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Smart Motor Manager User Manual

1. rien Cal LCD Setting Description Range o PT100 3 protection PT100 3 TRIP On Of p OFF J On Off 3 TRIP TEMP s0 200 P1003 o ripping temperature 50 C J pping temp PT100 4 TRIP onvorr P1100 4 protection OFF J On Off 4 TRIP TEMP s0 200 PT 100 4 o ripping temperature 50 C J pping temp T100 5 TRIP wor T1005 protection OFF J On Off 5 TRIP TEMP ieee PT100 5 o P ripping temperature 50 C J pping temp PT100 6 TRIP DINE Jor PT100 6 protection OFF On O 6 TRIP TEMP 50 200 Pr100 6 o ripping temperature 50 C J pping temp PT100 1 6 TRIP Alrelays PT 100 1 ex 4 rippin VAIN RELAY y pping p T100 1 6 RESET gt Manual in 1 6 reset PT100 MANUAL P auto Manual automatic P100 1 WARNING on ort PT100 1 warning OFF J On O 41 WARNING TEMP PT100 50 C 90 200 Warning temperature g 3j f PT100 42 warni PT100 2 WARNING On Of warning OFF J On O t WARNINGTEMP PT100 2 90 200 Warning temperature 50 C y g temp Publication 825 UM001B EN P January 2001 5 15 Setting the Operational Parameters Table 5 D Cat No 825 M Operating Parameters Continued Required Group Option
2. 24V AC DC R 00 L1 L2 L3 L1 L2 L3 Lo N o R I F I c q c A 1 5 A c c c A 1 5 A ahe pee NN CN LE vm HUE ERU ER REDE K1 K2 Gn 24 V AC DC 8mA mo O YaA2 Ym For setting the second rated current speed Il K2 refer to Chapter 5 Control input 2 K1 825 MST Secondary circuit II 100 MO5 j 100 M05 Sg 825 MCM 2 20 825 M 1 Separately Ventilated Motors Because they ate cooled constantly separately ventilated motors exhibit the same thermal behavior when stationary as when running Consequently the cooling ratio must be set to 1 LCD oap RATIO 00 For setting the cooling ratio refer to Chapter 5 Publication 825 UM001B EN P January 2001 9 9 Applications Wiring Basic Unit and Converter Module with Primary Current Transformer and Core Balance Current Transformer Main Circuit Figure 9 10 Typical Application Utilizing Primary Current Transformers and Core Balance Current Transformer T1 Converter module Cat No 825 MCM2 Cat No 825 MCM20 i 3 5 825 MCM 825 M Ht 2 4 e Kk z c T1 Primary Current Transformer A 5 A or A 1 A Selection refer to Chapter 2 Specifications Basi
3. Publication 825 UM001B EN P January 2001 7 4 Testing and Maintenance Table 7 A List of Recorded Values Continued LCD Description Fg N MAX T BEF L TRIP Maximum temperature before last trip in C PT100 1 6 ke C 3i f TN TH BEF LAST TRIP hermal capacity used before last trip 100 thermal trip ee yy f NUMBER START Total number of motor starts an J w NUMBER TH TRIP Total number of trips thermal NC A e N NUMBER AS TRIP Total number of trips asymmetry Cod p e 7N NUMBER OC TRIP Total trips overcurrent locked rotor NEC p a N NUMBER EF TRIP Total trips earth ground fault vu P va w NUMBER SC TRIP Total trips short circuit n p ka N NUMBER UL TRIP Total trips underload Gee D fa 3 NUMBER PTC TRIP otal trips overtemperature PTC ic J hi in NUMBER PR TRIP otal trips phase sequence motor supply 5 J NUMBER PL TRIP i1 U otal trips phase failure motor supply ERE p NUMB PT100 TRIP i1 100 otal trips overtemperature PT100 NE p fro CLEAR REC VAL To clear all recorded values except running time of basic unit go to GOTO END SET VAL ai a Eend eL values a N END REC VALUES End of recorded values w P Publication 825 UM001B EN P January 2001 Testing and Maintenance 7 5 Checking with Test Equipment
4. 6 2 Switching on the Control Voltage 0 eee 6 2 Checking the Set Parameters 0 0 0 cece cee nee 6 2 Motor Current 53s cierres docete yaaa d e i cs ei t e A 6 3 Locked Rotor or Starting Current celles eese 6 4 Locked Rotot Time eoe eL UPC Ree er EH d 6 4 Publication 825 UM001B EN P January 2001 iv Table of Contents Programming Setup and Operation 0 0 0 6 5 Nep ET 6 5 Operant ei oderit iie adepti dpt toa Qus Die dba dod 6 6 Chapter 7 Testing and Maintenance General cca vnus epe OXRRICUDEEENERQU ER Ud du uS 7 1 Checking without Test Equipment 0 0 00 ce eee 7 1 Functional Check with the Test Button 0 0 c eee eee 7 1 Indication of Recorded Values 0 0 ccc ce eee 7 2 Checking with Test Equipment 0 cles 7 5 West Waits s da soe onda tones Ge ivo S RA aes Stee 7 5 Chapter 8 Error Diagnosis and Troubleshooting Alarm Waring s nce saan ele Folks eee EI RE d Rx En t e a Rees 8 1 Procedure when Alarm Warning Picks Up 00004 8 1 TOD pP CEDE 8 2 Fault Codes 23222 e Set E bed Se REN RE erg 8 3 Procedure if ALARM does not Reset 0 000 cee eee eae 8 8 Procedure if TRIP cannot be Reset nunn cece eee 8 8 Chapter 9 Applications Wiring Bulletin 825 Smart Motor Manager with Contactors 0 9 1 Matti Citcutt dieser See Nd hea bres DS da ace dettes 9 1 Control Cireutt used sta d qoe oe etuer Ewa aes 9 2
5. Phase sequence protection PHASE REVER TRIP On Off nas d on motor supply OFF voltage Phase sequence M J On Off protection 825 MLV PHASE REVER TRIP B All relays Phase sequence protection MAIN RELAY J Assignment of output relay iA Phase failure PHASE LOSS TRIP On Off based on motor supply OFF J voltage On Off Phase failure 825 MLV PHASE LOSS TRIP j All relays Phase failure MAIN RELAY J Assignment of output relay ras PT100 protection PT100 PROT On Off stator bearings OFF J On Off PT100 1 TRIP B On off P1100 1 protection OFF 3j On Off PT 100 RTD 975 MMV ___ 1 TRIP TEMP A 50 209 PTtoo 1 temperature sensor 50 C a Tripping temperature S D PT100 2 TRIP b yor PT100 2 protection OFF On O f S D 2 TRIP TEMP l s0 200 Pr o ripping temperature 0 C Y pping temp If Phase Rever Trip is set to off the programming menu skips to parameter Phase Loss Trip f Phase Loss Trip is set to off the programming menu skips to parameter P7700 Prot f PT100 Prot is set to off the programming menu skips to parameter Output 4 20 mA Publication 825 UM001B EN P January 2001 Setting the Operational Parameters 5 14 Table 5 D Cat No 825 M Group PT 100 RTD temperature sensor continued Option Card Cat No 825 MMV Operating Parameters Continued
6. FacteySeting Thermal Utilization 7596 Asymmetry 2096 High Overload 21g Underload 75 All these functions Off Publication 825 UM001B EN P January 2001 Functions 3 42 Reset When the motor is at standstill a trip condition can be reset Kinds of Reset Manual reset Press the reset button on the Bulletin 825 for at least 200 ms Remote reset Short circuit terminals Y2 Y22 e Automatic reset In the mode set values set automatic reset for Thermal trip e PTC trip e PT100 trip Reset Conditions Thermal As soon as the temperature rise has dropped to the preset reset threshold PTC detector As soon as the temperature is below the reset threshold PT100 detector As soon as the temperature is below the tripping threshold Asymmetry Phase failure Manual or remote reset possible All other trips Can be reset immediately Table 3 V Reset Setting Parameters Setting range Manual Automatic Factory setting Manual Reset Threshold of the Thermal Trip Setting range 10 10096 Factory setting 7096 Setting increments 596 Function of the Cat No 825 MST Option Card Short Circuit Heavy phase currents caused by short circuits between phases and from phase to earth are detected by the Cat No 825 MST option card The supply can be interrupted immediately by controlling the power switching device e g circuit breaker Short circuit protec
7. switched on must be fed with an auxiliary contact of the contactor into control input 1 Publication 825 UM001B EN P January 2001 Applications Wiring 9 12 Connecting the PT100 Temperature Sensors Using the 2 3 4 Conductor Technique The Bulletin 825 MMV Option Card has been designed for the 3 conductor technique Given the diameter of the conductor it is also possible to connect the PT100 temperature sensors by using the 2 4 conductor technique Figure 9 13 2 3 4 Conductor Technique for PT100 Wiring ors O i i xT1 PT100 Option 3 conductor 825 MMV technique n s xT2 o YE SR NNNM fj E O j x xT1 e xT3 I PT100 Option 2 conductor LY i 825 MMV technique s O __ xT2 o He jJ zu ue pue EE mem Lyn mers O j Y xT1 l O i d xT3 PT100 Opti ption 4 conductor H 825 MMV technique od O 2 N auf xT2 O T p etd Vie iS Publication 825 UM001B EN P January 2001 9 13 Applications Wiring Basic Unit and Converter Module with Primary Current Transformer 2 Phase Current Evaluation Figure 9 14 Typical Application Utilizing 2 Phase Current Evaluation with Primary Current Transformers Y m A x Converter module cat nos 825 MCM2 825 MCM20 1 3 5 a Tr H 825 MCM 825 M 2 4 6 k T2
8. le otor curren phase L3 p g 0 20 1200 rated service curren uj M P ran N TRIP IN sec 1 9999 Unit will tripin s M E Publication 825 UMO001B EN P January 2001 6 7 Commissioning and Operation Table 6 A Checking the Actual Values Continued LCD Sorting Description ange f RESET IN sec 1 9999 Unit can be reset in s V ASYM SD 1 100 Current asymmetry in percent MV J earth H D 1 100 Earth ground fault current residual as percentage of oe actual service current I Me Be h earth C mA 3Y 999 mA Earth ground fault current in mA A with core balance 00 current transformer M A 50 00 A ra i E N Tambient C 0 210 Ambient temperature in C PT100 7 Nes J ir S N PT100 1 C 0 210 Temperature in C PT 100 1 M J iy PT100 2 C 0 210 Temperature in C PT100 2 Ns A A d N PT100 3 C 0 210 Temperature in C PT100 3 M J lo o N PT100 4 C 0 210 Temperature in C PT100 4 Xe P fes o N PT100 5 C 0 210 Temperature in C PT100 5 Nc P a n N PT100 6 C 0 210 Temperature in C PT100 6 M J Display of communication option Pa GET DevNe DeviceNet 825 MDN DevNet XX YY ZZZ R 1 0 Remote 1 0 3600 RIO i MODBUS Modbus 3600 MBS PROBUS PROFIBUS 825 MPB f
9. 500 VA 60 W as per UL CSA Contacts fitted 240 V 1 A pilot duty Auxiliary Relays 2 3 1 N O contact each Continuous thermal current 4A Max permissible switching voltage cos Q 1 48 VAC 30 VDC Max Switching Power 150W cos Q9 04 L R 7 ms Publication 825 UM001B EN P January 2001 60 W Equipment Description 2 9 Table 2 F Terminals Cat No 825 M plug in terminals as per UL as per VDE Range of gauges 0 5 2 5 m single wire AWG No 20 14 0 5 1 5 m double wire AWG No 20 16 AWG No 22 14 nominal gauge 1 5 mm Main circuit 825 MCM2 825 MCM20 825 MCM180 825 MCM630 N Terminals 2 x 2 5 mm2 1 x4 mm 2 x 0 0039 in2 1 x 0 006 in 2 x AWG No 20 14 1 x AWG No 20 12 Aperture or busbars Wire 2 19 mm max 20 16 x 4 mm 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 MCM2O the following specifications apply Table 2 G Main Current Transformer Ratings Minimum nominal operating voltage Nominal operating voltage of motor Minimum rated primary current J Nominal operating current of motor Rated secondary current 1Aor5A Class and nominal overcurrent factor 5P 10 ext 120 Power ratin
10. Allen Bradley Smart Motor Manager Bulletin 825 User Manual Automation 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 ate 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 wtitten permission of Rockwell Automation is prohibited Throughout this manual we use notes to make you awate of safety consi
11. END ACT VALUES End of actual values o J Publication 825 UM001B EN P January 2001 Chapter Testing and Maintenance General The correct functioning of the Smart Motor Manager can be checked by several methods depending on the requirements e With the Tes button With the test condition set With a single or 3 phase current source A test may be beneficial Duting commissioning Following an interruption in operation Following overhauls Following reconstruction of the installation After a test is conducted the display provides information on the running time of the Smart Motor Manager and the motor the number of operations performed by the motor the contactor etc From this information necessary maintenance and installation replacements can be derived Checking without Test Equipment Functional Check with the Test Button With the motor at standstill the thermal protection all alarms trips and tripping times can be checked with the aid of the Test button Page 3 9 for the specific procedures Publication 825 UM001B EN P January 2001 7 2 Testing and Maintenance Indication of Recorded Values All important statistical data can be read on the LCD of the basic unit Refer to page 5 8 for procedure From the recorded values data can be used to determine Running time of the motor the Smart Motor Managet contactor etc Necessary service jobs Operational behavio
12. 2l 4 6 2 Phase Current Evaluation lesse 4 7 Smart Motor Manager Basic Unit 04 4 8 Cat No 825 MST Option Card 0 00 4 9 Cat No 825 MLV Option Card sasssa 4 10 Cat No 825 MMV Option Card 0 4 11 Range of Starting Currents of Standard Motors Expressed as Multiple of the Rated Service Current cant ork tees EUDREPEAN UE E CHEER eae 6 4 Test with a 3 Phase Current Source 04 7 5 Test with a Single Phase Current Source 7 6 Basic Unit and Converter Module 9 1 Control by Momentary Contact sss esee 9 2 Basic Unit and Converter Module suu 9 3 Control by Momentary Contact sss eese 9 3 Basic Unit for Short Circuit Protection 9 4 Control by Momentary Contact 0 00005 9 5 Two Speed Application Utilizing One 825 MCM 9 6 Two Speed Application Utilizing 825 MCM180 9 7 Two Speed Application Utilizing Primary Current Transformer ocsevecve E E Civ ER chee 9 8 Typical Application Utilizing Primary Current Transformers and Core Balance Current TtansfOfmiet o esedpkes er eR EUR a eye arene glass 9 9 Typical Application Utilizing Core Balance Current Transtotmet oce Dx edet ede Deed 9 10 Application with Low Idling Current LL 9 11 2 3 4 Conductor Technique for PT100 Wiring 9 12 Typical Application Utilizing 2 Phase Current Evaluation with Primary Current
13. No indication Possible Causes Actions N ly volt i ae vo tage Check the supply Insert correct supply module If he voltage applied to the supply Wrong supply module EE in basic uit module was too high it and the unctions of the unit must be ested Basic unit defective If no fault is found or if in doubt send the unit back to the factory or repair Thermal trip of supply module e Supply voltage too high Ambient temp too high Switch off control supply Restore normal conditions and et the unit cool down for approx 30 min e Current consumption too high e Supply module failed end the unit back to the factory or repair V2 17 a and later Watch Dog Microprocessor Send the basic unit back to the No indication failure actory for repair M red LED on c DEFECT 1 Real time i Send the basic unit back to the clock fault RTC defective actory for repair M Z c S DEFECT 2 uP fault i Send the basic unit back to the RAM Microprocessor RAM defective actory for repair m Jl p Open circuit Check connections 825 MCM NOT CON basic unit to Cable from basic unit to converter converter module not connected or broken Test cable open short circuit M module Publication 825 Replace cable if necessary UM001B EN P January 2001 8 4 Error Diagnosis and Troubleshooting Table 8 A Possible Causes an
14. Not disabled PT100 RTD protection NOT DISABLED y disabled Active locked ou Setting the Operational Parameters 5 12 Table 5 D Cat No 825 M Required Group Option Card Cat No Control input 2 825 MST oococe If Control Input 2 is set to off Operating Parameters Continued Setting s LCD Range Description CONTROL INPUT 2 P Control input 2 On Off P OFF n Off Nd P fc Timer function of output DELAY AUX REL 3 On Off relay 3 OFF J On Off ON DELAY AUX 3 0 240 On delay of output relay 3 d sec J n N OFF DELAY AUX 3 0 240 Off delay of output 2 sec J relay 3 NEW FLC B On Off Setting 2nd rated motor OFF current Off On Nd P PRIMARY C T 42 oves e Use of primary c t for 2nd NO rated motor current hs PRIMARY C T RATIO 1 FEL E hi primary c t 2000 99 d E setting 160 NEW FLC 050 Serting 2nd rated motor 2 000 20A 5 On Off DISABLE FUNCTION Not disabled Disable protective function OFF disabled On Off N J ASYMMETRY PROT No disabled Asymmetry protection NOT DISABLED J disabled Active locked ou OVERCURRENT PROT Not disabled Nereutront lockertrotor NOT DISABLED j disabled active locked ou EARTH FAULT PROT Not disabled Earth faul protection NOT DIS
15. Star Delta Starter with Bulletin 825 Smart Motor Manager 9 3 Main Cireults oor Erud eher ate ances ene eS 9 3 Control Circuit or ess prese ee eee Ed IA Een 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 speiri gan teahees eter Rv eU I4 ydg 9 5 TEwo Speed Motors esae ek rp ee pind EE Weare RULR RR e 9 5 Matth Citc lt s ci inves ex peRUYP E rep venc cep e EP Eres 9 6 Two Speed Motor 0 5 A lt Speed I lt 20 A lt Speed II lt 180 A 9 7 Matti Circuits prome an ie dat eases ek ge MN adea RE EE 9 7 Two Speed Motors with Primary Current Transformer 9 8 Primary CIrCUlt d docs eaves wie ao ei wisweesovesdagtagese ts 9 8 Separately Ventilated Motors 0 00 cece eee eee 9 8 Publication 825 UM001B EN P January 2001 Table of Contents v Basic Unit and Converter Module with Primary Current Transformer and Core Balance Current Transformet nuansa lees 9 9 Main Circuit cs repe ood Hee e d dp ade added 9 9 Basic Unit and Converter Module with Core Balance Current TfanstOFtnet saeua p o es be dv ac ate wow A cnc MR UE t 9 10 Maitt CIEQUIU i ssi es anand TS en IX PE COE DN d deg AER Rea 9 10 Motors with Low Idling Current lt 20 Ie osoon na cesses 9 11 Main Circuit cvs dv ecce verbere pUNUTERSe repPb eda rine 9 11 Connecting the PT100 Temperature Sensors Using the 2 3 4 Con
16. N LI Ld 98 LILI Non Fail Safe Mode Note Terminal markings should be changed from those used in electrically held mode when switching to this mode Supply Off Supply On Supply On and Trip 97 E 98 i 95 co LJ L gt Applications of the Non Fail Safe Connection The non fail safe connection is suitable for use in situations where the failure of the control voltage must not interrupt the process Chemical processes Kneaders and mixers in which the mass would solidify Fresh air fans Cooling pumps etc Connection of the Alarm Relay AL In firmware versions before 2 18 the alarm relay was connected in the non fail safe mode Since V2 18 and later it can also be connected in the electrically held mode Publication 825 UM001B EN P January 2001 3 41 Functions Flectrically Held Mode Supply Off Supply On Supply On and Warning 13 9 1 13 18 0 31 14 ME 14 AN 14 EE Non Fail Safe Mode Supply Off Supply On Supply On and Warning 13 o 7 18 9 1 13 14 uL 14 x 14 AN Applications of the Electrically Held Connection Monitoring the supply voltage as well as operation of the communication option when the main relay is in non fail safe mode Alarm Relay AL Aside from the thermal overload short circuit and thermistor PTC protective functions all alarm and tripping functions may be assigned to the alarm relay AL Table 3 U Alarm Examples Warning
17. reserare ti ce Re Rd Rd Re 2 11 Response Supply Voltage Failure 0 0 0 0 cece eee 2 12 Automatic Recognition of Converter Module 00 2 13 Chapter 3 Functions Menu OVetyleWeodevercsenteee es Rer Rehd UP ER C eee te RE YE 3 1 Actual Values odes ete p E CHR eating a we s eR cvs 3 1 Set Values cccnedeeee uy x REX EXEREERPREUC RR reda QE 3 2 Recorded Values 4pIRRORE itok Re rect e URP hes E 3 3 Publication 825 UM001B EN P January 2001 ii Table of Contents ODEEFAHOD usse aa aded dia ent oca euis A E d la dae tue 3 4 Selecting the Setting Display Mode 0 eee eee eee 3 4 Setting the Operation Parameters Set Values 204 3 5 Indications of Actual Values esses 3 7 Indications of Recorded Values Statistics llleesees 3 8 Lest BUON bane das ur ae Shas de md wile LESIONES PARE 3 9 PUNCHON SUMMALy i556 oo ie Reg REA ete EEE eed Ee 3 13 Functions of the Basic Unit Cat No 825 M 0 00 0 eee 3 16 Thermal Overloads uve vr E RE Canes EP ERES TS 3 16 Adjustable Ratio of Cooling Constants 0000000000 3 17 Indication of the Time to Tripping 0 0 000008 3 18 Indication of the Time until the Thermal Trip can be Reset 3 18 Adjustable Setting Characteristic usunn eee eee 3 18 Asymmetry Phase Unbalance and Phase Failure 3 22 High Overload and Jam 0 eee eee eee 3 23 Underload e erexp e PUERO EUR EUER ha
18. 125V DC Relay 1 UL CSA 240V AC 125V DC 24 33 i Aux Auxiliary relay 2 j Relay 2 50V AC 30V DC 34 43 a Auxiliary relay 3 Aux 50V AC 30V DC j Relay 3 44 Analog output indicates the thermal utilization of the motor the motor temperature or the motor current b Indicating instrument 4 20 mA PLC input 0 300 W Recorder Ol oni o Y31 Control input 1 24V DC or 24V AC 9 Input 1 Y32 Control input 2 24V DC or 24V AC Control ze YA Input 2 o Y42 i Thermistor overtemperature protection max 6 PTC wired in series T1 Measuring lead Min cross section mm 05 075 1 15 25 PIS AWGNo 20 18 17 16 14 o T2 Max length m 200 300 400 600 1000 ft 656 984 1312 1968 3280 L1 L2 L3 Core balance transformer 5 500 mA at k I l External Internal For information regarding methods of actuation refer to Chapter 9 Method of installation up to 100 m 328 ft twisted more than 100 m additional unscreened Publication 825 UM001B EN P January 2001 Assembly and Installation 4 10 Figure 4 13 Cat No 825 MLV Option Card Either the 825 MLV or 825 MMV option card may be inserted in this ATTENTION p l position 53 Aux Relay 4 54 63 Aux Relay 5 64 L1 F L2 5 L3 External Internal T F l o L1 D L2 a Er External Internal Supply voltage gt 400 VAC UL CSA gt 240 VAC Auxiliary relay 4 IEC
19. 140 F If auxiliary relays 2 and 3 are assigned to the communication refer to page 5 16 they cannot be selected here Publication 825 UM001B EN P January 2001 3 25 Functions It is essential to set the Warning response level to a value less than ATTENTION the Trip response level Note If the starting current is below 1 2 FLC then the Monitoring the Start Time function must be activated After the set max starting Time has elapsed the High Overload Stall function will become active Applications Slip ring motors e Soft starters Motor protection with non fail safe mode after a control voltage failure Underload Motors that are cooled by the medium handled e g fans submersible pumps can become ovetheated despite being underloaded This can be a result of the absence of the medium or insufficient medium due to clogged filters closed valves etc Often these motors are installed in inaccessible places so repair is lengthy and expensive The consumption of less than a preset application specific amount of current may indicate a mechanical defect in the installation e g torn conveyor belt damaged fan blades broken shafts or worn tools Such conditions do not harm the motor but they do lead to loss of production Rapid fault detection helps to minimize damage The underload protection trip time can be delayed following each start to prevent tripping Th
20. 3 H Warning Functions Summary Functions Setting Factory Tripping Factory Relays 0 Factory Factory Range Settin Delay Setting Selection Settin Setting g 9 Range g g Bulletin 825 M Basic Unit Thermal utilization 95A load 0 50 99 75 AL 1 5 AL Asymmetry Za 0 5 80 20 AL 1 5 AL High overloading x Ze 0 1 6 Ip 2 Te AL 4 5 AL Underload 0 25 100 75966 AL 1 5 AL Bulletin 825 MST Option Card Earth ground fault uH uH core balance c t 0 5mA 50A 500 mA AL 1 5 AL Bulletin 825 MMV Option Card PT100 input 1 6 RTD o o stator bearings 0 50 200 C 50 C AL 1 3 AL Only one relay per function can be selected MR main relay AL alarm relay auxiliary relay 1 5 if auxiliary relays 2 and 3 are assigned to the communication refer to page 5 16 they cannot be selected here Same setting as for the Underload Trip function Publication 825 UM001B EN P January 2001 3 15 Functions Table 3 1 Control Functions Summary redu Setting Factory po Factory Factory Setting ge etting Range Setting Setting Bulletin 825 M Basic Unit n start of cold Off 50 100 70 4 60 min e 0min Emergency override of thermal trip Bulletin 825 MST O
21. 39 64 3 18 3 16 3 7 8 2 3 16 25 mm 1 1 2 720 102 72 53 53 WO 55 385 75 00 MCM180 4 95 64 4 2 13 16 3 16 3 16 37 9 2 3 16 M8 M8 1 177 2 61 64 100 117 Mounted on DIN Rail EN 50 022 35 Bus bar or opening for conductor max 19 mm With Cat No 825 MVM With Cat No 825 MVM2 eocec Figure 4 5 Cat Nos 825 MCM630 825 MCM630N Ej ogo ee bo O O o xu O od e Iru iri _ 9 D ion II e e WN cal Sla 9 lo l9 A Ter Exe o 9 lad Li gh lo i o gel ci Qaem c ua f Publication 825 UM001B EN P January 2001 Assembly and Installation 4 4 Table 4 B Cat Nos 825 MCM630 825 MCM630N Dimensions in millimeters inches Gat NE SSS MUCINE BOE NUR MU Ld 145 156 825 MCMB30 67 64 11 16 6 1 8 w Us a 55 0 erha MIO 4 7m 155 145 177 118 6 3 i 135 B25 MCMBIIN g req epu 631 32 Mes a A ese eaae MO ave Thermal Utilization Indicator Figure 4 6 Cat No 825 MTUM Thermal Utilization Indicator EN UU TRIP Panel cutout 91 5 x 91 5 mm 3 39 64 x 3 39 64 71 mm 1 16 0 5 mm 1 32 Mounting depth 55
22. 400 VAC 125 VDC UL CSA 240 VAC 125 VDC Auxiliary relay 5 IEC 400 VAC 125 VDC UL CSA 240 VAC 125 VDC Phase sequence protection Phase failure protection as per IEC SEV 110 400 VAC as per UL CSA 110 240 VAC Supply voltage gt 400 VAC UL CSA gt 240 VAC Internal Publication 825 UM001B EN P January 2001 4 11 Assembly and Installation Figure 4 14 Cat No 825 MMV Option Card Hither the 825 MLV or 825 MMV option cards may be inserted in ATTENTION g this position j9 IT PT100 inputs 1 6 RTD for PT100 1T3 monitoring the temperature of the stator 4472 Winding and motor bearings A 2T1 i ES f toa 0 212 2 3T1 vy 9 3 aa 7 471 i l ii 4T2 UN i 5T1 m A 1 PT100 7 for indication and inclusion of i i PT100 5 71 3 95T3 the coolant ambient temperature cooling 9 512 air in the thermal image If PT100 7 is ied not connected then a resistance of me eri 120 Q should be connected between T1 PT100 6 6T3 and T3 Lid era pu Tamb IN TH IMAGE PT100 7 mo 718 OFF tb 7T2 Method of Installation Short links up to 10 m laid separate from power cables need no screening Longer leads must be screened shielded e Separately screened connect screens to individual T2 e g 1T2 2T2 Common screening connect screen to T2 and all T2 together e g 1T2 212 Publication 825 UM001B EN P January 2001 Assembly and
23. Bulletin 825 M Basic Unit Thermal overload 0 100 MR No MR Asymmetry phase failure 0 5 80 35 1 25s 25s A MR High overloading jam 0 1 6 7 241g 0 1 5s 05s A MR Underload 0 25 100 7596 1 60 s 10s A MR Underload delayed enable 0 0 240s Os Earth ground fault residual 0 10 10096 50 0 1 5s 05s A MR Starting time monitor 0 1 240 s 10s A MR Limited starts per hour 0 1 10 2 A MR Bulletin 825 MST Option Card Short circuit 0 4 121 10 20 990ms 50ms 1 No 1 A Off 5mA 50A 1A 01 5s 05s A MR Stalling during start 0 o0 o0 Ale MRO Thermistor input PTC 0 800 ms A MR Bulletin 825 MLV Option Card Phase sequence motor supply 0 1s A MR Phase failure motor supply 0 2s A MR Bulletin 825 MMV Option Card ee o eae oe a 8 PT100 input 7 RTD 0 Via external speedometer control input 1 output and trip relays as for high overload Allowing for the ambient tempera Only one relay per function can be selected MR main relay AL alarm re gned to the communication refer to page 5 16 they cannot be selected e auxiliary relays 2 and 3 are assi here ure in the therma image ay auxiliary relay 1 5 if ATTENTION actuated before a trip occurs Warning function settings must be such that associated alarms are Publication 825 UM001B EN P January 2001 Functions 3 14 Table
24. Card LCD Sening Description Cat No 9 PT100 3 WARNING onorp PT 100 43 warning OFF On Of S D 3 WARNING TEMP iso a P110083 o arning temperature 0 C J g temp f PT100 44 warni PT100 4 WARNING On Of warning QFF On 0 S J A WARNINGTEMP sq qq P1008 o arning temperature 0 C J g temp f PT100 5 warni PT100 5 WARNING On Of warning OFF J 0n 0 PT 100 RTD temperature sensor 825 MMV 5 WARNING TEMP 50 200 M 00 di t continued 50 C J arning temperature o jJ PT100 6 warnin PT100 6 WARNING On Of g OFF On 0 M fi gt PT100 6 6 WARNING TEMP 50 200 rni o arning temperature 50 C J g temp ay 6 WARNING B AL PT100 1 6 warning 31 43 Assignment of output rela OFF J g p y f PT100 7 allowance for Tamb IN TH IMAGE On Off ambient temperature in OFF D hermal simulation NSULATION CLASS Br Insulation class o B ie winding Z _ Using the analog output for Th lutil pre Analog output 825 MST OUTPUT 4 20 mA age IZ thermal util zation THERMAL PT100 max motor current f Tamb in Thermal Image is set to Limiting winding temperatures of ambient temperature is taken into of the thermal model Without usi the thermal calculation on an ambient temperature of 40 C Publication 825 UM001B EN P January 2001 max PT100 temperature off the programming menu skips to parameter Output 4 20 mA he three insulations classes E 120 C B 130 C F 155 C Whe
25. Cc y rm O oOo ololololo o Bulletin 825 MLV Option Card Star delta starting 0 Y Aat 1 175 Y Aat 1 270s 10s Y 4 A 5 Forexample when used with two speed motors Functions of the Basic Unit Cat No 825 M Thermal Overload The Smart Motor Manager accurately simulates thermal conditions in the motor for all operating modes This permits maximum utilization of an installation and assures safe protection of the motor The basic unit 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 temperatute rise characteristics of both the stator windings and the iron mass of the motor into the thermal image The simulation of the Smart Motor Manager accurately represents the conditions in the motor at all times Publication 825 UM001B EN P January 2001 3 17 Functions While the motor is running the iron losses as well as losses caused by asymmetry are fed to the simulation model Allowance for the ambient temperature of the motor as an option enhances the maximum utilization of the installation even with considerable variation of the temperature Without the optional inclusion of the ambient temperature of the motor the thermal model bases the thermal calculation on an ambient temperature of 40 C The different cooling conditions of a self v
26. Circuit Setting Parameters Trip Function Factory setting Off Response Level Setting range 4 12 Ig Factory setting 10 Ip Setting increments 0 5 Ie Tripping Delay Setting range 20 990 ms Factory setting 50 ms Setting increments 10 ms Output Relay Selection relays 1 No output relay Factory setting 1 5 60 C 23 140 F Earth Ground Fault Protection with a Core Balance Current Transformer This function is integrated into the Cat No 825 MST option card Refer to page 3 28 Stalling During Start Function If the motor stalls during the starting phase the motor heats up very rapidly reaching the temperature limit of the insulation after the permissible stalling time Large low voltage motors and especially medium to high voltage motors often have short permissible stalling times although their starts may be considerably longer Accordingly the permissible stalling time must be set higher on the basic unit in these instances With an external speedometer or zeto speed switch the Smart Motor Manager recognizes that stalling has occurred during starting and it switches the motor off immediately Thus the motor and the driven installation are not exposed to unnecessary ot unacceptable stress from stalling Publication 825 UM001B EN P January 2001 3 45 Functions Applications Large low voltage motors Medium and high voltage motors Conv
27. Defective contacts Actions If the installation can be shut down without loss of production or without affecting safety Switch off the installation Search for the fault and repair it If it is important to keep the operation running Continuously monitor the level of ACTUAL VALUES ASYM If the alarm level continues to rise measures should be taken so that the installation can be shut down quickly Ifthe alarm level remains steady in the region of the set alarm threshold it is permissible to wait until the next planned interruption in operation to locate and repair the fault While the alarm is on red LED flashing the alarm function cannot ATTENTION be disabled refer to page 8 8 Trip EXAMPLE Asymmetry Faults in the motor or the installation can develop and lead to the set threshold being rapidly exceeded When this occurs and the related threshold is teached the following responses occur LED lights e LCD sien TRIP The assigned output relay picks up Publication 825 UM001B EN P January 2001 Error Diagnosis and Troubleshooting 8 3 Actions Determine the trip cause and correct the problem before re starting the motor installation ATTENTION While the trip is on ted LED on the protection function cannot be disabled refer to page 8 8 Fault Codes Table 8 A Possible Causes and Actions LCD Designation Ensure power supply is on YY
28. January 2001 Functions 3 4 Operation Selecting the Setting Display Mode Change mode by pressing Recorded Values ne cat ont ACTUAL VALUES SET VALUES JE Actual Change ft J Change le fr J change je ndication of actual Setting mode Indication o operational data set vary store parameters statistical data Publication 825 UMO001B EN P January 2001 3 5 Functions Setting the Operation Parameters Set Values Text and data are indicated alternately approximately 2 s text and 1 s data On the second line the data that is factory set or subsequently modified is displayed Functions not activated OFF are not indicated 1 To set the operation parameters repeatedly press the Values button until SET VALUES appears on the display Figure 3 1 Setting Mode SET VALUES Actual O Recorded iL Values Select Enter Settings 2 Press Select Up or Down until the desired parameter e g FULL LOAD CURR and 35 Amp appears display alternates between text and data Figure 3 2 Menu Selection Values Select Settings 3 Press the Settings Change button once The set value begins to flash A new set value can now be entered by means of the Se e keys Up or Down The entry is completed by pressing Settings Enter Publication 825 UM0
29. Transformets 9 13 Trip Characteristics 0 eee 9 14 Publication 825 UM001B EN P January 2001 viii Table of Contents Tables Table 2 A Table 2 B Table 2 C Table 2 D Table 2 E Table 2 F Table 2 G Table 2 H Table 2 1 Table 3 A Table 3 B Table 3 C Table 3 D Table 3 E Table 3 F Table 3 G Table 3 H Table 3 I Table 3 Table 3 K Table 3 L Table 3 M Table 3 N Table 3 0 Table 3 P Table 3 Q Table 3 R Table 3 S Table 3 T Table 3 U Table 3 V Table 3 W Environmental Ratings 0 0 ccc ee eee 2 5 Nominal Rated Voltages U 0000 e eee eee 2 6 Blecttical Ratings i see RR ete pte Res 2 6 Supply Ratings ix e eer REDIERE 2 7 Relay Ratings eee Re errR ETE EP RS E Rr env 2 8 Terminals 4222 yvx pU RRERIRTUP E Ties Tae 2 9 Main Current Transformer Ratings 2 10 Recommended Data for Core Balance Current JTr nstotmet c ker Y e hace weeks 2 11 Converter Module Related Error Messages 2 13 Actual Values Ovetview 0 0 0 cece eee 3 1 Set Values Overview 0 0 cc ce eee eee ee eens 3 2 Recorded Values Ovetview 0 0 eee eee eee 3 3 Display Example of Set Values Menu 3 6 Display Example of Actual Values Menu 3 7 Display Example of Recorded Values 3 9 Protective Functions Summaty 0 3 13 Warning Functions Summary 00004 3 14 Control Functions Summary 0005 3 15 Thermal
30. delta starting STAR AUX REL 4 Relay 4 Assignment of star output V J relay Star Delta Pa Star delta starting Wye Delta 825 MLV DELTA AUX REL 5 Relay 5 Assignment of delta output starting P relay A SET STAR TIME Star delta starting OFF On Off Max time on star on off M J TAR TIME B Star delta starting T 28 Max time on star 10 sec J eoce If Underload Trip is set to off t he programming menu skips to parameter UL Warning If UL Warning is set to off the programming menu skips to parameter Star Delta If Star Delta is set to off the programming menu skips to parameter Warm Starting If Set Star Time is set to off the programming menu skips to parameter Warm Starting Publication 825 UM001B EN P January 2001 5 9 Setting the Operational Parameters Table 5 D Cat No 825 M Operating Parameters Continued Required Group Option Card LCD ua Description Cat No NARM STARTING N owore Warm start OFF J On Of Warm start WARM START EACH 460 Warm start possible every 60 min J eamin VA Warm start tripping time as WARM TRIP TIME 50 100 a percentage of tripping VO 96 J time from cold Limiti ber of x START INHIBIT omote startshour OFF J On O Limiting number of MAX START HOUR f starts per hour a 2 10 Maximum starts hour sd e 2 ES Maxim
31. the locked rotor time so that the current converter does not trip lt 100 with the least favorable service load e g at the end of a heavy start Note that for this procedure the motor must be of adequate size for the intended application Programming Setup and Operation Duting programming setup and operation the actual operational values can be continuously monitored To do this switch the display to Actual Values refer to Chapter 3 Starting LCD Description The motor current depending on the type of motor pom 00 le Motor must drop from about 400 800 7 to the service current of 100 Ig start Publication 825 UM001B EN P January 2001 Commissioning and Operation 6 6 Operating Table 6 A Checking the Actual Values LCD fangs Description 7 N ACTUAL VALUES Indication of actual values S Aa B MOTOR A 0 00 49 99 50 24 000 Motor current in A N f N TH UTILIZ 0 100 Thermal utilization V i b M tage of rated MOTOR le otor current as a percentage of ra i 0 20 999 service current J ES f b M 11 L1 percentage of 11 le otor curren phase L1 p g i 0 20 1200 tod service curren o M J fc gt M 12 L2 percentage of 12 le otor curren phase L2 p g 0 20 1200 rated service current I e A fc M 13 L3 percentage of 13
32. using a core balance current transformer whose core surrounds all three of the phase leads to the motor According to the principle of the residual current protection circuit breaker sensitive protection against earth ground faults is possible With a low response threshold quite a minor insulation fault can lead to a warning or trip at an early stage Figure 3 14 Example of 2 Phase Current Sensing Example of 2 phase current detection and core balance current transformer for sensitive earth ground fault protection 3 phase current detection is also possible L1 L2 L3 l l i 2 j 5 H i EIS PIS l g25 MCM jezs ul i P2082 P2092 3 4 j Je Hee S1 i j Is chm Be es Mi 3 Publication 825 UM001B EN P January 2001 3 29 Functions Application High voltage motors Installations in a difficult environment with moisture dust etc c g mines gravel pits cement factory mills woodworking shops water pumping stations waste water treatment Table 3 P Core Balance Current Transformer Setting Parameters Current Ratio Setting range 1 2 000 Factory setting 100 Setting steps 1 Table 3 0 Earth Ground Fault Core Balance Setting Parameters Warning Trip Function Factory setting Off On Response Level Setting range 5 mA 50A 5mA 50A Factory sett
33. z Rs bod NEA Publication 825 UM001B EN P January 2001 Applications Wiring 9 14 Time Current Characteristic of Bulletin 825 Smart Motor Manager Figure 9 15 Trip Characteristics 100000 0 10000 0 1000 0 100 0 Trip time s 10 0 a 1 0 1 1 2 0 3 0 4 5 6 7 8 9 10 Load current as multiple of full load current nXle a Setting range for UL CSA applications b Setting range for IEC applications c The setting of Z4 t must be outside the range c e g when Z4 6 x Ze tta must be lt 100 s and gt 1 s Publication 825 UMO01B EN P January 2001 Chapter 10 References A Rotary Crusher Application Profile Publication 0825 1 3EN B Waste Water Application Profile Publication 0825 1 4EN C Multifunctional Motor Management Publication 825 BR001B EN P D Smart Motor Manager Relay Selection Guide Publication 825 CA001A EN P E Smart Motor Manager Hot Topics Publication 0825 9 0 F Smart Motor Manager User Manual Publication 0825 5 0 G DeviceNet Communication Card User Manual Publication 0825 5 4 Publication 825 UM001B EN P January 2001 References 10 2 Notes Publication 825 UM001B EN P January 2001 10 3 References Notes Publication 825 UM001B EN P January 2001 ww
34. 01B EN P January 2001 Functions 3 6 Figure 3 3 Entering a Data Value Actual x Set Recorded Enter Values Select Settings Note Hold down the Se ect button to change the values more quickly Table 3 D Display Example of Set Values Menu LCD Range Desaiption a N SET VALUES Mode setting parameters M C FULL LOAD CURR 0 5 2 000 Rated motor current in A 20A M P A N a CT No Yes Primary current transformer in use MV e ed C T RATIO 1 2000 Primary current transformer ratio M LOCKED ROT CURR Locked rotor current as 2 5 12 I 6 xle NS P LOCKED ROT TIME D Maximum permitted time for the rotor to be stalled 1 600 f dde rom cold M P Note For a complete list o f parameters refer to Chapter 5 Publication 825 UM001B EN P January 2001 3 7 Functions Indications of Actual Values In Actual Values mode all operating parameters can be selected and read from the LCD 1 Press Values until ACTUAL VALUES appears on the display 2 Press Se ect Up or Down until the desired information is displayed Figure 3 4 Selecting the Actual Values ACTUAL VALUES Recorded m Enter Values Select Settings I MOTOR 00 Ie Actual ii Change O co Recorded
35. 4 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 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 With the appropriate supply cable rating the supply module is short circuit proof Permissible voltage fluctuation Short circuit protection 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 as per UL CSA pilot duty 240 V V 24 110 125 220 250 380 440 Continuous thermal current A Rated operating current for AC 15 A 3 3 12 Max permissible switching current cos 0 3 AC 15 A 30 30 12 Rated operating current for DC 13 without prot network L R 300 ms A 2 0 3 02 Max rated current of back up fuse A 10A 500V AC Type gG Alarm Relay AL Auxiliary Relays 1 4 5 Contacts fitted 1 N O contact each Continuous thermal current 4A Max permissible switching voltage 400V AC 125 VDC Nominal Operating Current cos Q 1 4 A at 250V AC or 30V DC cos Q9 04 L R 7 ms 2 A at 250 VAC or 30V DC cos Q 1 Max Switching Power 1250 VA 150 W cos Q9 0 4 L R 7 ms
36. 5 D Cat No 825 M Operating Parameters Required Group Option Card LCD Serting Description Cat No 9 ie N SET VALUES Mode Set parameters M FULL LOAD CURR 0 5 2 000 Rated motor current in A 20A J u PRIMARY C T 1 wo ves o Use of the primary NO transformer Main settings c S Current ratio of the primary _ PRIM C T RATIO 1 2009 Current transformer e g u J au 500 A 5 A setting 100 800 A 5 A setting 160 EN LOCKED ROT CURR M ga merid rotor ay starting xle current in Ie 4 Maximum permissible LOCKED ROT TIME 1 600 locked rotor time of motor 0 sec J rom cold Z N Main Thermal trip motor THERMAL TRIP relay no Choice between main MAIN RELAY J relay output relay and no relay f A T i s THERMAL WARNING hermal warning motor On Off amp temp On Off OFF Thermal overload Pickup value for thermal tH WARNING LEVEL 50 99 warning temperature rise as 75 x percent of thermal V 0 ili a utilization E fH WARNING All except Thermal warning ALARM RELAY J main relay Assignment of output relay f Primary CT 1 is set to no the programming menu skips to parameter Locked Rot Curr If Thermal Warning is set to off the programming menu skips to parameter Asymmetry Trip Publication 825 UM001B EN P January 2001 5 5 Setting the Operational Para
37. 60 C 2 140 F If auxiliary relays 2 and 3 are assigned to the communication refer to page 5 16 they cannot be selected here High Overload and Jam When an overload is excessively high and the motor jams unnecessary mechanical and thermal loading of the motor and transmission elements can be avoided by switching the motor off immediately This reduces consequences of accident and loss of production A gradual increase in overload can be detected early and reported e g bearing damage The protective function activates as soon as the motor has started Publication 825 UM001B EN P January 2001 Functions 3 24 Application Conveying systems Mills Mixers Crushers Saws etc Figure 3 11 Function of High Overload and Jam Protection gt t le 5 1 Motor start gt 1 2 J ly Tripping delay 2 Nominal operation 4 Jam protection not active 3 High overload or jam 5 Jam protection active tripping threshold Table 3 M High Overload and Jam Setting Parameters Warning O Trip Function Factory setting Off On Response Level Setting range 1 6 Ie 1 6 Ie Factory setting 2h 24 Ig Setting increments 0 2 Ig 0 2 Ig Tripping Delay Setting range 0 1 5 s 0 04 s Factory setting 0 5 s 0 04 s Setting increments 0 1s Output Relay Selection relays AL 1 5 MR AL 1 5 Factory setting AL MR 5 60 C 23
38. 9 Publication 825 UM001B EN P January 2001 Assembly and Installation 4 8 Control Circuits Figure 4 11 Smart Motor Manager Basic Unit Supply 9 A1 0 A14 r p Y11 p l Emerg Start Y12 EM Disable Settings con m Y21 Remote Reset _______o Y22 13 gt _ ___ 14 o 13 14 o UR Supply AC or DC No fuse needed Emergency override of thermal trip Emergency start Push button key switch Disable settings and keys 9 Wire jumper switch key switch Remote reset Push button key switch Alarm relay AL non fail safe connection Factory setting IEC 400V AC 125V DC UL CSA 240V AC 125V DC Alarm relay AL electrically held connection from V2 18 selectable IEC 400 VA 125V DC UL CSA 240V AC 125V DC 95 0 Af 96 9 97 Output relay MR in electrically held A connection Factory setting 97 98 9 95 6 96 0 External Internal Q Setting via communication IEC 400V AC 125V DC UL CSA 240V AC 125V DC Output relay MR in non fail safe connection IEC 400V AC 125V DC UL CSA 240V AC 125V DC is also disabled as well as Test and Reset The remote reset is always active Publication 825 UM001B EN P January 2001 4 9 Assembly and Installation Figure 4 12 Cat No 825 MST Option Card 23 9 Auxiliary relay 1 Aux IEC 400V AC
39. A complete check of the Smart Motor Manager s components can be performed with the test unit and a 3 phase current source Test Unit With the test unit all protective functions set on the Smart Motor Manager can be checked including the pickup levels and tripping delays Test with 3 Phase Current Source ATTENTION This test should be performed only by qualified personnel Using a 3 phase current source the main circuit any primary current transformer and the current detection module Cat No 825 MCM can be tested Because the functions of the Smart Motor Manager have already been checked with the test unit it is sufficient to supply a current of 1 x 1 after approximately 60 min the thermal utilization reaches 83 As an alternative you can measure the 3 phase currents exactly and compare the readings with the values indicated by the LCD on the Smart Motor Manager Figure 7 1 Test with a 3 Phase Current Source 3 phase J HH O A Ig Measurement of phase currents 825 MCM 825 M 2 4 6 9 e e Connections A if current lt rated motor current ZA e g 20 A when using 825 MCM180 3 Publication 825 UM001B EN P January 2001 7 6 Testing and Maintenance Test with Single Phase Current Source This test should be performed only by qualified personnel ATTENTION ei i de The test with a 3 phase current source described on page 7 5 can also be perf
40. ABLED J disabled Active locked ou SHORT CIRC PROT Not disabled Short circuit protection NOT DISABLED J disabled Active locked ou he programming menu skips to parameter Phase Rever Trip 0 parameter New FLC If Delay Aux Rel 3 is set to off the programming menu skips After Off Delay Aux 3 is set the programming menu skips to parameter Phase Rever Trip If New FLC is set to off the programming menu skips to parameter Disable Function If Primary C T 2 is set to no the programming menu skips to parameter New FLC If Disable Function is set to off the programming menu skips to parameter Phase Rever Trip Publication 825 UM001B EN P January 2001 5 13 Setting the Operational Parameters Table 5 D Cat No 825 M Operating Parameters Continued Required Group Option Card LCD Sening Description Cat No 9 ONDERLOAD PROT No disabled Underload protection NOT DISABLED J disabled Active locked ou START INHIBIT gt Not disabled Limiting starts hour disabled Active locked ou Control input 2 825 MST WOT DISABLED A continued PTC PROT No disabled PTC protection NOT DISABLED J disabled Active locked ou P100 PROT gt No disabled PT100 RTD protection NOT DISABLED J disabled Active locked ou
41. CD Description fo gt SINCE 1 PRV TRIP Time since one trip prior to last trip in hours minutes c H MIN J l N SINCE 2 PRV TRIP Time since two trips prior to last trip in hours minutes kz H MIN J Gi DEI SE T ifs SINCE 3 PRV TRIP me since three trips prior to last trip in hours minutes c7 H MIN J fo N SINCE 4 PRV TRIP Time since four trips prior to last trip in hours minutes kz H MIN J CAUSE LAST TRIP Cause of last trip e g asymmetry ASYMMETRY TRIP J CAUSE 1 PRV TRIP USE 1 Cause of one trip prior to last trip e g asymmetry ASYMMETRY TRIP J A N CAUSE 2 PRV TRIP Cause of two trips prior to last trip e g overcurrent OVERCURRENT TRIP J fe N CAUSE 3 PRV TRIP Cause of three trips prior to last trip e g thermal THERMAL TRIP J CAUSE 4 PRV TRIP 4 Cause of four trips prior to last trip e g thermistor PTC TRIP J rA N SINCE EMG START Time elapsed since last emergency start in hours minutes kz H MIN J fe N SINCE POWER OFF Time elapsed since last power failure in hours minutes H MIN p OURATION POW OFF Duration of power failure in hours minutes c H MIN J BEF LAST TRIP Motor current before last trip as a percentage of rated service current Ue 9b JE Short circuit 999 wee P A N AS BEF LAST TRIP Asymmetry before last trip in percent 0 c EF BEF LAST TRIP Earth ground fault current before last trip as percentage of rated current Or m T
42. Ii Figure 3 18 Network Earthed through a High Impedance Earth Ground Fault on the Motor Leads The basic unit measures the vector sum of the earth currents through C y and the earthing resistance R Compensated network The basic unit measures the vector sum of the earth currents through C y and the compensating coil L MEM M1 3 AC Td Ka fe NC 3 p L R ONA l T Figure 3 19 Isolated Network Earth Ground Fault in the Motor The nearer the fault is to the motor star point the smaller the fault current T 825 M fe du ae u U I MT 3 As p NK I CILE i MR o IH Figure 3 20 Network Earthed through a High Impedance Earth Ground Fault on the Motor The basic unit measures vector sum of the earth currents through Cy and the earthing resistance R Compensated network The basic unit measures the vector sum of the earth currents through C y and the compensating coil L The nearer the fault is to the motor star point the smaller the fault current M1 _ 3 AC redd ki PM Lo hs Us Us HER 3 NR Lust ded L a 2B n Us m Publication 825 UM001B EN P January 2001 3 33 Functions Limiting the Number of Starts per Hour Start Lockout Function When the set number of starts is reached and the motor is switched off a new start is prevented Depending on its setting e
43. Installation 4 12 Option Communication Only one of the following options can be inserted at a time ATTENTION Cat No 825 MDN for DeviceNet Connection Refer to Publication 825 UM002A US P For more DeviceNet components refer to Publication B113 Cat No 3600 RIO for RI O Connection Refer to ProSoft 3600 RIO User Manual Cat No 3600 MBS for Modbus Connection Refer to ProSoft 3600 MBS User Manual Publication 825 UM001B EN P January 2001 Chapter 5 Setting the Operational Parameters Menu Overview All operating parameters can easily be set or altered at any time using the four operating keys on the front of the unit This procedure is described in Chapter 5 ATTENTION All parameters of option cards can be programmed set even when the option cards are not installed Verify product configuration before commissioning Main Settings The main settings have to be individually set for each motor Table 5 A Main Settings Parameter Setting range Factory setting Rated motor current or service current J 0 5 2 000 A 20A Current ratio of primary current transformer 9 1 2 000 1 Locked rotor current 2 5 12 Ig 6 Ie Locked rotor time 1 600 s 10s Q Accessing this parameter requires that the parameter Primary CT be set to yes O f instead of the permissible locked rotor time the maximum starting time is known the approximate locked rotor time is calculated as follows Starting tim
44. M 220 230V AC DC R 27kO 5W 110 120V AC DC R 12kO 4W I 24 V AC DC Y41 Y42 825 MST For setting the second current speed IT refer to Chapter 5 Control input 2 Publication 825 UM001B EN P January 2001 9 7 X Applications Wiring Two Speed Motor 0 5 A lt Speed I lt 20 A lt Speed II lt 180 A Main Circuit Figure 9 8 Two Speed Application Utilizing 825 MCM180 L N L1 L2 L3 R 24 V AC DC n L an nk p A X REN 1 3 5h Y41 Y42 825 MCM ii toi ot gn og 825 MST LET SE EIS ty IN 1t 2 4 6 a b C M 3 a b c 220 230V AC DC R 27kO 5W 110 120V AC DC R 12kQ 4W 0 5 A lt Speed I lt 20 A Motor supply cables loop n times through 825 MCM180 until n x J 2 20 A Current setting 825 M n x J I 20 A lt Speed I lt 180A Motor supply cables loop once through 825 MCM180 Current setting 825 M J Il For setting the second rated current speed IT refer to Chapter 5 Control input 2 Publication 825 UM001B EN P January 2001 Applications Wiring 9 8 Two Speed Motors with Primary Current Transformer When a primary current transformer is used two speed motors of any rating can be protected Primary Circuit Figure 9 9 Two Speed Application Utilizing Primary Current Transformer 220 230V AC DC R 27kQ 5W 110 120V AC DC R 12kQ 4W
45. M001B EN P January 2001 5 7 Setting the Operational Parameters Table 5 D Cat No 825 M Operating Parameters Continued Required 2 Group Option Card LCD Setting Description Cat No 9 Ya Earth ground fault EF CORE TRIP On Off protection core balance OFF J transformer On Off CORE C T RATIO 1 2 000 Core balance transformer 1 e current ratio S J Pa N Earth ground fault trip EF C TRIP LEVEL 1 ij 3 mi core balance transformer dA NOD Tripping level c N Earth ground fault trip EF C TRIP TIME 0 1 5 core balance transformer 0 50 sec v Tripping delay Earth ground fault 825 MST 5 ix ami ne uS EF CORE TRIP All relays transformer MAIN RELAY J Assignment of output relay c Earth ground faul EF C WARNING On Off warning core balance OFF transformer On Off Earth ground faul EF C WARN LEVEL 5 999 mA warning core balance 1 00 50 00 A transformer 900 mA Tripping level c ES _ Earth ground faul EF C WARNING All see n warning leor balance ALARM RELAY J transformer Pa n SHORT CIRC TRIP Short circuit protection OFF On Off On Off h v motors only Xx 4 Short circuit tri SC TRIP LEVEL Let p 10 00 x le 4 4 0 12 0 Tripping level I Short circuit 825 MST ye NN TE SC TRIP TIME 20 999 Shortcirc
46. Overload Setting Parameters 3 21 Protection Against Thermal Overload 3 22 Asymmetry Phase Unbalance Setting Parameters i ces esee Y RYE 3 23 High Overload and Jam Setting Parameters 3 24 Underload Setting Parametets 0000 3 26 Earth Ground Fault Holmgreen Residual Setting Parameters sisse RE dane eee 3 28 Core Balance Current Transformer Setting Parameters 0 0 eee 3 29 Earth Ground Fault Core Balance Setting Param ter oriri couha eee eee 3 29 Starts per Hour Setting Parameters 3 33 Monitoring Start Time Setting Parameters 3 35 Warm Start Setting Parameters llle 3 38 Alarm Examples a ese esee eere has EE PER RS 3 41 Reset Setting Parameters 0 0 2 0 000 c eee eee 3 42 Short Circuit Setting Parametets 00 3 44 Publication 825 UM001B EN P January 2001 Table 3 X Table 3 Y Table 3 Z Table 3 AA Table 3 AB Table 3 AC Table 3 AD Table 3 AE Table 3 AF Table 4 A Table 4 B Table 4 C Table 5 A Table 5 B Table 5 C Table 5 D Table 6 A Table 7 A Table 8 A Table of Contents ix Stalling during Start Setting Parameters 3 45 PTC Setting Parameters 3 46 Sensor Measuring Circuit Specifications 3 47 Phase Sequence Setting Parametets 3 54 Phase Failure Setting Parameters 3 54 Star Delta Wye Delta Starting Setting Parameters i i see d EIE ei
47. RR HESUSIPRAI 11 3 5 1 3 5 1 3 5 MV A1 A1 A1 KH A Vd K2D mess ky M VA e 2 4 6 2 4 2 4 6 LOCKED ROT CURR Tey Xe V H Ui 825 MCM 825 M F1 LOCKED ROT TIME fga sec U1 vi W1 U1 Converter module s d Cat No 825 MCM2 M Cat No 825 MCM20 A j Cat No 825 MCM180 START TIME gt gay Sec Cat No 825 MCM630 T U2 v2 We Cat No 825 MCM630N Core balance installation position Control Circuit Figure 9 4 Control by Momentary Contact F7 Us K1 Contactor L1 7 F1 Electronic control and protection soc 4 system Bulletin 825 with Cat No 825 MLV option card 1 On push button Ste Ki SO Off push button H Us Control voltage po San H1 Indicator Contactor closed r 2 997 Al tS o H2 Indicator 825 M tripped Ft MR f ALV jezsw MR Main relay do oo a etu J AL Alarm relay 96 198 JAZ i14 H3 Indicator Alarm Warning ss e EM F1 825 MLV DEAD NR NE 54 64 s ar A Y dra a H2 HQ H3 L2 F8 A2 JA2 a2 i i K3 Ku Ki A D H Publication 825 UM001B EN P January 2001 Applications Wiring 9 4 Short Circuit Protection of Medium High Voltage Motors Main Circuit with Cat No 825 MST Option Card 3 Phase Current Evaluation Figure 9 5 Basic Unit for Short Circuit Protection i L2 13 Variants e 2 phase current evaluation aub epe e 2 phase current evaluation and e
48. RT 3 Ifthe thermal release has tripped it can now be reset 4 Ifthe maximum number of starts per hour has been reached the counter has one start deducted 5 Start the motor 6 As soon as the motor starts the stator winding memory will be set to zero copper losses only Do not leave Y11 Y12 bridged because each start will reset the ATTENTION i y copper memory Publication 825 UM001B EN P January 2001 3 39 Functions Additional procedure when PT100 and or PTC are installed 1 Disable PTC and or PT100 SET VALUES j X A PrC TRIP D OFF Xe E PT100 1 6 TRIP OFF MV A 2 Alternatively the Smart Motor Manager can be set up such that inputs 1 and 2 deactivate the PTC and or PT100 tripping This can be achieved with a separate switch or a separate set of contacts on the key switch refer to page 3 52 The input should remain activated until the temperatures return to normal LED Alarm and Trip Indicator The LED indicator on the front of the Smart Motor Manager differentiates between two kinds of indication LED flashing indicates an alarm LED continuously lit indicates a tripped condition Publication 825 UM001B EN P January 2001 Functions 3 40 Connection of the Main Relay MR The main output relay can be operated as electrically held or non fail safe Flectrically Held Mode Supply Off Supply On Supply On and Trip 95 96 97 A
49. able 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 microprocessot 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 ef Cat No 825 MLV PT100 QD C
50. al data Set Setting mode set modify store parameters Recorded Indication of statistical data Select Select function and enter change operating parameter Settings Enable entry Change and memorize Enter Test Verifies operation of Smart Motor Manager Reset Enables the Smart Motor Manager after a trip eo eoo0 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 4 60 C 23 140 F Storage 40 4 60 C 40 140 F Transport 40 4 85 C 40 185 F Damp heat IEC 68 2 3 Climatic Withstand 40 C 104 F 92 relative humidity 56 days Climatic cycling IEC 68 2 30 825 M enclosed in panel 25 40 C 77 104 F 21 cycles Enclosure Protection Class IP65 Terminals as per IEC 68 2 6 as per IEC 68 2 27 IP20 Resistance to Vibration 10 150 Hz 3G Resistance to Shock 30 G shock duration 18 ms half a sine wave in x y z directions Publication 825 UMO01B EN P January 2001 2 6 Equipment Description Table 2 B Nominal Rated Voltages U 825 d t D 825 825 MCM180 Primary Detection Circuit 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 re
51. arth ground fault i protection with core balance transformer U1 Converter module Cat No 825 MCM2 Cat No 825 MCM20 3 5 F1 U2 Main current transformer 825 MCM 825 M A5 Aor A 1A For choice refer to Chapter 2 4 6 Publication 825 UM001B EN P January 2001 9 5 Applications Wiring Control Circuit Figure 9 6 Control by Momentary Contact Circuit breaker Shunt trip coil Contactor Bulletin 825 Electronic control and protection system On push button 0 Off push button Us Control voltage H Indicator Contactor closed H2 Indicator 825 M tripped except for short circuit protection MR Mainrelay AL Alarm relay H3 Indicator Alarm Warning 1 Aux relay short circuit indication SAE8 Converter Module 825 MCM2 825 MCM20 825 MCM180 825 MCM630 or F7 Li Us sot f Sa Siti K aM r4 95 nu 28 AL Fi ai 825 M an nC mo T Te i owl NE KIZI HACH RHI L2 F8 E 8 N E3S Two Speed Motors The following ranges are possible for speeds I and II Speed I II 0 5 25A with 25 20A with 20 180A with 160 680A with Publication 825 UM001B EN P January 2001 825 MCM630N Applications Wiring 9 6 Main Circuit Figure 9 7 Two Speed Application L1 L2 L3 825 MCM 825 M Utilizing One 825 MC
52. at No 825 MMV Communication Communication Network Cat No 825 MST N Thermal utilization module n N 4 20 mA Core Balance Current Transformer MEN o Converter module Available Communications Cards Cat No 825 MDN DeviceNet Cat No 3600 RIO Remote I O Cat No 3600 MBS Modbus 9 Cat No 825 MPB PROFIBUS FMS O Available from Prosoft Technology Inc not an Allen Bradley product References to third part products are provided for informational purposes only Prosoft Technology Inc is solely responsible for the accuracy of information supply and support of this product For further information regarding this particular referenced product please contact Prosoft Technology Inc in the U S at 661 664 7208 or your local Prosoft Technology Inc distributor Publication 825 UM001B EN P January 2001 2 3 Equipment Description Block Diagram Figure 2 2 Block Diagram Od r z adW Sze san oo9 OlH 009 NaW sze ee ay d sl E Pee Sere es Lit O0LL
53. by the earthing resistor through the fault location In the event of an earth fault on the power supply side of the measuring location current transformer installation location the basic unit measures the component of the earth current flowing via Cy The response sensitivity must be selected such that in this case the Smart Motor Manager does not trip On the other hand earth fault detection by the Smart Motor Manager should be as sensitive as possible since in the case of earth faults in the motor windings the displacement voltage becomes smaller the closer the fault location is to the neutral point The fault current decreases proportionally Normally a response threshold is selected that is greater than 5 10 of the current that flows in the event of a dead earth fault at the motor terminals Neutralized Networks Systems with earth fault neutralizers resonant earth system Petersen coil Although compensated industrial networks are rare their main features are shown in Figure 3 16 Figure 3 18 and Figure 3 20 Under fully compensated conditions the compensation reactor supplies a current of the same magnitude as that of the capacitive fault current but phase shifted by 180 so that only a small ohmic residual current flows via the fault location Publication 825 UM001B EN P January 2001 3 31 Functions Schematic Representation of Various Network Configurations and Earth Ground Fault Locations The earth ground fault
54. c 10 30 s 10000 0 1000 0 From cold without pre load 10s 20s 30s 100 0 a o E 2 E 10 0 10s 20s 30s 10 From warm pre load 1x amp 0 1 1 0 1 1 2 0 3 0 4 5 7 89 10 Load current as multiple of full load current nXle Publication 825 UMO01B EN P January 2001 Functions 3 20 Figure 3 9 Trip Characteristics 40 100 s Trip time s 100000 0 10000 0 1000 100 0 10 0 0 1 0 1 1 Load current as multiple of full load current From cold without pre load 40s 60s 100s 40s 60s 100s From warm pre load 1x e 2 0 3 0 4 5 67 89 10 For UL CSA applications refer to page 9 14 Publication 825 UMO001B EN P January 2001 3 21 Functions Table 3 J Thermal Overload Setting Parameters Detection Module 825 MCM2 825 MCM20 825 MCM180 825 MCM630 825 MCM630N Rated Current Setting range 0 5 25A0 25 20A 0 20 180A 160 630A 160 630 A Factory setting 20A 20A 20A 20A 20A Setting increments 0 01 2A 0 1 2A 1A 2A 2A Locked Rotor Current Multiple of Rated Current Setting range 2 5 12 I Factory setting 6 Ie Setting increments 0 1 Ig Locked Rotor Time Admissible Locked Rotor Time of Cold Motor Setting range 1 600 s Factory setting 10
55. c E Z Cooling constant ratio COOL CONST RATIO 1 0 10 0 between motor off and 2 5 J motor on PTC TRIP On Off Thermistor protection PTC ON On Of b PTC temperature 825 MST PTC TRIP B All relavs PTC trip Sensors MAIN RELAY y Assignment of output relay PTC RESET Manual Reset PTC trip MANUAL J auto Manual automatic CONTROLINPUT 1 onore Control input 1 OFF y On Of Ya Timer function of auxiliary DELAY AUX REL 2 On Off amp relay 2 OFF dj On Of Control input 1 825 MST ON DELAY AUX 2 gt 0 240 On delay of auxiliary sec J relay 2 OFF DELAY AUX 2 B 0 240 Off delay of auxiliary l2 sec J relay 2 f PIC Trip is set to off the programming menu skips to parameter Control Input 1 O f Control Input 1 is set to off the programming menu skips to parameter Control Input 2 f Delay Aux Rel 2 is set to off the programming menu skips to parameter Speed Switch o After Off Delay Aux 2 is set the programming menu skips to parameter Control Input 2 Publication 825 UM001B EN P January 2001 5 11 Setting the Operation al Parameters Table 5 D Cat No 825 M Operating Parameters Continued Required Settin Group Option Card LCD R g Description Cat No ange Speed switch stop indicator locked rotor during start a SWITCH On Off 9 On Off and or auxiliary contact OFF n of motor contactor motor switc
56. c Unit and Converter Module for setting refer to Chapter 5 T2 Core balance transformer Earth Ground Current 5 mA 60A Current ratio of core balance current transformer 1 2000 1 Output from core balance current transformer 0 500 mA Publication 825 UM001B EN P January 2001 Applications Wiring 9 10 Basic Unit and Converter Module with Core Balance Current Transformer Main Circuit Figure 9 11 Typical Application Utilizing Core Balance Current Transformer Li E2 L3 Converter module 825 MCM2 825 MCM20 825 MCM180 825 MCM630 825 MCM630N 1 3 5 825 MCM 2 4 6 825 M IH M T2 Core balance transformer Earth Ground Current 5 mA 60A Current ratio of core balance current transformer 1 2 000 1 Output from core balance current transformer 0 500 mA Publication 825 UM001B EN P January 2001 9 11 Applications Wiring Motors with Low Idling Current lt 20 Main Circuit Figure 9 12 Application with Low Idling Current L1 L2 L3 b 220 230V AC DC R 27KQ 5W R 110 120V AC DC R 12kQ 4W 825 MCM 825 M 24 V AC DC FORME Y31 Y32 825 MST Display di lt 20 IE e Motor switched on e Motor current lt 20 I Settings CONTROL INPUT 1 ON SPEED SWITCH ON If motors have an operational idling current of less than 20 I then the information motor
57. ct for the majority of self cooled AC motors For separately ventilated and special motors and those which respond very quickly or very slowly you may have to modify the cooling factor Publication 825 UM001B EN P January 2001 Functions 3 18 Indication of the Time to Tripping LCD IN sec This feature provides continuous indication of the time remaining before tripping when in an overload condition This enables you to intervene before tripping occurs Blank display means Time gt 9 999 s Indication of the Time until the Thermal Trip can be Reset LCD m IN sec Following a thermal trip the basic unit may not be reset until the reset threshold has been reached This is set to a temperature rise of 50 in the factory Adjustable Setting Characteristic The degree of inertia can be set to match the properties of the motor A suitable reference value among others is the admissible locked rotor time of the cold motor in conjunction with the associated current This makes it possible to protect motors that are thermally very fast or very slow See Figure 3 8 Figure 3 9 and Figure 9 15 The thermal capacity of the iron is particularly important at small overloads Allowing for this in the simulation enables the overload reserves of the motor to be utilized without risking a premature protective trip Publication 825 UM001B EN P January 2001 3 19 Functions Figure 3 8 Trip Characteristi
58. current 0 4VA Continuous thermal current 0 5A Thermal current 1 s duration 25A Frequency of input current 50 60 Hz A core balance current transformer current ratio 100 1 is available and might suit most applications Max earth ground fault current 30 A Short Circuit Protection Choosing a Circuit Breaker or Fuse and Associated Contactor The branch circuit short circuit protective device series circuit breaker or fuse must assure that the motor can start while interrupting short circuit currents rapidly enough to prevent damage to the installation To aid in the latter the fuse rating should be as low as possible The lowest possible fuse rating depends on the starting current of the motor and the tripping time set on the Smart Motor Manager The Short Circuit Coordination of the Starter Must Always be Taken into Account The contactor receives its tripping signal when the Smart Motor Manager basic unit trips The basic unit interrupts all current up to the point of intersection with the time current characteristics of the circuit breaker or fuse When starting large motors the main contacts on the contactor are subjected to high thermal loads If the motor starting time exceeds a certain limit the maximum permissible current has to be reduced The rating of the fuse or contactor must also allow for the prospective short circuit current The Bulletin 825 converter modules are short circuit proof The coordination grad
59. current characteristic after preloading with 1x when the trip time from cold t6x 10 s and WARM START function is disabled c Time current characteristic after preloading with 1x thermal utilization or winding temperature 82 when the trip time from cold t6x 10 s and WARM START function is enabled setting WARM TRIP TIME 70 of the trip time from cold The WARM TRIP TIME 7 3 s for 6x1 is higher than 70 x 10 7 s because it depends on the winding and iron temperature which are not at their highest value If the thermal utilization winding temperature is higher than 82 the WARM START function is automatically disabled If lower than 82 the WARM TRIP TIME depends on the winding and iron temperature and its range is 7 3 10 s d Publication 825 UM001B EN P January 2001 Functions 3 38 Table 3 T Warm Start Setting Parameters Function Factory setting Off Tripping Time from Warm State as a Percentage of Tripping Time from Cold State Setting Setting range 50 100 Factory setting 70 Setting steps 10 Minimum Time Between Two Warm Starts Setting Setting range 4 60 min Factory setting 60 min Setting steps 1 min Emergency Override of Thermal Trip Emergency Start Suggested Procedure Procedure when PT100 and PTC are not used 1 Momentarily bridge terminals Y11 Y12 voltage free contact A spring return key switch is recommended 2 LCD flashes EMERGENCY STA
60. current is below 1 2 FLC then the Monitoring the Start Time function must be activated After the set max starting Time has elapsed the High Overload Stall function will become active Applications Slip ring motors e Soft starters Motor protection with non fail safe mode after a control voltage failure Warm Start Function The motor windings may be heated for a short time above the permissible temperature limit This applies particularly to rotor critical motors The temperature that is permitted for this short period is approximately 250 C and is thus appreciably higher than the continuous operating temperature of 100 150 C This means that a motor warm from running has a relatively long permissible starting time This property of the motor can be used with the Smart Motor Manager which is factory set for one warm start per hour The tripping time is then 70 of that from cold The warm start function is switched off in the factory As additional protection for the motor too many warm starts can be prevented by the limiting the number of starts per hour function Publication 825 UM001B EN P January 2001 Functions 3 36 Figure 3 23 Current and Temperature Curves for Warm and Cold Motor Starts and the Smart Motor Manager Tripping Limits I In 1 2 3 4 Te Ete gt t 9 01 4 de z AUN pu N T h tw tw gt tw e Ip Starting c
61. current measured by the Smart Motor Manager with the aid of a core balance current transformer is dependent on the power supply network configuration and on the location of the earth fault The following diagrams indicate the relationships in the various applications The symbols used have the following meanings Cy Earth capacitance of phase conductor on power supply system side Cy Earth capacitance of motor including supply conductors between current transformer and motor L Compensating coil High earthing resistance T Transformer Ip Earth ground fault current Figure 3 15 Isolated Network Earth Fault on the Network Side The basic unit measures the earth current component through Cy 825 M ia Sd 1 i i a 7 U2 Ut poet 3 _ J W xL EN j S ss L 79 CN P IE c 0M Liy Figure 3 16 Network Earthed through a High Impedance Earth Fault on the Network Side The basic unit measures the earth current component through Cy Compensated network Through the fault a small current flows given by the vector sum of the earth currents 825 M Publication 825 UM001B EN P January 2001 Functions 3 32 Figure 3 17 Isolated network Earth Ground Fault on the Leads on the Motor Side The basic unit measures the earth current component through Cy ssa Kh M1_ 3 AC EX Ki a ES 2 d i AN 4 3 pH Y CN T p IE oL s CM y
62. d 1 500 rpm 3 Approximate value for 6 pole motors speed 1 000 rpm 4 Approximate value for 8 pole motors speed 750 rpm Py Rated output power in service Locked Rotor Time Normal setting of locked rotor time i e when using standard motors or permissible locked rotor time is known The setting of the locked rotor time must be equal to or less than the value quoted by the manufacturet The current converter factory setting is 10 s If no application details are available and the starting conditions are normal leave the setting at 10 s LCD LOCKED ROT TIME 10 sec Publication 825 UM001B EN P January 2001 6 5 Commissioning and Operation Setting locked rotor time to a minimum level This procedure enables you to set the locked rotor time to a minimum so that the motor and installation are better protected a Choose a locked rotor time that is less than the probable starting time e g 2 s for thermally rapid underwater motors b Start the motor and allow it to cool down after a thermal trip c Increase the locked rotor time until starting succeeds reliably Setting the locked rotor time when the motor starting time is known EXAMPLE Known starting time of the motor is 74 15 sec Locked rotor time to be set d tA 15 approximately 157 147 11s Setting the locked rotor time with the aid of the indication of thermal utilization Basic Unit ACTUAL VALUES display LCD UTILIZ 00 Set
63. d Actions Continued LCD pe ERROR wo Designation Converter module cannot be correctly recognized Possible Causes Link between basic unit and converter module defective Actions Check link between basic unit and converter module and replace if necessary Switch supply off and on again Fault in basic unit c If the fault cannot be remedied send the unit back to the factory for repair Rated current Converter module rated current does not agree with basic unit setting Check setting FULL LOAD CURR and converter module OUT OF RANGE and setting do Wrong converter module Loren PORBERCONVETIEL not agree Press Values until SET Wrong setting Values on LCD correct FULL LOAD CURR within about 5 s Press Reset ERROR ACT VALUES Error in actual Data could not be saved when Check power supply J values supply last interrupted If the fault repeatedly occurs send the unit back to the factory or repair ERROR REC VALUES Send the basic unit back to the f J Rardware fauli actory for repair Overloaded Reduce load Transported material jammed Switch off installation remedy p J trouble Mechanical damage bearings etc Repair the damage Settings of rated current or CURES Det ROT TIME to nn WARNING i Thermal tripping time too low permissible motor values warning Interrupted start moto Wait u
64. d emam i meisde PEA qiu erozio 9 L OOLLd ELL ZLL LLE AWIN S28 10 ATN SZ8 l iyl 891049 H 7 i E 7 J 7 E E z E es anej oseud c ejo1 Aueyixny p9 c9 L 3 A JET 1 p Kejo reyxny ps eg e eouenbes cel et D Pm fia stn att ar uu m E eil queg End eu de Od OV A vc s TY PHERB qu im OG OV rz rs idmoBoeuy 7 7 b vuroz v PERS p i Aejos Aieiixny pp ep gt a Jojsiuuou ZL LL eit kejas Aueyixny eyes t O ILSW Sz8 p P wnejuue3 909 1 3 L Aejau Avewxny vz ez i3 _ P S jv ejeiuuelv vPL EL b Se in tnde Jeso1 ejouiaH ZZA c in EA WOW YW eje1 uren 36 26 3 VEDI C 49 04 U0D Gz8 90 56 sbunies e ELA H s6um s ejqesid AR 58 dup Buruse yy uejs Aouebiows a A a21 uonejodo Ajddng e HR INNOCENS eer a rc utm E aan Publication 825 UM001B EN P January 2001 2 4 Equipment Description Operating Elements The Smart Motor Manager is very easy to operate All functions data and tests can be entered executed or displayed using the six membrane keys and the single line LCD which displays all available data and functions Figure 2 3 Front View with Operating Elements Bradley SMART MOTOR MANAGER AB Anen 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 operation
65. d 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 Ej of a Motor when Winding is Continuously Overheated Em Ey Average motor life A m 7 100 Og Temperature limit of the insulation 70 50 25 0 UG 5K 10K 15K 20K Rotor Temperature The rotors of squitrel 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 installati
66. derations 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 PP 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 Requitements and Tests For specific information required by EN 61131 2 refer to the approptiate sections in this publication as well as the Allen Bradley pub
67. ductor Technique eee eee eee t2 Basic Unit and Converter Module with Primary Current Transformer 2 Phase Current Evaluation 0 0 0 cece een 9 13 Time Cutrent Characteristic of Bulletin 825 Smart Motor Manager 9 14 Chapter 10 References Figures Figure 1 1 Bulletin 825 Smart Motor Manager 0 1 1 Figure 1 2 Operating Characteristics of an AC Motor 1 3 Figure 1 3 AC Current Profile of a Motor Starting Directo ine tian bie bb ener beri Y es 1 4 Figure 1 4 Temperature Rise Characteristics of Motor Windings 0 00 eee eee 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 liiis 2 2 Figure 2 2 Block Diagtam 2er needa epe danse hes 2 3 Figure 2 3 Front View with Operating Elements 2 4 Figure 3 1 Setting Mode ess cre etn reete p b 3 5 Figure 3 2 Menu Select ons 4i diee e DUMP S ae d s 3 5 Figure 3 3 Entering a Data Value lisse 3 6 Figure 3 4 Selecting the Actual Values 00 0 0000 3 7 Figure 3 5 Selecting Recorded Data lleeessse sess 3 8 Figure 3 6 Basic Unit Test Button 0 0 cee eee 3 9 Figure 3 7 Two Body Simulation of the Heating Up Of a MOtOE sectator RENE T Wise ea ER HEX 3 17 Figure 3 8 Trip Characteristic 10 30 s nananana asss 3 19 Publication 825 UM001B EN P January 2001 vi Table of Content
68. e If auxiliary relays 2 and 3 are assigned to the communication refer to page 5 16 they cannot be selected here Publication 825 UM001B EN P January 2001 3 27 Functions Earth Ground Fault The insulation in motors is often damaged by high voltage surges which may be caused by lightning strikes switching operations in the network capacitor discharges and power electronics equipment Other causes are aging and sustained or cyclic overloading as well as mechanical vibration and the entry of foreign objects Most insulation faults result in leakage to the grounded parts of the machine In earthed grounded networks the fault current can rapidly rise to a very high value Depending on the type of network and its requirements monitoring of earth ground faults is performed either by the residual method or by using a cote balance current transformer Earth Ground Fault Protection by the Holmgreen Method Residual Method Solidly Earthed Networks To detect an earth ground fault current in either a solidly earthed grounded network or one that is earthed through a low impedance the currents in each of the three pole conductors are measured In a healthy motor this sum is zero If a current is flowing to the frame of the motor and thus to earth a neutral current Jp proportional to the fault current is produced at the neutral of the current transformer This neutral current is detected by the earth gr
69. e Locked rotor time 14 All other parameters such as overcurrent underload asymmetry etc are set in the factory to values that are correct for the majority of applications These factory set values can be changed if requirements differ The same applies to special settings Publication 825 UM001B EN P January 2001 Setting the Operational Parameters 5 2 Special Settings These values are factory set to values that are correct for the majority of applications and should only be changed when requirements are outside the parameters allowed for by the factory settings Table 5 B Special Settings Parameter Connection of main relay MR Setting range Electrically held non fail safe Factory setting Electrically held Reset of thermal trip Manual auto Manual Reset at 96 thermal utilization 10 10096 5096 Reset PTC trip Manual auto Manual Cooling constant ratio motor off on 1 10 2 5 Motor insulation class 9 B E F B Motor insulation class needs to and can be set only if PT100 7 RTD is included in the thermal image Do not exceed the permissible va ATTENTION Lo one manufacturer ues quoted by the motor Publication 825 UM001B EN P January 2001 5 3 Setting the Operational Parameters Table 5 C Communication Settings Parameter Setting Range Factory Setting DeviceNet Station number MAC ID 0 63 2 Baud rate 125 250 500 kbaud 0 2 2 Rem
70. e 3 AD PT100 Temperature Detector Resistance per IEC 751 Temperature C Resistance Q 0 100 00 50 119 40 100 138 50 150 157 31 200 175 84 Sensors that are not connected must be switched off Temperature sensors 1 6 monitor the actual stator or bearing temperatures The temperature is continuously indicated in C The alarm and tripping temperatures can be set as desired Applications Large low voltage motors Medium and high voltage motors At high ambient temperatures When cooling is obstructed Publication 825 UM001B EN P January 2001 3 57 Functions Table 3 AE PT100 RTD Setting Parameters Warning Trip Function Fadoyseting T 0f Of Response Level Factory setting 50 C Setting steps 1 C Tripping Delay Fadoyseting 8s 8s Output Relay O Selection relay ALAH 43 MRAL 43 Factory setting AL MR If auxiliary relays 2 and 3 are assigned to the communication refer to page 5 16 they cannot be selected here It is essential to set the Warning response level to a value less than ATTENTION i the Trip response level PT100 7 Temperature Sensor RTD The PT100 7 temperature sensor measures the ambient temperature or the coolant in the motor and indicates it in C The Smart Motor Manager takes into account the temperature of the coolant in the thermal image The motor and the i
71. e warmer winding into the cooler iron until the temperature difference is minimal Figure 1 4 Temperature Rise Characteristics of Motor Windings M Og Temperature limit of the insulation s 1 re Ox Coolant temperature veld Os Temperature rise at start Ve Temperature rise when operated d continuously at rated current tA Starting time j gt t b Permitted stalling time Ota te Temperature rise in a motor winding During the starting time t 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 patticular attention must be paid to adhering to the permitted operating temperature for long petiods of time Note that overtemperatures of short duration an
72. e warning is actuated as soon as the underload threshold is reached Application Submersible pumps e Fans Conveyor systems Detection of fractures in mechanical transmission system Publication 825 UM001B EN P January 2001 Functions 3 26 Figure 3 12 Function of Underload Protection 1 Start 2 Nominal operation 3 Underload operation t Starting time gt t r Tripping threshold t Delayed activation underload protection not active t Tripping delay I Rated current tj Warning Table 3 N Underload Setting Parameters Warning Trip Function Factory setting Off On Response Level Setting range eo 25 10096 I Factory setting e 75 Setting increments e 596 Tripping Delay Setting range 1 60 s 0 2 s 40 4 s Factory setting 10s Setting increments 1s Delayed Activation of Underload Protection Setting range 0 240 s 0 4 s 0 8 s Factory setting Os Setting increments 1s Output Relay Selection relays AL 1 5 MR AL 1 5 Factory setting AL MR 5 60 C 23 140 F For warning the set Response Level is the same as the level set for tripping If the starting current is below 1 2 FLC then the Monitoring the Start Time function must be ac ivated After the set max starting Time has elapsed the High Overload Stall function will become activ
73. eere 3 55 PT100 Temperature Detector Resistance per DEC Polen ses one Eee se pane aes 3 56 PT100 RTD Setting Parameters 3 57 Motor Insulation Class Setting Parameters 3 58 Cat Nos 825 MCM2 825 MCM 20 825 MCM180 4 3 Cat Nos 825 MCM630 825 MCM630N 4 4 SPECHHICAHONS ose donde adn wha de e ees epe 4 7 Main Settings Leslie ike bee Reef etes EE eS 5 1 Special Settings sos dee eec pe D sedate east 5 2 Communication Settings s 0 0 0 0 cee eee eee 5 3 Cat No 825 M Operating Parameters 5 4 Checking the Actual Values 00 00005 6 6 List of Recorded Values 7 2 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 continu
74. endent of the thermal state of the motor The beginning of a start is recognized by the Smart Motor Manager when the motor current reaches 1 2 J Starting is deemed to have been completed when the motor current is less than 1 1 Ie Applications Installations in which an elevated load or stalling of the drive have to be detected during the starting stage in order to avoid serious damage Possible causes overloaded installation defective bearings or transmission elements Figure 3 22 Monitoring Starting Time lt 1 1 Ie gt t a 1 Motor starting current 2 1 2 J 2 Rated conditions ly Max starting time 3 Tripping if starting lasts too long Publication 825 UM001B EN P January 2001 3 35 Functions Table 3 S Monitoring Start Time Setting Parameters Function Factory setting Off Max Starting Time Setting range 1 240s 0 04 s Factory setting 10 s 0 04 s Setting increments 1s Output Relay Selection relays MR AL 1 5 Factory setting MR 5 60 C 23 140 F If auxiliary relays 2 and 3 are assigned to the communication refer to page 5 16 they cannot be selected here Note With Star Delta Wye Delta starting the total starting time Star and Delta is monitored If immediate switch off is demanded in the event of stalling monitoring must be provided by a zero speed switch function stalling during starting Note If the starting
75. entilated motor when running and at standstill are taken into account by two different time constants After switching off the rapid cooling of the winding to the iron temperature and the subsequent slow cooling of the motor as a whole are simulated The two body simulation can be represented as a capacitance resistance network See Figure 3 7 Figure 3 7 Two Body Simulation of the Heating Up of a Motor feu Iu klg Fe R1 C1 Capacitance representing the heat capacity of the winding adjustable C2 Capacitance representing the heat capacity of the iron an other masses of the machine R1 Resistance representing resistance to heat transfer between winding and iron R2 Resistance representing heat dissipation to the surroundings when stationary R3 Resistance representing heat dissipation to the surroundings when running Poy Input of a current proportional to the copper losses Pre Input of a current proportional to the iron losses S1 Changeover from stationary to running Im Motor current Ig Opposing component caused by asymmetry Donk Allowance for the temperature of the environment coolant optional PT100 7 k Constant factor according to IEC and NEMA Adjustable Ratio of Cooling Constants The ratio of the cooling constant when the motor is at standstill to the cooling constant when it is running allows for the difference in cooling in these states The cooling constant ratio is set to 2 5 in the factory This value is corre
76. erted 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 Zp Starting current i ta Starting time Ip Rated service hi Ei Hr s current g E e t Time Is M as ARI 5 o yyy NV YO lt ua Oscillogram of switching on a squirrel cage induction motor by direct on line starting The high motor starting current 74 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 ate 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 th
77. eyor systems Mills Mixets Crushers e Saws Cranes Hoists etc Figure 3 26 Stalling During Starting 1 Normal start without hindrance by high overload or stalling Stalling during standing Tripping delay aN le Table 3 X Stalling during Start Setting Parameters Trip Function Factory setting Off Tripping Delay The trip time tsp depends on the trip time to chosen for the overcurrent as Factory setting follows toy lt 400 ms tsp 600 ms toy 2 400 ms tsp toy 400 ms Actuation Message from zero speed switch to control input 1 Motor running 24V AC DC at control input 1 Motor standstill OV AC DC at control input 1 Output Relay Selection relays settable only there Publication 825 UM001B EN P January 2001 Same relay as for function High Overload and Jam Functions 3 46 PTC Thermistor Input Function The thermistor detectors PTCs are embedded in the stator winding of the motor They monitor the actual temperature of the winding Influences independent of the motor current such as ambient temperature obstructed cooling etc are taken into account The detectors and their leads are monitored for short circuit and open circuit Applications As additional protection for Motors above 7 5 kW 10 HP High ambient temperatures dusty environment Varying loads Plugeing etc Table 3 Y PTC Setting Parameters Funct
78. functions associated with ATTENTION option boatds that have not been mounted in the device However these warning and trip functions are not operational unless the corresponding option board is installed Publication 825 UM001B EN P January 2001 3 3 Functions Recorded Values In Recorded values mode all recorded data can be selected and read from the LCD Table 3 C Recorded Values Overview Option Option Display List Card Page Display List Card Page Cat No Cat No 825 M MAIN TIME h min 7 2 CAUSE 2PRV TRIP 7 3 MOTOR RUNNING HR h min 7 2 CAUSE 3PRV TRIP 7 3 SINCE LAST START h min 7 2 CAUSE 4PRV TRIP 7 3 SINCE 1PRV START h min 7 2 SINCE EMG START h min 7 3 SINCE 2PRV START h min 7 2 SINCE POWER OFF h min 7 3 SINCE 3PRV START h min 7 2 DURATION POW OFF hmin 7 3 SINCE 4PRV START h min 7 2 BEF LAST TRIP le 73 SINCE LAST TRIP h min 7 2 AS BEF LAST TRIP 7 3 SINCE 1PRV TRIP h min 1 3 EF BEF LAST TRIP n 7 3 SINCE 2PRV TRIP h min 7 3 MAXTBEFLAST TRIP C 825 MMV 74 SINCE 3PRV TRIP h min 7 3 TH BEF LAST TRIP 74 SINCE 4PRV TRIP h min 7 3 NUMBER START 74 CAUSE LAST TRIP 7 3 NUMBER TRIP TH AS OC EF SC UL 74 CAUSE 1PRV TRIP 1 3 PTC PR PL PT100 Publication 825 UM001B EN P
79. g According to power consumption in leads and measuring circuits Rated frequency 50 60 Hz Burd n 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 3A 24A Thermal current 1 s duration 250A 600A Frequency of input current 50 60 Hz 50 60 Hz General Notes on 825 MCM An open circuit secondary is permitted as the burden is No load Designation according to IEC 60044 part 2 5 Total measurement error percentage installed in the detection module 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 12096 of rated nominal primary current if motor 8796 of 120 rated nominal transformer current With starting current 10 J class 5 P 20 The current transformer error in addition to the basic unit error 25Awith Cat No 825 MCM2 20 A with Cat No 825 MCM20 Publication 825 UM001B EN P January 2001 Equipment Description 2 11 Core Balance Current Transformer Table 2 H Recommended Data for Core Balance Current Transformer minimum detectable earth ground fault Pickup current of basic unit earth ground fault protection Burden Measuring circuit 825 M Nominal ratio Ky Power consumption at max rated
80. h Overload Asymmetry have factory set values which ate correct for most applications Table 3 B Set Values Overview Option Option Parameter List Card Page Parameter List Card Page Cat No Cat No THERMAL TRIP 5 4 THERMAL RESET LEVEL 5 10 THERMAL WARNING 5 4 COOLING CONSTANT RATIO 5 10 ASYMMETRY TRIP 5 5 PTC TRIP 825 MST 5 10 ASYMMETRY WARNING 5 5 PTC RESET 825 MST 5 10 OVERCURRENT TRIP 5 5 CONTROL INPUT 1 5 10 OVERCURRENT WARNING 5 5 DELAY AUX REL 2 5 10 EARTH FAULT PROTECTION 5 6 SPEED SWITCH 825 MST 5 11 EARTH FAULT HOLMGREEN TRIP 5 6 DISABLE FUNCTION 5 11 EARTH FAULT CORE TRIP 825 MST 5 7 CONTROL INPUT 2 5 12 EARTH FAULT CORE WARNING 825 MST 5 7 DELAY AUX REL 3 825 MST 5 12 SHORT CIRCUIT PROTECTION 825 MST 5 7 NEW FULL LOAD CURRENT 5 12 UNDERLOAD TRIP 5 8 PHASE REVERSAL TRIP 5 13 UNDERLOAD WARNING 5 8 PHASE LOSS TRIP RES 5 13 STAR DELTA STARTING 825 MLV 5 8 PT100 PROTECTION WARM STARTING 5 9 PT100 RESET WARNING Re pee NS START INHIBIT 5 11 OUTPUT 4 20 mA 825 MST 5 15 START CONTROL 5 9 STATION NUMBER m 5 16 MAIN RELAY CONNECTION 5 10 REL 22 3 VIA COM 5 16 ALARM RELAY CONNECTION 5 10 CLEAR RECORDED VALUES 5 16 THERMAL RESET 5 10 FACTORY SETTINGS 5 16 All parameters can be set including those
81. hed on for motors with Jm 20 Ip Trip time tsp depends on the trip Z EY time chosen for the overcurrent SS TRIP TIME toy as follows 0 9 SEC J toy 400 ms t4 600 ms toy 2 400 ms tg toy 400ms Ss TRIP B Trip on relay chosen for VAIN RELAY J overcurrent locked rotor DISABLE FUNCTION Y On Off s protective function n OFF J ASYMMETRY PROT No disabled Asymmetry protection NoT DISABLED J disabled Active locked ou Control input 1 P Overcurrent locked rotor continued 825 MST OVERCURRENT PROT nor d neg protection NOT DISABLED j C599 Ative locked ou 2N EARTH FAULT PROT disabled Active locked ou Not disabled Earth fault protection NDERLOAD PROT NOT DISABLED Not disabled Underload protection disabled Active locked ou NOT DISABLED J SHORT CIRC PROT Not disabled Short circuit protection INOT DISABLED J disabled Ac ive ocked ou START INHIBIT Not disabled Limiting starts hour disabled Active locked ou f Speed Switch is set to off f Disable Function is set to off the programming menu ski Publication 825 UM001B EN P the programming menu skips January 2001 0 parameter Disable Function ps to parameter Control Input 2 OT DISABLED J PTC PROT Not disabled PTC protection NOT DISABLED J disabled Active locked ou PT100 PROT gt
82. hen running 7 EF HOLMG TRIP fault Primary current transformer e Correct wiring Holmgreen Wrongly wired residual trip Primary current transformer e Raise pickup threshold saturated High proportion of third Raise pickup threshold to 50 harmonic in star delta or more Trip during start Primary and Correct the wiring core balance EF C WARNING Earth ground core balance transformer wired transformer may only surround fault warning incorrectly the three motor leads with core balance transformer Long motor cable Raise pickup threshold Earth ground TE Earth ground fault in motor winding or cable due to EEGORE TRIE balance e Moisture Eliminate cause transformer Dirt e Mechanical damage Short circuit or earth ground F fault in motor winding or cable Repair damage SHORT CIRC PROT Short circuit Tyi is swi E trip Tip when motor I switched ON Increase trip delay to gt 0 1 s Pickup threshold is lt 74 Set pickup threshold to gt Za Eliminate cause lower pickup Underwater pump running dry threshold if necessary or increase trip delay D WARNING Underload If tripping takes place too soon warning Faulty fan blades after starting increase the start delay TR Torn conveyor belt ig TRIR neeroad P Broken transmission elements _ Eliminate cause Pumping against a closed valve Current setting 7 too high Set correct value Wait until another start is M b permissible Release will be START INHIB TRIP dis
83. i Enter Values Select Settings Table 3 E Display Example of Actual Values Menu LCD Range Description ACTUAL VALUES uH Display of the actual values M P fi N MOTOR A Pager Motor current in A NS fs N TH UTILIZ 0 100 Thermal utilization M J MOTOR j o le 0 20 999 Motor current as percent of rated current V J Note For a complete list o f parameters refer to Chapter 6 Publication 825 UM001B EN P January 2001 Functions 3 8 Applications The Actual Values mode provides Assistance during programming and setup Verification after maintenance or production change Continuous operational supervision Indications of Recorded Values Statistics In Recorded Values mode all recorded data can be selected and read from the LCD 1 Press Values until RECORDED VALUES appears on the display 2 Press Select Up or Down until the desired statistical information is displayed Figure 3 5 Selecting Recorded Data RECORDED VAL Actual a Set Recorded Values Select b Actual 3 lt Set Recorded Values Select Settings Publication 825 UM001B EN P January 2001 3 9 Functions Table 3 F Display Example of Recorded Values LCD Description RECORDED VALUES E U Display of the statistical data A Jl 625 M MAIN TIME Bu
84. ing diagrams for contactors are available on request Publication 825 UM001B EN P January 2001 2 12 Equipment Description Response Supply Voltage Failure If the supply voltage fails the setting data are retained Failure of Supply Voltage gt 30 ms e All energized output relays drop out The LED extinguishes The timer for duration of supply failure starts maximum 8 h The instantaneous set and statistical data are recorded The LCD extinguishes Recovery of the Supply Voltage Initialization routine is started The time of occurrence and the duration of the supply failure are entered into memory The thermal image is calculated and updated All output relays return to the state before the supply failure except for relay 2 and 3 when control is executed via communication LCD and LED activate Publication 825 UM001B EN P January 2001 Equipment Description 2 13 Automatic Recognition of Converter Module The Bulletin 825 regularly checks The link between the basic unit and the converter module e Verifies that the full load current set on the basic unit is within the range of the converter module The supervisory citcuits In the event of a fault the output relay MR trips and the type of fault is displayed on the LCD Table 2 1 Converter Module Related Error Messages Verify Link between basic unit and converter module Sequence After switching on supply S u
85. ing 500 mA 1 0 mA Setting increments 5 mA 0 25 A Tripping Delay Setting range 0 1 5s5x 0 04 s Factory setting 05s Setting increments 0 15 Output Relay Selection relay T AA A MRALZL 45 Factory setting AL MR 5 60 C 23 140 F If auxiliary relays 2 and 3 are assigned to the communication refer to page 5 16 they cannot be selected here Earth Ground Fault Protection in High Voltage Systems This section provides an overview of earth ground faults in isolated high impedance earth ot compensated networks With earth neutral point type networks the magnitude of the earth ground fault leak current is determined by the earth capacitance of the network and the earth resistance or the compensating reactor Because the size of industrial networks is limited earth fault currents are very small To a great extent earth capacitances are determined by the cables and the motots The capacitance values for cables are given in cable tables and range from approximately 0 2 1 2 WF km A value between 0 02 0 05 MF per MW of motor rating can be assumed for high voltage motors Publication 825 UM001B EN P January 2001 Functions 3 30 A tule of thumb for industrial medium voltage networks is to allow about 1 A of capacitive earth current for every 1 000 1 500 kVA of system power Usually the displacement voltage is measured at a single neutral point and is assumed to be representative of the entire
86. ion Factory setting Off Output Relay Selection relays MR AL 1 5 Factory setting MR If auxiliary relays 2 and 3 are assigned to the communication refer to page 5 16 they cannot be selected here Publication 825 UM001B EN P January 2001 3 47 Functions Table 3 Z Sensor Measuring Circuit Specifications Function Factory setting Off Sensor Measuring Circuit Max resistance of the PTC chain when cold 1 5kQ Max number of sensors as per IEC 34 11 2 6 Pickup value at 84 5 60 C 3 3 KQ 0 3 KQ Dropout value at 6 5 60 C 1 8 KQ 0 3 kQ Delay on pickup 800 ms 200 ms usc aa circuit in sensors circuit lt 15Q Measuring voltage as per IEC 34 11 2 2 5V DC Measuring Lead Minimum cross section mm2 0 5 0 75 10 15 2 5 AWG No 20 18 17 16 14 Maximum length m 200 300 400 600 1000 ft 656 984 1312 1968 3280 Method of installation 9 Q Twisted lead 25 times twisted per m Screened lead Screen connected to T2 Publication 825 UM001B EN P January 2001 up to 100 m 328 ft twisted unscreened Functions 3 48 Figure 3 27 Characteristic of PTC Sensors as per IEC 34 11 2 4000 1330 550 250 100 amp oc 20 20 C TNF 20K TNF 15K 0 C TNF 5K TNF 5K TNF TNF Nominal pickup temperature R Q Resistance to sensors Analog Output This output supplies a current of 4 20 mA proportional
87. ipping threshold c Nominal temperature load x Coolant temperature 40 C or via PT100 7 Thermal utilization calculation Therm utiliz PAAA 100 16 mA Publication 825 UM001B EN P January 2001 Functions 3 50 Figure 3 29 Analog Output for Motor Temperature 8 A 200 C 50 C 5 10 15 20 mA 4 Motor Temperature calculation op CIA 4mA o Motor temp C SEE Tr EE e 150 C Analog Output for Motor Current The output supplies a current of 4 20 mA proportional to the motor current Figure 3 30 Analog Output for Motor Current I 200 100 0 5 10 15 20 mA 4 12 Motor current calculation _ mA 4 mA Motor current Ia a oy ee e 200 I Publication 825 UM001B EN P January 2001 3 51 Functions Control Inputs 1 and 2 With control inputs 1 and 2 the following control and protection functions are available Timer functions Disabling of protection functions Protection against stalling during starting with an external speedometer refer to page 3 44 Changing over to a second rated current two speed motor Actuation Y31 24V AC or 24V DC 8 mA Input 1 4 vae Pick values On 12 36 V Y41 Off 2V Input 2 vae The control inputs are galvanically separated from the electronic circuits by optocouplers The control inputs are activated by applying 24V AC or DC to Y31 Y32 or Y42 Y42 For further information refe
88. ither the main relay changes to Fault or the selected auxiliary is activated As soon as a new start is permissible the start lockout is automatically reset Figure 3 21 Limiting the Number of Starts per Hour I L le le I I gt t tw 60 min I First start I Second start tw The selected relay MR or 1 5 remains in the tripped position until 60 min have expired If an additional start is allowed the number of starts can be increased by one Table 3 R Starts per Hour Setting Parameters Function Factory setting Off Setting Setting range 1 10 starts hour Factory setting 2 starts hour Setting increments 1 Output Relay Selection relays MR AL 1 5 Factory setting MR If auxiliary relays 2 and 3 are assigned to the communication refer to page 5 16 they cannot be selected here The motor manufacturer s instructions regarding the permissible ATTENTION i number of starts per hour and the minimum waiting time between individual starts must be complied with Note The thermal protection of the motor is independent of this function Each start depends on the thermal reserve of the motor Publication 825 UM001B EN P January 2001 Functions 3 34 Monitoring the Starting Time Function The starting time of the motor is monitored If starting has not finished by the set time the installation can be switched off This monitoring is indep
89. known 1 Set the motor current approximately 10 20 higher than the assumed service cuttent 2 With the installation running normally read the motor current on the LCD 3 Set the current converter to the service current reading EXAMPLE Set current oe CURR Measured motor current di 85 le Service current 259g aaa 119A Setting to service current rud CURR The motor current is now nm 100 le In software versions 3 11 and later the motor current can be displayed in amperes A and be set directly Publication 825 UM001B EN P January 2001 Commissioning and Operation 6 4 Locked Rotor or Starting Current Set the locked rotor or starting current as the multiple of rated current I4 I according to specifications given by the manufacturer f no specifications are available the starting current can either be measured with the current converter or read from Figure 6 1 The current converter factory setting is 6 x I LCD LOCKED ROT CURR 6 00 x le Figure 6 1 Range of Starting Currents of Standard Motors Expressed as Multiple of the Rated Service Current A 123 4 IA 40 Jes fof le TTC 6 ILI 4 1 0 2 0 4 1 2 4 10 20 40 100 200 kW PN 1 Approximate value for 2 pole motors speed 3 000 rpm 2 Approximate value for 4 pole motors spee
90. lay 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 Uj Uj Uj Uj p Imp Imp Imp as per IEC 947 25W 6W BV 12 kV Control Circuit Between control circuits and to all other circuits 9 Main relay MR 95 98 supply A1 A2 Phase sequence protection pu L1 12 L3 4 Alarm relay AL auxiliary relay 1 4 5 as per IEC 947 4 Core balance current transformer k Control inputs 1 2 Ump Auxiliary relays 2 3 2 5 kV as per IEC 947 4 The measuring inputs for PT100 and PTC the 4 isolated from one another Publication 825 UM001B EN P January 2001 20 mA output and the communication interface are not 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 2
91. lication 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 In order to achieve maximum performance from this product correct ATTENTION 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 ot 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 n 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 mu
92. lletin 825 M running time including interruption lt 8 hour of control H MIN voltage in hours minutes c HF f N MOTOR RUNNING TIME ERE h mifi Total motor running time in hours minutes UTE a Note For a complete list of parameters refer to Chapter 7 Applications The Recorded Values mode provides Analysis of motor faults and production interruptions Analysis of premature motor failures A means of determining maintenance jobs on the switchgear motor and installation Test Button When the motor is at standstill the alarms trips and tripping times of the protective functions can be checked without external aids by pressing the Tes button Figure 3 6 Basic Unit Test Button SMART MOTOR MANAGER Change 0 Q 3x Enter 0 Settings Reset Publication 825 UM001B EN P January 2001 Functions 3 10 Testing the Thermal Trip 1 Press the Test button LCD i THERMAL ON 2 After the set blocking time has expired the basic unit must trip LCD LOCK ROT TIME __ _ sec 3 The LED lights 4 The selected output relay picks up MR main relay on trip LCD Gd TRIP J Resetting Automatic The trip becomes inactive when the Test button is no longer pressed Manual Reset the trip with the Reset button Note After the test the thermal image resumes its correct state Simulation of the motor cooling is not affected by the te
93. llowing dimensions Figure 4 1 Basic Unit Mounted in an Enclosure o 18g M Gom ta X 7h 3 70 116 0 8 7 16 Dimensions in mm inches Q Front panel with cutout Dimensions Rubber gasket Panel cutout 138 x 138 mm Fixing nuts 0 mm 1 mm Mounting depth min 140 mm Publication 825 UM001B EN P January 2001 Assembly and Installation 4 2 Mounting Position Figure 4 2 Mounting Position 225 pa 225 22 5 o aao o ao Surface Mounting Figure 4 3 Basic Unit Mounted into Panel Mounting Frame Cat No 825 FPM 770mm 6 11 16 Dimensions in mm inches Publication 825 UM001B EN P January 2001 4 3 Assembly and Installation Converter Modules Figure 4 4 Cat Nos 825 MCM2 825 MCM 20 825 MCM180 car 825 MCM180 sea A m 3 Table 4 A Cat Nos 825 MCM2 825 MCM 20 825 MCM180 Dimensions in millimeters inches Cat Noii b c ci d d d di Ze Get e2 bi m wow 0 8 moa 66 53 s3 0 s 2 a 4 45 64 3 23 64 4 2 39 64 3 18 3 16 3 7 8 2 3 16 25 mm 1 1 2 wow UL 85 wz 66 53 53 100 o 2x aes _ 4 45 64 3 23 64 4 2
94. meters Table 5 D Cat No 825 M Operating Parameters Continued Required Setti Group Option Card LCD Ra ing Description Cat No ange f Asymmetry protection ASYMMETRY TRIP On Off 9 current measuring ON 3 asymmetry On Off AS TRIP LEVEL sso Asymmetry trip 35 J Tripping level in percent AS TRIP TIME D Asymmetry trip 1 25 ripping dela 2 5 Sec J pping y Asymmetn ASYMMETRY TRIP D All relays Asymmetry trip MAIN RELAY J Y5 Assignment of relays AS WARNING Ses Asymmetry warning OFF J as WARNING LEVEL P Asymmetry warning zi 20 5 80 Warning level in percent Cn As WARNING 4 Allexcept Asymmetry warning ALARM RELAY main relay Assignment of output relay a OVERCURR TRIP 3 On Off Overcurrent locked rotor ON J protection On Off A N E OC TRIP LEVEL 10 60 DN ac ed n or 2 4 X le E ZEE Overcurrent C TRIP TIME N gie Qvercurrent locked rotor 0 5 sec J ripping delay OVERCURRENT TRIP All relays Overcurrent locked rotor MAIN RELAY J YS Assignment of output relay c WARNING jJ On Off Overcurrent locked rotor OFF J warning On Off If Asymmetry Trip is set to off he programming menu skips to parameter AS Warning If AS Warning is set to off the programming menu skips to parameter Overcurr Trip e If OC Warni
95. mm 2 3 16 Wire size 2 x 2 5 mm 14 AWG To retrofit or replace options the assembly and testing instructions ATTENTION A i s supplied with the option must be followed exactly Publication 825 UM001B EN P January 2001 4 5 X Assembly and Installation Figure 4 7 Basic Unit Housing with Option Cards Normally the basic unit will be ordered and shipped with the required option cards Basic Unit housing Cat No 825 MMV or 825 MIV option card Communication board Cat No 825 MST option card Board with basic unit Rear cover Screws eococo cec Installation and Wiring General The Smart Motor Manager fulfills the stringent requirements imposed by global standards requirements regarding electromagnetic compatibility EMC This means that there is no need to observe any special stipulations when wiring the unit Nevertheless control leads should be laid separately from power leads In the circuit diagrams throughout this section any special wiring requirements are specifically noted The data of the output circuits and control inputs are dealt with in Chapter 2 Specifications Basic Unit and Converter Module Throughout this manual the contacts of the output relays are shown in their normal working position i c the Smart Motor Manager control voltage is switched on no warning no trip ATTENTION All assembly and installation work must be performed by qualified pe
96. n the consideration the insulation class needs to be programmed for correction ng PT100 7 as the ambient temperature input the thermal model bases Setting the Operational Parameters 5 16 Table 5 D Cat No 825 M Operating Parameters Continued Required Setti Group Option Card LCD Ra ing Description Cat No ange Basic unit station number STATION NUMBER RES OQ S 02 J 1 247 MODBUS Communication 1 126 PROFIBUS setting Baud rate 0 2 DeviceNet BAUD RATE 0 23 RI O 04 0 182 MODBUS 0 4 PROFIBUS Comm option REL 2 3 VIA COM B Control of relays 2 and 3 Relay control 825 MST NO No Yes via communication allowed T E Clear recorded En CLEAR REC VALUES Not clear Clear do not clear all values allclear recorded values INOT CLEAR J E FACTORY SETTINGS A is w Reset not reset to factory NOT RESET TO j e settings Reset settings to z iA E Reset not reset all Kerpen ARE YOU SURE No Yes parameters to factory values w A settings Cc Confirmation that all FACTORY SETTINGS parameters are reset to the ALL IS RESET TO D factory settings End of setting END SET VALUES n End of setting operating parameters parameters M P If auxiliary relays 2 and 3 are assigned to the communication refer to page 5 16 they cannot be selected here e If Factory Settings is set to Not Rese
97. network The earth ground fault is localized by using an earth ground fault current detector such as the Smart Motor Manager with earth ground fault protection in the motor feeders Often operation can continue since the earth currents are comparatively insignificant and the insulation of the non faulty phases can be operated at a higher voltage for a short period of time Isolated or High Impedance Earth Networks In the case of earth capacitances the neutral point of the network assumes earth potential and the sum of the currents flowing through the earth capacitances is zero Also no current flows in normal operation in the high value earth resistor Figure 3 16 Figure 3 18 and Figure 3 20 in the case of transformer with neutral point It avoids extreme overvoltages in the event of intermittent earth faults such as can occur in isolated networks If for example phase conductor 3 Figure 3 15 and Figure 3 17 becomes connected to earth due to an earth fault the two other phase conductors carry a line to line voltage with respect to earth Through their earth capacitances Cy on the power supply side as seen from the Smart Motor Manager and Cy on motor side a capacitive current flows toward earth and back to phase conductor 3 through the fault location In the case of high impedance earthing Figure 3 16 Figure 3 18 and Figure 3 20 the neutral point voltage now at a high value causes an additional current that is limited
98. ng Off Tripping Delay Factory setting 1s Output Relay Selection relays MR AL 1 5 Factory setting MR If auxiliary relays 2 and 3 are assigned to the communication refer to page 5 16 they cannot be selected here The phase sequence of the motor s ly can be monitored only at the ATTENTION P a upply ored only point of measurement usually before the contactor Exchanged leads between this point and the motor cannot be recognized Phase Failure Based on Voltage Measurement Function A phase failure is recognized by measuring the voltages before the switchgear and thus with the motor at standstill With phase failure protection where the phase currents ate measured the motor first has to be switched on although it cannot start with only two phases Table 3 AB Phase Failure Setting Parameters Function Factory setting Off Tripping Delay Factory setting 2s Output Relay Selection relays MR AL 1 5 Factory setting MR If auxiliary relays 2 and 3 are assigned to the communication refer to page 5 16 they cannot be selected here Publication 825 UM001B EN P January 2001 3 55 Functions Star Delta Wye Delta Starting The Smart Motor Manager issues the command to switch from stat to delta wye to delta as soon as the starting current has dropped to the rated value and thus the motor has reached its normal speed in star wye If starting has not been completed within the n
99. ng is set to off the programming menu skips to parameter Earth Fault Prot Publication 825 UM001B EN P January 2001 Setting the Operational Parameters 5 6 Table 5 D Cat No 825 M Operating Parameters Continued Ensute that the trip function is reset before it is inactivated ATTENTION Required a Setting Group Option Card LCD Description Cat No Range A B Overcurrent locked rotor U oe LEVEL 1 0 6 0 Warning level in I Overcurrent I continued 6c WARNING All except nr locked rotor ALARM RELAY J main relay Assignment of output relay c EN Earth ground fau EARTH FAULT PROT On Off protection ON J On OfF c N Earth ground fau EF HOLMG TRIP On Off protection Holmgreen ON J residual On Off Earth ground fault trip Earth d fault omaes GFATRIPLEVEL qoos Holmareen residua residual 50 s Tripping level percent of s J motor current c S Earth ground fault trip EF H TRIP TIME 0 1 5 Holmgreen residual 0 50 sec J Tripping delay c Earth ground fault trip EF HOLMG TRIP All relays Holmgreen residual MAIN RELAY p Assignment of output relay f Earth Fault Prot is set to off the programming menu skips to parameter Short Circ Trip e If EFHolmg Trip is set to off the programming menu skips to parameter EF Core Trip Publication 825 U
100. nstallation can be better used with deviating coolant temperatures PT100 PROT ON The temperature of the coolant ambient temperature is indicated as soon as the function is activated and PT100 7 is connected LCD of 825 M men Publication 825 UM001B EN P January 2001 Functions 3 58 This function must be activated so that the coolant temperature may be taken into account in the thermal image Tamb IN TH IMAGE ON Ambient temperature in the thermal image is taken into account Fila INSULATION CLASS B Insulation class of winding Table 3 AF Motor Insulation Class Setting Parameters Function Factory setting Off Insulation Class Selection B E F Factory setting B Limiting winding temperatures of the three insulations classes E 120 C B 130 C F 155 C When the ambient temperature is taken into consideration the insulation class needs to be programmed for correction of the thermal model Without using PT100 7 as the ambient temperature input the thermal model bases the thermal calculation on an ambient temperature of 40 C Application With large temperature variation day night Outdoor installations Pumps Conveyors Crushets e Saws Publication 825 UM001B EN P January 2001 Chapter 4 Assembly and Installation Assembly Flush Mounting To mount the Smart Motor Manager in a front panel cut a rectangular hole with the fo
101. nstallation instructions and the specifications for ATTENTION the contactors auxiliary relays etc Main Circuit Figure 9 1 Basic Unit and Converter Module L0 02 13 U1 Converter module Ai Cat No 825 MCM2 cde a Cat No 825 MCM20 Cat No 825 MCM180 Cat No 825 MCM630 5 Cat No 825 MCM630N U1 825 MCM 825 M F1 2 4 6 Publication 825 UM001B EN P January 2001 Applications Wiring 9 2 Control Circuit Figure 9 2 Control by Momentary Contact F7 U L1 S i Soe i Sie Kt i a f 95 197 AL 113 oe FH MRF 4 inl 825 M EC UM ea 96 198 J A2 114 i i i M Kil HO HQ HO L2 F8 A2 S1 S0 H1 H2 AL H3 Contactor Bulletin 825 Smart Motor Manager On push button Off push button Control voltage Indicator Contactor closed Indicator 825 M tripped Main relay Alarm relay Indicator Alarm Warning ATTENTION The mounting witing directions and the specifications of the contactor being used must be considered Publication 825 UM001B EN P January 2001 9 3 X Applications Wiring Star Delta Starter with Bulletin 825 Smart Motor Manager Main Circuit Figure 9 3 Basic Unit and Converter Module Basic Unit settings Li L2 130 ge ce 31 FULL LOAD CU
102. nti motor has cooled inadequately cooled et LCD TH UTIL appr THERMAL TRIP Thermal trip issible i More than one warm start hour Lee h Ambient temperature too high Function PT100 7 ON If possible reduce load Very high third harmonic e g star delta connection Raise I setting accordingly Cooling constant ratio has been changed Publication 825 UM001B EN P January 2001 Check and reset to correct setting factory setting 2 5 Error Diagnosis and Troubleshooting 8 5 Table 8 A Possible Causes and Actions Continued LCD Designation Possible Causes Actions Press Values until SET VALUES on LCD Set LOCKED ROT CURR to Setting of locked rotor current 6 x Ie E SEDYAMIES and or locked rotor time are Set LOCKED ROT TIME to 10s d 9 Set LOCKED ROT CURR and LOCKED ROT TIME correctly within permissible range refer to Chapter 3 If asymmetry inadmissibly high clarify cause with electric Mains unbalanced EE If asymmetry has values usual for the area raise threshold in the basic unit Blown fuse e Short circuit Earth e Repair the trouble replace the ground fault fuse e Failure during starting e Redimension fuse note short circuit coordination mm Raise threshold in basic unit to Motors idling e g pumps permissible level AS WARNING Asymmetry Po
103. on 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 cquipment construction touch protection insulated housing motor protective functions Earth ground fault High overload stalling and jam e 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 valu
104. or 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 ate 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 P Power Pe Rated operational power Pv Power losses Pve Power losses under rated conditions I Operational current Ip Rated service current Speed Ne Rated operational speed Ng Synchronous speed cos Power factor T Efficiency 25 50 75 100 125 B Pa 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 I and all of the power absorbed is converted into heat As the motor speed increases the power conv
105. or contacts terminals i warning contactor breaker etc Repair trouble Phase lead broken motor lead link between basic unit and Replace or repair cable ASYMMETRY TRIP iud converter module If asymmetry is acceptable raise Asymmetrical motor winding threshold in basic unit otherwise repair motor Main current transformer error e Metering class current Insert the correct current transformer instead of transformer protection current transformer Wrong current range e Replace the current transformer e Current transformer rating e Replace the current too low transformer e Incorrect current transformer e Check and correct wiring wiring Reduce load or raise pickup 0 i Overload threshold C WARNING vercurren Tr F i warning Transported material jammed Switch off installation remedy Pickup threshold set too low Raise pickup threshold Mechanical damage to bearings piensen TRIP Overcurrent a CN Bon 35 Repair the damage tri d Stalling during start causes as Switch off installation remedy for jamming when running Cause Publication 825 UM001B EN P January 2001 8 6 Error Diagnosis and Troubleshooting Table 8 A Possible Causes and Actions Continued LCD Designation Possible Causes Actions Earth ground fault motor 5 winding or cable Repair damage Earth ground Trip w
106. ormal time for this application max star wye operation a change to delta will be made regardless of the speed attained The permissible time for star wye operation can be switched on or off as desired If it is off the change to delta is made solely with reference to the motor current If the motor has to be switched off when the normal starting time in star wye is exceeded the monitoring starting time function must also be activated refer to page 3 34 Figure 3 32 Diagram of Star Delta Wye Delta Starting Motor on off Motor current NM Star operation relay 4 Delta operation relay 5 Changeover delay 80 ms Table 3 AC Star Delta Wye Delta Starting Setting Parameters Publication 825 UM001B EN P January 2001 Setting Star Wye Relay Delta Relay nn Function Fadoyseting Of Off Setting Setting range 1 240 s Factory setting Relay 4 Relay 5 10s Setting steps 1s Functions 3 56 Functions of the Cat No 825 MMV Option Card PT100 100 Q Platinum Temperature Sensor RTD The PT100 temperature detectors are often embedded in the stator winding and or the bearings especially in large motors The Smart Motor Manager monitors the actual stator bearing and coolant temperature The resistance from a PT100 temperature detector is dependent on the temperature and has a positive temperature coefficient 0 4 Q C Tabl
107. ormed with a single phase source To do this the earth ground fault protection by the Holmgreen method must be switched off Figure 7 2 Test with a Single Phase Current Source ae a 4 gt oe Connection 1 3 5 825 MCM 825 M 2 4 6 Connection tO The test current may not flow through the core balance current IMPORTANT 8 transformet Publication 825 UM001B EN P January 2001 Chapter 8 Error Diagnosis and Troubleshooting Alarm Warning If an impending defect is detected early enough motor damage can be minimized This leads to Lower repair costs Less downtime increased productivity Alarm thresholds can be set for Thermal utilization of the motor Overcurrent Asymmetry Underload e Earth ground fault with core balance transformer e Stator and bearing temperature with PT100 When the alarm threshold is reached the LED flashes the LCD indicates the type of alarm and the selected output relay picks up Procedure when Alarm Warning Picks Up EXAMPLE Asymmetry When an asymmetry condition occurs and the related threshold is reached the following responses occur LED flashes e LCD s WARNING The assigned output relay picks up Publication 825 UM001B EN P January 2001 8 2 Error Diagnosis and Troubleshooting Cause of the warning may be Unbalanced mains Defective motor winding
108. ote 1 0 Station number 0 63 2 Baud rate 9 0 23 4 Baud rate 0 118 5 Modbus Station number 0 247 2 Baud rate 0 182 4 Baud rate 0 118 5 PROFIBUS Station number 1 126 2 Baud rate 9 6 19 2 73 75 187 5 500 kbaud 0 4 4 500 kbd Baud Rate for Remote 1 0 Calculated according to the following formula Value 8 x baud 4 x last rack starting_mod_group Baud 0 57 6 kbaud 1 115 2 kbaud 2 230 4 kbaud last_rack 0 no 1 yes starting_mod_group 0 group 0 1 group 2 2 group 4 The 3 group 6 rack_size is fixed to 1 4 rack O Baud Rate for DF1 Calculated according to the following formula Value 64 x mode 32 x stop bits 8 x parity baud Mode Data protection 0 CRC 1 BCC stop_bits 0 1 stop bit 1 2 stop bit parity 0 none 1 odd 2 even baud 0 300 baud 1 600 baud 2 1 200 baud Baud Rate for Modbus Calculated according to the Value 64 x mode 32 x s 3 2 400 baud 4 4 800 baud 5 9 600 baud 6 19 200 baud ollowing formula top bits 8 x parity baud Mode Protocol 0 RTU 1 ASCII 7 bit 2 ASCII 8 bit stop bits 0 1 stop bit 1 2 2 stop bit parity 0 none 1 odd 2 even baud 0 300 baud 1 600 baud 2 1 200 baud 3 2 400 baud 4 4 800 baud 5 9 600 baud 6 19 200 baud Publication 825 UM001B EN P January 2001 Setting the Operational Parameters 5 4 Operating Parameters Table
109. ound fault detector and causes a trip A brief delay helps to avoid nuisance trips caused by transient current transformer saturation which can be caused by switching operations The sensitivity has to be such that neither transformation errors in the current transformer nor disturbance signals in star delta wye delta connections caused by the third harmonic cause nuisance tripping Figure 3 13 3 Phase Current Detection Measurement of the neutral current Zg in the neutral connection of the current transformer to detect an earth ground fault residual circuit Publication 825 UM001B EN P January 2001 Functions 3 28 Table 3 0 Earth Ground Fault Holmgreen Residual Setting Parameters Trip Function Fadoysettng On Response Level Setting range 10 100 Factory setting 50 Setting increments 0 Tripping Delay Setting range 0 1 58 04s Factory setting 0 5s Setting increments 0 1s Output Relay Selc on elays MRALZ 45 Factory setting MR 5 60 C 23 140 F If auxiliary relays 2 and 3 are assigned to the communication refer to page 5 16 they cannot be selected here Earth Ground Fault Protection with a Core Balance Current Transformer This function can be provided by the Cat No 825 MST option card In isolated high impedance earthed or compensated networks the necessary high sensitivity is obtained by
110. ous 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 MANAGER AD Aren Bradiey SMART MOTOR 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 ate 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 occut 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 mot
111. ow to Get Rid of Alarm Go to SET VALUES mode Switch on all alarm functions e g THERMAL WARNING ON As soon as the affected alarm function is switched on again then the alarm condition will disappear e Switch alarm function off if not required Procedure if TRIP cannot be Reset There are two reasons why a trip can not be reset if the motor is not running Thermal Trip Indication LCD THERMAL TRIP Red LED On How to Reset The motor must have cooled down to the pre set level before the reset is possible TH RESET LEVEL setting range 10 100 factory setting 50 Publication 825 UM001B EN P January 2001 Error Diagnosis and Troubleshooting 8 9 Other Trips Indication LCD Does not display the type of the trip LCD active Red LED ON Cause for this Condition If the tripped protection function has been switched OFF before the trip has been reset then the trip can not be reset the normal way How to Reset Go to RECORDED VALUES mode Go to CAUSE LAST TRIP e g ASYMMETRY TRIP Go to SET VALUES mode Go to tripped Protection Function e g ASYMMETRY TRIP Switch Protection Function on e g ASYMMETRY TRIP ON Reset Trip Red LED goes off Switch Protection Function off if not required Publication 825 UM001B EN P January 2001 Chapter 9 Applications Wiring Bulletin 825 Smart Motor Manager with Contactors Strictly observe the i
112. pervision while motor is stationary When running as soon as the link is interrupted d Holmgreen residual asymmetry overcurrent the basic unit will trip and isplay one or more of the following Causes e short circuit thermal earth fault Display 825 MCM NOT CON Verification that FLC on basic unit is within range of converter module A er switching on supply A er each change in setting of rated current le OUT OF RANGE Supervisory circuits Continuous monitoring hardware errors supply etc ERROR 825 MCM Publication 825 UM001B EN P January 2001 Chapter 3 Functions Menu Overview Actual Values In Actual Values mode all operating parameters can be selected and read from the LCD Table 3 A Actual Values Overview Display List Option pard Page Display List Option Card Page MOTOR A 6 6 earth H l 6 7 MOTOR LA 6 5 learth C mA 6 7 11 LA 6 6 Tambient C 825 MMV 6 7 12 LA 6 6 PT100 1 6 C 825 MMV 6 7 13 LJ 6 6 PROBUS 825 MPB 6 7 TRIP IN S 6 6 RIO 3600 RIO 6 7 RESET IN S 6 7 MODBUS 3600 MBS 6 7 ASYM 96 6 7 DevNet 825 MDN 6 7 Publication 825 UM001B EN P January 2001 Functions 3 2 Set Values The parameters Main Settings and Special Settings must be programmed for every application The other parameters e g Hig
113. ption Card Analog output assigned to 4 20 mA thermal utilization On 0 100 _ PT100 max 50 200 C temperature 0 200 I 1 Motor Bulletin 825 MST Option Card Control Input 1 24V AC DC 8 mA One of 3 functions can be selected 1 Pickup delay relay 2 0 0 240s 1s 2 1 Dropout delay relay 2 0 240s 2s 2 2 Speed switch 0 high relay 3 Disable protective functions Asymmetry phase failure 0 High overload jam 0 Earth ground fault 0 Short circuit 0 Underload 0 Limiting starts hour 0 PTC 0 PT100 RTD 0 Terminals Y11 Y12 must be jumpered Minimum waiting time between two warm starts Publication 825 UM001B EN P January 2001 Functions 3 16 Table 3 1 Control Functions Summary Continued Functions Setting Factory Tripping Factory Relays Factory Factory Range Settin Delay Setting Selection Settin Setting g 9 Range g g Bulletin 825 MST Option Card Control Input 2 24V AC DC 8 mA ne of three functions can be selected Pickup delay relay 0 3 e 0 240 s 1s 3 Dropout uelay relay T 0 240s 2s 8 Set second rated 0 5 current 9 0 2 000A 20A N 3 Disable protective functions Asymmetry phase failure igh overload jam arth ground fault hort circuit nderload miting starts hour PTC PT100 RTD
114. r asymmetry or the failure of a phase can be caused by defective contacts in circuit breakers or contactors loose terminals blown fuses and faults in the motor itself Rapid detection and interruption of these factors help to prevent damage caused by overheating in such equipment The stress on the installation and the motor bearings is reduced The Smart Motor Manager measures the phase currents and calculates the total copper losses according to the definition of voltage asymmetry per IEC and NEMA 2 Peu 7 U M ki g Definition of voltage asymmetry per IEC and NEMA Max deviation from the average of the phase voltages x 100 AU a Average of the phase voltages Publication 825 UM001B EN P January 2001 3 23 Functions Figure 3 10 Reduction in Permissible Motor Output Due to Voltage Asymmetry per IEC and NEMA fa fa Reduction factor for 1 0 motor output AU Voltage asymmetry in percent 0 9 0 8 AU 0 7 0 1 2 3 4 5 Table 3 L Asymmetry Phase Unbalance Setting Parameters tame Moma Trip Function Factory setting Off On Response Level Setting range 5 80 5 80 Factory setting 20 35 Setting increments 5 5 Tripping Delay Setting range 1 258 0 2s Factory setting 2 58 0 2s Setting increments 0 5s Output Relay Selection relays AL 1 5 MR AL 1 5 Factory setting AL MR 5
115. r of motor and installation Causes shortly before tripping and the moment of tripping Misuse information such as too many emergency starts etc The table below lists the recorded values accessible from the Smart Motor Manager Table 7 A List of Recorded Values LCD Description foi N RECORDED VALUES Mode Recorded values M A 25 M MAIN TIME Total basic unit running time including interruption of control voltage in H MIN hours minutes V ha gt MOT RUNNING TIME Total motor running time in hours minutes C H MIN J fey N SINCE LAST START Time since last start in hours minutes H MIN J fey N SINCE 1PRV START Time since one start prior to last start in hours minutes kz H MIN J SINCE2PRVSTART 2 Time since two starts prior to last start in hours minutes kz H MIN J SINCE 3PRVSTART 3 Time since three starts prior to last start in hours minutes k H MIN J lay N SINCE 4 PRV START Time since four starts prior to last start in hours minutes kz H MIN lo N SINCE LAST TRIP Time since last trip in hours minutes H MIN p Publication 825 UM001B EN P January 2001 Testing and Maintenance 7 3 Table 7 A List of Recorded Values Continued L
116. r to Chapter 9 Timer Functions The following functions can be programmed On Delay 7 0 240 s Off Delay 7 5 0 240 s On and off delay 0 240 s Assignment of the Output Helays Control input 1 to output relay 2 Control input 2 to output relay 3 Publication 825 UM001B EN P January 2001 Functions 3 52 Figure 3 31 Operating Diagram for Timer Functions Control input ssl 05s I Opurdy o On delay TN fot 0 Off delay lee On off delay on off On off delay con loft Applications Time graded switching on and off Delaying the transfer of alarm and trip messages Lock Out of Protection Functions With control inputs 1 and 2 one or more protective functions can be locked out as desired Asymmetry phase unbalance High overload jam Harth ground fault e Short circuit Underload Limiting the number of starts hour e PTC e PT100 Applications Lock out of protection functions Duting certain operational phases when the level differs from the normal values such as during starting earth fault and short circuit protection at no load protection against asymmetry and underload during brief overload phases high overload jam during commissioning and fault location localizing the source of the trouble Publication 825 UM001B EN P January 2001 3 53 Functions The selected functions are completely disabled as long as the control inpu
117. ripping D1f1t8 4 eu recep EROR E aba 3 36 Example for t6x 10 s and Warm Trip Time 70 cles 3 37 Interruption of a Short Circuit lisse 3 43 Stalling During Starting s sasssa eee 3 45 Characteristic of PTC Sensors as per IEC 34 11 2 3 48 Analog Output for Motor Temperature Rise 3 49 Analog Output for Motor Temperature 3 50 Analog Output for Motor Current 3 50 Operating Diagram for Timer Functions 3 52 Diagram of Star Delta Wye Delta Starting 3 55 Basic Unit Mounted in an Enclosure 4 1 Mounting Positions cios res Rer e eren 4 2 Basic Unit Mounted into Panel Mounting Frame Cat No 825 PPM na es seed vbs RR RR Ren 4 2 Publication 825 UM001B EN P January 2001 Figure 4 4 Figure 4 5 Figure 4 6 Figure 4 7 Figure 4 8 Figure 4 9 Figure 4 10 Figure 4 11 Figure 4 12 Figure 4 13 Figure 4 14 Figure 6 1 Figure 7 1 Figure 7 2 Figure 9 1 Figure 9 2 Figure 9 3 Figure 9 4 Figure 9 5 Figure 9 6 Figure 9 7 Figure 9 8 Figure 9 9 Figure 9 10 Figure 9 11 Figure 9 12 Figure 9 13 Figure 9 14 Figure 9 15 Table of Contents vii Cat Nos 825 MCM2 825 MCM 20 825 MCM180 4 3 Cat Nos 825 MCM630 825 MCM630N 4 3 Cat No 825 MTUM Thermal Utilization Indicator 4 4 Basic Unit Housing with Option Cards 4 5 Basic Unit with Converter Module 4 6 3 Phase Current Evaluation
118. rsonnel taking local codes into account Publication 825 UM001B EN P January 2001 Assembly and Installation 4 6 Main Circuits Basic Unit and Converter Module without Main Current Transformer Figure 4 8 Basic Unit with Converter Module Converter module cat nos 825 MCM2 825 MCM20 ses 825 MCM180 825 MCM630 825 MCM630N Cable with plugs Basic Unit and Converter Module with Main Current Transformer Figure 4 9 3 Phase Current Evaluation L1 L2 L3 Converter module 825 MCM2 825 MCM20 Ji 1 3 5 Cc Main current transformer C C 825 MCM 825 M A 5 0r A 1A 2 4 6 For selection refer to Chapter 2 My NE Publication 825 UM001B EN P January 2001 4 7 Assembly and Installation Basic Unit and Converter Module with Main and Core Balance Current Transformer Figure 4 10 2 Phase Current Evaluation L1 L2 L3 pe Converter module cat nos 825 MCM2 825 MCM20 Ti d 825 MCM 825 M k l de i z Table 4 C Specifications Main current transformer refer to Chapter 2 for selection information A 5 A or A 1 A Core Balance Current Transformer Earth ground current 5mA 50A Current ratio of core balance current transformer 1 2 000 1 0 500 mA Output from core balance current transformer Additional circuit diagrams can be found in Chapter
119. s Figure 3 9 Figure 3 10 Figure 3 11 Figure 3 12 Figure 3 13 Figure 3 14 Figure 3 15 Figure 3 16 Figure 3 17 Figure 3 18 Figure 3 19 Figure 3 20 Figure 3 21 Figure 3 22 Figure 3 23 Figure 3 24 Figure 3 25 Figure 3 26 Figure 3 27 Figure 3 28 Figure 3 29 Figure 3 30 Figure 3 31 Figure 3 32 Figure 4 1 Figure 4 2 Figure 4 3 Trip Characteristics 40 100s 000 3 20 Reduction in Permissible Motor Output Due to Voltage Asymmetry per IEC and NEMA 3 23 Function of High Overload and Jam Protection 3 24 Function of Underload Protection 3 26 3 Phase Current Detection 0 0 00 ee eee 3 27 Example of 2 Phase Current Sensing 3 28 Isolated Network Earth Fault on the Network Side 0 0 ccc eee 3 31 Network Earthed through a High Impedance Earth Fault on the Network Side 3 31 Isolated network Earth Ground Fault on the Leads on the Motor Side sepias eser eias Ca EEES 3 32 Network Earthed through a High Impedance Earth Ground Fault on the Motor Leads 3 32 Isolated Network Earth Ground Fault in the Mototzs rw ek Eer TEP EES 3 32 Network Earthed through a High Impedance Earth Ground Fault on the Motor 3 32 Limiting the Number of Starts per Hour 3 33 Monitoring Starting Time clie eese 3 34 Current and Temperature Curves for Warm and Cold Motor Starts and the Smart Motor Manager T
120. s Setting increments 1s Cooling Factor of Motor Off 0n Setting range 1 10 Factory setting 2 5 Setting increments 0 5 Resetting the Thermal Trip Setting range 10 100 of thermal utilization Factory setting 5096 Setting increments 196 Incl setting tolerance e e 4 Up to 2 000 A if pri Ultimate Release Current 105 1 15 1 mary current transformers are used 5 60 C 23 140 F UL CSA 160 434 A The cooling factor can be modified to reflect different motor cooling with running motor and at standstill Publication 825 UM001B EN P January 2001 Functions 3 22 Table 3 K Protection Against Thermal Overload Warning Trip Function Factory setting Off On Response Level O Setting range 55 99 Factory setting 75 100 Setting increments 1 Output Relay Selection ALA 45 MRNooututrelay Factory setting AL MR Thermal utilization 96 If auxiliary relays 2 and 3 are assigned to the communication refer to page 5 16 they cannot be selected here Asymmetry Phase Unbalance and Phase Failure Asymmetrical phase voltages usually occur when the leads closest to the motor are too long The resulting current asymmetry in the motor windings may then be 6 10 times the voltage asymmetry The Smart Motor Manager takes into account the additional temperature rise and thus prevents the life of the motor from being reduced Highe
121. se Failure Based on Voltage Measurement 3 54 Star Delta Wye Delta Starting 0 0 ce eee eee 3 55 Functions of the Cat No 825 MMV Option Card sssusa sesu 3 56 PT100 100 Q Platinum Temperature Sensor RTD 3 56 PT100 7 Temperature Sensor RTD 0 000 000 3 57 Chapter 4 Assembly and Installation PSS Gina Dyas ont ase eae trae eee aa aval tel ace haath Tha EE UE 4 1 Plush Mountings penei adat dien bI CARO IG E edu Rd 4 1 Mounting Position sasn e RII ehe Qe eae ees 4 2 Sutface Mountings eere ex sea mere e E OP eet Gente ee tweet 4 2 Converter Modules eye bv ees ee cue ieee das 4 3 Thermal Utilization Indicator 20 eee eee 4 4 Installation and Witness e cibRIRES Gd E RARE op iE E Ee 4 5 General ceive arene reed HERE CHE cee PF HE Ud Y ERR 4 5 Main Catc llSssivv esae Y RISE Nerve e wu Pp SA ER 4 6 Control CIrc lts a cael ke ER Were E EH ECKE DETUR REEF a 4 8 Chapter 5 Setting the Operational Parameters Menu OVERVIEW eec stesse pe RR E EVE VERE LER ER E PE 5 1 Matti Settings gs sed odd Ue xv XR E UP cemere p eee 5 1 Special SetthpS ccelis xxr Ree E EY VE VILE ERPDMER YR E E A EX HUE 5 2 Operating Parametets cenivd i uu ee elas a ee ag eas REESE 5 4 Chapter 6 Commissioning and Operation Checking the Installation cesse 6 1 Checking the Wiring ker RR RU ECE UEM UE EE edhe ee aes 6 2 Checking the Installation with the Control Voltage Applied
122. se Maximum number of starts has automatic reached Peen exceeded If another start is permissible increase number of start hour by 1 and start again Reduce load or raise max starting Start in max Overloaded time to permissible value START CONT TRIP starting time Transport material jammed Eliminate cause not possible Viscous material Publication 825 UM001B EN P January 2001 Raise max starting time to permissible value Error Diagnosis and Troubleshooting 8 7 Table 8 A Possible Causes and Actions Continued LCD Designation Possible Causes Actions Check leads remove fault PTC PTC or PTC leads short circuited Motor for repair If not possible or broken switch off PTC monitoring PTC PROT OFF Wait until motor has cooled down stator winding overheated by sufficiently for a reset Overload Search for cause and TRIP PTC trip eliminate e Too many starts hour e Reduce starts hour e Too many warm starts hour je Reduce number of warm starts hour e Obstructed cooling e Clean motor and cooling air intake e High ambient temperature e Protect against heat reduce load or switch off installation Phase PHASE REVER TRIP sequence Wrong phase sequence of supply Connect phase leads in correct protection to converter module sequence motor supply Faulty fuse Remedy damage replace the Phase failure Short circuit earth ground fa
123. st Testing the Trips Asymmetry Unbalance Underload etc Example Asymmetry 1 When in Set Values mode access the selected output relay LCD ASYMMETRY TRIP AUX RELAY 2 Publication 825 UM001B EN P January 2001 3 11 Functions 2 Ifno output is assigned the following readout appears LCD ASYMMETRY TRIP NO OUTPUT RELAY 3 Press the Test button LCD B 4 After the set trip delay expires the basic unit must trip LCD AS TRIP TIME _ _ Sec 5 The LED lights 6 The selected output relay picks up LCD dd TRIP Resetting Cancel the trip by pressing Reset Testing the Warning Functions Example Asymmetry warning 1 When in Set Values mode access the selected output relay LCD AS WARNING ALARM RELAY Publication 825 UM001B EN P January 2001 Functions 3 12 2 Press the Test button LCD E 3 The LED flashes and the selected output relay picks up immediately 4 LCD flashes LCD TEST AS WARNING Resetting As soon as the Test button is no longer pressed the unit will automatically reset Publication 825 UM001B EN P January 2001 3 13 Functions Function Summary Table 3 G Protective Functions Summary Tee Setting Factory jen Factory Relays 9 Factory Setting Range Setting Range Setting Selection Setting
124. st take the necessary safety measures to avoid this type of Occurtence 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 eese eese 1 2 lempetatute Rise jese e serre ARRIERE E EE Reed 1 2 Motor Operating Characteristics 6 6 1 2 Current and Temperature Curves liiis 1 3 Limiting Temperatures Insulation Classes 00 00005 1 4 Operational Requirements for Installation 0 0 0 0 0c eee 1 5 Personnel and Installation Safety 00 eee ee eee eee 1 6 Bulletin 825 Smart Motor Manager as an Automation Component 0 000 c cece eee eee 1 6 Chapter 2 Equipment Description System SEPUCLUFE eur d he eee aed pur dE 2 1 System Componentes eese eee eH E EE RS ET EVE 2 1 Installation ucc ves VER veda vau o v ER REP CREE 2 1 Modular Design ses fade te aa qs ee PA p es 2 2 Block Diagtat 5 3 5 estes ced en cad e ed er S eode daos 2 3 Operating Hlements 22 si eoe pe HE Re preesse n RR ee 2 4 Specifications Basic Unit and Converter Module 2 5 Standards ccs seed ep bad edad d p ae re Re bre ci Beh ci 2 7 Main Current Transformers for the Motor Circuit 2 10 Core Balance Current Transformer esee 2 11 Short Circuit Protecti n
125. t To the programming menu skips to parameter End Set Value Publication 825 UM001B EN P January 2001 Chapter 6 Commissioning and Operation Checking the Installation Careful correct commissioning of the Bulletin 825 Smart Motor Manager is an important prerequisite for reliable protection of the motor and economic operation of the installation Follow the procedures in this section to ensure that programming and setup are correct Checking and commissioning must be carried out only by qualified ATTENTION ae personnel Disconnect the main switch and isolate the control circuit before commissioning or installing the unit Current Converter Cat No 825 MCM Verify that the device s current range lies within the full load or the service current Primary Current Transformer if used The transformer rating must be greater or equal to the full load or the service current The current ratio must be___ A 1 Aor A 5 A for use with Cat No 825 MCM2 or 825 MCM20 current converters respectively Core Balance Current Transformer Verify that the output current of the core balance current transformer is 5 500 mA for the alarm or trip signal Basic Unit Cat No 825 M Verify that the power supply voltage has been properly selected for the control circuit voltage Verify that the appropriate option cards have been installed Verify that the indication meter if required is connected P
126. t is on 24V AC DC No alarm No trip no reset Tripping delays begin to run only after the function is re enabled Switching to a Second Rated Current In the Smart Motor Manager a second value can be selected for the rated current I The change to the second rated value is controlled by activating control input 2 with 24V AC DC Make sure the second rated current is compatible with the current range of the Cat No 825 MCM current converter module Application Two speed motors Briefly increased loading of the motor and installation Maximum loading when the ambient temperature varies appreciably Examples Exposed water pumps different conveying capacities during daytime and at night Functions of the Cat No 825 MLV Option Card Phase Sequence Function If a motor is switched on in the wrong direction of rotation the installation can be adversely affected The Smart Motor Manager monitors the phase sequence when voltage is applied and prevents the motor starting in the wrong direction Applications Mobile installations e g refrigerated transporters construction machines Installations that can be displaced as enclosed units e g mobile crushers conveyor belts saws Ifa reversed phase sequence must be expected after a repair Publication 825 UM001B EN P January 2001 Functions 3 54 Table 3 AA Phase Sequence Setting Parameters Function Factory setti
127. tion is always active Therefore the response level must be set somewhat higher than the maximum starting current Publication 825 UM001B EN P January 2001 3 43 Functions Tripping is delayed by 50 ms This enables the circuit breaker to be actuated rapidly while preventing unnecessary tripping by current peaks In the event of a short circuit the separate output relay 1 trips regardless of the other protective functions The output relay 1 actuates a circuit breaker with adequate breaking capacity To prevent the contactor from opening under short circuit conditions relay MR remains blocked at currents 2 12 1 If a thermal trip occurred shortly before the short circuit relay MR assumes the tripped position as soon as the current has dropped to lt 12 I Figure 3 25 Interruption of a Short Circuit Q1M Circuit breaker tripping relay I Current curve 23 Ix Pickup value 1215 wy lg Rated service current i Tripping delay 50 ms tq Operating time of the breaker jg Arc duration 1 Short circuit 2 Contact separation 3 Short circuit interruption esu loco t Relay MR blocked at gt 12 Jp Relais 1 Relais MR lt In le gt t ow T L y tQ ug tBL Application Medium high voltage motors The short citcuit protection function must not be used for switching ATTENTION i off the contactor Publication 825 UM001B EN P January 2001 Functions 3 44 Table 3 W Short
128. to one of the following selectable actual values Thermal utilization calculated temperature rise of the motor Motor temperature max PT100 temperature Motor current 1 Specifications Output 4 20 mA IEC 381 1 at 5 60 C 23 140 F Load 0 300 Q Analog Output for Thermal Load or Motor Temperature PT100 Max This output supplies a current of 4 20 mA either proportional to the calculated temperature tise of the motor or the motor temperature max temperature of the operating PT100 Sensors The thermal load in percentage is also indicated on the LCD of the Smart Motor Manager Publication 825 UM001B EN P January 2001 3 49 Functions Application Local indication for continuous supervision of the load on motor and installation Load control With the indication of the momentary temperature rise of the machine the load on the installation can be continuously controlled to the maximum permissible temperature rise of the motor The result is optimal utilization of the motor with full protection and maximum productivity of the driven installation Automatic load control by a controller or inverter drive e g for charging mills and crushers the Smart Motor Manager itself is unable to protect inverter driven motors Figure 3 28 Analog Output for Motor Temperature Rise e A max 9o k 5 10 15 20 mA 4 17 2 9 Temperature rise of motor Oma Permissible temperature limit tr
129. ublication 825 UM001B EN P January 2001 Commissioning and Operation 6 2 Checking the Wiring Primary current transformer core balance current transformers Converter module Basic Unit Link between basic unit and converter module Inputs outputs Supply Communication Contacts 95 98 are marked according to electrically held non fail safe connection required Checking the Installation with the Control Voltage Applied Switching on the Control Voltage After applying control voltage the current converter is ready for operation in approximately 3 s LCD shows ACTUAL VALUE Main relay contact 95 96 is closed Checking the Set Parameters Methods e With the current converter in Set Values mode Access the parameters ot print them out and compare them with the set values in the list of settings The main settings are Rated or service current Locked rotor or starting current Permissible locked rotor time These three settings must be made individually for each motor Refer to page 5 4 Operational Parameters for procedure Publication 825 UM001B EN P January 2001 6 3 Commissioning and Operation Motor Current Ensure that the current converter s rated current in amperes is equal to the ampere rating on the nameplate of the motor Set the current converter rated current based on the service current of the motor if the installation or motor nameplate current is not
130. uit trip 50 ms 3 Tripping delay Z E Short circuit trip choice SHORT CIRC TRIP prid between output relay 1 AUX RELAY 1 J Y land no relay f EFCore Trip is set to off the e If EFC Warning is set to off th programming menu skips to parameter EF C Warning e programming menu skips to parameter Short Circ Trip If Short Circ Trip is set to off the programming menu skips to parameter Underload Trip Publication 825 UM001B EN P January 2001 Setting the Operational Parameters 5 8 Table 5 D Cat No 825 M Operating Parameters Continued Required Group Option Card LCD Seting Description Cat No 9 NDERLOAD TRIP B On Off 9 es oad protection OFF vo S P A 3 Underload tri EN UL TRIP LEVEL 25 100 5h08 p 75 le y Tripping level Ig OL TRIP TIME ue Undertoad trip 10 sec J ripping delay E NDERLOAD TRIP D Underload trip Underload MAIN RELAY All relays Assignment of output relay x J L START DELAY b Underload trip 0 0 240 Start delay 0 sec J OL WARNING D Orte V der oad warning OFF m NS Underload warning 4 N assignment of output relay UL WARNING E warning level is equal to ALARM RELAY 3 y ripping level without ripping delay STAR DELTA Star delta starting On Off On Off OFF J nf Pa Star
131. ult fuse PHASE LOSS TRIP trip F Redimension fuse noting f based on Failure during start short circuit coordination motor supply Check cables and terminal Broken lead connections Wait until motor has cooled down PT100 1 6 Stator winding overheated by sufficiently to permit reset RTD e Overload e Search for cause and remedy PT100 WARNING temperature e Too many starts hour e Reduce start hour warning Je Too many warm starts hour e Reduce warm starts hour e Obstructed cooling e Clean motor and cooling air intake PT100 1 6 High ambient temperature je Protect against heat Reduce PT100 s TRIP RTD load or shut down the temperature installation and wait until trip motor has cooled down sufficiently for a restart PT100 SHORT CIRC PT100 RTD has been short or open circuited a NO CONNECT ers This message may appear together witha PT100 1 6 RTD TRIP Failure in PT100 RTD circuit Check cables terminal connection and PT100 RTD sensor Publication 825 UM001B EN P January 2001 8 8 X Error Diagnosis and Troubleshooting Procedure if ALARM does not Reset Indication LCD Does not display the type of the alarm LCD active Red LED Flashing Cause for this Condition If the affected alarm function is switched OFF before the alarm has disappeared or the motor has been switched off then the alarm stays on whether the motor is switched on or off H
132. um number of START INHIB TRIP All relays starts hour reached MAIN RELAY J Assignment of output relay 2 START CONTROL On Off Monitoring starting time OFF On Off itori fe N Monitoring Starup START TIME 240 Maximum starting time TR 0 sec J Ix START CONT TRIP B All relays S arting time exceeded MAIN RELAY J Assignment of output relay If Warm Starting is set to off tl If Start Control he programming menu skips to parameter Start Inhibit If Start Inhibit is set to off the programming menu skips to parameter Start Control Publication 825 UM001B EN P January 2001 is set to off the programming menu skips to parameter Main Relay Setting the Operational Parameters 5 10 Table 5 D Cat No 825 M Operating Parameters Continued Required Group Option Card LCD Sening Description Cat No 9 Yq Electrically Main output relay in MAIN RELAY held non jelectrically held or ELECTR HELD j fail safe inon fail safe connection A Electrically Alarm relay in non fail safe ALARM RELAY held non fail jor electrically held WON FAIL SAFE D safe connection Special settings m TRIP RESET Manual auto Reset of thermal trip p g VANUAL y Manual automatic u THE RESET LEVEL 49 409 Thermal reset at 96 of 50 b thermal utilization ec
133. urrent 1 First start cool I Rated current Zz First warm start Oe Permissible temperature 3 Second warm start of the motor in conti 4 Cold start after the motor nuous operation and has cooled down normal tripping limit t inimum time before first of 825 M for continuous start is possible operation t1 gt 10t6z 1 Motor temperature tw inimum waiting time permissible for a short warm starts 4 60 min time and tripping limit of 825 M with modified characteristic for warm start The motor manufacturer s instructions must be complied with ATTENTION especially regarding the minimum wait between two starts An attempt to start may be made before the time has elapsed The Smart Motor Manager will trip during starting if the thermal capacity available is not sufficient Publication 825 UM001B EN P January 2001 3 37 Functions Applications The Warm Start function can be used in any installation that may have to be re started immediately after a voltage interruption Chemical process and production plants e g mixers centrifuges pumps conveyor systems Mines and tunnels fresh air fans water pumps Figure 3 24 Example for t6x 10 s and Warm Trip Time 70 104 103 102 Trip Time s NO wo 1 6 1 0 0 1 nxIe 1 0 1 1 2 0 3 0 4 5 6 7 8 9 10 0 Load Current as Multiple of Full Load Current a Time current characteristic from cold when setting the trip time t6x 10 s b Time
134. w hue gee bes 3 25 Barth Ground Pault cs tig itis verbe me DER EREE E eet ea 3 27 Limiting the Number of Starts per Hour Start Lockout 3 33 Monitoring the Starting Time 2 cies 3 34 Warm Starts 425 54 pasits dats ating ebd ide gren des E a 3 35 Emergency Override of Thermal Trip Emergency Start 3 38 LED Alarm and Trip Indicator 0 00 0 eee eee 3 39 Connection of the Main Relay MR 0 0 00 0 ae 3 40 Connection of the Alarm Relay AL 000 002 eens 3 40 Alarm Relay A Lere kenten een eadeke see e ine bee eet gt 3 41 Reset p P ERU beth eed EVEN A rU ee es 3 42 Function of the Cat No 825 MST Option Card 0 0 0 3 42 ShortCircuib sss dde dye e ERES EROS QUIETE as 3 42 Earth Ground Fault Protection with a Core Balance Current Ttanstofm6f c sesca E CE ee ehe UE TA aie d 3 44 Stalling During Statt sasaa aarep da eR We eer ada e aes 3 44 PTC Thermistor Input sseeseeeeee aa a 3 46 Analog Output iios et scent HD arp bei 3 48 Analog Output for Thermal Load or Motor Temperature PT100 Max sese 3 48 Analog Output for Motor Current iilis ees 3 50 Control Inputs 1 and 42 celles 3 51 Switching to a Second Rated Current 0 00000 3 53 Publication 825 UM001B EN P January 2001 Table of Contents iii Functions of the Cat No 825 MLV Option Card suus 3 53 Phase Sequences 2 2 0 neti esae ted NDREEPTU CPG Ru eae 3 53 Pha
135. w rockwellautomation com Power Control and Information Solutions Headquarters Americas Rockwell Automation 1201 South Second Street Milwaukee WI 53204 2496 USA Tel 1 414 382 2000 Fax 1 414 382 4444 Europe Middle East Africa Rockwell Automation Vorstlaan Boulevard du Souverain 36 1170 Brussels Belgium Tel 32 2 663 0600 Fax 32 2 663 0640 Asia Pacific Rockwell Automation Level 14 Core F Cyberport 3 100 Cyberport Road Hong Kong Tel 852 2887 4788 Fax 852 2508 1846 Publication 825 UM001B EN P January 2001 Software Version 3 15 Supersedes Publication 825 5 0EN dated June 1998 PN 40055 158 01 B 2001 Rockwell International Corporation Printed in the U S A Supersedes PN 40055 158 01 A

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