fluctuationPower consumptionShort-circuit protection

50/60 Hz: 22...24, 33...36, 44...48, 110...120, 220...240, 380...415, 440V AC

24...48, 72...120V DCAC 0.85...1.1 Us, DC 0.80...1.1 Us

AC 13 VA, DC 10 W max.With the appropriate supply cable rating, the supply module is

short-circuit proof

RelaysContact Data of Output Relays, Main Relay (MR) 95...96

Contacts 1 N.O. and 1 N.C. contact, electrically insulatedNominal operating voltage per UL, CSA: pilot duty 240V [V] 24 110...125 220...250 380...440Continuous thermal current [A] 4Rated operating current AC-15 [A] 3 3 1.2Maximum permissible switching current (cos ϕ = 0.3) AC-15 [A] 30 30 12Rated operating current (L/R = 300 ms), no protection network necessary DC-13 [A] 2 0.3 0.2 —

Max. rated current of back-up fuse [A] fast (D) 16; slow (DT) 10, 500V Type gGAlarm relay (AL), Auxiliary relays #1, #4, #5

Contacts 1 N.O. contact eachContinuous thermal current [A] 4Maximum permissible switching voltage [V] 400 AC, 125 DCNominal operating currentcos ϕ= 1cos ϕ= 0.4, L/R = 7 ms

[A][A] 4 at 250V AC or 30V DC

2 at 250V AC or 30V DC1250/150500/60

240; 1 A pilot duty

Maximum switching powercos ϕ= 1cos ϕ= 0.4, L/R = 7 ms- per UL/CSA

[VA/W][VA/W]

[V]Auxiliary relays #2, #3

Contacts 1 N.O. contact eachContinuous thermal current [A] 4Maximum permissible switching voltage [V] 48 AC, 30 DCMaximum switching powercos ϕ= 1cos ϕ= 0.4, L/R = 7 ms

[W][W]

15060

TerminalsBulletin 825-M Plug-in Terminals

• per UL• per VDE

Range of gauges: [mm2][mm2]

[AWG No.]Nominal gauge: [mm2]

0.5...2.5, single-wire0.5...1.5, double-wire

22...141.5

Main circuit825-MCM2, 825-MCM20

Terminals: [mm2][AWG No.]

2 x 2.5/1 x 42 x 20...14/1 x 20...12

825-MCM180

825-MCM630(N)

Aperture: [mm]or bus bars: [mm]Bus bars [mm]

ø max. 1920/16 x 4

25 x 8



18


Bulletin 825-M Basic Unit and Bulletin 825-MCM Converter Module

➊ Current transformer (P = Protection): ±1% error at rated current (Ie)±5% error at rated overcurrent (10 · Ie)Rated thermal current = 120% IeFor starting current 10 · Ie: Class 5 P 20The current transformer error is added to the Bulletin 825-M error.

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

Main Current Transformers for the Motor CircuitWhen Bulletin 825-M is used as a secondary relay with Cat. Nos. 825-MCM2, 825-MCM20

Min. rated operating voltage [V]Min. rated primary current I1n [A]Rated secondary current [A]Class and nominal overcurrent factorPower ratingRated frequency [Hz]

Nominal operating voltage of motorsNominal operating current of motor

1 or 55 P 10 ext. 120% ➊

According to power consumption in leads and measuring circuits50/60

BurdenPower consumption at maximum rated current ➋ [VA]Continuous thermal current [A]Thermal current during 1 s [A]Rated frequency [Hz]

825-M + 825-MCM20.1 per Phase

3250

50/60

825-M + 825-MCM200.4 per Phase

24600

50/60General Notes on 825-MCM

No-load An open-circuit secondary is permitted, since the burden is installed in the detection module

Core Balance Current TransformerRecommended Core Balance Current Transformer (cable-type)

Nominal ratio Kn =Minimum detectable earth fault

Pick-up current of Bulletin 825 earth fault protectionBurden: Bulletin 825-M measuring circuitPower consumption at max. rated current 0.5 A [VA]Continuous thermal current [VA]Thermal current during 1 sec [A]Frequency [Hz]

0.40.525

50/60Short-Circuit Protection

Selection of circuit breaker or fuse and associated contactor

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.

Short-Circuit coordination of the starter must always be considered

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.


19



Bulletin 825-M Basic Unit and Bulletin 825-MCM Converter ModuleResponse During Supply Voltage Failure

If the supply voltage fails, the setting data is retained

Supply voltage failure > 30 ms

• All 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• All output relays return to the state they were in before the supply failure• LCD and LED are active

Automatic Recognition of the Converter ModuleIn the event of a fault, the output relay MR 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., ImotorDisplay rangeUtilisation [%]Wire [mm2]Front [mm]Panel cutout [mm]Mounting depth [mm]

0...100 (ΔϑIe at rated current Ie)2 x 2.596 x 96

91.5 x 91.5 (–0/+ 0.5)55

Power Supply ModulePermissible voltage fluctuation [Us]Power consumption [VA/W]Short-circuit protection

AC 0.85...1.1, DC 0.80...1.1AC 13/DC 10

The power supply module is short-circuit proof

Weights Bulletin 825-M with power supply module [g]Bulletin 825-M without power supply module [g]Power supply module 825-MPS [g]Options 825-MPB [g]

825-MST [g]825-MLV [g]825-MMV [g]

Converter modules 825-MCM2 [g]825-MCM20 [g]825-MCM180 [g]825-MCM630 [g]825-MCM630N [g]

Core balance transformer 825-CBCT [g]Thermal utilisation indicator 825-MTUM [g]Mounting frame 825-FPM [g]PC Option kit 825-VISU [g]T connector 825-PTS [g]Stub cable 825-PTL2 [g]

825-PTL4 [g]Bus cable segment 825-PCB1 [g]Bus termination 825-PCE [g]Bus cable 825-BC [g]Bus cable connector 825-CBC9 [g]Bus bar for Cat. No. 825-MCM180

825-MVM [g]825-MVM2 [g]

1000710290125909090

570570860

312054605001808601257540459520

59/m15

230230



20


Short-Circuit Protection of Medium- and High-Voltage Motors with Option 825-MST

Main Circuit

Control Circuit

Cat. No. 825-M for short-circuit protection

3-phase current evaluation

Converter Module U1825-MCM2825-MCM20

Main current transformer U2...A/5 A or...A/1 ASee Specifications for selection

Core balance transformer U35 mA...50 AOutput to Bulletin 825-M: 5...500 mA

825-MCM 825Bulletin

Impulse contact control

QM Circuit breakerQA Shunt trip coilK1 Contactor F1 825-MS1 ON buttonS0 OFF buttonUs Control voltageH1 Indicator: contact closedH2 Indicator: Bulletin 825 tripped

(except for short-circuit protection)H3 Indicator: short-circuit tripMR Main output relay#1 Auxiliary relay, short-circuit indicator

825-M


21


Approximate Dimensions

Dimensions are shown in millimeters. Dimensions are not intended to be used for manufacturing purposes.

Bulletin 825-M MountingBulletin 825-M devices are suitable for both flush- and surface mounting.

Flush Mounting

Mounting Depth

Mounting position

Surface MountingBulletin 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.

max. 6 mm

144

10

138 + 1 - 0144

138 + 1 - 0

22.5° 22.5°

90°

22.5°

∅

90° 170

6.5

170

165

150

170


22

Approximate Dimensions, Continued


Bulletin 825-MCM Converter Module

➊ For snapping on to DIN Rail (EN 50 022-35 x 15 or 35 x 7.5).➋ Cat. No. 825-MCM180; with bus bar or max. ø 19 mm aperture for looping the conductors.➌ With Cat. No. 825-MVM.➍ Cat. No. 825-MVM2➎ See below for bus bars for Cat. No. 825-MCM180.

Bus Bars

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 5.3 100 552 x 2.5 mm2

— 38.5

825-MCM20 120 85 102 66 5.3 5.3 100 552 x 2.5 mm2

— 38.5

825-MCM180 120 102 72 5.3 5.3 100 55 ➎ ➎ 38.5 75 ➌/➍100/118825-MCM630 155 145 156 118 6.3 6.3 135 88 11 M10 48

825-MCM630N 155 145 177 118 6.3 6.3 135 88 11 M10 48

Terminal DimensionsCat. No. Bottom Top

825-MVM M8 M8

d3 b b2

e2 e2d2a

c1c

ø e

➊

➋

d1

ø d

b1

➌

➍

e3

➌ ➍

Cat. No. 825-MCM2...825-MCM180 Cat. No. 825-MCM630

Cat. No. 825-MCM630N

Product Overview — Page 6Product Selection — Page 10Accessories — Page 11Specifications — Page 13

23


Approximate Dimensions, Continued


Core Balance Current Transformer

Cat. No. 825-CBCT

Optional TestWinding

SecondaryWinding

150

200175

35

Ø9

Ø110

80

175

Product Overview — Page 6Product Selection — Page 10Accessories — Page 11Specifications — Page 13


24

Notes

Basic Smart Motor ManagerProtection RelayBasic unit, no additional cards included❶.

MLV or MMV Option CardCards provide enhanced protection and controlfunctions in addition to the standard features ofthe basic unit. (Cat. Nos. 825-MLV, 825-MMV❶)

Communication OptionsWith the appropriate card, your SMM Protection Relay cancommunicate via: DeviceNet, Remote I/O, and Modbus.

MST Option CardCard provides additional protectionover the base unit. (Cat. No. 825-MST❶)

Motor Thermal Load IndicatorConnects to the MST option card andprovides an indication of thermal activityin your motor. (Cat. No. 825-MTUM)

Converter ModulePlugs into RJ-45 connection of the Basic BulletinSmart Motor Manager Protection Relay card andmonitors motor current consumption. (Cat. No. 825-MCM❷)

This card comes standard with the base unit. (Cat No. 825-M❷)

❶ See chart on page 3 for details.❷ Incomplete catalog number. See page 10 for full number.

Application-Specific OptionsThe Smart Motor Manager Protection Relay offers the flexibility of different optionsto fit your specific applications. (See the table on page 3 for protection options.)

Documents

Cat. No. 825-MThe Cat. No. 825-MST option card provides input terminals for connection of a speed switch. This enables the Smart Motor Manager to detect a stalled motor during start