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Smart Motor Manager User Manual

1. 1 A l O i X xT1 100 Option 3 conductor T ME 825 MMV technique lo LL T PEE E ee et 1 D r Q f E xT1 100 Option 2 conductor l i 825 MMV technique Lo L O5 xT2 p ia J E E ees os 1 LO o xT xT3 PT100 Option 4 conductor a 825 MMV technique i 1 NET lo yt xTP po cum eel Y L 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 a gue Converter module cat nos 825 MCM2 825 MCM20 1 5 Ti d d 825 MCM 825 M m 2 4 6 k 1 ul 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 0 1 1 0 1 1 2 0 3 0 4 5 6 7 8 9 10 Lo
2. Required Group Option Card LCD zeng Description Cat No 9 UNDERLOAD TRIP On Off Underload protection OFF y On Of 0 D Underload tri UL TRIP LEVEL 25 100 110 p 05 le J Tripping level Ze OL TRIP TIME Underload trip EJ Tan Tripping dela 10 sec J pping y fa gt _ UNDERLOAD TRIP All rel Underload trip relays Assi f output rel Underload MAIN RELAY y ssignment of output relay fa UL START DELAY Underload trip mH 0 240 Start dela 0 sec J y OL WARNING b Underload warning On Off On Of OFF p n Underload warning a assignment of output relay UL WARNING warning level is equal to ALARM RELAY J y ripping level without ripping delay STAR DELTA oworre a starting OFF p i Star delta starting STAR AUX REL 4 Relay 4 Assignment of star output 9 relay Star Delta Z N Star delta starting Wye Delta 825 MIV DELTA AUX REL 5 Relay 5 Assignment of delta output starting V p relay SET STAR TIME j Star delta starting OFF On Off Max time on star on off 2 STAR TIME Star delta starting time on star 10 sec J If Underload Trip is set to off the 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 prog
3. 3 32 Network Earthed through a High Impedance Earth Ground Fault on the Motor Leads 3 32 Isolated Network Earth Ground Fault it the Motor Shake OY xb SOS n 3 32 Network Eatthed through a High Impedance Earth Ground Fault on the 3 32 Limiting the Number of Starts per Hour 3 33 Monitoring Starting Time 3 34 Current and Temperature Curves for Warm and Cold Motor Starts and the Smart Motor Manager Tripping Limits sesei in E sae RS 3 36 Example for t6x 10 s and Warm Trip Time 70 0 0 eee eee ee 3 37 Interruption of a Short Circuit 3 43 Stalling During 5 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 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 Position ser eb ER Re n 4 2 Basic Unit Mounted into Panel Mounting Frame Cat No 825 FPM 0 ee eee 4 2 Publication 825 UM001B EN P January 2001 Figute 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
4. ci Assembly and Installation 4 4 Table 4 B Cat Nos 825 MCM630 825 MCM630N Dimensions in millimeters inches TIENS UE 145 825 MCM630 6 D 5 11 16 e 3 Us A 5 m B ha 10 uc 19 155 145 177 118 6 3 6 3 135 825 MCM630N 57 64 5 11 16 6 31 32 4 5 8 174 1 4 5 5 16 ere M10 uc E Thermal Utilization Indicator Figure 4 6 Cat No 825 MTUM Thermal Utilization Indicator MN Av Panel cutout 91 5 x 91 5 mm 3 39 64 x 3 39 64 71 mm 71 16 0 5 mm 1 32 Mounting depth 55 mm 2 3 16 hv Y Wire size 2 x 2 5 mm 14 AWG 0 1 Jl Ns To retrofit ot replace options the assembly and testing instructions ATTENTION 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 eooco 00 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
5. 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 SEU VALUES and or locked rotor time are Set LOCKED ROT TIME to 10 s 0018166 ine permissibie range ec 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 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 use e Failure during starting e Redimension fuse note short circuit coordination a Raise threshold in basic unit to Motors idling e g pumps permissible level AS WARNING Asymmetry Poor 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 PRA converter module f asymmetry is acceptable raise Asymmetrical motor winding hreshold in basic unit otherwise repair motor Main current transformer error e Metering class current e Insert the correct current transformer instead of transformer protection current transformer e Wrong current range e Replace the current transformer e Current transformer rating e Replace the current too low transformer e Incorrect current transformer e Che
6. Separately Ventilated Motors Because they are 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 COOL CONST RATIO 1 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 Converter module Cat No 825 MCM2 Cat No 825 MCM20 g x s 5 H 825 MCM 825 M 2 4 6 l a es T1 Primary Current Transformer A 5 A or A 1 A Selection refer to Chapter 2 Specifications Basic Unit and Converter Module for setting refer to Chapter 5 T2 Core balance transformer Earth Ground Current 5mA 60 A 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 L2 L3 Converter module
7. 2 10 Recommended Data for Core Balance Current Trans formet criba p dd palco iba oan 2 11 Converter Module Related Error Messages 2 13 Actual Values 3 1 Set Values Overview 3 2 Recorded Values 3 3 Display Example of Set Values Menu 3 6 Display Example of Actual Values Menu 3 7 Display Example of Recorded 3 9 Protective Functions 3 13 Warning Functions Summaty 3 14 Control Functions 3 15 Thermal Overload Setting Parameters 3 21 Protection Against Thermal Overload 3 22 Asymmetry Phase Unbalance Setting Parameters 3 23 High Overload and Jam Setting Parameters 3 24 Underload Setting 3 26 Earth Ground Fault Holmgreen Residual Setting Parameters oh ane tee Sew 3 28 Core Balance Current Transformer Setting Parameters vere e e ee EORR S 3 29 Earth Ground Fault Core Balance Setting Parameters sosedne DE ER ned 3 29 Starts per Hour Setting Parameters 3 33 Monitoring Start Time Setting Parameters 3 35 Warm Start Setting 3 38 Alarm Examples eroe uer ee t ees 3 41 Reset S
8. aouanbas 461 zi m seyd 205 Beets esi queg SYA Od OV A vc sjndui FRU i OG OV rz i 6297 A SSS 4o01siuuou a LSW Sz8 uue3 4 x 88 uun aiseg Jeso1 ejouioH ZZA v Iu E WOW 28 49 043u02 628 LT aiqesiq 1 ELA kai 9 11 KouebJjeui M 3 021 uoneiedo Ajddns i i a CBE a tee oe yee Publication 825 UMO01B EN P January 2001 2 4 X 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 mme P AB Allen Bradley SMART MOTOR MANAGER Aarm o 5 Fault indicator LED Flashing warning Steady state trip LCD Single line two lines of text are displayed alternately Values Selection of mode Actual Indication of actual operational data Set Setting mode set modify store parameters Recorded Indication of statistical data Select Select function and enter change operating parameter Settings Enable entry Change and memorize Enter Test Verifies operation of Smart Motor Manager Reset Enables the Smart Motor Manager after a trip ec eoo Publication
9. FH iu i 25 H3 icc eee 0 EE 96 198 1 2 14 az H2 H L2 F8 2 1 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 The mounting wiring directions and the specifications of the ATTENTION contactor being used must be considered Publication 825 UM001B EN P January 2001 9 3 Applications Wiring Star Delta Starter with Bulletin 825 Smart Motor Manager Main Circuit Figure 9 3 Basic Unit and Converter Module Basic Unit settings 11 L2 30 1 FULL LOAD CURR FLCx0 5774 A 1 3 5 1135 M S 1 1 1 1 are K2D pA Kevin N 2 4 2 4 6 2 4 8 LOCKED ROT CURR lga D c S Ut 825 MCM 825 M F1 LOCKED ROT TIME fg sec Ut VI W1 U1 Converter module x d db Cat No 825 MCM2 Cat 825 MCM20 gt i Cat No 825 MCM180 START TIME gt 58 NE Cat No 825 MCM630 M P 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 F1 Electronic cont
10. Allen Bradley Smart Motor Manager Bulletin 825 User Manual Rockwell 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 are many variables and requirements associated with any particular installation Allen Bradley does not assume responsibility or liability to include intellectual property liability for actual use based upon the examples shown in this publication Allen Bradley publication SGI 1 1 Safety Guidelines for the Application Installation and Maintenance of Solid State Control available from your local Allen Bradley office describes some important differences between solid state equipment and electromechanical devices that should be taken into consideration when applying products such as those described in this publication Reproduction of the contents of this copyrighted publication in whole or part without wtitten permission of Rockwell Automation is prohibited Throughout this manual we use notes to make you aware of s
11. 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 Response Level Setting range 55 99 Factory setting 7596 10096 Setting increments 196 Output Relay Selection AL 5 MRNoouputreay _ 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 Higher 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 volt
12. 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 e 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 0 A max 9c Ok 5 10 15 20mA 4 17 2 9 Temperature rise of motor Omax Permissible temperature limit tripping threshold 0g Nominal temperature load 75 Oy Coolant temperature 40 C or via PT100 7 Thermal utilization calculation Therm utiliz PAA 100 16 mA Publication 825 UM001B EN P January 2001 Functions 3 50 Figure 3 29 Analog Output for Motor Temperature 0 A 200 C 50 C 5 10 15 20 mA 4 Motor Temperature calculation Motor temp C Gas 150 C 16 mA 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 le 200 100 0 5 10 15 20 mA 4 12 Motor current calculation _ mA 4mA M
13. 825 MCM2 825 20 pem 825 MCM180 825 MCM630 825 MCM630N 1 3 5 825 MCM 825 4 6 kj IR 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 7 Main Circuit Figure 9 12 Application with Low Idling Current R 110 120V AC DC R 12kQ 4W 825 M 24 V AC DC E uc 1 2 825 5 Display Gali lt 20 IE e Motor switched on e Motor current lt 20 J Settings N SPEED SWITCH ON ae INPUT 1 0 220 230V 27kQ 5W If motors have an operational idling current of less than 20 I then the information motor 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
14. DELAY AUX 3 0 240 On delay of output relay 3 sec ad OFF DELAY AUX 3 0 240 Off delay of output 2 sec J relay 3 N NEW Setting 2nd rated motor OFF On Off rent Off On x m PRIMARY 2 Use of primary c t for 2nd NO J No Yes rated motor current N Current ratio of primary c t PRIMARY C T RATIO a e g 500 A 5 A d 2 setting 160 N Setting 2nd rated motor NEW FLC p sinen 20 A Jj On Off DISABLE FUNCTION D ot disabled Disable protective function OFF y disabled On Off ASYMMETRY PROT Not disabled Asymmetry protection NOT DISABLED J disabled Active locked ou OVERCURRENTPROT Not disabled Overcurrent locked rotor rotection NOT DISABLED J disabled etive iocked ou EARTH FAULT PROT Not disabled Earth fautt protection NOT DISABLED J disabled Active locked o SHORT CIRC PROT Not disabled Short circuit protection NOT DISABLED J disabled Active locked ou he programming menu skips to parameter Phase Rever Trip the programming menu skips 0 parameter New FLC 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 O
15. ole otal number of trips asymmetry Nen A 5 NUMBER OC TRIP Total trips overcurrent locked rotor c 2 NUMBER EF TRIP otal trips earth ground fault s J NUMBER SC TRIP Total trips short circuit cS A fa NUMBER UL TRIP otal trips underload NCC lt D NUMBER PTC TRIP otal trips overtemperature PTC T 7 NUMBER PR TRIP otal trips phase sequence motor supply Ca D NUMBER PL TRIP N otal trips phase failure motor supply C D NUMB PT100 TRIP otal trips overtemperature PT100 Ner E CLEAR REC VAL To clear all recorded values except running time of basic unit go to GOTOENDSETVAL J end set values c END REC VALUES End of recorded values V A Publication 825 UM001B EN P January 2001 Testing and Maintenance 7 5 Checking with Test Equipment 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 sufficie
16. 20K Rotor Temperature The rotors of squirrel cage induction motors with simple construction no insulation may continuously attain higher temperatures than rotors in motors with insulated windings However in larger motors the concentration of the rotor losses during starting is higher than the concentrations of losses in other parts of the motor The starting time of such motors is therefore limited by the thermal capacity of the rotor These types of motors are commonly referred to as rotor critical motors Critical to the rotor are the mechanical stresses caused by the temperature rise unsoldering of the rotor bars and for EExe motors motors for use in the chemical industry the high temperature as a source of ignition Operational Requirements for Installation Monitoring the application parameters and process data of an installation can be very important Even a slight change in the starting and operating behavior of the motor can indicate an impending fault The Smart Motor Manager helps eliminate potential trouble before major repairs are necessary and loss of production occurs Publication 825 UM001B EN P January 2001 1 6 Introduction The Smart Motor Manager fulfils these requirements by providing protection against the following high overload stalling and jam underload phase sequence Personnel and Installation Safety Personnel protection in the vicinity of control equipment is of primary importance
17. 5 The LED lights 6 The selected output relay picks up LCD oo 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 a 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 Functions Setting Factory Tripping Factory Relays 6 Factory Factory Range Setting Delay Setting Selection Setting Setting Range Bulletin 825 M Basic Unit Thermal overload On 100 MR No R Asymmetry phase failure On 5 80 35 1 25s 25s A R High overloading jam On 1 67 241 01 55 0 55 R Underload 0 25 100 75 1 60 s 10s A R Underload delayed enable On 0 240s 0s Earth ground fault residual On 10 100 50 0 1 5s 0 55 R Starting time monitor 0 1 240s 10s A R Limited starts per hour 0 1 10 2 A R Bulletin 825
18. Publication 825 UM001B EN P January 2001 Functions 3 8 Applications The Actual Values mode provides Assistance during programming and setup Verification after maintenance 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 Valves 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 lt Set Recorded A Values Select Settings Actual Change 9 Set Recorded i 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 j Display of the statistical data M J 825 MAIN TIME B Bulletin 825 M running time including interruption 8 hour of control H MIN voltage in hours minutes Co 55 2 f N MOTOR RUNNING TIME Total motor running time in hours minutes _h___min J 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 means of determining maintenance jobs o
19. Starting current 1 ta Starting time I Rated service current t Time 1 612 Ip 2 2 1 aam lA AAA gt Oscillogram of switching a squirrel cage induction motor by direct on line starting The high motor starting current J 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 not thermally homogeneous The winding stator iron and rotor have different heat capacities and conductivities Following unduly heavy loads e g during starting temperature equalization occurs between the various parts of the machine heat flows from the warmer winding into the cooler iron until the temperature difference is minimal Figure 1 4 Temperature Rise Characteristics of Motor Windings Og Temperature limit of the insulation pe H Oy Coolant temperature e XM Og Temperature rise at start Oe Temperature rise when operated continuously at rated current tA Starting time ot gt t Permitted stalling time ta lg Temperature rise in a motor winding During the starting time t4 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
20. EF C TRIP TIME 0 1 5 core balance transformer 0 50 sec J Tripping delay Earth ground fault 825 MST x ana M EF CORE TRIP All relays trans ormer MAIN RELAY J Assignment of output relay N Earth ground fault EF C WARNING On Off warning core balance OFF J ransformer On Off Earth ground fault EF C WARN LEVEL 5 999 mA warning core balance 1 00 50 00 A transformer 500 mA S Tripping level N Earth ground fault EF C WARNING All warning core balance ALARM RELAY J y ransformer N mee SHORT CIRC TRIP Short circuit protection OFF On Off On Off h v motors only 2 Short circuit tri SC TRIP LEVEL p 10 00 x le 4 0 12 0 Tripping level Ze Short circuit 825 MST N MET SC TRIP TIME 20 990 Short circuit trip 50 ms J d Tripping delay N Relay 1 Short circuit trip choice SHORT CIRC TRIP fio ci between output relay 1 AUX RELAY 1 J Y land no relay f EF Core Trip is set to off the programming menu skips to parameter EF C Warning f EFC Warning is set to off the programming menu skips to parameter Short Circ Trip f 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
21. L1 L2 L3 l l 4L 3 47 6 P19S1 19516 1951 25 zsm Publication 825 UM001B EN P January 2001 Functions 3 28 Table 3 0 Earth Ground Fault Holmgreen Residual Setting Parameters Trip Function Factory setting Response Level Setting range 10 100 Factory setting 50 Setting increments 10 Tripping Delay Setting range 0 1 58 04s Factory setting 0 5s Setting increments 0 18 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 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 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 carly 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 prot
22. et AR pA ERO 8 3 Procedure if ALARM does not Reset 8 8 Procedure if TRIP cannot be 8 8 Chapter 9 Applications Wiring Bulletin 825 Smart Motor Manager with 9 1 DUREE A RONG SESTO ORO ROC ac 9 1 Control CITCUb sepas 02 der deed PE NER e or HERR ER a deed 9 2 Star Delta Starter with Bulletin 825 Smart Motor Manager 9 3 Main e Pia dia sede vane nee AR VP Ed 9 5 Control 9 3 Short Circuit Protection of Medium High Voltage Motots 9 4 Main Circuit with Cat No 825 MST Option Card 9 4 Control Circuit sperrir eder Y v TIERE T E TE 9 5 Two Speed Motors isses eee tk ere Rear e e e 9 5 Mam Citita E E TEE LE LR 9 6 Two Speed Motor 0 5 lt Speed I lt 20 lt Speed lt 180 Dy Main CI CUIU ex p RR aun Ree ee 9 7 Two Speed Motors with Primary Current Transformer 9 8 Primary CIFCUIE ers 9 8 Separately Ventilated Motors 0 0 0 0 eese 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 9 9 COECUIG i eee Doa RA ere eie A ac AUR Ce C e RUN de
23. 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 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 4 6 2 Phase Current 4 7 Smart Motor Manager Basic 4 8 Cat No 825 MST Option 4 9 Cat No 825 MLV Option 4 10 Cat No 825 MMV Option 4 11 Range of Starting Currents of Standard Motors Expressed as Multiple of the Rated Service oe oia oy Pete es sente dest he gees 6 4 Test with a 3 Phase Current 7 5 Test with a Single Phase Current Soutce 7 6 Basic Unit and Converter Module lusu 9 1 Control by Momentary Contact 9 2 Basic Unit and Converter 9 3 Control by Momentary Contact 9 3 Basic Unit for Short Circuit Protection 9 4 Control by Momentary Contact 9 5
24. 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 EW FULL LOAD CURRENT 5 12 UNDERLOAD TRIP p 5 8 PHASE REVERSAL TRIP 5 13 UNDERLOAD WARNING 5 8 PHASE LOSS TRIP SEM 5 13 STAR DELTA STARTING 825 MLV 5 8 PT100 PROTECTION WARM STARTING 5 9 PT100 RESET WARNING START INHIBIT 5 11 OUTPUT 4 20 mA 825 MST 5 15 START CONTROL 5 9 STATION NUMBER 5 16 AIN RELAY CONNECTION 5 10 REL 2 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 functions associated with ATTENTION option boards 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 Li
25. DC 825 MCM 180 Y41 Y42 825 MST 220 230V AC DC R 27 5W 110 120V AC DC R 12kQ AW 0 5 A Speed 1 20A Motor supply cables loop n times through 825 MCM180 until n x J gt 20A Current setting 825 M n x J I 20 A lt Speed II lt 180A Motor supply cables loop once through 825 MCM180 Current setting 825 M Z II 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 AW 24V AC DC R 0Q L1 L2 L3 L1 L2 L3 Lo N R ie I dr 10 5 5 ae K1 K2 M 3 24 V AC DC 8 Oo YA2 Y4 For setting the second rated current speed Il refer to Chapter 5 Control input 2 Ki 825 5 Secondary circuit I I 34 I 100 5 REM Idee BRE RE c EY 825 MCM 2 20 825 M In
26. DC 97 6 Output relay MR in electrically held connection Factory setting IEC 400V AC 125V DC 98 0 UL CSA 240V AC 125V DC Output relay MR in non fail safe connection e 400V AC 125V DC 95 9 UL CSA 240V AC 125V DC 96 9 External Internal Setting via communication 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 Aux Relay 1 24 33 9 3 1 Aux j Relay 2 34 43 9 1 Aux j Relay 3 44 l 4 20 MA 0 300 W j ol Control Y31 Input 1 9 Y32 Control Y41 Input 2 o Y42 T1 PTC o T2 L1 L2 L3 k External Internal Auxiliary relay 1 IEC 400V AC 125V DC UL CSA 240V AC 125V DC Auxiliary relay 2 50V AC 30V DC Auxiliary relay 3 50V AC 30V DC Analog output indicates the thermal utilization of the motor the motor temperature or the motor current Indicating instrument PLC input Recorder Control input 1 24V DC or 24V AC 9 Control input 2 24V DC or 24V AC 9 Thermistor overtemperature protection max 6 PTC wired in series Measuring lead Min cross section 05 075 1 1 5 2 5 AWG No 20 18 17 16 14 Max length m 200 300 400 600 1000 ft 656 984 1312 1968 3280 Core balance transform
27. Delta Wye Delta Starting Setting Parameters Setting Star Wye Relay Delta Relay Bg ee Function Factory setting Off Off Setting Settingrange 1 20s Factory setting Relay 4 Relay 5 10s Setting steps 1s Publication 825 UM001B EN P January 2001 Functions 3 56 Functions of the Cat No 825 MMV Option Card PT100 100 C 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 Table 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 beating temperatures The temperature is continuously indicated in The alarm and tripping temperatures can be set as desired Applications Large low voltage motors Medium and high voltage motors e 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 Fun
28. January 2001 Functions 3 20 Figure 3 9 Trip Characteristics 40 100 s Trip time s 100000 0 10000 0 1000 0 100 0 10 0 1 0 1 1 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 Load current as multiple of full load current nXle For UL CSA applications refer to page 9 14 Publication 825 UM001B EN P January 2001 3 21 Functions Table 3 J Thermal Overload Setting Parameters Detection Module 6 825 MCM2 825 MCM20 825 MCM180 825 MCM630 825 MCM630N Rated Current Setting range 0 5 25A0 25 20A 0 20 180A 160 630 160 630 A Factory setting 20A 20A 20A 20A 20A Setting increments 0 01 2A 0 1 2A 1A 2 2 Locked Rotor Current Multiple of Rated Current Setting range 25 121 Factory setting 6 Io Setting increments 0 1 I Locked Rotor Time Admissible Locked Rotor Time of Cold Motor Setting range 1 600s Factory setting 10s 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 Ultimate Release Current Incl setting tolerance 1 05 1 15 Ze Upto 2 000 A if primary current transformers are used 5 60 C 23 140 F UL CSA 160 434 A
29. 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 higher than the temperature limit reduces the motor life by half This life law shows that particular attention must be paid to adhering to the permitted operating temperature for long periods of time Note that overtemperatures of short duration and infrequent occurrence do not seriously affect the life of the machine The Bulletin 825 Smart Motor Manager s ability to accurately limit excessive current conditions greatly aids in extending motor life In practice it may be expected that there will be reduced loads and pauses so that when the temperature limit is reached the motor life will not be impaired Figure 1 5 Reduction in Average Life Ej of a Motor when Winding is Continuously Overheated M EM Average motor life S 100 Og Temperature limit of the insulation 70 50 25 45K 10K 15
30. MR Electrically held non fail safe Electrically held Reset of thermal trip Manual auto Manual Reset at thermal utilization 10 100 50 Reset PTC trip Manual auto Manual Cooling constant ratio motor off on 1 5 10 25 Motor insulation class 9 B E F B Motor insulation class needs to and be set only if PT100 7 RTD is included in the thermal image ATTENTION Do not exceed the permissible values quoted by the motor manufacturer 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 7 2 Remote 1 0 Station number 0 63 2 Baud rate 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 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 3 group 6 The rack size is fixed to 1 4 rack Baud Rate for DF1 Calculated according to the following formula Value 64 x mode 32 x stop bits 8 x parity
31. 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 Norn 25 Continuous thermal current 4 Rated operating current for AC 15 3 3 12 peu T ML current 30 30 12 Rated operating current for DC 13 PUE network N 2 03 02 s ax rated current of back up fuse A 104A 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 o 1 4 A at 250V AC or 30V DC cos o 0 4 L R 7 ms 2 A at 250 VAC or 30V DC Max Switching Power cos 1 1 250 VA 150 W cos 0 4 L R 7 ms 500 VA 60 W as per UL CSA 240 V 1 A pilot duty Contacts fitted 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 o 04 L R 7 ms 60 W Publication 825 UM001B EN P January 2001 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 AW
32. 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
33. QA Shunt trip coil K1 Contactor Fi Bulletin 825 Electronic control and protection system 51 push button S0 Off push button 0 Control voltage H1 Indicator Contactor closed H2 Indicator 825 M tripped except for short circuit protection MR Main relay AL Alarm relay H3 Indicator Alarm Warning 1 Aux relay short circuit indication Converter Module 825 MCM2 825 MCM20 825 MCM180 F7 L1 sot f sit Ki pues 495 7 23 _ __ M Ft ui B 825 M ES fes as PUTAS QM KIZI HACH RHI L2 F8 E id g Two Speed Motors The following ranges are possible for speeds I and II Speed 1 11 0 5 25A with 25 20A with 20 080A with 160 630A with Publication 825 UM001B EN P January 2001 825 MCM630 or 825 MCM630N Applications Wiring 9 6 Main Circuit Figure 9 7 Two Speed Application Utilizing One 825 MCM Li 12 L3 L N af 5 220 230V AC DC R 27kQ 5W R 110 120V AC DC R 12kQ 4W 825 MCM 825 M 24 V AC DC 2 4 6 XM Y41 Y42 M 825 MST 3 For setting the second current speed refer to Chapter 5 Control input 2 Publication 825 UM001B EN P January 2001 9 7 Applications Wiring Two Speed Motor 0 5 lt Speed I lt 20 A lt Speed Il lt 180 A Main Circuit Figure 9 8 Two Speed Application Utilizing 825 MCM180
34. 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 Known starting time of the motor is 15 sec Locked rotor time to be set tA 15 approximately l4 147 115 Setting the locked rotor time with the aid of the indication of thermal utilization Basic Unit ACTUAL VALUES display LCD UTILIZ 00 96 Set the locked rotor time so that the current converter does not trip 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 Gd 00 le Motor peneing yp must drop from about 400 800 7 to the service current of 100 Jp start Publication 825 U
35. Sim 1 0 473 04 0472 F T Sn PT100 7 for indication and inclusion of PT100 5 r 95T3 thecoolant ambienttemperature cooling L___ 4 512 air in the thermal image If PT100 7 is i not connected then a resistance of 251 981 7120 Q should be connected between 1 PT100 6 t o6Ts andT3 em Tamb IN TH IMAGE PT100 47 2L o 773 OFF 9772 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 212 Common screening connect screen to 2 and all T2 together e g 1T2 212 Publication 825 UM001B EN P January 2001 Assembly and 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 3 All parameters of option cards can b
36. The corresponding requirements of regulatory agencies are therefore becoming increasingly severe The Smart Motor Manager reflects this by providing the following protection equipment construction touch protection insulated housing motor protective functions e Earth ground fault High overload stalling and jam e Wrong direction of rotation 5 Bulletin 825 Smart Motor Manager as Automation Component The Bulletin 825 Smart Motor Manager detects abnormal operating conditions and faults in motor branch circuits The data made available by the Smart Motor Manager can be used for operational control and optimization of the installation A large number of supervisory protective and control functions improve operational control and avoid unnecessary downtime This maximizes your motor investment making the Smart Motor Manager a valuable component in modern automation systems Publication 825 UM001B EN P January 2001 Chapter 2 Equipment Description System Structure The Bulletin 825 Smart Motor Manager is a microprocessor based protection and control system for motors For the AC motor and the operated installation this means e 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 protec
37. Two Speed Application Utilizing One 825 MCM 9 6 Two Speed Application Utilizing 825 MCM180 9 7 Two Speed Application Utilizing Primary Current Ttanstotmet seems hi REED CAE as 9 8 Typical Application Utilizing Primary Current Transformers and Core Balance Current Transformer yer Ta Were en dr aes 9 9 Typical Application Utilizing Core Balance Current Transformer oe a iene es 9 10 Application with Low Idling 9 11 2 3 4 Conductor Technique for PT100 Wiring 9 12 Typical Application Utilizing 2 Phase Current Evaluation with Primary Current Transformers 9 13 Tap Characteristic cese thee eee t re 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 I 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 1 Table 3 J 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 5 Table 3 T Table 3 U Table 3 V Table 3 W Environmental Ratings 2 5 Nominal Rated Voltages 2 6 Electrical Ratings ecce gente eet eee anias 2 6 Supply Ratings 245 p eased RYE VER EE 2 7 Relay ROREM RA CERE RET 2 8 beet PROPRES 2 9 Main Current Transformer
38. 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 and all of the power absorbed is converted into heat As the motor speed increases the power converted into heat decreases But if the rotor remains locked the temperature of the stator and rotor windings rises considerably caused by the high losses and the short time that heat can flow into the laminated core If the motor is not switched off quickly the stator 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
39. before tripping occurs Blank display means Time gt 9 999 s Indication of the Time until the Thermal Trip can be Reset LCD en IN sec Following thermal trip the basic unit may not be reset until the reset threshold has been reached This 15 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 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 Characteristic 10 30 s 10000 0 1000 0 From cold without pre load 10s 20s 30s 100 0 9 E 2 E 10 0 10s 20s 30s 10 From warm pre load 1x e 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 UM001B EN P
40. increased productivity Alarm thresholds can be set for Thermal utilization of the motor Overcurrent e Asymmetry Underload Earth ground fault with core balance transformer 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 Asymmetry When an asymmetry condition occurs and the related threshold is reached the following responses occur e LED flashes LCD AS WARNING The assigned output relay picks up Publication 825 UMO01B EN P January 2001 8 2 Error Diagnosis and Troubleshooting Cause of the warning may be Unbalanced mains Defective motor winding Defective contacts Actions If the installation can be shut down without loss of production or without affecting safety e Switch off the installation e Search for the fault and repair it If it is important to keep the operation running Continuously monitor the level of ACTUAL VALUES ASYM e If the alarm level continues to rise measures should be taken so that the installation can be shut down quickly e 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
41. is set to off the programming menu skips to parameter Control Input 1 If 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 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 Operational Parameters Table 5 D Cat No 825 M Operating Parameters Continued Required Group Option Card Cat No Control input 1 continued 825 MST f Speed Switch is set to off e Setting LCD Range Description Speed switch stop indicator locked rotor during start rr SWITCH On Off On Off and or auxiliary contact OFF n Off of motor contactor motor switched on for motors with Im lt 20 Ig Trip time tsp depends on the trip N time chosen for the overcurrent SS TRIP TIME tov as follows 0 9 SEC J tov lt 400 ms tsp 600 ms toy 2 400 ms tsp toy 400ms SS TRIP D Trip on relay chosen for MAIN RELAY J overcurrent locked rotor DISABLE FUNCTION Disable protective function oi On Off On Of M J ASYMMETRY PROT Y Not disabled Asymmetry protection NoT DISABLED J disabled Active locked ou t locked rot OVERCURRE
42. mA Earth ground fault current in mA A with core balance 1 00 current transformer M 50 00 A fTambient C j ambient 0 210 Ambient temperature in C PT100 7 V 2 o gt PT100 1 C 0 210 Temperature in C PT100 1 Ne J 5 PT100 2 C 0 210 Temperature in C PT100 2 M 2 N PT100 3 C 0 210 Temperature in C PT100 3 22 p N PT100 4 C 0 210 Temperature in C PT100 4 V 2 o o PT100 5 C 0 210 Temperature in C PT100 5 MV o o PT100 6 C 0 210 Temperature in C PT100 6 V J Display of communication option AREA N DevNet DeviceNet 825 MDN DevNet XX YY ZZZ R 1 0 Remote 1 0 3600 RIO ks J MODBUS Modbus 3600 MBS PROBUS PROFIBUS 825 MPB END ACT VALUES End of actual values V 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 button e With the test condition set e With a single or 3 phase current source A test may be beneficial During 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
43. 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 e Running time of the motor the Smart Motor Manager contactor etc Necessaty service jobs Operational behavior 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 fo gt RECORDED VALUES Mode Recorded values SS 2 625 MAIN TIME Total basic unit running time including interruption of control voltage in H MIN hours minutes C P 4 gt MOT RUNNING TIME Total motor running time in hours minutes H MIN J a gt SINCE LAST START Time since last start in ho
44. 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 Motor Operating Characteristics Electric motors absorb electrical energy and supply mechanical energy During this energy convetsion 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 at no load losses caused by remagnetization and eddy currents Mechanical losses caused by friction and ventilation Losses dependent on the current these losses increase with load i e with the current consumed by the motor Heat losses caused by the current in the stator Heat losses caused by the current in the rotor Increased temperature rise caused by poor cooling e g cooling fins are dusty or damaged coolant temperature is too high Publication 825 UM001B EN P January 2001 Introduction 1 3 Figure 1 2 Operating Characteristics of an AC Motor P Power Pe Rated operational power Pv Power losses Pve Power losses under rated conditions I Operational current Ie Rated service current n Speed Rated operational speed Ng Synchronous speed cos Power factor n Efficiency 25 50 75 100 125 US Operating characteristics of
45. 01B 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 installation instructions and the specifications for ATTENTION the contactors auxiliary relays etc Main Circuit Figure 9 1 Basic Unit and Converter Module Li L2 L3 U1 Converter module 1 Cat No 825 MCM2 EZ A Cat 825 MCM20 Cat No 825 MCM180 Cat No 825 MCM630 t 3 5 Cat No 825 MCM630N 825 M F1 Publication 825 UM001B EN P January 2001 Applications Wiring 9 2 Control Circuit Figure 9 2 Control by Momentary Contact F7 Us K1 L1 F1 Sor i S1 S0 i Us 5164 Ki HI i H2 95 TIN At 118 BR po npe
46. 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 ot subsequently modified is displayed Functions not activated OFF are not indicated 1 To set the operation parameters repeatedly press the Va ves button until SET VALUES appears on the display Figure 3 1 Setting Mode SET VALUES Actual Q Set Recorded Enter Select Settings Values 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 Actual Change Recorded 4 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 ect keys Up or Down The entry is completed by pressing Settings Enter Publication 825 UM001B EN P January 2001 Functions 3 6 Figue3 3 Entering a Data Value Actual lt Recorded Values Select Settings Note Hold down the 5 button to change the values more quickly Table 3 D Display Example of Set Values Menu LCD Range Desaiption SET VALUES Mode setting parameters M A FULL LOAD CUR
47. 25 UM001B EN P January 2001 Table of Contents iii Functions of the Cat No 825 MLV Option 3 53 Phase Sequence se rani sse veter RES brane T QR ER Er des 3 53 Phase Failure Based on Voltage 3 54 Star Delta Wye Delta 5 3 55 Functions of the Cat No 825 MMV Option 3 56 PT100 100 Q Platinum Temperature Sensor RTD 3 56 100 7 Temperature Sensor 3 57 Chapter 4 Assembly and Installation e ded equ 4 1 Blush Mounties rr tret a Sen RENE SR 4 1 Mounting Postti n SVG nei eR d e dran 4 2 Sutiac Montin vae rre Re heey ee aes ERRORES ECT ERA 4 2 Converter Modules ERI REPE EPOR UE ERIS 4 3 Thermal Utilization Indicator 00 ee eese 4 4 Installation and Waning st ses xp gee we COSA RE Res 4 5 General sve eser ERR CR 4 5 Main Circutts 4i baa thee Cede die QE SE Gd ie 4 6 Control Citcutts Lii aset ebbe tee oad aqu 4 8 Chapter 5 Setting the Operational Parameters Menu Overview cescetekek eene E chee ER EE ess 5 1 Main Settlos 32 oie pep IN REP EC PEE 5 1 Special Settings ences RE He ERE IRURE she egies kata 5 2 Opera np Parameters ilte teer hr peers aX RE TR PERS 5 4 Chapter 6 Commissioning and Operation
48. 825 825 Test Voltage MCM20 MCM180 825 MCM630N MCM630 Mo Uimp as per IEC 947 1 60 P 12W Control Circuit Between control circuits and to all other circuits Main relay MR 95 98 supply A1 A2 u Phase sequence protection AN 11 12 13 Alarm relay AL auxiliary relay 1 4 5 as per IEC 947 4 Core balance current transformer k Control inputs 1 2 Auxiliary relays 2 3 2 5 kV as per IEC 947 4 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 950 60 Hz 22 24 33 36 44 48 110 120 220 240 Nominal supply voltage Us 380 415 440V AC 24 48 72 120 220V DC AC 0 85 1 10 Us 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
49. 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 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 9296 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 ae 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 relay MR 95 98 supply A1 A2 Phase sequence protection L1 L2 L3 as per IEC 947 400V AC as per SEV 380V AC as per UL CSA 240V AC Alarm relay AL 13 14 Auxiliary relay 1 4 5 as per IEC 947 400V AC as per SEV 250V AC as per UL CSA 240V AC Auxiliary relays 2 3 50V AC 30V AC Control inputs 1 2 24V AC DC Table 2 C Electrical Ratings
50. 90 AL 1 5 AL Bulletin 825 MST Option Card Earth ground fault 7 un balance et 0 5mA 50A 500mA AL 1 5 AL Bulletin 825 MMV Option Card PT100 input 1 6 RTD o o stator bearings 0 50 200 C 50 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 Setting Factory old Factory Relays Factory Setting Range Setting Range Setting Selection Setting Bulletin 825 M Basic Unit nou start of tod of sp iyw 70 4 60 min S D Emergency override of thermal trip Bulletin 825 MST Option Card Analog output assigned to 4 20 mA thermal utilization On 0 100 100 50 200 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 0 240 1 2 1 Dropout delay relay 7 0 2405 2s 2 2 Speed switch 0 nigh ib 3 Disable protective functions Asymmetry phase failure 0 High overload jam 0 Earth g
51. Bradley publication Industrial Automation Wiring and Grounding Guidelines For Noise Immunity publication 1770 4 1 This equipment is classified as open equipment and must be mounted in an enclosure during operation to provide safety protection 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 or means of production may only be carried out by competent electricians 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 scorched cables must be eliminated immediately The Bulletin 825 Smart Motor Manager features supervision and protection functions that can automatically switch devices off bringing motors to a standstill Motors can also be stopped by mechanical blockage as well as mains failures and voltage fluctuations In case of functional disturbances the machine plant must be switched off and protected and the disturbance eliminated immediately The elimination of a disturbance may cause the motor to restart This may endanger persons damage
52. C 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 e Overload e Search for cause and TRIP PTC trip eliminate e Too many starts hour e Reduce starts hour e many warm starts hour Reduce number of warm starts hour e Obstructed cooling e Clean motor and cooling air intake e Highambient temperature je Protect against heat reduce oad 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 fault fuse PHASE LOSS TRIP trip Redimension fuse noting f based on Failure during start short circuit coordination motor supply Broken lead Check cables and terminal connections PT100 1 6 Stator winding overheated by Wait until motor has cooled down sufficiently to permit reset RTD e Overload e Search for cause and remedy PT100 WARNING temperature e many starts hour e Reduce start hour warning e 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
53. Checking the Installaion 235 ceret ee Re REI RH Re ER EE 6 1 Checking the Wining cese vex RR Rv e EE ES Seb beh eta 6 2 Checking the Installation with the Control Voltage Applied 6 2 Switching on the Control Voltage 6 2 Checking the Set Parameters 6 2 Motor Cuttent oil Gd bbe idan goa der ride 6 3 Locked Rotor or Starting Current 6 4 Locked Rotot Time c osecev ere eth Gee acs ok e eee ey n 6 4 Publication 825 UM001B EN P January 2001 iv Table of Contents Programming Setup and Operation 6 5 desde S see e dene 6 5 Operates tee et deabus tts 6 6 Chapter 7 Testing and Maintenance Generale rert eame ven EA ES CR EE E 7 1 Checking without Test 7 1 Functional Check with the Test Button 7 1 Indication of Recorded 7 2 Checking with Test 7 5 Test ce ee ac Pac etn CO Pe e dens 7 5 Chapter 8 Error Diagnosis and Troubleshooting Alarm Warnings ERR p98 OS Te aT eR SG Eie 8 1 Procedure when Alarm Warning Picks 8 1 etae Shan a ad tse atleti mesi 8 2 Fault Codes dp adr
54. G 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 mm 1 x4 mm 2 0 0039 2 1 x 0 006 in 2 x AWG No 20 14 1 x AWG 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 inimum nominal operating voltage Nos 825 MCM2 and 825 20 the following specifications apply Table 2 G Main Current Transformer Ratings Nominal operating voltage of motor inimum rated primary current J Nominal operating current of motor Rated secondary current 1Aor5A Class and nominal 5P 10 ext 120 9 overcurrent factor Power rating According to power consumption in leads and measuring circuits Rated frequency 50 60 Hz Burden 825 MCN 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 60044 part 2 5 Total measurem
55. I Rated current ty Warning Table 3 N Underload Setting Parameters Warning O Trip Function Factory setting Off On Response Level Setting range 25 100 I Factory setting 2 7596 Setting increments 5 Tripping Delay Setting range 1 60 s 0 2 5 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 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 activated After the set max starting Time has elapsed the High Overload Stall function will become active e here If auxiliary relays 2 and 3 are assigned to the communication refer to page 5 16 they cannot be selected 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
56. M001B EN P January 2001 Commissioning and Operation 6 6 Operating Table 6 A Checking the Actual Values LCD maed Description A ACTUAL VALUES Indication of actual values MV a N MOTOR A SO EN Motor current in A x 2 TH UTILIZ 0 100 Thermal utilization 2 le 0 20 999 uot percentage of rated K N 11 le otor current J 1 phase L1 percentage of 5 0 20 1200 rated service current V 2 ff gt 12 le otor current 7 2 phase L2 percentage of 0 20 1200 rated service current V 2 ie gt 13 le otor current J 3 phase L3 percentage of 0 20 1200 rated service current V 2 f N TRIP IN sec 1 9999 JUnitwilltipin s lt 2 Publication 825 UMO01B EN P January 2001 6 7 Commissioning and Operation Table 6 A Checking the Actual Values Continued LCD Pad Description amp gt RESET IN sec 1 9 999 Unit can beresetin s MV J G gt ASYM 1 100 Current asymmetry in percent V 2 f earth H 96 D 1 100 Earth ground fa It current residual as percentage of PE actual service current I Ns 2 D 999
57. MST Option Card Short circuit 0 4 121 e 101 120 990 50ms 1 No 1 eee Off 5mA 50A 1A 01 55 055 Al R Stalling during start 0 Alo RO Thermistor input PTC 0 800 ms All R Bulletin 825 MLV Option Card Phase sequence motor supply 0 1s All R Phase failure motor supply 0 2s All R Bulletin 825 MMV Option Card stato bearing Off 80 209 soe 8s MR PT100 input 7 RTD 0 Via external speedometer control input 1 output and trip relays as for high overload Allowing for the ambient temperature in the thermal image 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 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 3 H Warning Functions Summary Functions Setting Factory Tripping Factory Relays Factory Factory Delay Setting Range Setting Range Setting Selection Setting Bulletin 825 M Basic Unit Thermal utilization load 0 50 99 75 AL 1 5 AL Asymmetry 7 0 5 8096 2096 AL 1 5 AL High overloading x 0 1 6 Ig 2 Io 1 5 AL Underload 0 25 100 75
58. NT PROT Not disabled MEE locked rotor DISABLED J disabled Jactive locked ou EARTH FAULT PROT gt No disabled Earth fault protection DISABLED J disabled Active locked ou SHORT CIRC PROT INot disabled Short circuit protection INOT DISABLED J disabled Ac ive locked ou UNDERLOAD PROT Y Not disabled Underload protection NOT DISABLED J disabled Ac ive locked ou START INHIBIT gt No disabled Limiting starts hour NOT DISABLED J disabled Active locked ou PTC PROT gt No disabled PTC protection DISABLED J disabled Active locked ou PT100 PROT Y Not disabled PT100 RTD protection NOT DISABLED disabled Active locked ou Ne the programming menu skips to parameter Disable Function If Disable Function is set to off the programming menu sk Publication 825 UM001B EN P January 2001 ips to parameter Control Input 2 Setting the Operational Parameters 5 12 Table 5 D Cat No 825 M Required Group Option Card Cat No Control input 2 825 MST 60206000906 If Control Input 2 is set to off If Delay Aux Rel 3 is set to off Operating Parameters Continued LCD rmi Description CONTROL INPUT 2 On Off qu input 2 OFF J Timer function of output DELAY AUX REL 3 On Off relay 3 OFF Ji On Off gt
59. OT TIME 1 600 locked rotor time of motor 0 sec J rom cold Va Main Thermal trip motor THERMAL TRIP relay no Choice between main MAIN RELAY J relay output relay and no relay THERMALWARNING Thermal warning motor lt On Off emp On Off 2 Themmalovenigad Pickup value for thermal __ TH WARNING LEVEL B 50 99 warning temperature rise as 75 a percent of thermal S J utilization n TH WARNING A Al except Thermal warning ALARM RELAY y main relay Assignment of output relay f Primary CT 1 is set to no the programming menu skips to parameter Locked Rot Curr f 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 Parameters Table 5 D Cat No 825 M Operating Parameters Continued Required Group Option Card LCD Description Cat No g Asymmetry protection ASYMMETRY TRIP On Off current measuring ON p asymmetry On Off AS TRIP LEVEL 5 Asymmety trip 85 y n Tripping level in percent AS TRIP TIME Asymmetry trip ES 1 25 ripping dela 2 5 Sec y pping y Asymmetr ASYMMETRY TRIP 7 Asymmetry trip RELAY Jj Assignment of relays AS WARNING DET Asymme ry warning FF J As WARNING LEVEL b 5 80 Asymmetry war
60. Out of Protection Functions With control inputs 1 and 2 one or more protective functions can be locked out as desired e 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 During 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 input is 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 e Briefly increased loading of the motor and installation e Maximum loading when the ambient temperature varies appreciably Exampl
61. R U U 0 5 2 000 Rated motor current in A 20A M PRIMARY No Yes Primary current transformer in use NO V J PRIMARY C T RATIO j 1 um 1 2 000 Primary current transformer ratio V J LOCKED ROT CURR j5 d Locked rotor current as 6 xle k E LOCKED ROT TIME 1 600 Maximum permitted time for the rotor to be stalled 10 sec id from cold V A Note For a complete list of 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 Valves until ACTUAL VALUES appears on the display 2 Press Select Up or Down until the desired information is displayed Figure 3 4 Selecting the Actual Values ACTUAL VALUES Actual ii Change Recorded m Enter Values Select Settings I MOTOR 00 1 Actual Change Recorded Values Select Settings Table 3 E Display Example of Actual Values Menu LCD Range Description ACTUAL VALUES __ Display 2 the actual values V 2 D MOTOR A COE Motor current in A 96 2 a B TH UTILIZ 0 100 Thermal utilization V 27 MOTOR j 5 le 0 20 999 Motor current as percent of rated current M P Note For a complete list of parameters refer to Chapter
62. RTD oad or shut down the temperature installation and wait until trip motor has cooled down sufficiently for a restart SHORT CIRC 100 has been short or open circuited A TE Check cables terminal connection This message Failure in PT100 RTD circuit and PT100 RTD sensor may appear PT100 NO CONNECT together witha PT100 1 6 RTD TRIP Publication 825 UM001B EN P January 2001 8 8 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 How 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 e LCD THERMAL TRIP e 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 UM0
63. S af 2 TRIP TEMP 7 PT100 2 50 o Tripping temperature f 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 PT100 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 Operating Parameters Continued Group PT 100 RTD temperature sensor continued Required Option Card Cat No 825 MMV Setting Me LCD Range Description PT100 3 TRIP On Off PT100 3 protection OFF J On Off 3 TRIP TEMP Tnm tdt Prog 3 o ripping temperature 50 C J pping temp T i PT100 4 TRIP On Off PT100 4 protection J On Off 4 TRIP TEMP s0 200 o ripping temperature 0 C J pping temp ra gt T PT100 5 TRIP On Off PT100 5 protection y On Off 5 TRIP TEMP DE PTIOD 5 o e ripping temperature 0 C J pping temp o PT100 6 protecti PT100 6 TRIP On Off protection J On Off N y 6 TRIP TEMP 50 200 PT100 6 o Tripping temperature 50 C J pping temp PT100 4H 6 TRIP AI ss 00 1 6 ex 4 rippin RELAY J ppin
64. Setting increments 1 Output Relay O 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 ine 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 independent 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 Tools 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 21 2 le lt 1 1 Ie 1 Motor starting current gt 1 2 I 2 Rated conditions y Max starting time 3 Tripping if starti
65. The Smart Motor Manager will trip during starting 1f 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 10 Trip Time s 1 6 1 0 0 1 1 0 1 1 2 0 30 4 5 6 7 8 9100 Load Current as Multiple of Full Load Current a Time current characteristic from cold when setting the trip time t6x 10 s b Time current characteristic after preloading with 1x g when the trip time from cold t6x 10 s and WARM START function is disabled 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 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 8296 the WARM START function is automatically disabled If lower than 8296 the WARM TRIP TIME depends on the windi
66. 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 circuits 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 Sequence e After switching on supply e Supervision while motor is stationary e When running as soon as the link is interrupted the basic unit will trip and Link between basic unit and display one or more of the following converter module causes e short circuit thermal earth fault Holmgreen residual asymmetry overcurrent Display 825 MCM NOT CON Verification that FLC on basic e After switching on supply unit is within range of converter e After each change in setting of rated module current le OUT OF RANGE e Continuous monitoring hardware Supervisory circ
67. ad 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 must be outside the range c e g when 74 6 x Ze tj must be lt 100 s and gt 1 s Publication 825 UMO001B 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 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 UMO01B EN P January 2001 10 3 References Notes Publication 825 UM001B EN P January 2001 www 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 2 665 0640 Asia Pacific Rockwell Automation Level 14 Core F Cyberport 3 100 Cyberport Road Hong Kong Tel 852 2887 4788 Fax 852 2508 1846
68. afety considerations Identifies information about practices or circumstances that can lead ATTENTION to personal injury or death property damage or economic loss Attention statements help you to identify a hazard avoid a hazard recognize the consequences Identifies information that is critical for successful application and IMPORTANT understanding of the product Allen Bradley is a trademark of Rockwell Automation European Communities EC Directive Compliance If this product has the CE mark it is approved for installation within the European Union and EEA regions It has been designed and tested to meet the following directives EMC Directive This product is tested to meet the Council Directive 89 336 EC Electromagnetic Compatibility EMC by applying the following standards in whole or in part documented in a technical construction file e EN 50081 2 EMC Generic Emission Standard Part 2 Industrial Environment EN 50082 2 EMC Generic Immunity Standard Part 2 Industrial Environment This product is intended for use in an industrial environment Low Voltage Directive This product is tested to meet Council Directive 73 23 EEC Low Voltage by applying the safety requirements of EN 61131 2 Programmable Controllers Part 2 Equipment Requirements and Tests For specific information required by EN 61131 2 refer to the appropriate sections in this publication as well as the Allen
69. age asymmetry per IEC and NEMA 2 Pe 26 Definition of voltage asymmetry per and NEMA AU Max deviation from the average of the phase voltages x 100 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 96 Table 3 L Asymmetry Phase Unbalance Setting Parameters Warning O Current Asymmetry Trip Function Factory setting Off Response Level Setting range 5 80 5 80 Factory setting 20 35 Setting increments 5 5 Tripping Delay Setting range 1 255 0 28 Factory setting 255 025 Setting increments 0 5s Output Relay Selection relays AL 1 5 MR AL 1 5 Factory setting AL MR 5 60 C 2 140 F If auxiliary relays 2 and 3 are assigned to the communication refer page 5 16 they cannot be selected here High Overload and Jam When an overload is excessively high and the motor jams unnecessaty 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
70. arm 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 2 4 le t 0 91 Ve Y 5 2 gt t tw tw gt gt lw gt In Starting current 1 First start cool I Rated current 2 First warm start e 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 Minimum time before first of 825 M for continuous start is possible operation t1 gt 10tgig 01 otor temperature ty Minimum 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
71. baud Mode Data protection 0 CRC 1 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 3 2 400 baud 4 4 800 baud 5 9 600 baud 6 19 200 baud Baud Rate for Modbus Calculated according to the following formula Value 64 x mode 32 x stop 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 stop bit parity 0 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 5 D Cat No 825 M Operating Parameters Required Group Option Card LCD esi Description Cat No Z SET VALUES Mode Set parameters M 7 FULL LOAD CURR 0 5 2 000 Rated motor current in A 20 PRIMARY 1 INO Use of the primary No Yes transformer Main settings Rea ae ee Current ratio of the primary mu PRIM C T RATIO 1 2000 Current transformer e g 1 500 A 5 A setting 100 800 A 5 A setting 160 Na LOCKED ROT CURR B Locked rotor and starting EE 2 5 12 currentin 7 6 x le J 4 aximum permissible LOCKED R
72. be 9 9 Basic Unit and Converter Module with Core Balance Current a do dei dae PPP E ced eae V 9 10 Citeult ROG Danae que RENE Ya Y YE qus 9 10 Motors with Low Idling Current lt 20 9 11 Main Ciro donare Ea RU EDU PS dad Cuts 9 11 Connecting the PT100 Temperature Sensors Using the 2 3 4 Conductor Technique esee ee eee 9 12 Basic Unit and Converter Module with Primary Current Transformer 2 Phase Current 9 13 Time Current Characteristic of Bulletin 825 Smart Motor Manager 9 14 Chapter 10 References Figures Figure 1 1 Bulletin 825 Smart Motor 1 1 Figure 1 2 Operating Characteristics of an AC Motor 1 3 Figure 1 3 AC Current Profile of a Motor Starting Ditect otzL4nG s et Rv v ey ae 1 4 Figure 1 4 Temperature Rise Characteristics of Motor 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 2 2 Figure 2 2 Block Diaptam 3 504 ER oe RARE Rx 2 3 Figure 2 3 Front View with Operating 2 4 Figure 3 1 Setting Mode ii oe eere etn ede tps 3 5 Figure 3 2 Menu SelecHon ie e e Rep EE RECEPERAT 3 5 F
73. be disabled refer to page 8 8 Trip 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 reached the following responses occur LED lights e LCD pose 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 red LED on the protection function cannot be disabled refer to page 8 8 Fault Codes Table 8 A Possible Causes and Actions LCD NA Designation No indication Possible Causes 0 supply voltage Actions Ensure power supply is on Check the supply Wrong supply module in basic unit nsert correct supply module If the voltage applied to the supply module was too high it and the unctions of the unit must be tested Basic unit defective f 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 e Ambient temp too high Switch off control supply Restore normal conditions and etthe unit cool down for Publication 825 _ approx 30 min e Current consumption to
74. c Unit and Converter Module with Main and Core Balance Current Transformer Figure 4 10 2 Phase Current Evaluation Converter module cat nos 825 MCM2 825 MCM20 1 3 5 gt 825 825 M i 2 4 6 k T2 C z e Table 4 C Specifications Main current transformer refer to Chapter 2 for selection information Core Balance C A 5 A or A 1 A urrent Transformer Earth ground current 5 mA 50 A Current ratio of core balance current transformer 1 2 000 1 Output from core balance current transformer 0 500 mA Additional circuit diagrams can be found in Chapter 9 Publication 825 UM001B EN P January 2001 Assembly and Installation 4 8 Control Circuits Figure 4 11 Smart Motor Manager Basic Unit Supply A1 9 9 11 L X Emerg Start Y12 Disable Settings 9 n moya Remote Reset Lo Y22 13 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 14 6 IEC 400 VA 125V DC UL CSA 240V AC 125V
75. 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 grading 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 30 ms e All energized output relays drop out The LED extinguishes The timer for duration of supply failure starts maximum 8 h e The instantaneous set and statistical data are recorded The LCD extinguishes Hecovery of the Supply
76. citance 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 Pou Input of a current proportional to the copper losses Pre Input of a current proportional to the iron losses 51 Changeover from stationary to running Im Motor current Ig Opposing component caused by asymmetry amb 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 correct 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 E IN sec This feature provides continuous indication of the time remaining before tripping when in an ovetload condition This enables you to intervene
77. ck and correct wiring wiring Reduce load or raise pickup 0 7 Overload threshold OC WARNING Vercurren i i i e warning Transported material jammed Switch off installation remedy Pickup threshold set too low Raise pickup threshold Mechanical damage to bearings pe TRIP Overcurrent transmission eam 9 Repair the damage tri n 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 winding or cable Repair damage Earth ground D i Coe E HOLMG TRIP i faut ransformer orrect wiring residual tip M rrent transformer e Raise pickup threshold e High proportion of third e Raise pickup threshold to 50 harmonic in star delta or more Trip during start Primary and Correct the wiring core balance C WARNING Earth ground 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 UID ground fault in motor CORE TRIP core winding or cable due to le Moisture Elimi
78. ction Factory setting Off Off Response Level Factory setting 50 Setting steps 196 Tripping Delay Factory setting 85 85s Output Relay Selection relays ALA 48 MRALA 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 gt 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 installation can be better used with deviating coolant temperatures PT100 PROT ON IW J 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 ffambient C N M 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 E INSULATION CLASS Insulation class of winding Table 3 AF Motor Insulation Class Setting Parameters Function Factory setting Off Insula
79. d 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 0 4 13 13 0 4 14 9 14 AN 14 o9 3 Non Fail Safe Mode Supply Off Supply On Supply On and Warning 13 1 13 0 3 4 13 A 14 14 o 14 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 Factory Setting Thermal Utilization 75 Asymmetry 2096 High Overload 21 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 e Remote reset Short circuit terminals 21 22 e Automatic reset In the mode set values set automatic reset for e Thermal trip e PTC trip e PT100 trip Reset Conditions Thermal As soon as the temperature tise has dropped to the preset reset thresho
80. dance earth or 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 motors The capacitance values for cables are given in cable tables and range from approximately 0 2 1 2 LF km A value between 0 02 0 05 UF per MW of motor rating can be assumed for high voltage motors Publication 825 UM001B EN P January 2001 Functions 3 30 A rule 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 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 potentia
81. device s current range lies within the full load or the service current e Primary Current Transformer if used e The transformer rating must be greater or equal to the full load or the service current e The current ratio must ___ 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 Vetify that the appropriate option cards have been installed Verify that the indication meter if required is connected Publication 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 e 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 e LCD shows ACTUAL VALUE Main relay contact 95 96 is closed Checking the Set Parameter
82. e programmed set even when ATTENTION P E ae 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 Settingrange Factorysetting Rated motor current or service 05 200A 20 Current ratio of primary current transformer 9 1 2 000 1 Locked rotor current 2 5 12 Ip 6 Ie Locked rotor time 1 600 s 10s Accessing this parameter requires that the parameter Primary CT be set to yes If instead of the permissible locked rotor time the maximum starting time is known the approximate locked rotor time is calculated as follows Starting time 1 4 Locked rotor time 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 Setting range Factory setting Connection of main relay
83. earthing resistance T Transformer Ig Earth ground fault current Figure 3 15 Isolated Network Earth Fault on the Network Side The basic unit measures the earth current component through C y 825 M MEC USES UM Ki N U2 U1 2 NS P 3 NT N Rete U3 CN jIE 0M y Figure 3 16 Network Earthed through a High Impedance Earth Fault on the Network Side The basic unit measures the earth current component through Cp Compensated network Through the fault a small current flows given by the vector sum of the earth currents T 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 C y 825 M Tj Ki N 3 Ld T T 1 N N N OM 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 Cy and the earthing resistance Compensated network The basic unit measures the vector sum of the earth currents through Cy and the compensating coil L 825 Figure 3 19 Isolated Network Earth Ground Fault in the Motor The nearer the fault is to the motor star point the smalle
84. ection 3 phase current detection is also possible 11 2 L3 l 1 2 15 6H Fist 1 81 825 2 P2052 P2052 t 3 4 4 qe Ec SRM 51 j ue S2 3 Publication 825 UM001B EN P January 2001 3 29 Functions Application High voltage motors Installations in a difficult environment with moisture dust etc e g mines gravel pits cement factory mills woodworking shops water pumping stations waste water treatment Table 3 P Core Balance Current Transformer Setting Parameters Setting range Current Ratio 1 2000 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 5 mA 50A Factory setting 500 mA 1 0 mA Setting increments 5mA 0 25 A Tripping Delay Setting range 0 1 5s5x 0 04 s Factory setting 0 5s Setting increments 015 Output Relay Selection relays AL 1 5 MR AL 1 5 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 impe
85. ent 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 120 of rated nominal primary current if J motor gt 87 of 120 rated nominal transformer current With starting current 10 class 5 P 20 The current transformer error in addition to the basic unit error 25Awith Cat No 825 2 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 Kp Power consumption at max rated current 0 4 VA Continuous thermal current 05 Thermal current 1 s duration 25A Frequency of input current 50 60 Hz 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
86. equipment The user must take the necessary safety measures to avoid this type of occurrence e 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 1 2 Temperature Rise zs obses pte et NUR RR PIS 1 2 Motor Operating Characteristics 1 2 Current and Temperature 1 3 Limiting Temperatures Insulation Classes 1 4 Operational Requirements for 1 5 Personnel and Installation Safety 1 6 Bulletin 825 Smart Motor Manager as an Automation Component 1 6 Chapter 2 Equipment Description System SEU CEDUFe is bs bee vao ae hand E ve ees 2 1 system Components re ec kr saws eae eee keene ees 2 1 Installation EReRRRHRI Re due taeat 40 bh tea 2 1 Modular Desig iere A ERR PERCHE I Pe 2 2 Block Diaptam olia xo DA REI RETIRER EE eR 2 3 Operating FIEMMEN Ss iesus bee hee da aep ade dete kgs 2 4 Specifications Basic Unit and Converter 2 5 Standatds i iere n E EA RARUS PH Ie HA CLE eas 2 7 Main Current Transformers for the Motor Circu
87. er 5 500 mA at k I 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 534 Aux Relay 4 546 63 External Supply voltage 400 VAC UL CSA 240 VAC Aux Relay 5 64 9 L1 Internal Internal Assembly and Installation 4 10 Figure 4 13 Cat No 825 MLV Option Card ATTENTION Either the 825 MLV or 825 MMV option card may be inserted in this position Auxiliary relay 4 IEC 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 External Internal Supply voltage gt 400 VAC UL CSA gt 240 VAC Publication 825 UM001B EN P January 2001 4 11 Assembly and Installation Figure 4 14 Cat No 825 MMV Option Card Either the 825 MLV or 825 MMV option cards may be inserted in ATTENTION this position 1 0 171 PT100 inputs 1 6 RTD for PT100 1 1T3 monitoring the temperature of the stator 112 winding and motor bearings 2T1 i PT100 2 1 2T3 3T1 PT100 3 E hT 27 471 PT100 4
88. es 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 e Ifa reversed phase sequence must be expected after repair Publication 825 UM001B EN P January 2001 Functions 3 54 Table 3 AA Phase Sequence Setting Parameters Function Factory setting Off Tripping Delay Factory setting 1s Output Relay O 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 ATTENTION The phase sequence of the motor supply can be monitored only at the 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 curre
89. etting 3 42 Short Circuit Setting 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 0 liess 3 46 Sensor Measuring Circuit Specifications 3 47 Phase Sequence Setting 3 54 Phase Failure Setting 3 54 Star Delta Wye Delta Starting Setting Parameters s s oer RR VOR EVERY 3 55 PT100 Temperature Detector Resistance per IEG 751 bee A he AR ICH ERR Eu E ges 3 56 PT100 RTD Setting 3 57 Motor Insulation Class Setting Parametets 3 58 Cat Nos 825 2 825 MCM 20 825 180 4 3 Cat Nos 825 MCM630 825 MCM630N 4 4 Specifications uoce be Geb eed 4 7 Main Set tigs 3a lec be eae Sere ae oe 5 1 Special Settings is ciao ee wee ade het addi 5 2 Communication 5 3 Cat No 825 M Operating Parametets 5 4 Checking the Actual 6 6 List of Recorded 7 2 Possib
90. fes via communication allowed ie A Clear recorded u CLEAR REC VALUES Notclear Clear do not clear all values NOT CLEAR J allclear recorded values E Not reset to FACTORY SETTINGS All reset to reset to factory settings NOT RESET TO J 9 Reset settings to JA Reset not reset all e ARE YOU SURE No Yes parameters to factory values NO J settings N Confirmation that all FACTORY SETTINGS parameters are reset to the ALL IS RESET TO J factory settings End of setting END SET VALUES __ End of setting operating parameters J parameters Ne If auxiliary relays 2 and 3 are assigned to the communication refer to page 5 16 they cannot be selected here If Factory Settings is set to Not Reset 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 ate correct Checking and commissioning must be carried out only by qualified ATTENTION personnel Disconnect the main switch and isolate the control circuit before commissioning or installing the unit Current Converter Cat No 825 MCM e Verify that the
91. g 6T100 1 6 RESET Manual EE ARR reset PT100 MANUAL P auto anual automatic T i PT100 1 WARNING On Off PT100 1 warning OFF J On Off 1 WARNING TEMP 100 1 50 C SITAM Warning temperature x T i PT100 2 WARNING On Off PT100 2 warning J On Off i2 WARNING TEMP PT100 42 50 200 Warning temperature 50 J 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 Card LCD agi Description Cat No g PT100 3 WARNING on PT100 3 warning OFF On O f 9 WARNING TEMP mo 200 MULA o arning temperature 0 C p g temp N T PT100 4 WARNING On Off PT100 4 warning OFF On O f 4 WARNING TEMP 50 200 rud arning temperature 50 E g temp N T PT100 45 WARNING On Off PT100 5 warning OFF On O f 2 PT 100 RTD Z temperature sensor 825 5 WARNING TEMP 50 200 n 00 i continued 50 J arning temperature o PT100 46 warni PT100 6 WARNING On Off warning OFF On Off NS 6 WARNINGTEMP 50 20 PTS ou o arning temperature 50 C J g temp 1 6 WARNING NI AL PT100 1 46 warning OFF a 1 43 Assignment of output relay PT100 7 allowance for Tamb IN TH IMAGE O
92. h 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 3 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 Of Supply On Supply On and Trip 95 Em d ir 96 m A sn 97 ia o _ mE N 98 T o i 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 OE got 98 e 95 o 96 oe o LILI 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 connecte
93. igure 3 3 Entering a Data 3 6 Figure 3 4 Selecting the Actual 3 7 Figure 3 5 Selecting Recorded 3 8 Figure 3 6 Basic Unit e 3 9 Figure 3 7 Two Body Simulation of the Heating Up epa HOA Es 3 17 Figure 3 8 Trip Characteristic 10 30 5 3 19 Publication 825 UM001B EN P January 2001 vi Table of Contents 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 40 100 5 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 3 27 Example of 2 Phase Current 3 28 Isolated Network Earth Fault on the Network Side 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
94. ill 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 The 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 r ripping threshold s Delayed activation underload protection not active Tripping delay
95. ip e g overcurrent OVERCURRENT TRIP P a N CAUSE 3 PRV TRIP Cause of three trips prior to last trip e g thermal THERMAL TRIP J K CAUSE 4 PRV TRIP Cause of four trips prior to last trip e g thermistor TRIP J A SINCE EMG START Time elapsed since last emergency start in hours minutes MIN J e N SINCE POWER OFF Time elapsed since last power failure in hours minutes kz H MIN y OURATION POW OFF Duration of power failure in hours minutes kz MIN J LAST TRIP Motor current before last trip as a percentage of rated service current Ze IE Short circuit 999 lt J A gt AS BEF LAST TRIP Asymmetry before last trip in percent 0j kr 2 EF LAST TRIP Earth ground fault current before last trip as percentage of rated current J or mA Publication 825 UM001B EN P January 2001 7 4 Testing and Maintenance Table 7 A List of Recorded Values Continued LCD Description K MAX T BEF L TRIP Maximum temperature before last trip in C PT100 1 6 ane J lt m TH BEF LAST TRIP hermal capacity used before last trip 100 thermal trip ko 96 J fa B 2 NUMBER START otal number of motor starts P NUMBER TH TRIP Total number of trips thermal C E NUMBER AS TRIP
96. ircuit 150 easuring voltage as per IEC 34 11 2 2 5V DC Measuring Lead inimum cross section mm4 0 5 0 75 1 0 15 2 5 AWGNo 20 18 17 16 14 aximum length m 200 300 400 600 1 000 ft 656 984 1312 1968 3280 ethod of installation 9 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 20 20 TNF 20K 15 TNF 5K LTNF 5K TNF TNF ominal pickup temperature RIQ Resistance to sensors Analog Output This output supplies a current of 4 20 mA proportional 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 rise of the motor or the motor temperature max temperature of the operating PT100 Sensors The thermal load in percentage 1s also indicated on the LCD of the Smart Motor Manager Publication 825 UM001B EN P January 2001
97. 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 shown in their normal working position i e the Smart Motor Manager control voltage is switched on no warning no trip ATTENTION All assembly and installation work must be performed by qualified personnel 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 1 5 825 MCM Converter module cat nos 825 MCM2 825 MCM20 825 MCM180 825 MCM630 825 MCM630N Cable with plugs 2 Basic Unit and Converter Module with Main Current Transformer Figure 4 9 3 Phase Current Evaluation L1 L2 L3 Converter module 825 MCM2 825 20 i 3 5 CTC Main current transformer C 1 BEOMON SSM A 5 0r A 1 A 2 4 6 For selection refer to Chapter 2 Publication 825 UM001B EN P January 2001 4 7 Assembly and Installation Basi
98. it LL 2 10 Core Balance Current 2 11 Short Circuit 2 11 Response Supply Voltage 2 12 Automatic Recognition of Converter Module 2 13 Chapter 3 Functions Menu OVerview XO RS Eq dre 3 1 Actual Valu s 24 2 niga ers eG 3 1 Set Values toos eae te desta e deb ue esq esu gue 3 2 Recorded Values visas wv T REESE Ve RA Bae OR EROS eee 3 3 Publication 825 UM001B EN P January 2001 ii Table of Contents Schn Em 3 4 Selecting the Setting Display 3 4 Setting the Operation Parameters Set 3 5 Indications of Actual Values 0 0000 ese 3 7 Indications of Recorded Values 3 8 Test BOO 3 0 Punction Sumy 3 13 Functions of the Basic Unit Cat No 825 3 16 Thermal Oyerloada acer Ee REL ERR PP PI ET ESqu Sd 3 16 Adjustable Ratio of Cooling 3 17 Indication of the Time to 3 18 Indication of the Time until the Thermal Trip can be Reset 3 18 Adjustable Setting Characteristic 3 18 Asymmetry Phase U
99. l 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 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 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 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 windi
100. lay Assignment of output relay A Earth ground fau EARTH FAULT PROT On Off protection ON J On Off c Earth ground fau EF HOLMG TRIP On Off protection Holmgreen ON j residual On Off Earth ground fault trip Earth d fault EF H TRIP LEVEL j 10 100 Holmgreen residua ripping level percent of residual Q0 6 J motor current Earth ground fault trip EF H TRIP TIME 0 1 5 Holmgreen residual 0 50 sec J Tripping delay Ya gt 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 f EFHolmg Trip is set to off the programming menu skips to parameter EF Core Trip Publication 825 UM001B EN P January 2001 5 7 Setting the Operational Parameters Table 5 D Cat No 825 M Operating Parameters Continued Required Group Option Card LCD M Description Cat No g N Earth ground fault EF CORE TRIP On Off protection core balance OFF D transformer On Off CORE C T RATIO D 1 2 000 Core balance transformer 1 J y current ratio Earth ground fault trip EF C TRIP LEVEL 1 is MS n core balance transformer 1A Age SF Tripping level Earth ground fault trip
101. ld detector As soon as the temperature is below the reset threshold PT100 detector As soon as the temperature is below the tripping threshold e Asymmetry Phase failure Manual or remote reset possible Allother 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 10 100 Factory setting 7096 Setting increments 5 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 protection 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 I If a thermal trip
102. le Causes and 8 3 Publication 825 UM001B EN P January 2001 x Table of Contents Notes Publication 825 UM001B EN P January 2001 Chapter 1 Introduction Why Have an Electronic Control and Protection System The need to optimize production facilities requires enhanced control monitoring and protection systems Motor and installation use must be maximized while minimizing both the downtime required for maintenance and that caused by motor failures these requirements are easily met by the microprocessor based Bulletin 825 Smart Motor Manager The Bulletin 825 Smart Motor Manager has a modular design and is easily programmed Its attributes enable an optimum fit to a wide variety of motor and installation requirements The Bulletin 825 Smart Motor Manager provides continuous monitoring of motor operating data in one of two ways The data can be viewed directly on the unit or it can be monitored remotely via a network by using a PC or process computer The main statistical data can also be accessed at any time Figure 1 1 Bulletin 825 Smart Motor Manager Publication 825 UM001B EN P January 2001 12 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
103. leakage to the grounded parts of the machine In earthed grounded networks the fault current can rapidly rise to a vety 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 ground 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 the neutral connection of the current transformer to detect an earth ground fault residual circuit
104. n Off ambient temperature in OFF J thermal simulation A gt INSULATION CLASS BEF Insulation class of B x winding Z Using the analog output for Th 1 util ase Analog output 825 MST OUTPUT 4 20 mA S Motor 12 thermal utilization THERMAL _ PT100 max motor current max PT100 temperature f Tamb in Thermal Image is set to off the programming menu skips to parameter Output 4 20 mA Limiting winding temperatures of the three insulations classes E 120 C 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 Publication 825 UM001B EN P January 2001 Setting the Operational Parameters 5 16 Table 5 D Cat No 825 M Operating Parameters Continued Required Group Option Card LCD Setting Description Cat No Range Basic unit station number 0 63 DeviceNet _ STATION NUMBER PEE S ee 02 1 247 MODBUS Communication 1 126 PROFIBUS setting Baud rate Va 0 2 DeviceNet BAUD RATE 0 23 04 J 0 182 MODBUS 0 4 PROFIBUS Comm option REL 2 3 VIA COM Control of relays 2 and 3 Relay control 825 MST NO No
105. n 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 Test button Figure 3 6 Basic Unit Test Button SMART MOTOR MANAGER Enter Settings Publication 825 UM001B EN P January 2001 Functions 3 10 Testing the Thermal Trip 1 Press the Test button LCD a THERMAL ON 2 After the set blocking time has expired the basic unit must trip LCD LOCK ROT TIME ___5 3 The LED lights 4 The selected output relay picks up MR main relay on trip LCD ee TRIP 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 test 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 P b y 4 After the set trip delay expires the basic unit must trip LCD E TRIP TIME Sec p
106. nate cause transformer e Dirt e Mechanical damage Short circuit or earth ground s fault in motor winding or cable Repair damage SHORT CIRC PROT Short circuit T is swi e trip winen motor iS switched on Increase trip delay to gt 0 1 s Pickup threshold is lt A Set pickup threshold to gt Za Eliminate cause lower pickup Underwater pump running dry threshold if necessary or increase rip delay WARNING Underload f tripping takes place too soon warning Faulty fan blades after starting increase the start delay Torn conveyor belt dug TRIP neer oac tri groken 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 i stent 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 PT
107. nbalance and Phase Failure 3 22 High Overload i 3 23 Undetload ee ert ER Peer deerit ch 3 25 Earth Ground Fault vac eee uk RE Re n Ea 3 27 Limiting the Number of Starts per Hour Start Lockout 3 33 Monitoring the Starting 3 34 Warm Statt s ces sp wea c yv T ie a eee dre Rr EY Y dos 3 35 Emergency Override of Thermal Trip Emergency Start 3 38 LED Alarm and Trip Indicator 3 39 Connection of the Main Relay MR 3 40 Connection of the Alarm Relay 3 40 Alarm Relay AL sua gU up ux toes dade dda die oe 3 41 ReSetiss 04 n eb assu mei hats 3 42 Function of the Cat No 825 MST Option 3 42 3 42 Earth Ground Fault Protection with a Core Balance Current Transtotmet s i2ixmdeme sies wide aes 3 44 Stalling During Statt ies 3 44 PIC Themmistor cee eave pr E E eee DIS 3 46 Analogs Output arises ren a wea e e rte etes sa YOU Redes 3 48 Analog Output for Thermal Load or Motor Temperature PT100 3 48 Analog Output for Motor 3 50 Control Inputs 2 cise cae te Rb e een 3 51 Switching to a Second Rated Current 3 53 Publication 8
108. nd assures safe protection of the motor The basic unit uses a two body simulation to calculate a more precise representation of a motof s thermal condition during all modes of operation A two body simulation incorporates the temperature rise characteristics of both the stator windings and the iron mass of the motor into the thermal image The simulation of the Smart Motor Manager accurately represents the conditions in the motor at all times Publication 825 UMO01B EN P January 2001 3 17 Functions While the motor is running the iron losses as well as losses caused by asymmetry 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 ventilated 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 Pu p kle Fe Ri amb C1 Capa
109. ng and iron temperature and its range is 7 3 10 s C 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 7096 Setting steps 1096 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 spring return key switch is recommended 2 LCD flashes EMERGENCY START 3 If the 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 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 MV E TRIP b UT J PT100 1 6 TRIP ue J 2 Alternatively the Smart Motor Manager can be set up suc
110. ng db Wrong converter module nstall the correct converter not agree module 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 values supply last interrupted f the fault repeatedly occurs send the unit back to the factory or repair ERROR REC VALUES Send the basic unit back to the Hardware fault actory for repair Overloaded Reduce load X Switch off installation remedy Transported material jammed rouble TAM Repair the damage Raise FULL LOAD Settings of rated currentor CURR LOCKED ROT TIME to ds WARNING Thermal pping permissible motor values warning nterrupted start motor Wait until motor has cooled inadequately cooled LCD TH UTIL appr THERMAL TRIP Thermal trip if Pee a permissible increase ore than one warm start hour number of warm starts h Ambient temperature too high Function PT100 7 ON If possible reduce load Very high third harmonic e g star delta connection Raise J 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
111. ng 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 O Setting range 1 240s x 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 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 w
112. ngs 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 carth 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 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 Earth capacitance of phase conductor on power supply system side Barth capacitance of motor including supply conductors between current transformer and motor L Compensating coil R High
113. ning 20 y Warning level in percent Lx AS WARNING All except Asymmetry warning ALARM RELAY J main relay Assignment of output relay N OVERCURR TRIP On Off Overcurrent locked rotor rotection On Of ON J p oc TRIP LEVEL D 10 60 Overcurrent locked rotor 9 Tripping level in 7 Q 4 Xle J e 6 Overcurrent OC TRIP TIME 01 15 Overcurrent locked rotor 0 5 sec J Tripping delay OVERCURRENT TRIP All rela Overcurrent locked rotor Assignment of output rela RELAY p g p y A gt OC WARNING Overcurrent locked rotor OFF On Off warning On Off f Asymmetry Trip is set to off he programming menu skips to parameter AS Warning f AS Warning is set to off the programming menu skips to parameter Overcurr Trip If OC Warning 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 Ensure that the trip function is reset before it is inactivated ATTENTION Required Setting ae Group Option Card LCD Description Cat No Range a Overcurrent locked rotor OC WARNING LEVEL 20xle 10 60 Warning level in Ip Overcurrent continued 6c WARNING N All except eo ALARM RELAY J main re
114. ning 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 no specifications are available the starting current can either be measured with the current converter or rcad from Figure 6 1 The current converter factory setting is 6 x 1 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 JA 10 le 1 02 04 1 2 4 10 20 40 100 200 kW 1 Approximate value for 2 pole motors speed 3 000 rpm 2 Approximate value for 4 pole motors speed 1 500 rpm 3 Approximate value for 6 pole motors speed 1 000 rpm 4 Approximate value for 8 pole motors speed 750 rpm Rated output power in service Locked Rotor Time Normal setting of locked rotor time i e when using standard motors or permissible ocked rotor time is known The setting of the locked rotor time must be equal to or less than the value quoted by he manufacturer The current converter factory setting is 10 s If no application details are available and he 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
115. nt to supply a current of 1 x I 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 C A Ip Measurement of phase currents 1 3 5 825 MCM 825M 2 4 6 9 6 Connections if current rated motor current W e g 20 A when using 825 MCM180 A 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 mero dia The test with a 3 phase current source described on page 7 5 can also be performed 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 A e Connection 825 MCM __ 825 M a o Connection IMPORTANT The test current may not flow through the core balance current transformer 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
116. nts 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 O 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 star 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 normal 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 5 54 Figure 3 32 Diagram of Star Delta Wye Delta Starting Motor on off Motor current ee Star operation relay 4 Delta operation relay 5 Changeover delay 80 ms Table 3 AC Star
117. o high e Supply module failed end the unit back to the factory or repair V2 17 4 and later Watch Dog Microprocessor Send the basic unit back to the No indication failure actory for repair M red LED on j ic uni DEFECT 4 Real time Send the basic unit back to the clock fault defective actory for repair D a gt ic uni DEFECT 2 uP fault Send the basic unit back to the RAM Microprocessor RAM defective factory for repair M A Open circuit Check ti 825 MCM NOT CON basic unit to Cable from basic unit to converter io pd converter module not connected or broken Test cable open short circuit M module Replace cable if necessary UMO001B EN P January 2001 8 4 Error Diagnosis and Troubleshooting Table 8 A Possible Causes and Actions Continued LCD d ERROR 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 f the fault cannot be remedied send the unit back to the factory or repair Converter module rated current does not agree with basic unit setting Check setting FULL LOAD CURR and converter module Rated t IE OUT OF RANGE and cati
118. 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 Pickup value 1 Y 23 yv 12 Ie I Rated service current t delay 50 ms G tq Operating time of the breaker Arc duration Short circuit gt Contact separation 3 Short circuit interruption 825 M tp Relay MR blocked at 2 12 J Relais 1 Relais MR Q1M lev Medium high voltage motors 1 yo Application The short circuit protection function must not be used for switching ATTENTION E off the contactor Publication 825 UM001B EN P January 2001 Functions 3 44 Table 3 W Short Circuit Setting Parameters Trip Function Factory setting Off Response Level Setting range 4 12 Ig Factory setting 10 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
119. on 825 UM001B EN P January 2001 4 3 Assembly and Installation Converter Modules Figure 4 4 Cat Nos 825 MCM2 825 20 825 MCM180 m al b cw 825 MCM180 T 1 J c1 s Table 4 A Cat Nos 825 MCM2 825 MCM 20 825 MCM180 Dimensions in millimeters inches cat Noi b lc ct d d d2 Ze Oel e2 b2 120 85 102 66 53 53 Wo 5 2x 385 _ 4 45 64 3 23 64 4 2 39 64 3 16 3 16 3 7 8 2 3 16 25 mm 1 1 2 MCM20 120 85 102 66 5 3 5 3 100 55 2x 38 5 4 45 64 3 23 64 4 2 39 64 3 16 3 16 3 7 8 2 3 16 25 2 1 12 7 me 120 102 72 5 3 5 3 100 55 38 5 15 eo MCM180 2 13 16 3 16 3 16 37 9 2 3 16 8 1 172 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 MVI With Cat No 825 MVM2 Figure 4 5 Cat Nos 825 MCM630 825 MCM630N IN m NAA E E Res d Publication 825 UM001B EN P January 2001
120. otor current 10 em 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 24V AC or 24V DC 8 Input 1 Pick values On 12 36 V 4 41 Off 2V Input 2 v42 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 refer to Chapter 9 Timer Functions The following functions can be programmed On Delay 7 0 240 s Off Delay 4 6 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 5055 gt 0 5 gt Output relay On delay on p off Off delay cl is On off delay lon loft On off delay Ton lott Applications e Time graded switching on and off e Delaying the transfer of alarm and trip messages Lock
121. perational Parameters Table 5 D Cat No 825 M Operating Parameters Continued Required Group Option Card LCD Description Cat No g UNDERLOAD PROT No disabled Underload protection NOT DISABLED J disabled Active locked ou START INHIBIT pum sable ctive locked ou Control input 2 825 MST NOT DISABLED P continued PTC PROT Not disabled PTC protection NoT DISABLED J disabled Active locked ou 100 PROT disabled PT100 RTD protection NoT DISABLED J disabled Active locked o E Phase sequence protection PHASE REVER TRIP On Off 2 motor supply OFF voltage Phase sequence d Es J On Off protection 825 MLV PHASE REVER TRIP All relays Phase sequence protection MAIN RELAY y Assignment of output relay Phase failure PHASE LOSS TRIP On Off based on motor supply OFF J voltage On Off Phase failure 825 MLV PHASE LOSS TRIP All relays Phase failure MAIN RELAY y Assignment of output relay PT100 protection PT100 PROT On Off stator bearings OFF x On Off 100 1 TRIP oor PT100 1 protection OFF On Off lt D PT 100 RTD 44 TRIP TEMP 100 1 temperature sensor PAS MMV o 90 200 Tripping temperature 90 J PT100 2 TRIP PT10052 protection OFF On Off S
122. r the fault current 1 3 AC TQ ki 825 M A 2 F 3 HS CN T T T T CM 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 Cy and the compensating coil L The nearer the fault is to the motor star point the smaller the fault current T 825 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 either 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 T le I II Lt tw 60 min I First start II Second start hy 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
123. rameter Main Relay Setting the Operational Parameters 5 10 Table 5 D Cat No 825 M Operating Parameters Continued Required Group Option Card LCD zeng Description Cat No 9 Electrically Main output relay MAIN RELAY held non electrically held or ELECTR HELD j fail safe fail safe connection A Electrically Alarm relay in non fail safe ALARM RELAY held non fail jor electrically held NON FAIL SAFE D safe connection i m TH TRIP RESET Reset of thermal trip Special settings MANUAL Manual auto Manual automatic x THE RESET LEVEL 10 100 Thermal reset at__ of 50 xh thermal utilization v 2 Z N Cooling constant ratio COOL CONST RATIO 1 0 10 0 between motor off and 2 5 motor on TC TRIP B On ort Thermistor protection PTC ON On Off 2 temperature PTC trip sensors 825 MST MAIN RELAY J All relays Assignment of output relay PTC RESET ius s trip y auto anual automatic ANUAL J CONTROL INPUT 1 Control input 1 OFF On O f SS 2 lt B Timer function of auxiliary DELAY AUX REL 2 On Off relay 2 OFF J On Off Control input 1 825 MST ON DELAY AUX 42 0240 On delay of auxiliary 1 sec J relay 2 OFF DELAY AUX 2 0240 Off delay of auxiliary 2 sec relay 2 If PIC Trip
124. ramming 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 ag Description Cat No 9 S WARM STARTING Warm star OFF On Off 9 On Off SS D Warm start m ARM START EACH b 460 Warm start possible every 60 min y min s Warm start tripping time as WARM TRIP TIME 50 100 percentage of tripping VO J time from cold ie Limiting number of START INHIBIT On Off starts hour OFF J On Off Limiting number of MAX START HOUR starts per hour 1 10 starts hour lt 2 Maximum number of START TRIP All relays starts hour reached MAIN RELAY J Assignment of output relay Em START CONTROL On Off Monitoring starting time OFF On Off 2 Monitoring startip START TIME 1 240 Maximum starting time timg 10 sec k 2 t START CONT TRIP All relays Star ing time exceeded MAIN RELAY Y Assignment of output relay f Warm Starting is set to off the programming menu skips to parameter Start Inhibit f Start Inhibit is set to off the programming menu skips to parameter Start Control If Start Control Publication 825 UM001B EN P January 2001 is set to off the programming menu skips to pa
125. 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 Figure 3 11 Function of High Overload and Jam Protection Table 3 M High Overload and Jam Setting Parameters Conveying systems e Mills Mixets e Crushers e Saws etc Motor start 2 1 2 I Nominal operation High overload or jam ty Tripping delay 4 Jam protection not active 5 Jam protection active tripping threshold Warning O Trip Function Factory setting Off On Responselevel Setting range 1 6 72 Factory setting 21 24 Ie Setting increments 0 2 Ie 0 2 Ie C mipingDeay Setting range 0 1 55x 0 04 s Factory setting 0 5 s 0 04 s Setting increments 0 15 o QupuRelayO Selection relays ALA MAAS 7 Factory setting AL MR 5 60 23 140 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 PLC then the Monitoring the Start Time function must be activated After the set max starting Time has elapsed the High Overload Stall function w
126. rol and protection Sot 1 system Bulletin 825 with Cat 825 MLV option card S1 On push button SIE SO Off push button U Control voltage eae i H1 Indicator Contactor closed 95 d 1 219 H2 Indicator 825 M tripped F1 MR f ALV 25 Main relay ect TEN AL Alarm relay 96 198 2 114 H3 Indicator Alarm Warning 53 D T T1 1 825 i L 15 i oi cul H2G L2F8 2 2 2 jq 7 K3 K2 Ki 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 U 12 1 Variants e 2 phase current evaluation e 2 phase current evaluation and earth ground fault gr Y protection with core balance transformer QA m U1 Converter module Cat No 825 MCM2 Ki 7 4 A2 Cat 825 MCM20 i sl 5 Fi U2 Main current transformer u2 U1 825 MCM 825 M 5 Aor A 1A dT For choice refer to Chapter 2 Publication 825 UM001B EN P January 2001 9 5 Applications Wiring Control Circuit Figure 9 6 Control by Momentary Contact Circuit breaker
127. round 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 Setting Range Setting Range Setting Selection Setting Bulletin 825 MST Option Card Control Input 42 24V AC DC 8 mA One of three functions can be selected 1 Pickup delay relay 0 0 2405 15 n 3 1 Dropout delay relay __ 0 240 s 25 3 2 Set second rated 0 5 current 0 2000A 20A 3 Disable protective functions Asymmetry phase 0 failure High overload jam Earth ground fault Short circuit Underload Limiting starts hour PTC oO GO CO CO ol GO PT100 RTD Bulletin 825 MLV Option Card Star delta starting 0 Y Aat 1 1 Ze Y Aat 1 2 40s 10s Y 4 A3 5 For example 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 a
128. s Methods e With the current converter in Set Values mode Access the parameters or print them out and compare them with the set values in the list of settings The main settings are e Rated ot service current Locked rotor or starting current e Permissible locked rotor time These three settings must be made individually for cach 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 e Set the current converter rated current based on the service current of the motor if the installation or motor nameplate current is not known 1 Set the motor current approximately 10 20 higher than the assumed service current 2 With the installation running normally read the motor current on the LCD 3 Set the current converter to the service current reading Set current FULL LOAD CURR 140A Measured motor current pun 85 le 96 1 xI Service current 2 DTNA 119A 100 100 Setting to service current E LOAD CURR 119A The motor current is now id 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 Commissio
129. s 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 r SdlA Sc8 SHIA 009 019 009 NIIA S28 OMION AWW SZ8 10 AIW S28 eJnyejeduiej jusiquiy aru 1st 00LLd T amp 1 81 11 a 1 9 100114 1 19 c19 L19 resa ELL ZLL LLL Si Aejas 9 9 L eunjrej oseud vit Keja Arelixny G eg jndino Boyeuy e p eit Areyixny ve ee m Ht e e vz ez wely b 86 26 0 HIN 8J84 UIEN 96 66 I e 1
130. st Card Page Display List Card Page Cat No Cat No 825 M MAIN TIME h min 7 2 CAUSE 2PRV TRIP 7 3 OTOR 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 73 SINCE LAST TRIP h min 7 2 AS BEF LAST TRIP 96 7 3 E mA SINCE 1PRV TRIP h min 7 3 EF BEF LAST TRIP lg 7 3 SINCE 2PRV TRIP h min 7 3 MAX T BEF LAST TRIP 825 MMV 7 4 SINCE 3PRV TRIP h min 7 3 TH BEF LAST TRIP 7 4 SINCE 4PRV TRIP h min 7 3 UMBER START 7 4 CAUSE LAST TRIP 7 3 NUMBER TRIP TH AS OC EF SC UL 7 4 CAUSE 1PRV TRIP 7 3 PTC PR PL PT100 Publication 825 UM001B EN P January 2001 Functions Operation Selecting the Setting Display Mode Actual Change mode by pressing Recorded Values 3 4 HH ACTUAL SET VALUES J Actual f E Change Actual fr Change Actual fr Change ndication of actual Setting mode Indication of operational data set vary store parameters statistical data Publication 825 UM001B EN P January
131. tandstill o Selection relays OV AC DC at control input 1 Output Relay Same relay as for function High Overload and Jam settable only there Publication 825 UM001B EN P January 2001 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 Motots above 7 5 kW 10 HP High ambient temperatures dusty environment Varying loads Plugging etc Table 3 Y PTC Setting Parameters Function 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 ax resistance of the PTC chain when cold 15kQ ax number of sensors as per IEC 34 11 2 6 Pickup value at 5 60 C 33 KQ 0 3 KQ Dropout value at 5 460 C 1 8 KQ 0 3 KQ Delay on pickup 800 ms 200 ms E e circuit in sensors c
132. tion 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 e Pumps Conveyors Crushers e Saws Publication 825 UM001B EN P January 2001 Chapter Assembly and Installation Assembly Flush Mounting To mount the Smart Motor Manager in a front panel cut a rectangular hole with the following dimensions Figure 4 1 Basic Unit Mounted in an Enclosure o 13g My N Sam d x DYE Dimensions in mm inches Q Front panel with cutout Dimensions Rubber gasket Panel cutout 138 x 138 mm Fixing nuts 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 225 225 T i ad 225 Surface Mounting Figure 4 3 Basic Unit Mounted into Panel Mounting Frame Cat No 825 FPM 170mm 6 11169 _ Dimensions in mm inches Publicati
133. tion system consists of The basic control and protection unit e 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 e Thermal utilization meter to indicate the thermal load Installation The Smart Motor Manager can be either flush mounted in an enclosure door 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 Option Cat No 825 MLV Cat 825 MMV 4 as a ae gt Communication Communication Network Cat No 825 MST LE Thermal utilization module N 4 20 mA Core Balance Current Transformer PENNE c Converter module Available Communications Cards Cat No 825 MDN DeviceNet Cat No 3600 RIO Remote I O Cat No 3600 MBS Modbus 0 Cat No 825 MPB PROFIBUS FMS Available from Prosoft Technology Inc not an Allen Bradley product References to third part products are provided for informational purposes only Prosoft Technology Inc i
134. uits errors supply etc ERROR 825 MCM Publication 825 UM001B EN P January 2001 Chapter J 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 vard Page Display List Option card Page MOTOR A ES 6 6 l earth H l 6 7 MOTOR hle 6 5 l earth C mA 6 7 1 6 6 Tambient G 825 MMV 6 7 2 hle 6 6 PT100 1 6 C 825 MMV 6 7 3 Sle 6 6 PROBUS 825 MPB 6 7 TRIP IN 5 6 6 RIO 3600 RIO 6 7 RESET IN 5 6 7 MODBUS 3600 MBS 6 7 ASYM 6 7 DevNet 825 MDN 6 7 Publication 825 UM001B EN P January 2001 Functions 3 2 Set Values e parameters ain Settings an ecial Settings must be programmed for every Th ters Main Settings and S 1 Settings tb g d fi y application The other parameters e g High Overload Asymmetry have factory set values which are 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 x 5 5 PTC RESET
135. up very rapidly reaching the emperature 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 or unacceptable stress from stalling Publication 825 UM001B EN P January 2001 3 45 Functions Applications Large low voltage motors Medium and high voltage motors Conveyor systems e Mills e Mixers Crushers e Saws Cranes e Hoists etc Figure 3 26 Stalling During Starting Te 1 Normal start without hindrance by high overload or stalling Stalling during standing Tripping delay Table 3 X Stalling during Start Setting Parameters Trip Factory setting Factory setting Function Off Tripping Delay The trip time tsp depends on the trip time to chosen for the overcurrent as follows toy lt 400 ms tsp 600 ms ty 2 400 ms tsp toy 400 ms Actuation essage from zero speed switch to control input 1 or running o 24V AC DC at control input 1 or s
136. urs minutes MIN 7 SINCE 1PRV START Time since one start prior to last start in hours minutes k MIN p SINCE2 PRVSTART ig 5 2 PRVS ime since two starts prior to last start in hours minutes kz MIN J SINCE 3 PRV START Time since three starts prior to last start in hours minutes k MIN J N SINCE 4 PRV START Time since four starts prior to last start in hours minutes H MIN J A N SINCE LAST TRIP Time since last trip in hours minutes k MIN p Publication 825 UM001B EN P January 2001 Testing and Maintenance 7 3 Table 7 A List of Recorded Values Continued LCD Description SINCE 1 PRV TRIP ime since one trip prior to last trip in hours minutes MIN J a No SINCE 2 PRV TRIP ime since two trips prior to last trip in hours minutes kz MIN 9 4 DD m SINCE 3 PRV TRIP ime since three trips prior to last trip in hours minutes MIN J fe E e SINCE 4 PRV TRIP ime since four trips prior to last trip in hours minutes MIN J CAUSE LAST TRIP b Cause of last trip e g asymmetry ASYMMETRY TRIP J CAUSE 1 PRV TRIP 1 Cause of one trip prior to last trip e g asymmetry ASYMMETRY TRIP J gt CAUSE 2 PRV TRIP Cause of two trips prior to last tr

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