Bulletin 825 Plus Component Configuration
Contents
1. ALLEN BRADLEY PROGRAMMABLE MOTOR PROTECTOR BULLETIN 1406 ATO MODULE 1406 R16 Instrumentation Option Cat No 1406 5 1500 IN058D EN E June 2013 E 2 Bulletin 1406 Product Overview 1500 IN058D EN E June 2013 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 2 663 0640 Asia Pacific Rockwell Automation Level 14 Core F Cyberport 3 100 Cyberport Road Hong Kong Tel 852 2887 4788 Fax 852 2508 1846 Medium Voltage Products 135 Dundas Street Cambridge ON NIR 5X1 Canada Tel 1 519 740 4100 Fax 1 519 623 8930 www ab com mvb Publication 1500 INO58D EN E June 2013 Supersedes Publication 1500 IN058C EN E February 2007 Copyright 2013 Rockwell Automation Inc All rights reserved Printed in Canada2. H LII Il BN I MIN CANIN JE SILVI Modular Protection System Conversion Kit INSTALLATION MANUAL Bulletin 1406 to Bulletin 825 Plus EP Rockwell ALLEN Brapley Rockwell Sorrwas Automation Important User Information Read this document and the documents listed in the Additional Resources section about installation configuration and operation of this equipment before you install configure operate or maintain this product Users are required to familiarize themselves with installation and wiring instructions in addition to requirements of all applicable codes laws and standards Activities including installation adjustments putting into service use assembly disassembly and maintenance are required to be carried out by suitably trained personnel in accordance with applicable code of practice If this equipment is used in a manner not specified by the manufacturer the protection provided by the equipment may be impaired In no event will Rockwell Automation Inc be responsible or liable for indirect or consequential damages resulting from the use or application of this equipment The examples and diagrams in this manual are included solely for illustrative purposes Because of the many variables and requirements associated with any particular installation Rockwell Automation Inc cannot assume responsibility or liability for actual use based on the examples and diagrams No patent lia
3. cont Kit Highlights and Limitations Personnel Safety 1500 IN058D EN E June 2013 The elimination of a disturbance may cause the motor to start running again by itself This may endanger persons N or damage equipment The user must take the necessary safety measures to protect against this type of occurrence so that any danger is avoided The Bulletin 1406 to Bulletin 825 Plus Conversion Kit provides most of the features and functionality of the Bulletin 1406 However the Conversion Kit also provides additional features and functions not provided supported by the Bulletin 1406 The Bulletin 825 Plus Conversion Kit provides easy installation modular design no additional wiring uses existing low voltage door and panels in most cases various communication methods DeviceNet 0 Modbus 12 RTD inputs with remote RTD Scanner optional programmable analog output Option card required Does not support interconnection method used by the Bulletin 1406 P and 1406 AA Note The user must validate the control and protection capabilities of the 825 Plus Protection of personnel in the vicinity of control equipment is of primary importance The corresponding requirements of regulatory agencies are therefore becoming increasingly severe The Bulletin 825 Plus reflects this by providing the following protection e Equipment construction Touch protection Insulated housing Motor protective fun
4. 4 13 6 To ensure the hole is of the correct size place a mounting collar over the hole There should be no metal showing on the inside of the collar and the collar should not pass through the cutout Figure 4 14 Remove all metal chips before mounting the 825 Plus ATTENTION Failure to remove all metal chips can result in equipment damage or hazardous operation dee Figure 4 13 Figure 4 14 1500 IN058D EN E June 2013 46 Installation Preparing Low Voltage Door for 825 Plus cont 1 Mount the 825 Plus through the low voltage door cutout Re member to place a mounting collar on both sides of the low volt age door Figure 4 15 2 Fasten the 825 Plus to the low voltage door using the mounting hardware provided with the 825 Plus LLOJI Tighten the screws with minimal force Do not over tighten Figure 4 15 3 Before completely tightening the mounting hardware ensure the 825 Plus is mounted on a level plane both horizontally and verti cally Figures 4 16 and 4 17 Figure 4 16 Figure 4 17 1500 IN058D EN E June 2013 Installation 4 7 Reinstalling the Low Voltage Door 1 Re install the low voltage door Caution must be taken when re installing the door It is recommended that two people remount the door one person to hold the door and a second person to replace the hinge pins Figure 4 18 ATTENTION Ensure sufficient personnel are present to safely replace the low vol
5. damage personal injury N and or death 1500 IN058D EN E June 2013 4 10 Installation Post Installation Testing Failure to follow these steps can result in damage to equipment and or personal injury 1 Inspect the interior of the enclosure for contamination loose bolts tools or metal chips and vacuum clean if necessary 2 Account for all the tools used If a tool or hardware is unaccounted for do not energize the equipment SA ar gy wo p Inspect the wiring and the control scheme to ensure proper operation Extra care should be taken when inspecting the connections for the current transformer and ground fault circuits to ensure neither circuit is open or short circuited during power up Y 4 For medium voltage controllers follow items 5 though 7 For other styles of controllers the intent of this section is to apply control voltage to the controller circuit including the 825 Plus 5 The isolation switch must be in the fully opened position the isolation switch handle moved to the OFF down position 6 Connect a remote 120VAC external power source to the NORMAL OFF TEST N O T switch assembly test receptacle located in the low voltage compartment Figure 4 24 7 Turn the N O T selector switch to the TEST position Figure 4 25 With the selector switch in the test position power will be applied to the control circuit Additional caution must be taken to prevent accidental cont
6. ohms CSA certified and UL listed Important This current transformer is used to step down an existing 50 5 ground fault current transformer The secondary of this current transformer is connected to the secondary of the existing ground fault current transformer This results in an equivalent 50 1 ground fault current transformer This is done to prevent possible damaging current levels for the 825 Plus Voltage Transformer not provided with the standard kits Optional for speed switch appliclations Primar Seconda Current Rating Class Insulation Di electric Withstand Approvals Design Type Recommended Transformer 115 V AC 24 V AC 60 Hz 85 mA 105 C Hi Pot test of 2000 V RMS CSA certified and UL listed Dual bobbin design no electrostatic shield required M anufacturer Hammond Manufacturing P art Number 166C24 Auxiliary Relays Bulletin 700 HK32A1 Temperature Enclosure Coll Voltage Permissible Coil Voltage Variation Power Consumption Rated Insulation Voltage Dielectric Withstand Voltage Contacts Type Material S Mechanical Operations Switching Frequency Operations Rated Thermal Current Break Current at 120 V AC Make Current at 120 V AC Operating Time Maximum Operating Rate Operating 30 C to 55 C 22 F to 131 F Storage 55 C to 85 C 67 F to 185 F Transparent Dust Cover 120 V AC 60 Hz 102 V AC to 132 V AC 10 AC 1 1 VA 250 V IEC 300 V UL CSA Pole to Po
7. 58D EN E June 2013 1406 TB 1406 TB OM BB ND gt je 11 opy as required Bulletin 825 P TB3 TB RTD Interface Panel Installation Guide C 3 lus RTD Scanner Interface Conversion Kit Wire Number Table 825 Plus RTD Scanner TB 1406 TB TB1 825 Plus RTD Scanner TB 2 1 E TB2 sn werte ely e e 5 e a Ta ow To a ss ow a a ow a ow s a a o9 Lx 5 12 2 14 12 1 13 1500 IN058D EN E June 2013 C 4 RTD Interface Panel Installation Guide 1500 IN058D EN E June 2013 Bulletin 825 Plus Component Configuration Communication Card DeviceNet Modbus 825 Plus E Lp T 2 a i sf Pu L i E s d e MA e vs P 825 Plus Interface Panel with 825 MCM 825 Plus RTD Scanner Interface Panel 1500 IN058D EN E June 2013 D 2 Bulletin 825 Plus Component Configuration 1500 IN058D EN E June 2013 Bulletin 1406 Product Overview L1 Medium Voltage Power Bus Protective Module Cat No 1406 P16 AB ALEENGHBUNDERY AB Interlock BULLETIN 1406 To Contral Circuit PROG RA MM A BLE MOTOR PROTECTOR Mech Interlack NS NN Programmer Monitor Cat No 1406 G or Display Module Cat No 1406 D RTD Module Cat No 1406 R16 Pal a duerme o 6 Winding RTDs 2 Bearing RTDs Squirrel Cage Motor
8. acking Your Kit Unpacking and Storage This chapter describes the procedures for unpacking inspecting and storing the Bulletin 1406 to Bulletin 825 Plus Conversion Kit As you unpack the conversion kit follow the steps listed below 1 Handle each component carefully to avoid damage 2 Unpack the box es enough to inspect the shipment for missing or damaged equipment 3 Inthe event that a component is missing damaged or shows evidence of rough handling THE BUYER SHALL NOTE SUCH ON THE CARRIER S DELIVERY RECEIPT and immediately notify the carrier OE Save all packaging material for the insurance company inspection 4 If the above conditions are not complied with any right to recovery for missing or damaged components as described above may be forfeited 5 Make sure that the components received are correct based on what was ordered If the Conversion Kit will be stored for any length of time the following precautions should be taken 1 The ambient temperature must be between 40 C to 60 C 40 F to 140 F 2 If the storage area is damp and or cool it is important to dry the Conversion Kit out in a warm dry environment before using Also clean all terminals to help provide integrity of the electrical connections 3 Cover the Conversion Kit with a heavy plastic or similar material to help prevent the accumulation of dirt on the equipment Bye For storage in harsh or caustic environments consult a R
9. act with the 120VAC 1 3 9 4 Figure 4 25 1500 IN058D EN E June 2013 Installation 4 11 8 Test the control circuit functionality by electrically operating the contactor air or vacuum in test mode Figure 4 26 This may require the use of test jumpers depending on the control circuit Refer to original drawings supplied with the equipment 9 Program the 825 Plus with the correct motor and protection parameters Figure 4 27 Refer to the User Manual publication 825 UM004_ EN P included with the 825 Plus for programming instructions 10 Turn test switch to OFF Return the controller to service by removing any test voltage supply and turning the selector switch back to the NORMAL position 11 Close the low voltage door and tighten down the door screws Figure 4 26 Figure 4 27 1500 IN058D EN E June 2013 4 12 Installation 1500 IN058D EN E June 2013 Appendix Bul 1406 P16 to Bulletin 825 Plus Conversion Kit Wire Number Table TB2 TBI TB TB TB Copy As Required 1500 IN058D EN E June 2013 A 2 1500 IN058D EN E June 2013 Technical Data 825 Plus Refer to Publication 825 UM004_ EN P Description Specification Ground Fault Interposing Current Transformer Conversion Kit Interface Panel Primary 1A Secondary 5A Operating Frequency Class 600 Accurac Primary Impedance Approvals 50 60 Hz V Less than 2 ratio error at 5 VA burden 2 5
10. bility is assumed by Rockwell Automation Inc with respect to use of information circuits equipment or software described in this manual Reproduction of the contents of this manual in whole or in part without written permission of Rockwell Automation Inc is prohibited Throughout this manual when necessary we use notes to make you aware of safety considerations WARNING Identifies information about practices or circumstances that can cause an explosion in a hazardous environment which may lead to personal injury or death property damage or economic loss ATTENTION Identifies information about practices or circumstances that can lead to personal injury or death property damage or economic loss Attentions help you identify a hazard avoid a hazard and recognize the consequence PP IMPORTANT Identifies information that is critical for successful application and understanding of the product Labels may also be on or inside the equipment to provide specific precautions SHOCK HAZARD Labels may be on or inside the equipment for example a drive or motor to alert people that dangerous voltage may be present BURN HAZARD Labels may be on or inside the equipment for example a drive or motor to alert people that surfaces may reach dangerous temperatures ARC FLASH HAZARD Labels may be on or inside the equipment for example a motor control center to alert people to potential Arc Flash Arc Flash will cause severe inj
11. ctions Earth ground fault High overload stalling and jam Phase reversal Overview Operational Requirements Equipment Description This chapter describes the features of the Bulletin 1406 to Bulletin 825 Plus Conversion Kit Monitoring application parameters and process data of an installation 1s very important Even a slight change in the starting and operating behavior of the motor can indicate an impending fault The Bulletin 825 Plus helps eliminate the potential trouble before major repairs are necessary and loss of production occurs The Bulletin 825 Plus fulfills these requirements by providing the following protective functions High overload stalling Underloading Wrong direction of rotation However the Bulletin 825 Plus functionality does not directly correspond to the Bulletin 1406 Below is a summary of some of the features offered by the Bulletin 825 Plus In most cases the 825 Plus provides improved and additional features protection Function Description Bul 825 Plus Parameters Current Transformer Primary 25A 1500A rating 0 5 5000 A Full Load Current FLC 0 5 A 5000 A Thermal Overload Protection Yes Overcurrent Protection Yes Allowable Acceleration Time 1s 240s Mora RTD ypes ET ei Number of Winding RTDs 1 6 1 12 0 Number of Bearing RTDs 1 2 1 12 0 NPA NUD ST NEMUS specified ine E m Lm Phase Unbalance Trip Current 5 80 percent of FLC Phase Unbalance Alarm Curr
12. ent BE 5 80 percent of FLC Phase Reversal Protection S Q Features require additional 1406 S option card Total of twelve 12 inputs for winding bearing or other RTD 1500 IN058D EN E June 2013 2 2 Equipment Description Operational Requirements cont 1500 IN058D EN E June 2013 Function Description Jam Protection Undervoltage Protection Ground Fault Alarm Current Ground Fault Trip Current Ground Fault Trip Time Short Circuit Protection Jam Trip Current Underload Trip Current Underload Trip Time Delay Ultimate Trip Current Winding Alarm Temperature Winding Trip Temperature Bearing Alarm Temperature Bearing Trip Temperature Ambient Temperature Sensor Input Reset Condition Speed Switch Input Analog Output Communication P Trip Contacts Alarm Contacts Bul 1406 Parameters lt CD an Yes O Ye 1A 25A 1A 25A 10ms 15s Oo 2 10 multiple of FLC 50 90 percent of FLC 1s 10s 100 125 percent of FLC 20 C 180 C 20 C 1809C 0 20 C 1809C 0 20 C 180 C Pad Oo Auto Manual 2z lt o 8 LC only 2 form C contacts fail safe 2 form C contacts fail safe Q Feature requires additional 1406 S option card Bul 825 Plus Parameters Yes S 0 01 25A 0 25A 25A 0 5s Yes 1 6 multiple of FLC 10 100 percent of FLC 0 120s 4 12 multiple of FLC 0 250 C 250 C 250 C 0 250 C Yes Auto Manua
13. formation on the Bulletin 825 P Modular Protection System for Motors refer to Publication 825 UM004_ EN P Rockwell Automation reserves the right to adapt the products described in this manual at any time to suit the N latest technical developments Accordingly attached information is not an object of the contract and thus may change without notification Prerequisite for proper operation is correct transport proper and competent storage and installation as well as careful operation and maintenance 1 The power supply must be switched off prior to any intervention in the electrical or mechanical part of the equipment 2 In accordance with the applicable rules work on electrical equipment or means of production may only be carried out by competent electricians or suitably trained persons guided and supervised by a competent electrician 3 The electrical equipment of a machine plant must be inspected tested Deficiencies such as loose connections or scorched cables must be eliminated immediately 4 The described control and protection system 825 Plus provides starting and stopping functions for a motor wed In case of electrical or mechanical faults the machine must be switched off and protected immediately The N elimination of disturbances must be organized without delay Failure to do so may result in personal injury and or damage to the equipment 1500 IN058D EN E June 2013 1 2 Introduction Overview
14. hich this kit is being installed The pictures should be used as a general basis only 1500 IN058D EN E June 2013 4 2 Installation 825 Plus Interface Panel Disconnect and lockout all sources of power entering the low voltage compartment where the 1406 P16 is located N This may include opening the main disconnect isolation switch Failure to disconnect and lock out power can result in personal injury and or damage to the equipment 1 Disconnect the control wires connected to the 1406 P16 Using the wire number table in Appendix A mark each wire with the corresponding 1406 terminal block number for reference later in the procedure 2 Remove the 1406 P16 module from the low voltage panel Save all the mounting hardware Figure 4 1 3 Use the saved mounting hardware from the previous step to mount the 825 Plus Interface Panel in the same location the 1406 occupied Figure 4 2 If a 1406 R16 RTD module was used with the 1406 P16 the RTD module must also be removed The RTD wiring to the old 1406 RTD module must be rewired to the 825 Plus RTD Panel Refer to the 825 Plus RTD Panel Installation Guide Appendix C Handle existing wiring with care Replace any damaged or worn wiring Figure 4 2 1500 IN058D EN E June 2013 Installation 4 3 Door Cover KA 1 Disconnect and remove the communication cable from 1406 n bx programming module located on the low voltage door Figure 4 3 2 Remove the 1406
15. l Yes Yes DeviceNet Remote 1 0 PROFIBUS Modbus 2 form C contacts fail safe 2 form C contacts fail safe Anadditional voltage transformer is required Refer to Technical Data in Appendix B of this manual Equipment Description 2 3 Ordering Information Conversion Kit Numbers m Electrical Drawing Description Catalog Number Standard Conversion Kit 825PK1 BDVXXC Standard Kit with DeviceNet 825PK1 BDVDXC Standard Kit with Modbus 825PK1 BDVMXC Standard Kit with RTDs 825PK1 BDVXPC Standard Kit with RTDs and DeviceNet 825PK1 BDVDPC Standard Kit with RTDs and Modbus 825PK1 BDVMPC NOTE When ordering a conversion kit with the RTD option refer to the 825 Plus RTD Scanner Interface Installation Guide Appendix C for additional information 1500 IN058D EN E June 2013 2 4 Equipment Description Catalog Number Breakdown Part Part Description Part Number Mounting Bezel ANSI 49 80185 279 05 Mounting Bezel ANSI 61 80185 279 06 Cutout Cover ANSI 49 80185 316 02 Cutout Cover ANSI 61 80185 316 03 Base 825 Plus Relay 825 PD 825 Plus I O Card 825 PIOD 825 Plus Voltage Card 825 PVS 1406 to 825P Interface Panel Assembly 80185 323 52 with DeviceNet 825 Plus DeviceNet Card 825 PDN with Modbus 825 Plus Modbus RTU Card 825 PMB 825 Plus RTD Scanner 825 PR12D wi th RTDs RTD Scanner Mounting Assembly 80185 329 52 Fiber Optic Cable 80026 385 02 Standard Conversion Kit 1500 IN058D EN E June 2013 Unp
16. le VRMS 1500 V AC Contact to Coil VRMS 1500 V AC DPDT 2 Pole 2 Form C ilver Cadmium Oxide AgCdO 5 x 106 11 800 hr 5A 3A 30 A P ickup 15 ms Dropout 15 ms 3 Ops s 1500 IN058D EN E June 2013 B 2 Technical Data Conversion Kit Interface Description Specification Panel cont Terminals TB1 and TB3 Type Screw terminal with wire clamp Approvals CSA certified and UL listed Voltage Rating 300 V AC DC Maximum Current 25 Wire Range 0 5 to 1 5 mm 22 14 AWG Wire Strip Length 6 4 mm 0 25 inch Recommended Tightening Torque 6 14 Ib in 0 7 1 6 Nm Insulation Temperature Range 40 C to 105 C 40 F to 221 F Terminals TB2 Type Screw terminal with 6 screw Approvals CSA certified and UL listed Voltage Rating 600 V AC DC Maximum Current 20A Wire Range 0 5 to 1 5 mm 22 14 AWG Wire Strip Length Prepared Conductors Only Recommended Tightening Torque 12 1b in 1 4 Nm Insulation Temperature Range 40 C to 105 C 40 F to 221 F Prepared conductors utilize ring spade or hook connectors Converter Module Description Specification Terminals 0 5 to 1 5 mm 20 AWG to 14 AWG single wire Bulletin 825 plug in terminals 0 5 to 1 5 mm 20 AWG to 14 AWG double wire Range of cross section 0 5 to 1 5 mm 20 AWG to 14 AWG Nominal 1 5 mm 0023 in 2 2x 2 5 mm 1 x 4 mm 2 x 0039 in 1 x 006 in Cat No 825 MCM5 2x 0 5 to 1 5 mm 20 AWG to 14 AWG I 1 x 0 5
17. must be taken Figure 4 8 when removing the door It is recommended that two people remove the door one person to hold the door and a second person to remove the hinge pins Figure 4 9 ANIME Ensure sufficient personnel are present to safely remove the low voltage door Failure to do so may result in N personal injury and or damage to the equipment Figure 4 9 1500 IN058D EN E June 2013 Installation 4 5 Preparing Low Voltage Door for 825 Plus 1 Once the door has been removed place the door on a level work surface 2 Position an 825 Plus Mounting Collar squarely on the low voltage door to locate the required cutout Figure 4 10 Position the 825 Plus cutout on the door properly to ensure that the low voltage door and low voltage panel can swing open without difficulty It is recommended that the edge of the cutout be positioned at least 5 inches 127 mm from the unhinged side of the low voltage door to allow for proper clearance to open the low voltage door with the 825 Plus installed Figure 4 10 3 Using the collar as a template lightly trace the cutout area on the inside and outside of the collar This outline represents the minimum and maximum size required by the 825 Plus relay Figure 4 11 4 Drill a pilot hole in the center of the traced cutout area Figure 4 12 5 Double check the measurements before cutting With a cutting tool cut on the outside edge of the inside cutout trace Figure
18. ockwell Automation representative 1500 IN058D EN E June 2013 32 Unpacking and Storage 1500 IN058D EN E June 2013 Installation Overview This chapter describes the procedures for the installation of the Bulletin 1406 to Bulletin 825 Plus Conversion Kit within a medium voltage controller Installation within other controller types can also be accomplished by following the principal philosophy of the retrofit described This manual is intended for use by personnel trained and familiar with medium voltage solid state power equipment and general industrial controls Pre installation To avoid shock hazards lock out incoming power before working on the equipment Verify with a hot stick or N appropriate voltage measuring device that all circuits are voltage free Failure to do so may result in severe burns injury or death Eur RARE The National Electrical Code NEC and or Canadian Electrical Code CEC or other local codes outline N provisions for safely installing electrical equipment Failure to follow locally applicable codes can result in hazards to personnel or a non compliant installation Tools required e Sheet metal cutting tools capable of cutting up to 12 gauge material e Hand drill and drill bits e Screw drivers e Allen key wrench set e Drop sheets or tarp The following pictures shown are illustrating a common controller layout These pictures may not necessarily N illustrate the exact equipment on w
19. programming module from the low voltage door xi Save the mounting hardware for use later in the installation process Figure 4 4 3 Use the saved hardware to mount the 1406 door filler cover supplied with the conversion kit Ensure that the correct colored door filler cover is used The 825 Plus Conversion Kit contains ANSI 49 and 61 colored door filler covers Figures 4 5 and 4 6 at Pier Figure 4 4 Figure 4 5 1500 IN058D EN E June 2013 4 4 Installation Removing Low Voltage Door It is recommended to remove the low voltage doors to facilitate cutting the mounting hole for 825 Plus The hole can be cut without removing the door if proper tools are used and blankets drop sheets or tarps are used to prevent drill and saw chips from entering the controller If you chose to do so skip to page 4 5 and ignore page 4 7 MOB TO 825 Tip The packing box from the 825 Plus can be used to determine nji feasibility of a specific mounting location Tape the box to the rear of the low voltage door to validate the door swing and component interference on the low voltage panel RENE Failure to check for clearance can result in damage to equipment and or personal injury 1 Remove all door mounted devices Note wire numbers and locations It is recommended to create a sketch of the component layout and associated wiring locations Figures 4 7 and 4 6 sh NJ 2 Remove the low voltage door hinge pins Caution
20. ristan CPSs no a te ons 4 10 Bulletin 1406 P16 to Bulletin 825 Plus Conversion Kit Wire Number Table c ccccccccecccceccccccecccececceceececccsceccecaseecesces A 1 Technical Data OO B 1 Conversion Kit Interface Panel se B 1 Converter Modi B 2 1500 IN058D EN E June 2013 li Table of Contents Bulletin 1406 to 825 Plus Conversion Kit Installation Manual Appendix C Appendix D Appendix E 1500 IN058D EN E June 2013 Bulletin 1406 R 16 to Bulletin 825P Smart Motor Manager Conversion Kit OO A C 1 Installation InstEUCtlOBS 2 2 0 2 07 Erie semer au dd C 2 Bulletin 825 Plus RTD Scanner Interface Conversion Kit Wire Number Table otro etse la aaa C 3 Bul 825 Plus RTD Interface Panel Conversion Kit Wire Number Table C 4 Bul 825 Plus Component Configuration 4404 C 5 Bulletin 825 Plus Component Configuration ns D 1 Bulletin 1406 Product Overview nm E 1 Overview Chapter L Introduction This manual describes the installation of the Bulletin 825 Plus Conversion Kit within a typical medium voltage MV controller Simple troubleshooting is also included Although this manual outlines the implementation within a medium voltage controller the basic philosophy also applies for installation within any voltage controller where a Bulletin 1406 has been used To use this manual effectively you must be familiar with electrical procedures and terminology For setup programming and operation in
21. tage door Failure to do so may N result in personal injury and or damage to the equipment 2 Remount all door mounted devices that were removed Figure 4 19 Figure 4 18 1500 IN058D EN E June 2013 48 Installation 1 Reconnect the control wires to the corresponding 825 Plus Interface Panel terminal blocks These are located and numbered the same as those on the 1406 P16 Use the wire number table created as part of the procedures on page 4 2 in Appendix A to verify the wire numbers and the terminal block location Figures 4 20 and 4 21 2 Using the provided spiral wrap combine the existing and new door control wire bundles Figure 4 22 Figure 4 22 1500 IN058D EN E June 2013 Installation 49 3 Route the new wire harness along the low voltage door to the 825 Plus Figure 4 23 4 Cut strip and connect each numbered wire to the corresponding numbered green 825 Plus terminal plug 5 Route the black converter module cable along the low voltage door and plug the telephone style connector to the back of the 825 Plus Refer to the supplied wiring diagram during installation of 825 Plus Interface Panel Refer to the Ordering Information section for Electrical Diagram ED drawing number 6 Ifthe RTD option is used refer to the 825 Plus RTD Scanner Installation Guide Appendix C for additional information ATTENTION Failure to reconnect all wires and cables correctly may result in equipment
22. to 2 5 mm 20 AWG to 12 AWG 1500 IN058D EN E June 2013 Introduction Appendix C Bulletin 1406 R16 to Bulletin 825P Smart Motor Manager Conversion Kit 825 Plus RTD Scanner Installation Guide The 825 Plus RTD panel provides easy installation modular design 12 configurable RTD inputs Fiber optic communication port to 825 Plus max length 500 m The 1406 RTD module provided for eight 8 RTD input six 6 stator winding RTD inputs and two 2 bearing RTD inputs The 825P RTD Panel provides up to 12 RTD inputs for either winding bearing RTD inputs and or other applications 1500 IN058D EN E June 2013 C 2 RTD Interface Panel Installation Guide Installation Instructions Failure to follow these steps can result in damage to the equipment and or personal injury 1 Ensure the RTD wires are disconnected from the 1406 RTD module Using the wire number table in Appendix C mark each wire with the corresponding 1406 RTD module terminal block number 2 Remove the 1406 RTD module from the low voltage panel Save all the mounting hardware 3 Using the mounting hardware saved in the previous step mount the 825 Plus RTD Panel in the location vacated by the 1406 RTD module 4 Reconnect the RTD wires to the corresponding 825P RTD Panel terminal blocks 5 Using the spiral wrap provided combine the existing and RTD Scanner fiber optic communication link to the back of the 825 Plus 1500 IN0
23. ury or death Wear proper Personal Protective Equipment PPE Follow ALL Regulatory requirements for safe work practices and for Personal Protective Equipment PPE gt gt gt Allen Bradley Rockwell Software Rockwell Automation and TechConnect are trademarks of Rockwell Automation Inc Trademarks not belonging to Rockwell Automation are property of their respective companies Introduction Equipment Description Unpacking and Storage Installation Appendix A Appendix B Table of Contents Chapter 1 GO PN 1 1 Kit Highlights and Limitations aaa eee enen e eee eee ee eee eee eee even enes 1 2 Personel K pene e CEP DN M DIMUS EUM 1 2 Chapter 2 O T M M 2 Operational Requirements pe aaa unioni palio 2 1 Orderin INTO MATON a ed D ED REN ME 2 3 Catalog Number Breakdown nenen eee ee eee 2 4 Chapter 3 GJ NE A 3 1 Unpackin Y QUE IE uo moon ores cuenta een ad ee renee omes oe DL cute AIDE cess 3 SI setis spetta de se M MIN MEME ee 3 Chapter 4 OI KC Hm 4 PERS a Eu onori 4 825 Plus Interface Patel cicci 4 2 baud ua ene e o oa 4 3 Removing Low Voltage Door 4 4 Preparing Low Voltage Door for 825 Plus sess 4 5 Zi SR 4 6 Re Installine the Low Voltage Door gjumccvniomr in eke 4 7 Maro the Control Circuit e 4 8 Post T
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