SMM™ Smart Motor Manager

Smart Motor Manager
Cat. No. 825-MÄ

Bulletin 825 SMM™ Smart Motor Manager

0.5…2000 A Current Range
Modular Construction
Built-in Keypad and LCD
Test and Reset Buttons
Alarm/Trip LED
NEMA 4 (IP65) Housing
Communication Options
Suitable for Low- and Medium-Voltage Applications

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

Thermal Overload

Two-Body Simulation

Most thermal overload protective devices employ a one-body thermal simulation model. This model assumes that a motor’s thermal response is uniform throughout. The Smart Motor Manager uses a two-body simulation to calculate a more precise representation of a motor’s thermal condition during all modes of operation. A twobody simulation incorporates the temperature rise characteristics of both the stator

windings and the iron mass of the motor into the thermal image.

Starting: In a two-body simulation, the fast rise in the winding temperature and the much slower conduction of heat to the iron during starting are correctly simulated.

Running: While the motor is running, both the iron and current imbalance losses are entered into the model. The optional addition of the ambient temperature into the simulation improves the level of motor use, even in cases where the temperature is subject to considerable fluctuations.

Stopped: The different cooling rates of a self-cooled motor while running and at rest are taken into account by two separate time constants. The simulation includes the faster cooling of the windings relative to the temperature of the iron mass after switching off the motor, as well as the slower cooling of the motor as a whole.

Thermal Capacity Utilization

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

Adjustable Settings

To allow maximum utilization of a motor, the Smart Motor Manager provides the following adjustable settings that allow the installer to match the electronic thermal overload protection to the time-current response of the motor:

Full Load Current
Locked Rotor Current
Locked Rotor Time

The thermal capacity of the iron is particularly important at low-level overloads; allowance for it in the thermal image enables the overload reserves of the motor to be used without risking a premature trip.

Adjustable Ratio of Cooling Time Constants

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

Tripping Time Display

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

Reset Time Display

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

Thermal Warning

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

Motor Temperature Monitoring

Direct motor temperature monitoring can provide enhanced protection against influences that are independent of current, such as ambient temperature and obstructed motor ventilation. Doing so requires a motor with temperature sensors embedded in the windings. The Smart Motor Manager offers two options for direct temperature monitoring.

Thermistor Input: The option card (Cat. No. 825-MST) allows connection of a maximum of six positive temperature coefficient (PTC) thermistors in series. The resistance of a thermistor increases immediately when its rated response temperature is exceeded. The Smart Motor Manager provides an instantaneous trip when the measures thermistor response resistance level is achieved.

RTD Input: The option card (Cat. No. 825-MMV) allows connection of six 100 W platinum resistant temperature detectors (RTDs) for monitoring motor winding and bearing temperature. A seventh input for monitoring the ambient temperature is also available. User-adjustable settings are provided for programming separate warning and trip temperature values. The monitored temperatures are displayed through the Actual Values menu.

Ground Fault

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

Residual Method (Holmgreen)

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

Zero Sequence Method (Core Balance)

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

Imbalance/Phase Loss

The Smart Motor Manager continuously monitors and calculates the current imbalance of an operational motor. The measured current imbalance is entered into the thermal image calculation to simulate the resulting increased motor heating.
User-adjustable trip and warning settings for current imbalance are available with a preset range of 5…80% of full-load current.
Phase loss, a severe form of imbalance, is one of the primary causes of motor failure. A phase loss can occur as a result of a blown fuse or a poor electrical connection. Under a phase loss condition, the current draw of the remaining two powered phases increases by as much as 1.73 times the normal operating current.
The Smart Motor Manager offers two options for obtaining phase loss protection.
Basic Unit: With the basic unit, phase loss protection is gained by using the current imbalance (asymmetry) settings.
Cat. No. 825-MLV: This option card provides terminals for connection to the threephase power system. With the connection made before the motor-starting contactor, a phase loss condition is recognized even while the motor is stopped. The Smart Motor Manager’s phase loss protection provides a preset delay of 2 s prior to a trip.

Rapid Trip/Mechanical Jam

When a driven load is jammed, causing the motor to stall, undue stress is applied to the transmission elements (gears, bearings, motor shaft, etc.). Additionally, as the motor stalls, its current draw begins to increase to the level of its locked rotor current rating.
The Smart Motor Manager provides the capability to quickly take a motor off line in the event of a mechanical jam, thereby reducing the potential for mechanical damage. It can also monitor and warn of impending jam situations. User-adjustable trip and warning settings are available with a range of 1…6 times the motor full-load current.

Underload

A sudden drop in motor current can signal conditions such as:

Pump cavitation
Tool breakage
Belt breakage

In these instances rapid fault detection can help minimize damage and aid in reducing production downtime.
Additionally, monitoring for underload can provide enhanced protection for motors that are cooled by the medium being handled (e.g., submersible water pumps). Such motors can become overheated despite being underloaded. This can result from an absence or insufficient amount of the medium (due to clogged filters, closed valves, etc.).
The adjustment range of the underload trip and warning settings is 25…100% of the motor’s full load current rating.

Short Circuit

In the event of a short circuit (phase-to-phase or phase-to-ground), excessive currents, typically much greater than a motor’s locked rotor current rating, are generated. Given the magnitude of this current, it is generally preferable or necessary to interrupt three-phase power to the motor through the branchprotecting circuit breaker rather than the motor-starting contactor due to the differences in the short-circuit withstand rating.
In the event of a short circuit, the Smart Motor Manager trips output relay #1 of the option card (Cat. No. 825-MST) regardless of other protective functions, actuating the circuit breaker with adequate breaking capacity. To prevent the contactor from opening under short-circuit conditions, its main relay is blocked from operating at currents greater than or equal to 12 times the motor’s full-load current rating. Tripping is delayed by 50 ms.

Start Time Monitoring

The Smart Motor Manager furnishes a setting for the installer to define the time that the motor should accelerate the load to full speed. The adjustment is 1…240 s. Start time monitoring begins when the motor’s starting inrush current is recognized (current is greater than 110% of the motor’s full-load current rating). Acceleration to full speed is deemed to have been completed when the starting inrush current has fallen below 110% of the motor’s full-load current rating.
Start time monitoring is independent of thermal overload protection.

Speed Switch Input

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

Two-Speed Motor Protection

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

Control Functions

Contactor Operation

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

Wye-Delta Control

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

Emergency Restart

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

Outputs

Output Relays

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

Isolated Analog Output

The Cat. No. 825-MST option card provides an isolated 4…20 mA analog output signal. This can be set to indicate one of the following:

Motor current (as a percentage of the motor’s full-load current rating)
Maximum RTD temperature measured
Thermal capacity utilization

Monitoring and Diagnostic Display

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

Actual Values

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

Recorded Values

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

Communications

The Smart Motor Manager provides a dedicated communication expansion slot for connection to the following automation networks:

DeviceNet

This can enhance process operation by allowing the user to do the following via the network:

Control the motor starter
Modify settings
Access operational, diagnostic, and historical data

Basic and Optional Features

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

⋆ Available

Possible Combinations of Option Cards with Basic Unit

Basic Bulletin 825Ä	Option Cards‡
Basic Bulletin 825Ä	Cat. No. 825-MST	Cat. No. 825-MLV	Cat. No. 825-MMV
⋆	⋆	⋆	—
⋆	⋆	—	⋆
⋆	⋆	—	—
⋆	—	⋆	—
⋆	—	—	⋆
⋆	—	—	—

⋆ The features and protective functions provided by each option card can be monitored through the communication network with any of the communication cards. ‡ A single communication card can be used with any combination of option cards. § Available in shown combination.

Standards Compliance and Certifications

Standards Compliance

IEC 947-4
CSA C22.2 No. 14
UL 508

Certifications

CE
CSA Certified
UL Listed

Product Selection

Your order must include: Cat. no. of the Smart Motor Manager selected with supply Voltage Suffix Code, Cat. no. of Converter Module selected, and, If required, Cat. no. of any option cards or accessories.

Product Selection — Smart Motor Manager Basic Unit

	Description	Cat. No.
	Basic Unit Programmable electronic motor overload protection relay with communication capability Thermal Overload Phase Imbalance Jam (High Overload) Underload Ground (Earth) Fault Starting Time Monitor Limited Starts per Hour	825-MÄ

Ä Control Voltage Suffix Code

The cat. no. as listed is incomplete. Select a control Voltage Suffix Code from the table below to complete the cat. no. Example: Cat. No. 825-MÄ for 120V power supply becomes Cat. No. 825-MD.

Voltage AC	24V	120…220V	220…240V	380…415V	440V	Voltage DC	24…48V
50/60 Hz	KD	D	AJ	N	GB	Code	Z48

Converter Module

	Description	Current Range	Cat. No.
	Converter Module Connection to the Smart Motor Manager is made by a cable wire plug provided as standard with the converter module.	0.5…2.5 A	825-MCM2
		2.5…20 A⋆	825-MCM20
Cat. No. 825-MCM180		20…180 A	825-MCM180
		160…434 A	825-MCM630
Cat. No. 825-MCM630		160…630 A	825-MCM630N

⋆ Up to 2000 A when using primary current transformers.

Core Balance Current Transformer

	Description	Current Ratio	Cat. No.
	Measure from earth current 0.5...10 A	100:1	825-CBCT

⋆ Up to 2000 A when using primary current transformers.

Accessories

	Description	Cat. No.
	MST option — Features Short Circuit Ground (Earth) Fault (Core Balance CT) Stalling During Start Thermistor Input (PTC) Analog Output Two-speed Motor Protection	825-MST
	MLV option ‡ — Features Wye-Delta (Star-Delta) Starting Phase Reversal (Sequence) Phase Failure (Motor Supply)	825-MLV
	MMV option ‡ — Features 100 W Platinum RTD Inputs #1…#6 (Stator/Bearings) 100 W Platinum RTD Input #7 (Ambient Temperature)	825-MMV
	DeviceNet Communication Card DeviceNet Conformance Tested (Passed)	825-MDN
	M8 connections Set of three 4 x 16 x 102 mm (1/8 x 5/8 x 4-1/64 in.) (125 A max.) Universally applicable Weight: 230 g	825-MVM
	Thermal Utilization Meter	825-MTUM

⋆ Option cards include a connector set. ‡ Cat. Nos. 825-MLV and 825-MMV occupy the same slot, therefore only one of the option cards may be used at one time.

	Description		Cat. No.
Cat. No. 825-FPM	Panel Mounting Frame		825-FPM
	Connector Sets Provided as Standard with option card	For use with Cat. No. 825-MÄ	825-CSB
Cat. No. 825-PTS		Cat. No. 825-MST	825-CSST
		Cat. No. 825-MMV	825-CSMV
		Cat. No. 825-MLV	825-CSLV
Cat. No. 825-MPS	Connection Cable (Replacement) Bul. 825-P to Bul. 825-MCM Connection		825-MCA
	Power Supply Module (replacement)		825-MPSÄ

Ä Control Voltage Suffix Code

The cat. no. as listed is incomplete. Select a control Voltage Suffix Code from the table below to complete the Cat. No. Example: Cat. No. 825-MPSÄ for 120V power supply becomes Cat. No. 825-MPSD.

Voltage AC	24V	120…220V	220…240V	380…415V	440V	Voltage DC	24…48V
50/60 Hz	KD	D	AJ	N	GB	Code	Z48

⋆ Maximum Cable Lengths for Various Transmission Rates

Specifications

Controls

1	Values Actual Set Recorded	Mode Selection Display current operating data Setting mode (set, change, save, and store parameters) Display recorded data	5	Reset	Reset trips
2	Select	Select functions and enter/change operating parameters	6	LCD	Single Line (two lines of text are displayed alternately)
3	Settings Change Enter	Entry Enable entry Save entry	7	Fault Indicator Blinking Continuous	LED Warning Trip
4	Test	Test functions (Alarm, trip, trip time)

Settings

The following parameters must be programmed for every application. The other parameters (e.g., high overload, asymmetry) have factory-set values, which are correct for most applications.

Main Settings	Setting Range	Factory Setting
Rated motor current or operating current I_e Use of a primary current transformer Current ratio of primary current transformer Locked-rotor current Locked-rotor time⋆	0.5...2000 A No/Yes 1...2000 2.5...12 I_e 1...600 s	20 A No 1 6 I_e 10 s

⋆ If, instead of the permissible locked-rotor time, the maximum starting time is known, the approximate locked-rotor time is calculated as follows: Locked rotor time = Starting time ÷ 1.4

Special Settings	Setting Range	Factory Setting
Connection of main relay (MR) Connection of alarm relay (AL) Reset of thermal trip Reset at...% thermal utilization Reset PTC trip Cooling constant motor ON/OFF ratio Motor insulation class	Electrically held/non-fail-safe Non-fail-safe/electrically held Manual/automatic 10...100% Manual/automatic 1...5 B/E/F	Electrically held Non-fail-safe Manual 50% Manual 2.5 B

Function Overview

	Function	Setting		Tripping Delay		Relays§
	Factory Setting	Range	Factory Setting	Range	Factory Setting	Selection	Factory Setting
Protective Functions
Bulletin 825-M basic unit Thermal overload Asymmetry/Phase loss High overload/Stalling Underload Underload delay Earth fault (Holmgreen) Start time monitoring Limited number of starts per hour	On On On Off On On Off Off	— 5...80% 1...6 I_e 25...100% — 10...100% — 1...10	— 35% 2.4 I_e 75% — 50% — 2	— 1...5 s 0.5...25 s 1...60 s 0...240 s 0.1...5 s 1...240 s —	— 2.5 s 0.5 s 10 s 0 s 0.5 s 10 s —	MR All All All — All All All	MR MR MR MR — MR MR MR
Option 825-MST Short circuit Earth fault (core balance transformer) Stalling during start⋆ PTC Thermistor input	Off Off Off Off	4...12 I_e 5 mA...50 A — —	10 I_e 1 A — —	20...990 ms 0.1...5 s — —	50 ms 0.5 s — 800 ms	#1 All All⋆ All	#1 MR MR⋆ MR
Option 825-MLV Phase sequence (motor supply) Phase loss (motor supply)	Off Off	— —	— —	— —	1 s 2 s	All All	MR MR
Option 825-MMV 100 W Platinum RTD inputs #1...#6 (stator, bearings) 100 W Platinum RTD input #7‡	Off Off	50...200 °C —	50 °C —	— —	<8 s —	MR, AL#1...3 —	MR —
Alarm Functions
Bulletin 825-M basic unit Thermal utilisation (% D J load) Asymmetry (% I_e) High overload (% II_e) Underload	Off Off Off Off	50...99% 5...80% 1...6 I_e 25...100%	75% 20% 2 I_e 75%	— — — —	— — — —	AL,#1...5 AL,#1...5 AL,#1...5 AL,#1...5	AL AL AL AL
Option 825-MST Earth fault (core balance transformer)	Off	5 mA...50 A	500 mA	—	—	AL,#1...5	AL
Option 825-MMV 100 W Platinum RTD inputs #1...#6 (stator, bearings)	Off	50...200 °C	50 °C	—	—	AL,#1...5	AL

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

Function Overview, Continued

	Function	Setting		Tripping Delay		Relays§
	Factory Setting	Range	Factory Setting	Range	Factory Setting	Selection	Factory Setting
Control Functions
Bulletin 825-M basic unit Warm start (% of cold trip) Emergency start	Off Off	50...100% Jumper Terminals	70% Y11- Y12	4...60 min. —	60 min. —	— —	— —
Option 825-MST Analog output assigned to: - Thermal utilisation - PT100 max. Temperature - I Motor	On	4...20 mA 0...100% 5...200 °C I_e0...200%	—	—	—	—	—
Control Auxiliary Relays #2, #3 via communication	—	—	—	—	—	—	—
Control Input #1: (24V AC/DC; 8 mA) Alternatively, one of two functions may be selected: • Pick-up delay, relay #2 • Drop-out delay, relay #2 • Disabling of protective functions: - Asymmetry/phase loss - High overload/stalling - Earth fault - Short circuit - Underload - Limited starts per hour - Thermistor PTC - 100 W Platinum RTD	Off Off Off Off Off Off Off Off Off Off	— — — — — — — — — —	— — — — — — — — — —	0...240 s 0...240 s — — — — — — — —	1 s 2 s — — — — — — — —	— — — — — — — — — —	#2 #2 — — — — — — — —
Control Input #2: (24V AC/DC; 8 mA) Alternatively, one of three functions can be selected: • Pick-up delay, relay #3 • Drop-out delay, relay #3 • Set 2nd rated current • Disabling protective functions: - Asymmetry/phase loss - High overload/stalling - Earth fault - Short circuit - Underload - Limited starts per hour - Thermistor PTC - 100 W Platinum RTD	Off Off Off Off Off Off Off Off Off Off	— — 0.5...2000 A — — — — — — — —	— — 20 A — — — — — — — —	0...240 s 0...240 s — — — — — — — — —	1 s 2 s — — — — — — — — —	— — — — — — — — — — —	#3 #3 — — — — — — — — —
Option 825-MLV Star-Delta starting	Off		Y-D: 1.1 · I_e	Y-D: 1...240 s	10 s		Y: #4 D: #5

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

Specifications

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

Ambient Conditions
Temperature Operation Storage Transport	–5...+60 °C –40...+60 °C –40...+60 °C
Climatic Withstand Damp heat IEC 68-2-3 Climatic cycling IEC 68-2-30	40 °C, 92% relative humidity, 56 days 25/40 °C, 21 Cycles
Protection Class Bulletin 825, enclosed in panel Terminals	IP65 IP20
Vibration Resistance per IEC 68-2-6	10...150 Hz, 3 G
Shock Resistance per IEC 68-2-27	30 G, shock duration 18 ms, half of a sin wave in x, y, z directions

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

Rated Voltage U_e
Primary Control Circuit	825-MCM2	825-MCM20	825-MCM630 825-MCM630N 825-MCM180
Motor Circuit per IEC, SEV, VDE 0660 per CSA, UL	400V AC 240V AC	660V AC 600V AC	1,000V AC 600V AC
Control Circuit Main relay (MR) 95...98, supply A1, A2 Phase-sequence protection L1, L2, L3 • per IEC 947 • per SEV • per CSA, UL Alarm relay (AL) 13/14, Auxiliary Relays #1, #4, #5 • per IEC 947 • per SEV • per CSA, UL Auxiliary Relays #2, #3 Control Inputs #1, #2	400V AC 380V AC 240V AC 400V AC 250V AC 240V AC 120V AC/30V DC 24V AC/DC
Electrical Ratings
Test Voltage	825-MCM2	825-MCM20	825-MCM630 825-MCM630N 825-MCM1808
Motor Circuit per IEC 947-4	U_imp 2.5 kV	U_imp 6 kV	U_imp 8 kV
Control Circuit Control circuits against each other and against all other sets⋆ Main relay (MR) 95...98, supply A1, A2 Phase sequence protection L1, L2, L3 Alarm relay (AL) 13/14, Auxiliary relays #1, #4, #5 • per IEC 947-4 Core-balance transformer k, I Auxiliary relays #2, #3 Control inputs #1, #2 • per IEC 947-4	U_imp 4 kV U_imp 2.5 kV
EMC Standard
Noise emission Noise proof	per EN 50 081-1 and EN 50 081-2 per EN 50 082-1 and EN 50 082-2
Standards	IEC 947-4, CSA C22.2 No. 14, UL 508
Approvals	CE, UL-Listed, CSA
Supply
Nominal supply voltage U_s Permissible voltage fluctuation Power consumption Short-circuit protection	50/60 Hz: 22...24, 33...36, 44...48, 110...120, 220...240, 380...415, 440V AC 24...48, 72...120V DC AC 0.85...1.1 Us, DC 0.80...1.1 U_s AC 13 VA, DC 10 W max. With the appropriate supply cable rating, the supply module is short-circuit proof
Terminals
Bulletin 825-M Plug-in Terminals • per UL • per VDE	Range of gauges: Nominal gauge:	[mm²] [mm²] [AWG No.] [mm²]	0.5...2.5, single-wire 0.5...1.5, double-wire 22...14 1.5
Main circuit 825-MCM2, 825-MCM20	Terminals:	[mm²] [AWG No.]	2 x 2.5/1 x 4 2 x 20...14/1 x 20...12
825-MCM180 825-MCM630(N)	Aperture: or bus bars: Bus bars	[mm] [mm] [mm]	Æ max. 19 20/16 x 4 25 x 8

⋆ The measuring inputs PT100 and PTC, 4...20 mA analog output and the RS 485 communication interface are not isolated from one another.

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

Relays
Contact Data of Output Relays, Main Relay (MR) 95...96
Contacts			1 N.O. and 1 N.C. contact, electrically insulated
Nominal operating voltage per UL, CSA: pilot duty 240V		[V]	24	110...125	220...250	380...440
Continuous thermal current		[A]	4
Rated operating current	AC-15	[A]	3		3	1.2
Maximum permissible switching current (cos f = 0.3)	AC-15	[A]	30		30	12
Rated operating current (L/R = 300 ms), no protection network necessary	DC-13	[A]	2	0.3	0.2	—
Max. rated current of back-up fuse		[A]	fast (D) 16; slow (DT) 10, 500V Type gG
Alarm relay (AL), Auxiliary relays #1, #4, #5
Contacts			1 N.O. contact each
Continuous thermal current		[A]	4
Maximum permissible switching voltage		[V]	400 AC, 125 DC
Nominal operating current cos f= 1 cos f= 0.4, L/R = 7 ms		[A] [A]	4 at 250V AC or 30V DC 2 at 250V AC or 30V DC
Maximum switching power cos f= 1 cos f= 0.4, L/R = 7 ms - per UL/CSA		[VA/W] [VA/W] [V]	1250/150 500/60 240; 1 A pilot duty
Auxiliary relays #2, #3
Contacts			1 N.O. contact each
Continuous thermal current		[A]	4
Maximum permissible switching voltage		[V]	48 AC, 30 DC
Maximum switching power cos f= 1 cos f= 0.4, L/R = 7 ms		[W] [W]	150 60

Main Current Transformers for the Motor Circuit
When Bulletin 825-M is used as a secondary relay with Cat. Nos. 825-MCM2, 825-MCM20
Min. rated operating voltage Min. rated primary current I_1n Rated secondary current Class and nominal overcurrent factor Power rating Rated frequency	[V] [A] [A] [Hz]	Nominal operating voltage of motors Nominal operating current of motor 1 or 5 5 P 10 ext. 120%⋆ According to power consumption in leads and measuring circuits 50/60
Burden Power consumption at maximum rated current‡ Continuous thermal current Thermal current during 1 s Rated frequency	[VA] [A] [A] [Hz]	825-M + 825-MCM2 0.1 per Phase 3 250 50/60	825-M + 825-MCM20 0.4 per Phase 24 600 50/60
General Notes on 825-MCM
No-load		An open-circuit secondary is permitted, since the burden is installed in the detection module

⋆ Current transformer (P = Protection): ±1% error at rated current (I_e) ±5% error at rated overcurrent (10 · I_e) Rated thermal current = 120% I_e For starting current 10 · I_e: Class 5 P 20 The current transformer error is added to the Bulletin 825-M error. ‡ 2.5 A with Cat. No. 825-MCM2, 20 A with Cat. No. 825-MCM20

Core Balance Current Transformer
Recommended Core Balance Current Transformer (cable-type)
Nominal ratio K_n =	Minimum detectable earth fault Pick-up current of Bulletin 825 earth fault protection
Burden: Bulletin 825-M measuring circuit Power consumption at max. rated current 0.5 A[VA] Continuous thermal current[VA] Thermal current during 1 sec[A] Frequency[Hz]	0.4 0.5 25 50/60
Short-Circuit Protection
Selection of circuit breaker or fuse and associated contactor	The line-side circuit breaker or fuse must ensure that the engine will start, while still switching off short-circuit currents fast enough. Because of the latter, the fuse selected should always be as small as possible. The lowest possible fuse rating depends on the starting current of the motor and the tripping time set on the Bulletin 825-M.
Short-Circuit coordination of the starter must always be considered	The contactor receives its tripping signal when the Bulletin 825 trips and must interrupt all currents up to the point of intersection of the time/current characteristics of the Bulletin 825 and circuit breaker or fuse. When starting large motors, the main contacts on the contactor are subjected to high thermal loads so that if the motor starting time exceeds a certain limit, the maximum permissible current has to be reduced. The fuse or contactor rating must also allow for the prospective short-circuit current. The Bulletin 825-MCM converter modules are short-circuit proof. The contactor coordination diagrams are available upon request.

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

Response During Supply Voltage Failure If the supply voltage fails, the setting data is retained
Supply voltage failure > 30 ms	• All attracted output relays drop out • LED extinguishes • The timer for duration of supply failure starts (max. 8 h) • The current and recorded data are memorized • LCD extinguishes
Recovery of the supply voltage	• Start of initialization routine • The time of occurrence and the duration of the supply voltage failure are recorded • Thermal image is calculated and updated • All output relays return to the state they were in before the supply failure • LCD and LED are active
Automatic Recognition of the Converter Module In the event of a fault, the output relay MR trips and the type of fault appears on the LCD
Bulletin 825-M devices regularly check	• The Bulletin 825-M <-> 825-MCM link • Agreement between the rated current set and the current range of the Bulletin 825-MCM • The supervisory circuits
Bulletin 825-MTUM Device for Indicating Thermal Utilisation, PT 100 max., I_motor
Display range Utilisation[%] Wire[mm2] Front[mm] Panel cutout[mm] Mounting depth[mm]	0...100 (DJI_e at rated current I_e) 2 x 2.5 96 x 96 91.5 x 91.5 (–0/+ 0.5) 55
Power Supply Module
Permissible voltage fluctuation[ U_s] Power consumption[VA/W] Short-circuit protection	AC 0.85...1.1, DC 0.80...1.1 AC 13/DC 10 The power supply module is short-circuit proof

Weights
Bulletin 825-M with power supply module		[g]	1000
Bulletin 825-M without power supply module		[g]	710
Power supply module	825-MPS	[g]	290
Options	825-MPB	[g]	125
	825-MST	[g]	90
	825-MLV	[g]	90
	825-MMV	[g]	90
Converter modules	825-MCM2	[g]	570
	825-MCM20	[g]	570
	825-MCM180	[g]	860
	825-MCM630	[g]	3120
	825-MCM630N	[g]	5460
Core balance transformer	825-CBCT	[g]	500
Thermal utilisation indicator	825-MTUM	[g]	180
Mounting frame	825-FPM	[g]	860
PC Option kit	825-VISU	[g]	125
T connector	825-PTS	[g]	75
Stub cable	825-PTL2	[g]	40
	825-PTL4	[g]	45
Bus cable segment	825-PCB1	[g]	95
Bus termination	825-PCE	[g]	20
Bus cable	825-BC	[g]	59/m
Bus cable connector	825-CBC9	[g]	15
Bus bar for Cat. No. 825-MCM180
	825-MVM	[g]	230
	825-MVM2	[g]	230

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

Main Circuit

3-phase current evaluation

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

Converter Module U1
825-MCM2
825-MCM20

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

Core balance transformer U3
5 mA...50 A
Output to Bulletin 825-M: 5...500 mA

Control Circuit

Impulse contact control

QM	Circuit breaker
QA	Shunt trip coil
K1	Contactor
F1	825-M
S1	ON button
S0	OFF button
Us	Control voltage
H1	Indicator: contact closed
H2	Indicator: Bulletin 825 tripped
	(except for short-circuit protection)
H3	Indicator: short-circuit trip
MR	Main output relay
#1	Auxiliary relay, short-circuit indicator

Approximate Dimensions

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

Bulletin 825-M Mounting

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

Flush Mounting

Surface Mounting

Bulletin 825-M devices can be installed on a mounting frame (Cat. No. 825-FPM). The terminals can then be easily accessed without unmounting the device.

Mounting Depth

Mounting Position

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

Bulletin 825-MCM Converter Module

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

Cat. No. 825-MCM630N

Dimensions
Cat. No.	a	b	c	c1	ø d	d1	d2	d3	ø e	ø e1	e2	b1	b2
825-MCM2	120	85	102	66	5.3	5.3	100	55	2 x 2.5 mm²	—	38.5
825-MCM20	120	85	102	66	5.3	5.3	100	55	2 x 2.5 mm²	—	38.5
825-MCM180	120		102	72	5.3	5.3	100	55	∆	∆	38.5	75	§ /♣ 100/118
825-MCM630	155	145	156	118	6.3	6.3	135	88	11	M10	48
825-MCM630N	155	145	177	118	6.3	6.3	135	88	11	M10	48

⋆ For snapping on to DIN Rail (EN 50 022-35 x 15 or 35 x 7.5). ‡ Cat. No. 825-MCM180; with bus bar or max. ø 19 mm aperture for looping the§ conductors. § With Cat. No. 825-MVM. ♣ Cat. No. 825-MVM2 ∆ See below for bus bars for Cat. No. 825-MCM180.

Bus Bars

Terminal Dimensions
Cat. No.	Bottom	Top
825-MVM	M8	M8

Dimensions are not intended to be used for manufacturing purposes.

Core Balance Current Transformer

Cat. No. 825-CBCT