Smart Motor Manager Bulletin 825 User Manual
Important User Information Because of the variety of uses for the products described in this publication, those responsible for the application and use of this 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.
Throughout this manual we use notes to make you aware of safety considerations: ATTENTION Identifies information about practices or circumstances that can lead to personal injury or death, property damage or economic loss ! Attention statements help you to: • identify a hazard • avoid a hazard • recognize the consequences IMPORTANT Identifies information that is critical for successful application and understanding of the product.
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-Bradley publication Industrial Automation Wiring and Grounding Guidelines For Noise Immunity, publication 1770-4.1.
Table of Contents Chapter 1 — Introduction Why Have an Electronic Control and Protection System? . . . . . . . . . . . . Operational Demands of the Motor/Drive . . . . . . . . . . . . . . . . . . . . . . . . Temperature Rise . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Motor Operating Characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Current and Temperature Curves. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ii Table of Contents Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4 Selecting the Setting/Display Mode. . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4 Setting the Operation Parameters (Set Values) . . . . . . . . . . . . . . . . . . 3-5 Indications of Actual Values. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7 Indications of Recorded Values (Statistics) . . . . . . . . . . . . . . . . . . . . .
Table of Contents iii Functions of the Cat. No. 825-MLV Option Card . . . . . . . . . . . . . . . . . Phase Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Phase Failure (Based on Voltage Measurement) . . . . . . . . . . . . . . . . Star-Delta (Wye-Delta) Starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Functions of the Cat. No. 825-MMV Option Card . . . . . . . . . . . . . . . . . PT100 (100 Ω Platinum) Temperature Sensor (RTD) . . . . . . .
iv Table of Contents Programming, Setup, and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5 Starting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5 Operating. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6 Chapter 7 — Testing and Maintenance General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Table of Contents v Basic Unit and Converter Module with Primary Current Transformer and Core Balance Current Transformer . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-9 Main Circuit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-9 Basic Unit and Converter Module with Core Balance Current Transformer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-10 Main Circuit. . . . . . . . . . . . . . . . . . . .
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 s) . . . . . . . . . . . . . . . . . . 3-20 Reduction in Permissible Motor Output Due to Voltage Asymmetry per IEC and NEMA . . . .
Table of Contents Figure 4.4 Figure 4.5 Figure 4.6 Figure 4.7 Figure 4.8 Figure 4.9 Figure 4.10 Figure 4.11 Figure 4.12 Figure 4.13 Figure 4.14 Figure 6.1 Figure 7.1 Figure 7.2 Figure 9.1 Figure 9.2 Figure 9.3 Figure 9.4 Figure 9.5 Figure 9.6 Figure 9.7 Figure 9.8 Figure 9.9 Figure 9.10 Figure 9.11 Figure 9.12 Figure 9.13 Figure 9.14 Figure 9.15 vii Cat. Nos. 825 MCM2, 825-MCM-20, 825-MCM180 . . . 4-3 Cat. Nos. 825-MCM630, 825-MCM630N . . . . . . . . . . . 4-3 Cat. No.
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.I Table 3.J Table 3.K Table 3.L Table 3.M Table 3.N Table 3.O Table 3.P Table 3.Q Table 3.R Table 3.S Table 3.T Table 3.U Table 3.V Table 3.W Environmental Ratings . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5 Nominal Rated Voltages Ue . . . . . . . . . . . . . . . . . . . . . .
Table of Contents 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 ix Stalling during Start Setting Parameters . . . . . . . . . . . . 3-45 PTC Setting Parameters . . . . . . . . . . . . . . . . . . . . . . . . . 3-46 Sensor Measuring Circuit Specifications . . . . . . . . . . . . 3-47 Phase Sequence Setting Parameters. . . . . . . . . . . . . . . .
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.
1-2 Introduction Operational Demands of the Motor/Drive Temperature Rise Motor designs and applicable standards require that, when a motor is operated under specified loads and ambient conditions, the critical parts of the motor will remain within an allowable temperature range and short-term overloads will not harm the motor. The device protecting the motor must permit full use of the motor and its economical operation.
Introduction 1-3 I Pv cos ϕ, η, n ne, Ie, Pve Figure 1.2 Operating Characteristics of an AC Motor P Pe Pv Pve e n ne ns cos ϕ η 1.5 1.4 1.3 1.2 1.1 Ie ns 1.0 n 0.9 η 0.8 0.7 cos ϕ 0.5 I Pv 25 50 75 100 Power Rated operational power Power losses Power losses under rated conditions Operational current Rated service current Speed Rated operational speed Synchronous speed Power factor Efficiency 125 P [%] Pe Operating characteristics of an AC motor as a function of load.
1-4 Introduction Figure 1.3 AC Current Profile of a Motor Starting Direct-on-Line 2 2 Ie 1.6 2 IA I 2 2 IA A Starting current tA Starting time e Rated service current t Time tA Oscillogram of switching on a squirrel-cage induction motor by direct-on-line starting. The high motor starting current A 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.
Introduction 1-5 Insulation Aging The aging of insulation material is a chemical process that is accelerated by continuous overtemperature. It may be assumed that a winding temperature that is constantly 10 K higher than the temperature limit reduces the motor life by half. This “life law” shows that particular attention must be paid to adhering to the permitted operating temperature for long periods of time.
1-6 Introduction The Smart Motor Manager fulfils these requirements by providing protection against the following: • high overload, stalling and jam • underload • phase sequence Personnel and Installation Safety Personnel protection in the vicinity of control equipment is of primary importance. The corresponding requirements of regulatory agencies are therefore becoming increasingly severe.
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: • 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.
2-2 Equipment Description Modular Design The Cat. No. 825-M basic unit can be fitted with additional option (function) cards to suit the requirements. Figure 2.1 Modular Design of the Bulletin 825 Smart Motor Manager Basic unit, Cat. No. 825-M… Option: Cat. No. 825-MLV Cat. No. 825-MMV PT100 Communication Communication Network Cat. No. 825-MST Thermal utilization module 4...20 mA Core Balance Current Transformer Converter module Available Communications Cards Cat. No. 825-MDN: DeviceNet Cat. No.
ϑamb M 3~ ∑ 825MCM PT100 #7 (RTD) Phase failure Phase sequence 7T1/7T2/7T3 L1 L2 L3 Control inputs PT100 #1…#6 (RTD) F #2 #1 Thermistor overload Earth fault Remote reset 825-MDN 3600-RIO Ambient temperature 825-MMV 825-MLV 825-MST 825-M LCD Stator / bearing temperature Basic unit 825-M Controller Operation Communication Interface Disable settings Emergency start Supply 1T1/1T2/1T3 …6T1/6T2/6T3 L1 L2 L3 Y31 Y32 Y41 24 V AC/DC Y42 24 V AC/DC T1, T2 k, l Y21 Y22 A1 (-) A2
2-4 Equipment Description Operating Elements The Smart Motor Manager is very easy to operate. All functions, data, and tests can be entered, executed, or displayed using the six membrane keys and the single-line LCD, which displays all available data and functions. Figure 2.
Equipment Description 2-5 Specifications — Basic Unit and Converter Module Table 2.
2-6 Equipment Description Table 2.
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.
2-8 Equipment Description Table 2.E Relay Ratings Contacts fitted Nominal operating voltage as per UL, CSA: pilot duty 240 V Continuous thermal current Rated operating current for AC-15 Max. permissible switching current (cos ϕ = 0.3) AC-15 Rated operating current for DC-13 without prot. network, L/R = 300 ms Max. rated current of back-up fuse: Contact Data of Output Relays Main Relay (MR) 95…96 1 N/C and 1 N/O contact, galvanically separated [V] 24 220…250 380…440 [A] [A] 4 3 110…125 3 1.
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 m2, single wire (AWG No. 20…14) 0.5…1.5 m2 double wire (AWG No. 20…16) AWG No. 22…14 nominal gauge 1.5 mm 2 Main circuit 825-MCM2/ 825-MCM20 825-MCM180 825-MCM630(N) Terminals: 2 x 2.5 mm2/1 x 4 mm2 (2 x 0.0039 in2/1 x 0.006 in2) 2 x AWG No. 20…14/1 x AWG No. 20…12 Aperture or busbars: Wire ∅ 19 mm max.
2-10 Equipment Description Main Current Transformers for the Motor Circuit When the Cat. No. 825-M Control and Protection Unit is used as a secondary relay with Cat. Nos. 825-MCM2 and 825-MCM20, the following specifications apply: Table 2.G Main Current Transformer Ratings Minimum nominal operating voltage Minimum rated primary current 1n Rated secondary current Class and nominal overcurrent factor Nominal operating voltage of motor Nominal operating current of motor 1 A or 5 A 5 P 10 ext.
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… Power consumption at max. rated current Continuous thermal current Thermal current, 1 s duration Frequency of input current Nominal ratio Kn = 0.4 VA 0.
2-12 Equipment Description Response Supply Voltage Failure If the supply voltage fails, the setting data are retained.
Equipment Description 2-13 Automatic Recognition of Converter Module The Bulletin 825 regularly checks: • The link between the basic unit and the converter module • 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.
Chapter 3 Functions Menu Overview Actual Values In “Actual Values” mode, all operating parameters can be selected and read from the LCD. Table 3.A Actual Values Overview Display List Option Card Cat. No. Page Display List Option Card Cat. No.
Functions 3-2 Set Values The parameters “Main Settings” and “Special Settings” must be programmed for every 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 Card Cat. No.
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 Card Cat. No. Display List Page Display List Option Card Cat. No. Page 825-M MAIN TIME h min. — 7-2 CAUSE 2PRV TRIP — — 7-3 MOTOR RUNNING HR h min. — 7-2 CAUSE 3PRV TRIP — — 7-3 SINCE LAST START h min. — 7-2 CAUSE 4PRV TRIP — — 7-3 SINCE 1PRV START h min. — 7-2 SINCE EMG START h min. — 7-3 SINCE 2PRV START h min.
Functions 3-4 Operation Selecting the Setting/Display Mode SET Actual Change mode by pressing Set Recorded Values ACTUAL VALUES Actual Indication of actual operational data Change SET VALUES Actual RECORDED VALUES Change Setting mode (set/vary, store parameters) Actual Change Indication of statistical data Publication 825-UM001B-EN-P January 2001
3-5 Functions Setting the Operation Parameters (Set Values) Text and data are indicated alternately (approximately 2 s text and 1 s data). On the “second line,” the data that is factory set or subsequently modified is displayed. Functions not activated (OFF) are not indicated. 1. To set the operation parameters, repeatedly press the Values button until “SET VALUES” appears on the display. Figure 3.1 Setting Mode SET VALUES Actual Change Set Recorded Enter Values Select Settings 2.
Functions 3-6 Figure 3.3 Entering a Data Value 35 AMP Actual Change Set Recorded Values Enter Select Settings Note: Hold down the Select button to change the values more quickly. Table 3.D Display Example of Set Values Menu LCD SET VALUES Range Description — Mode: setting parameters 0.5…2 000 Rated motor current in A No/Yes Primary current transformer in use PRIMARY C.T. RATIO 1 1…2 000 Primary current transformer ratio LOCKED ROT CURR 6 x Ie 2.
3-7 Functions Indications of Actual Values In “Actual Values” mode, all operating parameters can be selected and read from the LCD. 1. Press Values until “ACTUAL VALUES” appears on the display. 2. Press Select (Up or Down) until the desired information is displayed. Figure 3.4 Selecting the Actual Values ACTUAL VALUES Actual Change Set Recorded Enter Values Select Settings I MOTOR 00 % Ie Actual Change Set Recorded Values Enter Select Settings Table 3.
Functions 3-8 Applications The “Actual Values” mode provides: • Assistance during programming and setup • Verification after maintenance or production change • Continuous operational supervision Indications of Recorded Values (Statistics) In “Recorded Values” mode, all recorded data can be selected and read from the LCD. 1. Press Values until “RECORDED VALUES” appears on the display. 2. Press Select (Up or Down) until the desired statistical information is displayed. Figure 3.
3-9 Functions Table 3.F Display Example of Recorded Values LCD Description RECORDED VALUES Display of the statistical data 825-M MAIN TIME _ _ _ H_ _ _MIN Bulletin 825-M* running time (including interruption ≤ 8 hour of control voltage in hours, minutes) MOTOR RUNNING TIME _ _ _h_ _ _min Total motor running time in hours, minutes Note: For a complete list of parameters, refer to Chapter 7.
Functions 3-10 Testing the Thermal Trip 1. Press the Test button. LCD: TEST THERMAL ON 2. After the set blocking time has expired, the basic unit must trip. LCD: LOCK ROT TIME _ _ _sec 3. The LED lights. 4. The selected output relay picks up (MR, main relay, on trip). LCD: THERMAL 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.
3-11 Functions 2. If no output is assigned the following readout appears: LCD: ASYMMETRY TRIP NO OUTPUT RELAY 3. Press the Test button. LCD: TEST 4. After the set trip delay expires, the basic unit must trip. LCD: AS TRIP TIME _ _ _sec 5. The LED lights. 6. The selected output relay picks up. LCD: ASYMMETRY TRIP Resetting Cancel the trip by pressing Reset. Testing the Warning Functions Example: Asymmetry warning 1.
Functions 3-12 2. Press the Test button. LCD: TEST 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.
3-13 Functions Function Summary Table 3.G Protective Functions Summary Thermal overload Asymmetry (phase failure) High overloading/jam Underload Underload delayed enable Earth (ground) fault (residual) Starting time monitor Limited starts per hour Short-circuit Earth (ground) fault (core balance c.t.) Stalling during start Thermistor input (PTC) Off 5 mA…50 A 1A 0.
Functions 3-14 Table 3.H Warning Functions Summary Functions Factory Setting Thermal utilization (%∆ϑ load) Asymmetry (% e) High overloading (x e) Underload Earth (ground) fault (core balance c.t.
3-15 Functions Table 3.I Control Functions Summary Warm start (% of “cold” trip) Emergency override of thermal trip ➊ Tripping Delay Range Bulletin 825-M… Basic Unit Functions Factory Setting Setting Range Factory Setting Off 50…100% 70% 4…60 min. ➋ 60 min. ➋ — — — — — — — — — Factory Relays Factory Setting Selection Setting Bulletin 825-MST Option Card Analog output assigned 4…20 mA to: 0…100% thermal utilization On — — — — 50…200 °C PT100 max.
Functions 3-16 Table 3.I Control Functions Summary (Continued) Tripping Functions Setting Factory Relays Factory Factory Delay Factory Setting Selection Setting Range Setting Range Setting Bulletin 825-MST Option Card, Control Input #2: (24V AC/DC; 8 mA) One of three functions can be selected: 1) Pickup delay, relay Off — — 0…240 s 1s — #3 #3 1) Dropout delay, relay — — — 0…240 s 2s — #3 #3 0.
3-17 Functions While the motor is running, the iron losses as well as losses caused by asymmetry are fed to the simulation model. Allowance for the ambient temperature of the motor, as an option, enhances the maximum utilization of the installation even with considerable variation of the temperature. Without the optional inclusion of the ambient temperature of the motor, the thermal model bases the thermal calculation on an ambient temperature of 40° C.
Functions 3-18 Indication of the Time to Tripping LCD: TRIP IN…sec This feature provides continuous indication of the time remaining before tripping when in an overload condition. This enables you to intervene before tripping occurs. (Blank display means: Time > 9 999 s) Indication of the Time until the Thermal Trip can be Reset LCD: RESET IN …sec Following a thermal trip, the basic unit may not be reset until the reset threshold has been reached.
3-19 Functions Figure 3.8 Trip Characteristic (10…30 s) 10000.0 1000.0 From cold, without pre-load 10s 30s 20s Trip time [s] 100.0 10.0 10s 20s 30s From warm, pre-load 1xIe 1.0 0.1 1.0 1.1 2.0 3.
Functions 3-20 Figure 3.9 Trip Characteristics (40…100 s) 100000.0 10000.0 From cold, without pre-load 40s 60s 100s Trip time [s] 1000.0 100.0 10.0 40s 60s 100s From warm, pre-load 1xIe 1.0 1.0 1.1 2.0 3.0 4 Load current as multiple of full load current . 5 6 7 8 9 10 nxI e For UL/CSA applications refer to page 9-14.
3-21 Functions Table 3.J Thermal Overload Setting Parameters Detection Module ➋ 825-MCM20 825-MCM180 825-MCM630 Rated Current 0.5…2.5 A ➊ 2.5…20 A ➊ 20…180 A 160…630 A ➌ 20 A 20 A 20 A 20 A 0.01…2 A 0.1…2 A 1A 2A Locked-Rotor Current (Multiple of Rated Current) 2.5…12 e 825-MCM2 Setting range Factory setting Setting increments Setting range Factory setting Setting increments 825-MCM630N 160…630 A 20 A 2A 6 e 0.
Functions 3-22 Table 3.K Protection Against Thermal Overload Warning Trip Function Factory setting Setting range Factory setting Setting increments Selection Factory setting Off Response Level ➊ 55…99% 75% 1% Output Relay ➋ AL, #1…#5 AL On — 100% — MR, No output relay MR ➊ Thermal utilization % ➋ If auxiliary relays #2 and #3 are assigned to the communication (refer to page 5-16) they cannot be selected here.
3-23 Functions Figure 3.10 Reduction in Permissible Motor Output Due to Voltage Asymmetry per IEC and NEMA fR fR 1.0 ∆U 0.9 Reduction factor for motor output Voltage asymmetry in percent 0.8 ∆U 0.7 0 1 2 3 4 5 [%] Table 3.
Functions 3-24 Application • • • • • Conveying systems Mills Mixers Crushers Saws, etc. Figure 3.11 Function of High Overload and Jam Protection I Ie ≥ 1.2 1 3 2.4 2 1.1 t tv 4 1 2 3 Motor start ≥ 1.2 e Nominal operation High overload or jam 5 tV 4 5 Tripping delay Jam protection not active Jam protection active (tripping threshold) Table 3.
3-25 Functions ATTENTION It is essential to set the “Warning” response level to a value less than the “Trip” response level. ! Note: If the starting current is below 1.2 FLC, then the “Monitoring the Start Time” function must be activated. After the set max. starting Time has elapsed, the “High Overload/Stall” function will become active.
Functions 3-26 Figure 3.12 Function of Underload Protection I I Ie 1 2 Ie IT 3 3 t tA tp ts 1 2 3 tA e tv tp r Tripping threshold ts Delayed activation (underload protection not active) tv Tripping delay tp Warning Start Nominal operation Underload operation Starting time Rated current Table 3.
3-27 Functions Earth (Ground) Fault The insulation in motors is often damaged by high-voltage surges, which may be caused by lightning strikes, switching operations in the network, capacitor discharges and power electronics equipment. Other causes are aging and sustained or cyclic overloading, as well as mechanical vibration and the entry of foreign objects. Most insulation faults result in leakage to the grounded parts of the machine.
Functions 3-28 Table 3.O Earth (Ground) Fault — Holmgreen/Residual Setting Parameters Trip ➊ Function Factory setting On Response Level Setting range Factory setting Setting increments 10…100% 50% 10% Tripping Delay Setting range Factory setting Setting increments 0.1…5 s ± 0.4 s 0.5 s 0.1 s Output Relay ➋ Selection (relays) Factory setting MR, AL, #1…#5 MR ➊ –5…60 °C (23…140 °F) ➋ If auxiliary relays #2 and #3 are assigned to the communication (refer to page 5-16) they cannot be selected here.
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 Current Ratio Setting range Factory setting Setting steps 1…2 000 100 1 Table 3.
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.
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.
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 M. T 1 2 3 K1 M1 825-M 3 AC U2 U1 U3 CN IE CM Figure 3.18 Network Earthed through a High Impedance: Earth (Ground) Fault on the Motor Leads The basic unit measures the vector sum of the earth currents through C N and the earthing resistance R.
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 I I Ie Ie II I t tw tw 60 min.
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 e. Starting is deemed to have been completed when the motor current is less than 1.1 e.
3-35 Functions Table 3.S Monitoring Start Time Setting Parameters Function Factory setting Off Max. Starting Time ➊ Setting range Factory setting Setting increments 1…240 s ± 0.04 s 10 s ± 0.04 s 1s Output Relay ➋ Selection (relays) Factory setting MR, AL, #1…#5 MR ➊ –5…60 °C (23…140 °F) ➋ If auxiliary relays #2 and #3 are assigned to the communication (refer to page 5-16) they cannot be selected here.
Functions 3-36 Figure 3.
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,e = 10 s and Warm Trip Time = 70% 10 4 10 3 Trip Time [s] a 10 2 c d 10.0 7.3 b 1.6 1.0 0.1 1.0 1.1 2.0 3.0 4 5 6 7 nxIe 8 9 10.
Functions 3-38 Table 3.T Warm Start Setting Parameters Function Factory setting Off Tripping Time from Warm State as a Percentage of Tripping Time from Cold State Setting Setting range 50…100% Factory setting 70% Setting steps 10% Minimum Time Between Two Warm Starts Setting Setting range 4…60 min. Factory setting 60 min. Setting steps 1 min. Emergency Override of Thermal Trip (Emergency Start) Suggested Procedure Procedure when PT100 and PTC are not used: 1.
3-39 Functions Additional procedure when PT100 and/or PTC are installed: 1. Disable PTC and/or PT100. SET VALUES PTC TRIP OFF PT100 #1…6 TRIP OFF 2. Alternatively, the Smart Motor Manager can be set up such that inputs #1 and #2 deactivate the PTC and/or PT100 tripping. (This can be achieved with a separate switch or a separate set of contacts on the key switch, refer to page 3-52.) 3. The input should remain activated until the temperatures return to normal.
Functions 3-40 Connection of the Main Relay (MR) The main output relay can be operated as electrically held or non-fail-safe. Electrically Held Mode Supply Off Supply On Supply On and Trip 95 96 97 98 Non-Fail-Safe Mode Note: Terminal markings should be changed from those used in electrically held mode when switching to this mode.
3-41 Functions Electrically Held Mode Supply Off Supply On Supply On and Warning 13 13 13 14 14 14 Non-Fail-Safe Mode Supply Off Supply On Supply On and Warning 13 13 13 14 14 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.
Functions 3-42 Reset When the motor is at standstill, a trip condition can be reset. Kinds of Reset • Manual reset — Press the reset button on the Bulletin 825 for at least 200 ms • Remote reset — Short circuit terminals Y2l/Y22 • Automatic reset — In the mode “set values”, set automatic reset for: • Thermal trip • PTC trip • PT100 trip Reset Conditions • Thermal — As soon as the temperature rise has dropped to the preset reset threshold.
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 ≥ 12 Ie.
Functions 3-44 Table 3.W Short Circuit Setting Parameters Trip ➊ Function Factory setting Off Response Level 4…12 e Setting range Factory setting 10 e Setting increments 0.5 e Tripping Delay Setting range Factory setting Setting increments 20…990 ms 50 ms 10 ms Output Relay Selection (relays) Factory setting #1, No output relay #1 ➊ –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.
3-45 Functions Applications • • • • • • • • • Large low-voltage motors Medium- and high-voltage motors Conveyor systems Mills Mixers Crushers Saws Cranes Hoists, etc. Figure 3.26 Stalling During Starting 1 I I 2 1 Ie 2 tv Normal start without hindrance by high overload or stalling Stalling during standing Tripping delay Ie t tv Table 3.
Functions 3-46 PTC Thermistor Input Function The thermistor detectors (PTCs) are embedded in the stator winding of the motor. They monitor the actual temperature of the winding. Influences independent of the motor current, such as ambient temperature, obstructed cooling, etc., are taken into account. The detectors and their leads are monitored for short-circuit and open circuit. Applications As additional protection for: • • • • Motors above 7.
3-47 Functions Table 3.Z Sensor Measuring Circuit Specifications Function Factory setting Off Sensor Measuring Circuit Max. resistance of the PTC chain when cold Max. number of sensors as per IEC 34-11-2 Pickup value at δA = –5…+60 °C Dropout value at δA = –5…+60 °C 1.5 kΩ 6 3.3 kΩ ± 0.3 kΩ 1.8 kΩ ± 0.3 kΩ 800 ms ± 200 ms Delay on pickup Pickup value when short-circuit in sensors circuit at δA = –5…+60 °C ≤ 15 Ω Measuring voltage as per IEC 34-11-2 < 2.
Functions 3-48 Figure 3.27 Characteristic of PTC Sensors as per IEC 34-11-2 4000 1330 550 250 R [Ω] 100 20 10 -20°C 0°C TNF-20K TNF- 5K TNF+15K TNF+ 5K TNF TNF R [Ω] Nominal pickup temperature 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.
3-49 Functions Application • Local indication for continuous supervision of the load on motor and installation. • Load control: With the indication of the momentary temperature rise of the machine, the load on the installation can be continuously controlled to the maximum permissible temperature rise of the motor. The result is optimal utilization of the motor with full protection and maximum productivity of the driven installation. • Automatic load control by a controller or inverter drive (e.g.
Functions 3-50 Figure 3.29 Analog Output for Motor Temperature ϑ 200˚C 50˚C 5 10 15 20 mA 4 Motor Temperature calculation: ( …mA 4 mA ) Motor temp. (°C ) = ------------------------------- • 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.
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 Input #1 Input #2 Y31 (+) Y32 (-) Y41 (+) 24V AC or 24V DC; 8 mA Pick values: On: 12…36 V Off: < 2 V Y42 (-) The control inputs are galvanically separ
Functions 3-52 Figure 3.31 Operating Diagram for Timer Functions Control input Output relay On-delay Off-delay On-off-delay > 0.5 s toff = 0 ton toff ton = 0 toff ton On-off-delay ton toff Applications • Time-graded switching on and off • Delaying the transfer of alarm and trip messages Lock-Out of Protection Functions With control inputs #1 and #2, one or more protective functions can be locked out as desired.
3-53 Functions The selected functions are completely disabled as long as the control input is “on” (24V AC/DC). • No alarm • No trip, no reset • Tripping delays begin to run only after the function is re-enabled. Switching to a Second Rated Current In the Smart Motor Manager, a second value can be selected for the rated current Ie. The change to the second rated value is controlled by activating control input #2 with 24V AC/DC.
Functions 3-54 Table 3.AA Phase Sequence Setting Parameters Function Factory setting Off Tripping Delay Factory setting 1s Output Relay ➊ Selection (relays) Factory setting MR, AL, #1…#5 MR ➊ 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).
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.
Functions 3-56 Functions of the Cat. No. 825-MMV Option Card PT100 (100 Ω 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 Ω/°C). Table 3.
3-57 Functions Table 3.AE PT100 (RTD) Setting Parameters Warning Trip Function Factory setting Setting range Factory setting Setting steps Factory setting Selection (relays) Factory setting Off Response Level 50…200 °C — — Tripping Delay <8s Output Relay ➊ AL, #1…#3 AL Off 50…200 °C 50 °C 1 °C <8s MR, AL, #1…#3 MR ➊ If auxiliary relays #2 and #3 are assigned to the communication (refer to page 5-16) they cannot be selected here.
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. MOTOR INSULATION CLASS B Insulation class of winding Table 3.AF Motor Insulation Class Setting Parameters Function Factory setting Off Insulation Class Selection Factory setting B, E, F B Limiting winding temperatures of the three insulations classes: E = 120 °C, B = 130 °C, F = 155°C.
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 ➊ 13 8m m (57/1 6" ➋ +1 -0 +1 - 0 /16 ) 10 m m (3 /8 ") max. 6 mm (1/4") Trip Se t Ch an ge lues Sel ec t Set En ter tin gs Te st m ") m 6 4 1 /1 1 4 -1 (5 Res et Dimensions in mm (inches) Dimensions: Panel cutout: 138 x 138 mm (-0 mm, +1 mm) Mounting depth: min.
Assembly and Installation 4-2 Mounting Position Figure 4.2 Mounting Position 22.5˚ 22.5˚ 90 ˚ 22.5˚ SMART MOTOR MANAGER Surface Mounting Figure 4.3 Basic Unit Mounted into Panel Mounting Frame (Cat. No. 825-FPM) 17 0 (6- mm 11 /16 ") 90 ˚ Hinge m m (6 - 1/ 2" ) 150 mm (5- 7/8") m 16 5 m ") m 16 0 1/ 17 - 1 (6 Alar 170 mm (6- 11/16") Ø 6.
4-3 Assembly and Installation Converter Modules Figure 4.4 Cat. Nos. 825 MCM2, 825-MCM-20, 825-MCM180 øe d3 b b ød ➊ d1 ➌ e2 ➋ c1 e2 c d2 a Table 4.A Cat. Nos. 825 MCM2, 825-MCM-20, 825-MCM180 Dimensions in millimeters (inches) Cat. No. 825- a b c c1 ∅d d1 d2 ∅e d3 ∅ e1 2x 120 85 102 66 5.3 5.3 100 55 — (4-45/64) (3-23/64) (4) (2-39/64) (3/16) (3/16) (3-7/8) (2-3/16) 2.5 mm2 2 x 120 85 102 66 5.3 5.3 100 55 — MCM20 (4-45/64) (3-23/64) (4) (2-39/64) (3/16) (3/16) (3-7/8) (2-3/16) 2.
Assembly and Installation 4-4 Table 4.B Cat. Nos. 825-MCM630, 825-MCM630N Dimensions in millimeters (inches) Cat. No. 825-MCM630 825-MCM630N a 155 (6-7/64) 155 (6-7/64) b 145 (5-11/16) 145 (5-11/16) c 156 (6-1/8) 177 (6-31/32) c1 118 (4-5/8) 118 (4-5/8) ∅d 6.3 (1/4) 6.3 (1/4) d1 6.3 (1/4) 6.3 (1/4) d2 135 (5-5/16) 135 (5-5/16) d3 88 (3-7/16) 88 (3-7/16) ∅ e1 M10 M10 e2 48 (1-7/8) 48 (1-7/8) Thermal Utilization Indicator Figure 4.6 Cat. No.
4-5 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. ➊ ➊ ➋ ➌ ➍ ➎ ➏ ➐ Basic Unit housing Cat. No. 825-MMV or 825-MLV option card Communication board Cat. No.
Assembly and Installation 4-6 Main Circuits Basic Unit and Converter Module without Main Current Transformer Figure 4.8 Basic Unit with Converter Module L1 1 L2 L3 3 5 Cable with plugs 825-M 825-MCM 2 4 6 Converter module cat. nos. 825-MCM2 825-MCM20 825-MCM180 825-MCM630 825-MCM630N M 3~ Basic Unit and Converter Module with Main Current Transformer Figure 4.
4-7 Assembly and Installation Basic Unit and Converter Module with Main and Core Balance Current Transformer Figure 4.10 2-Phase Current Evaluation L1 L2 L3 Converter module cat. nos. 825-MCM2 825-MCM20 1 T1 3 5 825-M 825-MCM 2 4 6 k l Σ T2 M 3~ Table 4.
Assembly and Installation 4-8 Control Circuits Figure 4.11 Smart Motor Manager Basic Unit Supply: A1 A1 + Y11 Emerg.
4-9 Assembly and Installation Figure 4.12 Cat. No. 825-MST Option Card 23 Aux Relay #1 Auxiliary relay #1 IEC 400V AC/125V DC UL/CSA 240V AC/125V DC Aux Relay #2 Auxiliary relay #2 50V AC/30V DC 24 33 34 43 Aux Relay #3 44 Analog output indicates the thermal utilization of the motor, the motor temperature, or the motor current Indicating instrument PLC input Recorder I+ A 4...20 mA (0...
Assembly and Installation 4-10 Figure 4.13 Cat. No. 825-MLV Option Card Either the 825-MLV or 825-MMV option card may be inserted in this position.
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 this position. ATTENTION ! 1T1 PT100 #1 1T3 1T2 PT100 inputs #1…#6 (RTD) for monitoring the temperature of the stator winding and motor bearings. 2T1 PT100 #2 2T3 2T2 3T1 PT100 #3 3T3 3T2 4T1 PT100 #4 4T3 4T2 5T1 PT100 #5 5T3 5T2 6T1 PT100 #6 6T3 PT100, #7 for indication and inclusion of the coolant/ambient temperature (cooling air) in the thermal image.
Assembly and Installation 4-12 Option Communication ATTENTION Only one of the following options can be inserted at a time. ! 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.
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. ATTENTION ! All parameters of option cards can be programmed/set even when the option cards are not installed. Verify product configuration before commissioning. Main Settings The main settings have to be individually set for each motor. Table 5.
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.
5-3 Setting the Operational Parameters Table 5.C Communication Settings Parameter Setting Range Factory Setting 0…63 0…2 2 2 0…63 0…23 0…118 2 4 5 0…247 0…182 0…118 2 4 5 1…126 0…4 2 4 (500 kbd) DeviceNet Station number (MAC ID) Baud rate: 125/250/500 kbaud Remote I/O Station number Baud rate ➊ Baud rate ➋ Modbus Station number Baud rate ➌ Baud rate ➋ PROFIBUS Station number, Baud rate 9.6/19.2/73.75/187.
Setting the Operational Parameters 5-4 Operating Parameters Table 5.D Cat. No. 825-M… Operating Parameters Group Required Option Card Cat. No. LCD Setting Range Description — SET VALUES — FULL LOAD CURR 20 A 0.5…2 000 Rated motor current in A — PRIMARY C.T. #1 NO Use of the primary No/Yes ➊ transformer — PRIM. C.T. RATIO 1 Current ratio of the primary 1…2 000 current transformer e.g. 500 A/5 A, setting = 100 800 A/5 A, setting = 160 — LOCKED ROT CURR 6 x Ie 2.
5-5 Setting the Operational Parameters Table 5.D Cat. No. 825-M… Operating Parameters (Continued) Group Asymmetry Overcurrent Required Option Card Cat. No. LCD Setting Range Description Asymmetry protection On/Off ➊ (current measuring asymmetry) On/Off — ASYMMETRY TRIP ON — AS TRIP LEVEL 35 % 5…80 Asymmetry trip Tripping level in percent — AS TRIP TIME 2.
Setting the Operational Parameters 5-6 Table 5.D Cat. No. 825-M… Operating Parameters (Continued) ATTENTION Ensure that the trip function is reset before it is inactivated. ! Group Required Option Card Cat. No. Setting Range Description Overcurrent/locked-rotor Warning level in… e — OC WARNING LEVEL 2.0 x Ie 1.0…6.
5-7 Setting the Operational Parameters Table 5.D Cat. No. 825-M… Operating Parameters (Continued) Group Required Option Card Cat. No. LCD On/Off ➊ Earth (ground) fault protection (core balance transformer) On/Off CORE C.T. RATIO 1 1…2 000 Core balance transformer current ratio EF C TRIP TIME 0.50 sec Short circuit Description EF CORE TRIP OFF EF C TRIP LEVEL 1A Earth (ground) fault Setting Range Earth (ground) fault trip 5…999 mA (core balance transformer) 1.00…50.00 A Tripping level 0.
Setting the Operational Parameters 5-8 Table 5.D Cat. No. 825-M… Operating Parameters (Continued) Group Underload Required Option Card Cat. No.
5-9 Setting the Operational Parameters Table 5.D Cat. No. 825-M… Operating Parameters (Continued) Group Warm start Limiting number of starts per hour Monitoring startup time Required Option Card Cat. No. LCD — WARM STARTING OFF — WARM START EACH 60 min — Setting Range On/Off ➊ Description Warm start On/Off 4…60 Warm start possible every ___min.
Setting the Operational Parameters 5-10 Table 5.D Cat. No. 825-M… Operating Parameters (Continued) Group Special settings PTC temperature sensors Control input #1 ➊ ➋ ➌ ➍ Required Option Card Cat. No. LCD Setting Range Description Electrically Main output relay in held/non electrically held or fail-safe non fail-safe connection — MAIN RELAY ELECTR.
5-11 Setting the Operational Parameters Table 5.D Cat. No. 825-M… Operating Parameters (Continued) Group Required Option Card Cat. No. LCD SPEED SWITCH OFF 825-MST Description Speed switch/stop indicator (locked-rotor during start) On/Off and/or auxiliary contact On/Off ➊ of motor contactor “motor switched on” for motors with m < 20% e. SS TRIP TIME 0.
Setting the Operational Parameters 5-12 Table 5.D Cat. No. 825-M… Operating Parameters (Continued) Group Control input #2 ➊ ➋ ➌ ➍ ➎ ➏ Required Option Card Cat. No.
5-13 Setting the Operational Parameters Table 5.D Cat. No. 825-M… Operating Parameters (Continued) Group Control input #2, continued Phase sequence protection Phase failure PT 100 (RTD) temperature sensor Required Option Card Cat. No.
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.
5-15 Setting the Operational Parameters Table 5.D Cat. No. 825-M… Operating Parameters (Continued) Group PT 100 (RTD) temperature sensor, continued Required Option Card Cat. No.
Setting the Operational Parameters 5-16 Table 5.D Cat. No. 825-M… Operating Parameters (Continued) Group Required Option Card Cat. No. LCD — STATION NUMBER 02 0…63 0…63 1…247 1…126 — BAUD RATE 04 0…2 0…23 0…182 0…4 Communication setting Relay control Clear recorded values Reset settings to factory settings (clear recorded values) End of setting parameters Setting Range Comm.
Chapter 6 Commissioning and Operation Checking the Installation Careful, correct commissioning of the Bulletin 825 Smart Motor Manager is an important prerequisite for reliable protection of the motor and economic operation of the installation. Follow the procedures in this section to ensure that programming and setup are correct. ATTENTION ! Checking and commissioning must be carried out only by qualified personnel.
Commissioning and Operation 6-2 Checking the Wiring • • • • • • • • Primary current transformer, core balance current transformers Converter module Basic Unit Link between basic unit and converter module Inputs, outputs Supply Communication Contacts 95…98 are marked according to “electrically held”/“non-fail-safe” connection required.
6-3 Commissioning and Operation Motor Current • Ensure that the current converter’s rated current in amperes is equal to the ampere rating on the nameplate of the motor. • Set the current converter rated current based on the service current of the motor, if the installation or motor nameplate current is not 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.
Commissioning and Operation 6-4 Locked Rotor or Starting Current • Set the locked-rotor or starting current as the multiple of rated current IA: Ie according to specifications given by the manufacturer. • If no specifications are available, the starting current can either be measured with the current converter or read from Figure 6.1 • The current converter factory setting is 6 x Ie. LCD: LOCKED ROT CURR 6.00 x Ie Figure 6.
6-5 Commissioning and Operation • Setting locked rotor time to a minimum level This procedure enables you to set the locked rotor time to a minimum, so that the motor and installation are better protected. a. Choose a locked rotor time that is less than the probable starting time (e.g., 2 s for thermally rapid underwater motors). b. Start the motor and allow it to cool down after a thermal trip. c. Increase the locked-rotor time until starting succeeds reliably.
Commissioning and Operation 6-6 Operating Table 6.A Checking the Actual Values LCD ACTUAL VALUES Setting Range — Description Indication of actual values I MOTOR…A 0.00…49.
6-7 Commissioning and Operation Table 6.A Checking the Actual Values (Continued) LCD RESET IN…sec Setting Range 1…9 999 Description Unit can be reset in ___s ASYM…% 1…100 Current asymmetry in percent I earth-H…% I 1…100 Earth (ground) fault current (residual) as percentage of actual service current (I) I earth-C…mA 5… 999 mA 1.00… 50.
Chapter 7 Testing and Maintenance General The correct functioning of the Smart Motor Manager can be checked by several methods, depending on the requirements: • With the Test button • With the test condition set • 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 Sma
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 3-8 for procedure. From the recorded values, data can be used to determine: • • • • • Running time of the motor, the Smart Motor Manager, contactor, etc. Necessary 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.
Testing and Maintenance 7-3 Table 7.A List of Recorded Values (Continued) LCD Description SINCE 1 PRV TRIP --- H -- MIN Time since one trip prior to last trip in hours, minutes SINCE 2 PRV TRIP --- H -- MIN Time since two trips prior to last trip in hours, minutes SINCE 3 PRV TRIP --- H -- MIN Time since three trips prior to last trip in hours, minutes SINCE 4 PRV TRIP --- H -- MIN Time since four trips prior to last trip in hours, minutes CAUSE LAST TRIP ASYMMETRY TRIP Cause of last trip, e.g.
7-4 Testing and Maintenance Table 7.
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 This test should be performed only by qualified personnel.
7-6 Testing and Maintenance Test with Single-Phase Current Source This test should be performed only by qualified personnel. ATTENTION ! 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.
Chapter 8 Error Diagnosis and Troubleshooting Alarm, Warning If an impending defect is detected early enough, motor damage can be minimized.
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: • Switch off the installation • Search for the fault and repair it If it is important to keep the operation running: • Continuously monitor the level of ACTUAL VALUES ASYM…% • If the alarm level continues to rise, measures should be taken so that the installation can be sh
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 DEFECT #1 DEFECT #2 825-MCM NOT CON Designation Possible Causes Actions Ensure power supply is on. No supply voltage Check the supply. Insert correct supply module.
8-4 Error Diagnosis and Troubleshooting Table 8.
Error Diagnosis and Troubleshooting 8-5 Table 8.A Possible Causes and Actions (Continued) LCD ERROR SET VALUES Designation — Possible Causes Setting of locked rotor current and/or locked rotor time are outside the permissible range Mains unbalanced Blown fuse • Short-circuit/Earth (ground) fault • Failure during starting Motors idling (e.g., pumps) AS WARNING ASYMMETRY TRIP OC WARNING OVERCURRENT TRIP Actions Press “Values” until “SET VALUES” on LCD. Set “LOCKED ROT CURR” to 6 x e.
8-6 Error Diagnosis and Troubleshooting Table 8.
Error Diagnosis and Troubleshooting 8-7 Table 8.A Possible Causes and Actions (Continued) LCD PTC TRIP Designation PTC trip Possible Causes Actions Check leads, remove fault. PTC: PTC or PTC leads short-circuited Motor for repair. If not possible, or broken switch off PTC monitoring “PTC PROT/OFF“. Wait until motor has cooled down Stator winding overheated by: sufficiently for a reset. • Overload • Search for cause and eliminate. • Too many starts/hour • Reduce starts/hour.
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”).
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.
Chapter 9 Applications/Wiring Bulletin 825 Smart Motor Manager with Contactors Strictly observe the installation instructions and the specifications for the contactors, auxiliary relays, etc. ATTENTION ! Main Circuit Figure 9.1 Basic Unit and Converter Module L1 L2 U1 Converter module Cat. No. 825-MCM2 Cat. No. 825-MCM20 Cat. No. 825-MCM180 Cat. No. 825-MCM630 Cat. No.
Applications/Wiring 9-2 Control Circuit Figure 9.
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: L1 L2 L3 ➊ Ls 1) FLC x 0.5774 [A] FULL LOAD CURR K1H BL∆ (…x e) LOCKED ROT TIME BL∆ (…sec.) 5 K2D A2 LOCKED ROT CURR 3 1 A1 2 U1 4 6 A1 A2 K3Y 2 4 6 A1 A2 1 3 5 2 4 6 825-M F1 825-MCM U1 V1 W1 U1 Converter module Cat. No. 825-MCM2 Cat. No. 825-MCM20 Cat. No. 825-MCM180 Cat. No. 825-MCM630 Cat. No.
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 L1 L2 Variants L3 • 2-phase current evaluation • 2-phase current evaluation and earth (ground) fault protection with core balance transformer QM QA U1 Converter module Cat. No. 825-MCM2 Cat. No.
9-5 Applications/Wiring Control Circuit Figure 9.
Applications/Wiring 9-6 Main Circuit Figure 9.7 Two-Speed Application Utilizing One 825-MCM* L1 L3 L2 L 1 3 N 5 220...230V AC/DC: R = 27kΩ / 5W 110...120V AC/DC: R = 12kΩ / 4W R 825-M 825-MCM 2 4 24 V AC/DC + – 6 I II M Y41 Y42 825-MST 3~ For setting the second current (speed II), refer to Chapter 5, “Control input #2”.
9-7 Applications/Wiring Two-Speed Motor: 0.5 A < Speed I < 20 A < Speed II < 180 A Main Circuit Figure 9.8 Two-Speed Application Utilizing 825-MCM180 L L1 L3 L2 N R 220...230V AC/DC: R = 27kΩ / 5W 110...120V AC/DC: R = 12kΩ / 4W 24 V AC/DC + – 0.
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 = 27kΩ / 5W 110...120V AC/DC: R = 12kΩ / 4W 24V AC/DC R = 0Ω L1 L2 L3 L1 L2 L3 (I) R ... A / 1 (5) A K2 M 3~ 24 V AC/DC 8 mA Y42 For setting the second rated current (speed II) K2 N (-) (II) ...
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 L1 L2 Converter module Cat. No. 825-MCM2 Cat. No.
Applications/Wiring 9-10 Basic Unit and Converter Module with Core Balance Current Transformer Main Circuit Figure 9.
9-11 Applications/Wiring Motors with Low Idling Current (< 20% ,e) Main Circuit Figure 9.12 Application with Low Idling Current L1 L2 L3 L 1 3 N 5 220...230V AC/DC: R = 27kΩ / 5W 110...
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.
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 L1 L2 L3 Converter module cat. nos.
Applications/Wiring 9-14 Time/Current Characteristic of Bulletin 825 Smart Motor Manager Figure 9.15 Trip Characteristics 100000.0 10000.0 c 100.0 b 10.0 a Trip time [s] 1000.0 c 1.0 0.1 1.0 1.1 2.0 3.0 4 Load current as multiple of full load current 5 6 7 8 9 10 nxI e a: Setting range for UL/CSA applications b: Setting range for IEC applications c: The setting of A/t tA must be outside the range “c” (e.g., when A = 6 x e, t tA must be ≤ 100 s and ≥ 1 s).
Chapter 10 References A. Rotary Crusher Application Profile (Publication 0825-1.3EN) B. Waste Water Application Profile (Publication 0825-1.4EN) C. Multifunctional Motor Management (Publication 825-BR001B-EN-P) D. Smart Motor Manager Relay Selection Guide (Publication 825-CA001A-EN-P) E. Smart Motor Manager Hot Topics (Publication 0825-9.0) F. Smart Motor Manager User Manual (Publication 0825-5.0) G. DeviceNet Communication Card User Manual (Publication 0825-5.
References 10-2 Notes: Publication 825-UM001B-EN-P January 2001
10-3 References Notes: Publication 825-UM001B-EN-P January 2001
Back Cover Publication 825-UM001B-EN-P January 2001 Supersedes Publication 825-5.0EN dated June 1998 © 2001 Rockwell International Corporation. Printed in the U.S.A. Software Version 3.
