Modular Protection System
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Bulletin 825-P
- 0.5…5000 A current range
- Suitable for low- and medium-voltage applications
- Modular design with pluggable options
- Voltage input card
- Expansion I/O cards
- Communications cards, including DeviceNet
- RTD scanner module
- Voltage input card
- Comprehensive protection functions
- Built-in keypad and backlit 2-line LCD
- Test/Reset button
- Status LEDs
- Front accessible RS232 port
- 3 output relays
- 2 configurable inputs
- NEMA 12 (IP65) compatible
Standards Compliance and Certifications
Standards Compliance
IEC 60947-1
IEC 60947-4 Type 2 Coordination
CSA C22.2, No. 14
UL 508
Certifications
UL Listed (File No. E 14840, Guide NKCR)
CSA Certified (File No. LR1234)
CE
C-tick
Product Overview
Description
The Bulletin 825-P Modular Protection System for motors offers a compact, modular design that uniquely allows an installer to configure a device’s functional capabilities to match the application requirements. Flexibility is also afforded by accommodating future expansion of the system as the application requirements grow. Finally, ease of installation is provided through pluggable options and accessories.
Comprehensive Protection
The 825-P Modular Protection System offers in-depth motor protection coverage by monitoring the critical elements of motor current, line voltage and temperature. High resolution settings allow the installer to configure a precise envelope of protection to achieve maximum motor utilization while avoiding damage and downtime.
| ANSII No. | Function | ANSII No. | Function |
| Current Elements | Temperature Elements | ||
| 51 | Thermal Overload | 49 | PTC Thermistor |
| 46 | Current Imbalance/Phase Loss | 49 | Stator RTD |
| 50G/51G | Ground Fault | 38 | Bearing RTD |
| 37 | Undercurrent (Load Loss) | — | Ambient and Other RTD |
| 48 | Overcurrent (Load Jam) | Power Elements | |
| 50 | Short Circuit | 37 | Underpower |
| 47 | Phase Reversal | 55/78 | Power Factor |
| 81 | Frequency | — | Reactive Power |
| 86 | Overload Lockout | — | — |
| Voltage Elements | Motor Starting Elements | ||
| 27 | Undervoltage | 66 | Starts/Hour |
| 59 | Overvoltage | — | Stall - Acceleration Time Monitoring |
| 47 | Phase Reversal | 14 | Speed Switch Monitoring |
| 81 | Frequency | 19 | Reduced Voltage Starting |
| — | — | 48 | Incomplete Start |
| Note:Voltage, power, and energy elements are only available with the installation of the voltage input option card. | |||
Full Function Metering
| Current Elements | Voltage Elements | Power Elements | Energy Elements | Thermal Elements |
| Phase Currents | Line-Line Voltages | Real Power (kW) | Real Energy (kWh) | % Thermal Capacity Utilization |
| Average Current | Avg. Line-Line Voltage | Reactive Power (kVAR) | Reactive Energy Forward (kVARh) | RTD Values |
| % Motor Load | Line-Neutral Voltages | Apparent Power (kVA) | Reactive Energy Reverse (kVARh) | — |
| Current Imbalance | Avg. Line-Neutral Voltage | Power Factor | Apparent Energy (kVAh) | — |
| Ground Fault Current | Voltage Imbalance | — | — | — |
| System Frequency | System Frequency | — | — | — |
| Note:Voltage and power elements are only available with the installation of the voltage input option card. | ||||
Product Overview, Continued
Statistical Values
The 825-P Modular Protection System provides the following valuable statistical values of motor operation:
Historical Data
The 825-P Modular Protection System saves records for the five most recent trip events. Each trip event is summarized with record of the following prior to trip data capture:
Function Overview
| Description | Trip Level Setting Range | Trip Delay Setting Time | Warning Level Setting Range |
| Motor FLA Ie | 0.5…5000 A | — | — |
| Locked Rotor Current | 2.5…12 x Ie | — | 50…100% TCU |
| Locked Rotor Time | 1…600 s | — | — |
| Short Circuit | 4…12 x Ie | 0…5.00 s | 4…12 x Ie |
| Ground Fault (Residual) | 0.1…1.0 x Ie | 0…5.00 s | 0.1…1.0 x Ie |
| Ground Fault (Core balance) | 0.01…25 A | 0…5.00 s | 0.01…25 A |
| Jam | 1.0…6.0 x Ie | 0…5.00 s | 1.0…6.0 x Ie |
| Undercurrent | 0.1…1.0 x Ie | 0…120 s | 0.1…1.0 x Ie |
| Current Imbalance | 5…80% | 0…240 s | 5…80% |
| Start Monitoring | — | 0…240 s | — |
| RTD Temp | 0…250 °C | — | 0…250 °C |
| Phase Reversal | Disable, Enable | — | — |
| Undervoltage | 0.60…1.00 x Vnom | 0…120 s | 0.60…1.00 x Vnom |
| Overvoltage | 1.00…1.20 x Vnom | 0…120 s | 1.00…1.20 x Vnom |
| Underpower | 1…25000 kW | 0…240 s | 1…25000 kW |
| Power Factor | 0.05…0.99 | 0…240 s | 0.05…0.99 |
| VAR | 1…25000 kVAR | 0…240 s | 1…25000 kVAR |
| Frequency | 45…55/55…65 Hz | 0…240 s | 45…55/55…65 Hz |
| Start Inhibit (Starts/hour) | 1…15 | — | — |
| Speed Switch | — | 0…240 s | — |
Product Selection
| Description | Cat. No. | ||
|
Basic Unit Note: The minimum requirements for a complete basic system are one basic unit and one converter module. |
120…240V AC/DC | 825-PD¬ |
| 24…48V DC | 825-PZ¬ | ||
|
Converter Module | 0.5…2.5 A | 825-MCM2 |
| 1.0…5.0 | 825-MCM5 | ||
| 2.5…20 A | 825-MCM20 | ||
| 9…100 A | 825-MCM180 | ||
| 160…420 | 825-MCM420 | ||
| 160…630 A | 825-MCM630N | ||
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Core Balance Ground Fault Sensor | 100:1 | 825-CBCT |
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RTD Scanner Module 12 RTD input channels with individual programming for 10 W copper, 100 W nickel, 120 W nickel, or 100 W platinum. Fiber optic connection to Basic Unit. Class I, Division 2, Group T48. |
120 / 240V AC | 825-PR12D |
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Voltage Input Card Monitoring of VA, VB, VC, and VN |
300V AC Line to Neutral Max. | 825-PVS¬ |
| Expansion I/O Card (3) Inputs (4) Output relays (1) 4…20 mA analog output |
120V AC Rated Inputs | 825-PIOD¬ | |
| 24V DC Rated Inputs | 825-PIOR¬ | ||
| DeviceNet Communication Card DeviceLogix™ technology, Node address selection switches, ODVA conformance tested. |
— | 825-PDN¬ | |
| Modbus RTU Communication Card | — | 825-PMB¬ | |
| MPS Explorer Software ‡ | Windows-based configuration tool | ||
| Operation Instructions T | Quick Start Guide | 825-QS001_-EN-P | |
| Basic Unit User Manual | 825-UM004_-EN-P | ||
| DeviceNet Card | 825-UM005_-EN-P | ||
| ¬ Factory modification available. For conformal coating add CC to the cat. no. Example: Cat. No. 825-PZ becomes Cat. No. 825-PZ-CC. | |||
| ‡ Please contact your local Rockwell Automation sales office or Allen-Bradley distributor. | |||
| T Detailed operation instructions ship separately from the product. Please contact your local Rockwell Automation sales office or Allen-Bradley distributor to obtain printed copies. | |||
| Note:A no-charge download can be found at www.ab.com/industrialcontrols/products/iec_motor_controls/overload_relays/825p.html | |||
Accessories
| Description | Cat. No. | ||
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Bus Bars for 825-MCM180 Three-piece set includes terminals and screws |
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 |
| M8 connections Set of three 4 x 20 x 117 mm (1/8 x 25/32 x 4-39/64 in.) (180 A max.) Universally applicable |
825-MVM2 | ||
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M6 lower connections Set of three For mounting on Bul. 100-D95 and 100-D110 contactors with conventional coil |
825-MVS | |
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M8 lower connections Set of three For mounting on Bul. 100-D140, 100-D180 conventional and Bul. 100-D95E…100-D180E contactors with electronic coil |
825-MVS2 | |
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Terminal Shields Set of two Protection class IP10 per IEC 60529 and DIN 40 050 For direct-on-line, reversing, two-speed, and wye-delta/star-delta assemblies |
100-D95, 100-D110 | 100-DTS110 |
| 100-D140, 100-D180, 100-D95-E…100-D180-E | 100-DTS180 | ||
| 100-D210...100-D420 | 100-DTS420 | ||
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Terminal Lugs Set of two Protection class IP2X per IEC 60529 and DIN 40 050 |
100-D95, 100-D110 | 100-DTB110 |
| 100-D140, 100-D180, 100-D95E…D180E, 193-EC_F, 193-EE_F | 100-DTB180 | ||
| 100-D210...100-D420, 193-EC_G, 193-EF2C, 193-EE_G | 100-DTB420 | ||
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Thermal Utilization Meter | For display of percent thermal capacity utilized Requires the use of an Expansion I/O Card |
825-MTUM |
| — | Connection Cable (Replacement) Bul. 825-P to Bul. 825-MCM connection |
825-MCA | |
| Package Quantity = 3 Discount Group MPC |
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Specifications
Electrical Ratings
| Main Circuits | |||||||
| Rated Operating Voltage Ue | 825-MCM2 825-MCM5 |
825-MCM20 | 825-MCM180 825-MCM420 825-MCM630N |
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| IEC CSA/UL |
400V AC 240V AC |
690V AC 600V AC |
1000V AC 600V AC |
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| Rated Impulse Strength Uimp | 2.5 kV | 6 kV | 8 kV | ||||
| Operating Current Range (A) | 825-MCM2 | 825-MCM5 | 825-MCM20 | 825-MCM180 | 825-MCM420 | 825-MCM630N | |
| 0.5…2.5 | 1…5 | 2.5…20 | 20…180 | 160…420 | 160…630 | ||
| Rated Continuous Thermal Current (A) | 3 | 6 | 24 | 216 | 504 | 756 | |
| Rated Saturation Current (A) | 30 | 60 | 240 | 1350 | 3400 | 4600 | |
| Rated Frequency | 50/60 Hz ±3 Hz | ||||||
| Voltage Input Option Card | |||||||
| Rated Operating Voltage Ue | 250V AC Max | ||||||
| Operating Range | 0.8…1.1 Ue | ||||||
| Rated Continuous Voltage | 300V AC | ||||||
| Rated Insulation Voltage Ui | 300V AC | ||||||
| Rated Impulse Strength Uimp | 4kV | ||||||
| Rated Frequency | 50/60 Hz ±5 Hz | ||||||
| Control Circuits | |||||||
| Supply | |||||||
| Rated Supply Voltage Us | 110…240V AC, 110…250V DC | 24…48V DC | |||||
| Operating Range | 0.8…1.1 Ue | 0.8…1.1 Ue | |||||
| Rated Frequency (V AC) | 50/60 Hz ±5 Hz | — | |||||
| Max. Power Consumption | 40VA (AC) / 15W (DC) | 15 W | |||||
| Output Relays | |||||||
| Type of Contacts | Trip | Form C SPDT | |||||
| Aux1…Aux6 | Form A SPST — N.O. | ||||||
| Rated Insulation Voltage Ui |
300V AC | ||||||
| Rated Operating Voltage Ue | 240V AC | ||||||
| Rated Impulse Strength Uimp | 4kV | ||||||
| Rated Thermal Current Ithe | 5 A | ||||||
| Rated Operating Current Ie | 120V AC | 3 A | |||||
| 240V AC | 1.5 A | ||||||
| Contact Rating Designation | B300 | ||||||
| Utilization Category | AC15 | ||||||
| Contact Reliability | 5 mA @ 17V | ||||||
| Inputs | |||||||
| Rated Operating Voltage Ue | IN1 and IN2 | IN3, IN4, and IN5 | |||||
| 24V AC/DC | 120V AC/DC (825-PIOD), 24V AC/DC (825-PIOR) | ||||||
| Operating Range | 0.8…1.1 Ue | ||||||
| Rated Insulation Voltage Ui | 300V AC | ||||||
| Rated Impulse Strength Uimp | 4kV | ||||||
| Rated Frequency (V AC) | 50/60 Hz ±5 Hz | ||||||
| On-State Voltage | 15V | 79V | |||||
| On-State Current (turn-on) | 2 mA | 2 mA | |||||
| Steady-State Current | 15 mA | 15 mA | |||||
| Off-State Voltage | 5V | 20V | |||||
| Off-State Current | 0.5 mA | 1 mA | |||||
| Transition Voltage | 5…15V | 20…79V | |||||
| PTC Thermistor Input | |||||||
| Type of Control Unit | Mark A | ||||||
| Max. No. of Sensors in Series | 6 | ||||||
| Max. Cold Resistance of PTC Sensor Chain | 1500 W | ||||||
| Trip Resistance | 3400 W ± 150 W | ||||||
| Reset Resistance | 1500…1650 W | ||||||
| Short-Circuit Trip Resistance | 25 W ± 10 W | ||||||
Specifications, Continued
Mechanical Ratings
| Environmental | ||
| Ambient Temperature | Storage | -40…+85 °C (-40…+185 °F) |
| Operation (open) | -20…+60 °C (-4…+140 °F) | |
| Humidity (Operating) | 5…95%, non-condensing | |
| Max. Altitude | 2000 m | |
| Vibration (Per IEC 68-2-6) | 3 G | |
| Shock (per IEC 68-2-27) | 30 G | |
| Control Terminals | ||
| Terminal Screw | M3 | |
| Cross Section (1 wire, stranded/solid) | 0.14…2.5 mm2 (#20…12 AWG) | |
| Terminal Screw Torque | 0.79 N•m (7 lb-in) | |
Electromagnetic Compatibility
| Electrostatic Discharge Immunity | Test Level | 8 kV Air Discharge, 6 kV Contact Discharge |
| Performance Criteria | 1 ‡ T | |
| RF Immunity | Test Level | 10V/m |
| Performance Criteria | 1 ‡ T | |
| Electrical Fast Transient/Burst immunity | Test Level | 4 kV (Power), 2 kV (Control and Comms) |
| Performance Criteria | 1 ‡ T | |
| Surge Immunity | Test Level | 2 kV L-E, 1 kV L-L |
| Performance Criteria | 1 ‡ T | |
| Radiated Emissions | Class A | |
| Conducted Emissions | Class A | |
| ‡ Performance Criteria 1 requires the DUT to experience no degradation or loss of performance. | ||
| T Environment 2. | ||
Specifications, Continued
RTD Scanner Module
| Supply | ||
| Rated Supply Voltage Us | 110/240V AC | |
| Operating Range | 0.80…1.2 Us | |
| Rated Frequency | 50/60 Hz ± 5 Hz | |
| Max. Power Consumption | 5VA | |
| Rated Insulation Voltage Ui | 300V AC | |
| Rated Impulse Strength Uimp | 4 kV | |
| Pollution Degree | 2 | |
| Environmental | ||
| Ambient Temperature | Storage | -40…+85 °C (-40…+185 °F) |
| Operation (open) | -20…+60 °C (-4…+140 °F) | |
| Humidity (Operating) | 5…95%, Non-condensing | |
| Max. Altitude | 2000 m | |
| Vibration (per IEC 68-2-6) | 3 G | |
| Shock (per IEC 68-2-27) | 30 G | |
| Inputs | ||
| No. of Input Channels | 12 | |
| Type | 3-wire | |
| Compatibility | CU10, NI100, NI120, PT100 (per IEC 60751: 1983) | |
| Range | -50…+250 °C | |
| Accuracy | ± 2 °C | |
| Open Circuit Detection | >250 °C | |
| Short-Circuit Detection | < -50 °C | |
| Control Terminals | ||
| Terminal Screw | M3 | |
| Cross Section (1 wire, stranded/solid) | 0.25…2.5 mm2 (#24…12 AWG) | |
| Torque | 0.4…0.6 N•m (3.5…5.3 lb•in.) | |
| Degree of Protection | IP20 | |
Trip Curves
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Wiring Schematic¬
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¬ Open Delta Voltage Connection
Approximate Dimensions
Dimensions are in millimeters. Dimensions are not intended to be used for manufacturing purposes.
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Core Balance Current Transformer
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Approximate Dimensions, Continued
Dimensions are in millimeters. Dimensions are not intended to be used for manufacturing purposes.
Bulletin 825-MCM Converter Module
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| Dimensions | |||||||||||||
| Cat. No. | a | b | c | c1 | ø d | d1 | d2 | d3 | ø e | ø e1 | e2 | b1 | b2 |
| 825-MCM2, -MCM5, -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 |
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| 825-MCM420 | 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 | ||
| z For snapping on to DIN Rail (EN 50 022-35 x 15 or 35 x 7.5). T 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. |
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Bus Bars
| Terminal Dimensions | ||
| Cat. No. | Bottom | Top |
| 825-MVM | M8 | M8 |
Approximate Dimensions, Continued
Dimensions are in millimeters (inches). Dimensions are not intended to be used for manufacturing purposes.
RTD Scanner
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