Overload Relays

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SMM™ Smart Motor Manager

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 Ie 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 Ie 1...600 s	20 A No 1 6 Ie 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 Ie 25...100% — 10...100% — 1...10	— 35% 2.4 Ie 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 Ie 5 mA...50 A — —	10 Ie 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 (% Ie) High overload (% IIe) Underload	Off Off Off Off	50...99% 5...80% 1...6 Ie 25...100%	75% 20% 2 Ie 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 Ie0...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 · Ie	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 Ue
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	Uimp 2.5 kV	Uimp 6 kV	Uimp 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	Uimp 4 kV Uimp 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 Us 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 Us 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 I1n 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 (Ie) ±5% error at rated overcurrent (10 · Ie) Rated thermal current = 120% Ie For starting current 10 · Ie: 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 Kn =	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., Imotor
Display range Utilisation[%] Wire[mm2] Front[mm] Panel cutout[mm] Mounting depth[mm]	0...100 (DJIe at rated current Ie) 2 x 2.5 96 x 96 91.5 x 91.5 (–0/+ 0.5) 55
Power Supply Module
Permissible voltage fluctuation[ Us] 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