Allen-Bradley 825-P User manual

Modular Protection System for Motors
Catalog Number 825-P
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.
The illustrations, charts, sample programs and layout examples shown in this guide are intended solely for purposes of
example. Since there are many variables and requirements associated with any particular installation, Rockwell Automation
does not assume responsibility or liability (to include intellectual property liability) for actual use based upon the examples
shown in this publication.
Rockwell Automation publication SGI-1.1, Safety Guidelines for the Application, Installation and Maintenance of Solid-
State Control (available from your local Allen-Bradley distributor), describes some important differences between solid-
state equipment and electromechanical devices that should be taken into consideration when applying products such as
those described in this publication.
Reproduction of the contents of this copyrighted publication, in whole or part, without written permission of
Rockwell Automation, is prohibited.
Throughout this manual we use notes to make you aware of safety considerations:
DeviceNet and the DeviceNet logo are trademarks of the Open Device Vendors Association (ODVA).
Microsoft Windows is a registered trademark of the Microsoft Corporation.
WARNING: Identifies information about practices or circumstances that can cause an explosion in a hazardous environment,
which may lead to personal injury or death, property damage, or economic loss.
ATTENTION: Identifies information about practices or circumstances that can lead to personal injury or death, property
damage, or economic loss. Attentions help you identify a hazard, avoid a hazard, and recognize the consequence.
SHOCK HAZARD: Labels may be on or inside the equipment, for example, a drive or motor, to alert people that dangerous
voltage may be present.
BURN HAZARD: Labels may be on or inside the equipment, for example, a drive or motor, to alert people that surfaces may
reach dangerous temperatures.
IMPORTANT
Identifies information that is critical for successful application and understanding of the product.

Rockwell Automation Publication 825-UM004D-EN-P - November 2012 3
European Communities (EC)
Directive Compliance
If this product has the CE mark it is approved for installation within the European Union and European Economic Area
(EEA). It has been designed and tested to meet the following directives.
EMC Directives
This product is tested to meet the Council Directive 89/336/EEC Electromagnetic Compatibility (EMC) by applying the
following standards, in whole:
• EN 60947-4-1 — Low-Voltage Switchgear and Controlgear: Part 4: Contactors and Motor Starters - Section 1:
Electromechanical Contactors and Motor Starters
• EN 60947-5-1 — Low-Voltage Switchgear and Controlgear: Part 5: Control Circuit Devices and Switching Elements -
Section 1: Electromechanical Control Circuit Devices
This product is intended for use in an industrial environment.
Low Voltage Directive
This product is tested to meet Council Directive 73/23/EEC Low Voltage as amended by 93/68/EEC by applying the
safety requirements of EN 60947-4-1 and EN 60947-5-1. For specific information required by EN 60947-4-1 and EN
60947-5-1, see the appropriate sections in this publication.
Notice
This product has been designed for environment A. Use of this product in environment B can cause unwanted
elctromagnetic disturbances in which case the user could be required to take adequate mitigation measures.

4Rockwell Automation Publication 825-UM004D-EN-P - November

Rockwell Automation Publication 825-UM004D-EN-P – November 2012 5
Table of Contents
Important User Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
European Communities (EC) Directive Compliance . . . . . . . . . . . . . . . . . 3
EMC Directives. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Low Voltage Directive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Preface Manual Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Conventions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Chapter 1
Introduction
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Options and Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Applications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Chapter 2
Installation
Relay Placement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Physical Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Relay Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Rear-Panel Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Rear-Panel Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Top-Panel Diagram. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Power Connections. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
I/O Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
AC/Control Connection Diagrams. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Fail-Safe/Non-Fail-Safe Tripping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Converter Module Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Core Balance Current Transformer Connections . . . . . . . . . . . . . . . 24
Voltage Connections. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Full-Voltage Non-Reversing Starter . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Full-Voltage Reversing Starter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Star-Delta Starting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Two-Speed Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Field Serviceability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Fuse Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Real-Time Clock Battery Replacement . . . . . . . . . . . . . . . . . . . . . . . . . 32
Chapter 3
Front Panel Operation
Front Panel Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Normal Front Panel Display. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Front Panel Automatic Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Front Panel Menus and Operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Front Panel Security . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Front Panel Main Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
View or Change Settings Using the Front Panel. . . . . . . . . . . . . . . . . . . . . 41
Setting Entry Error Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

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Chapter 4
Hardware Commissioning
Connecting a Converter Module (MCM) . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Adding an Optional I/O Card . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Adding the Optional
Voltage Card. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Adding the Optional Communication Card. . . . . . . . . . . . . . . . . . . . . . . . 49
Removing an Option Card. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Chapter 5
Using MPS Explorer
Software Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Communications Settings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Connection/Access Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Data Management. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Save/Open
Configuration Files. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Button Summary. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
ANA (Test Analog Output). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
MOT (Motor Operating Statistics) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
SER (Serialized Events Recording) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
STA (Relay Status) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
SUM (Events Summary Report) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
MET (Instantaneous Metering)
RTD (RTD/Thermal Metering). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
TAR (Display Target Words) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Data Visualization/Trending. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Validate Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
I/O Mapping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Resetting/Restoring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Chapter 6
Configuring Protection & Logic
Functions
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Application Data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Main Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Identifier Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Phase Rotation, Nominal Frequency Settings . . . . . . . . . . . . . . . . . . . 67
Date Format . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Current Transformer (CT) Configuration, Full Load Current
Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
Voltage Transformer (VT) Configuration Settings . . . . . . . . . . . . . . 69
Basic Motor Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
Overload (Thermal Model) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
Short Circuit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
Ground Fault . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
Jam . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
Undercurrent (Load Loss) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77

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Table of Contents
Current Imbalance/
Phase Loss . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
Protection Disable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
Start Monitoring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
Star-Delta (Wye-Delta) Starting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
Start Inhibit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
Phase Reversal Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
Speed Switch (Stalling
During Start) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
Thermistor (PTC) Monitoring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
RTD-Based Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
Voltage-Based Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
Undervoltage. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
Overvoltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
VAR Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
Underpower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
Power Factor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
Frequency. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
Load Control Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
I/O Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
Analog Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
Trip Inhibit (Block) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
Output Relay Behavior. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
Timer Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
Front Panel Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
Display Enable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
I/O Assignments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
Logic Explanation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
Stop/Trip Logic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
Initiate Trip. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
Unlatch Trip. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
Start & Emergency Restart Logic. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
Overload Curves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
Chapter 7
Metering & Monitoring
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
Metering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
Instantaneous Metering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
Thermal Metering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
Power Measurement Conventions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
Motor Operating Statistics. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
Chapter 8
Analyzing Events
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
Event Summary Reports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
Serialized Events Recording (SER) Report. . . . . . . . . . . . . . . . . . . . . . . . . 110

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SER Triggering. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
Example Reports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
Chapter 9
825-PDN DeviceNet
Communication Card
Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
Required Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
Equipment Shipping with the Card . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
User-Supplied Equipment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
Node Commissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
Setting the Hardware Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
Using RSNetWorx for DeviceNet . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
Explicit Messaging. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
Setting Up the MSG instruction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
DeviceLogix . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
DeviceLogix Programming Example. . . . . . . . . . . . . . . . . . . . . . . . . . . 125
Parameter Groups . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
Chapter 10
Modbus RTU Communications
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
Mounting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
Commissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
Modbus Queries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
Modbus Responses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
Supported Modbus Function Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
Modbus Exception Responses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136
Cyclical Redundancy Check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136
03h Read Holding Register Command . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136
06h Preset Single Register Command . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
10h Preset Multiple Registers Command. . . . . . . . . . . . . . . . . . . . . . . . . . 138
60h Read Parameter Information Command . . . . . . . . . . . . . . . . . . . . . . 139
61h Read Parameter Text Command . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
62h Read Enumeration Text Command . . . . . . . . . . . . . . . . . . . . . . . . . . 142
7Dh Encapsulated Packet With Control Command . . . . . . . . . . . . . . . 143
7Eh NOP Command. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144
Modbus Password Control and Parameter Modification. . . . . . . . . . . . 144
Modbus Serialized Events Recording Register Operation . . . . . . . . . . . 145
Modbus Load Profile Register Operation. . . . . . . . . . . . . . . . . . . . . . . . . . 145
Chapter 11
Testing & Troubleshooting
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
Commissioning Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147

Rockwell Automation Publication 825-UM004D-EN-P - November 2012 9
Table of Contents
Selected Functional Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151
Periodic Tests (Routine Maintenance) . . . . . . . . . . . . . . . . . . . . . . . . 155
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157
Field Serviceability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158
Power Supply Fuse Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158
Real-Time Clock (RTC) Battery Replacement . . . . . . . . . . . . . . . . . 159
Troubleshooting DeviceNet. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160
Troubleshooting Device Backplane Communication . . . . . . . . . . . . . . . 160
Chapter 12
ASCII Serial Communications
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161
ASCII Serial Port Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161
Required Equipment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161
Connect Your PC to the Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162
Configure Your Terminal Emulation Software . . . . . . . . . . . . . . . . 163
Serial Port Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163
Using Terminal Commands . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164
Serial Port Access Levels. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165
Command Summary. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166
Description of Commands . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167
ACC and 2AC (Level 1 or 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167
ANALOG (Level 2). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167
DATE (Level 1 or 2). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167
METER (Level 1 or 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168
MOTOR (Level 1 or 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170
PASSWORD (Level 1 or 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170
QUIT (Level 1 or 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171
SER (Level 1 or 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171
SET (Level 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172
SHOW. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173
STATUS (Level 1 or 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174
STOP (Level 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177
STR (Level 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177
SUMMARY (Level 1 or 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177
TARGET (Level 1 or 2). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178
TIME (Level 1 or 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179
View or Change Settings with Front Panel Serial Port . . . . . . . . . . . . . . 179
Chapter 13
Firmware Upgrade Instructions
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 183
Required Equipment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 183
Upgrade Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 183
Appendix A
Specifications
Electrical Ratings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 187

10 Rockwell Automation Publication 825-UM004D-EN-P - November 2012
Table of Contents
Main Circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 187
Control Circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 188
Mechanical Ratings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 189
RTD Scanner Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 189
Electromagnetic Compatibility . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 190
Metering Accuracy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 190
Standards. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 190
Processing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 190
Primary Current Transformers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 191
825-CBCT Core Balance Current Transformer . . . . . . . . . . . . . . . . . . . 191
DeviceNet Communication Card . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 192
Appendix B
Parameter List
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 193
Appendix C
Relay Word Bits
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 235
Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 235
Appendix D
ASCII Port Relay Command
Summary
ASCII Port Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 239
Appendix E
DeviceNet Information
Electronic Data Sheets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 242
Product Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 242
DeviceNet Objects . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 242
Identity Object - CLASS CODE 0x0001. . . . . . . . . . . . . . . . . . . . . . . . . . 243
Message Router - CLASS CODE 0x0002 . . . . . . . . . . . . . . . . . . . . . . . . . 244
DeviceNet Object - CLASS CODE 0x0003 . . . . . . . . . . . . . . . . . . . . . . . 244
Assembly Object - CLASS CODE 0x0004 . . . . . . . . . . . . . . . . . . . . . . . . 245
Custom Parameter Based Input (Produced) Assembly
Instance 100 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 246
Standard Input (Produced) Assemblies. . . . . . . . . . . . . . . . . . . . . . . . . . . . 247
Standard Output (Consumed) Assemblies . . . . . . . . . . . . . . . . . . . . . . . . 250
Connection Object - CLASS CODE 0x0005. . . . . . . . . . . . . . . . . . . . . . 251
Discreet Input Point Object - CLASS CODE 0x0008. . . . . . . . . . . . . . 254
Discreet Output Point Object - CLASS CODE 0x0009 . . . . . . . . . . . . 255
Discrete Output Point Object Special Requirements . . . . . . . . . . . . . . . 256
Parameter Object - CLASS CODE 0x000F . . . . . . . . . . . . . . . . . . . . . . . 257
Parameter Object - CLASS CODE 0x0010. . . . . . . . . . . . . . . . . . . . . . . . 258
Discrete Output Group Object - CLASS CODE 0x001E. . . . . . . . . . . 259
Control Supervisor Object - CLASS CODE 0x0029 . . . . . . . . . . . . . . . 261
Acknowledge Handler Object - CLASS CODE 0x002b . . . . . . . . . . . . 261
Overload Object - CLASS CODE 0x002c. . . . . . . . . . . . . . . . . . . . . . . . . 262
DeviceNet Interface Object - CLASS CODE 0x00B4 . . . . . . . . . . . . . . 262

Rockwell Automation Publication 825-UM004D-EN-P - November 2012 11
Preface
Manual Overview The 825-P Modular Protection System User Manual describes common aspects
of motor relay application and use. It includes the necessary information to
install, set, test, and operate the relay and more detailed information about
settings and commands. The chapter descriptions are as follows:
•Preface
Describes the manual organization and conventions used to present
information.
•Chapter 1: Introduction
Describes the basic features and functions of the 825-P.
•Chapter 2: Installation
Describes how to mount and wire the 825-P; illustrates wiring connections
for various applications.
•Chapter 3: Front Panel Operation
Explains features and use of the front panel, including front-panel
command menu, default displays, and automatic messages.
•Chapter 4: Hardware Commissioning
Describes how to install and commission the various hardware options for
the 825-P.
•Chapter 5: Using MPS Explorer
Describes how to use MPS Explorer software to read diagnostic
information and configure the 825-P.
•Chapter 6: Configuring Protection & Logic Functions
Describes the operating characteristic of each protection element and
explains how to calculate their settings; describes contact output logic.
•Chapter 7: Metering & Monitoring
Describes the operation of each metering function; describes the
monitoring functions.
•Chapter 8: Analyzing Events
Describes front-panel LED operation, trip-type front-panel messages,
event summary data, standard event reports, and Serialized Events
Recording (SER) report.
•Chapter 9: 825-PDN DeviceNet Communication Card
Describes the communication features supported by the 825-P DeviceNet
option card.
•Chapter 10: Modbus RTU Communications
This chapter describes the communications features supported by the 825-
P Modbus RTU Option Card.
•Chapter 11: Testing & Troubleshooting
Describes protection element test procedures, relay self-test, and relay
troubleshooting.
•Chapter 12: ASCII Serial Communications
Describes the serial port commands supported by the 825-P.
•Chapter 13: Firmware Upgrade Instructions
Describes the process to upgrade the firmware for the 825-P.

12 Rockwell Automation Publication 825-UM004D-EN-P - November 2012
Preface
•Appendix A: Specifications
Provides detailed specification and certification information for all
components of the 825-P Modular Protection System.
•Appendix B: Parameter List
Describes the available parameters for the 825-P.
•Appendix C: Relay Word Bits
Lists and describes the Relay Word bits (e.g., real-time status of relay I/O,
protection functions).
•Appendix D: ASCII Port Relay Command Summary
Briefly describes the serial port commands that are fully described in
Chapter 12: ASCII Serial Communications.
•Appendix E: DeviceNet Information
Describes the details of the features supported by the 825-P DeviceNet
option card.
Conventions Typographic Conventions
The primary ways to configure the 825-P are by using:
•MPS Explorer configuration and monitoring software.
•a command line interface on a PC terminal emulation window, such as
Microsoft® HyperTerminal.
•the front-panel menus and push buttons.
Examples
This instruction manual uses several example illustrations and instructions
to explain how to effectively operate the 825-P. These examples are for
demonstration purposes only. The firmware identification information or
settings values included in these examples may not necessarily match those
in the current version of your 825-P.
Example Description
STATUS Commands typed at a command line interface on a PC.
Enter Single keystroke on a PC keyboard.
Ctrl+D Multiple/combination keystroke on a PC keyboard.
Start > Settings PC dialog boxes and menu selections.
The “>” character indicates submenus.
CLOSE Relay front-panel push buttons.
ENABLE Relay front-panel or rear-panel labels.
MAIN > METER Relay front-panel LCD menus and relay responses.
The “>” character indicates submenus.

Rockwell Automation Publication 825-UM004D-EN-P - November 2012 13
Chapter 1
Introduction
Overview The 825-P Motor Relay is designed to protect three-phase motors. The basic
relay provides locked rotor, overload, unbalance, and short circuit protection.
Voltage-based and RTD-based protection is available as an option. All relay
models provide monitoring functions.
This manual contains the information for installing, setting, testing, operating,
and maintaining an 825-P. It is not necessary to review the entire manual to
perform specific tasks.
A Quick Start Guide, Publication 825-QS001, is also available. It will help to step
the first-time user through the device commissioning process.
Features Standard Protection Features
•Thermal Overload (thermal model)
•PTC (positive temperature coefficient) Overtemperature
•Undercurrent (Load Loss)
•Current Imbalance and Phase Loss
•Overcurrent (Load Jam)
•Short Circuit
•Ground Fault (Residual)
•Ground Fault (Zero Sequence)
•Motor Starting/Running
–Protection Inhibit During Start
–Start Motor Timer
–Notching or Jogging Device
–TCU (Thermal Capacity Utilization) Start Inhibit
–Anti-Backspin Timer
–Emergency Start
–Two Speed Protection
–Reduced Voltage Starting (Star-Delta)
–Stall-Speed Switch
•Frequency

14 Rockwell Automation Publication 825-UM004D-EN-P - November 2012
Chapter 1 Introduction
Optional Protection Features
Voltage-Based Protection
•Undervoltage
•Overvoltage
•Underpower
•Reactive Overpower
•Phase Reversal
•Power Factor
RTD-Based Protection
Up to 12 RTDs can be monitored when an external 825-PR12D RTD Scanner is
used. There are separate trip and warn settings for each RTD.
Monitoring Features
The monitoring features of the 825-P are as follows:
•Event summaries contain relay ID, date and time, trip cause, and current/
voltage magnitudes.
•Serialized Events Recording (SER).
•Motor running time since the last reset.
•Start cycles since the last reset.
•Emergency start cycles since the last reset.
•A complete suite of accurate metering functions.
Options and Accessories Options
•The 825-P has the following options:
–Voltage Option: four-wire wye or open-delta connected potential
transformers
–Input/Output (I/O) Option: one 4…20 mA analog (transducer)
output, three additional control inputs, and four additional contact
outputs
–Network communications options
•DeviceNet
•Modbus

Rockwell Automation Publication 825-UM004D-EN-P - November 2012 15
Introduction Chapter 1
Accessories
Phase current inputs require one of the following external 825-MCM
converter modules:
The ground fault current (zero sequence) feature requires an external 825-CBCT
Core Balance Current Transformer, or equivalent.
The following devices are required to add RTD protection:
•An external RTD scanner Cat. No. 825-PR12D RTD. A fiber-optic cable
is not included with the 825-PR12D).
•A simplex 62.5/125 μm fiber-optic cable with ST connector for
connecting the external RTD scanner to the 825-P (e.g., part# 1570FCBL-
MM-SX-62-STST-2M from Ultra Spec Cable - http://store.ultraspec.us).
Applications The 825-P can be used with the following across the line starter applications:
•Low and medium voltage with 2 or 3 potential transformers
•With or without phase current transformers
•With or without zero-sequence core balance current transformer
•With or without external RTD module
•Reversing starter
•Star-delta starting
•Two -sp ee d mot ors
Figure 1 shows “across the line starting” AC connections for the case where
external current transformers are not required. Refer to Chapter2: Installation
for additional applications and the related connection diagrams.
Table 1 - Converter Module List
Description Cat. No.
0.5…2.5 A Converter Module 825-MCM2
1.0…5.0 A Converter Module 825-MCM5
2.5…20 A Converter Module 825-MCM20
20…180 A Converter Module 825-MCM180
160…630 A Converter Module 825-MCM630
160…630 A Converter Module 825-MCM630N

16 Rockwell Automation Publication 825-UM004D-EN-P - November 2012
Chapter 1 Introduction
Figure 1 - AC Connections Without CTs
825-P
825-MCM
L3L2L1
A1
13 5
642
A2
M
3 ~
Converter Module
Cat. No. 825-MCM2
Cat. No. 825-MCM5
Cat. No. 825-MCM20
Cat. No. 825-MCM180
Cat. No. 825-MCM420
Cat. No. 825-MCM630N

Rockwell Automation Publication 825-UM004D-EN-P - November 2012 17
Chapter 2
Installation
Relay Placement Proper placement of the 825-P Motor Relay helps make certain that you receive
years of trouble-free motor protection. Use the following guidelines for proper
physical installation of the 825-P.
Physical Location
You can mount the 825-P in a sheltered indoor environment (a building or an
enclosed cabinet) that does not exceed the temperature and humidity ratings
for the relay. The relay can be mounted indoors or in an outdoor (extended)
enclosure where the relay is protected against exposure to direct sunlight,
precipitation, and full wind pressure, but neither temperature nor humidity
are controlled.
Refer to Appendix:A Specifications for environmental ratings.
Relay Mounting
To flush mount the 825-P in a panel, cut a rectangular hole with the dimensions
shown in Figure 2.
Figure 2 - Relay Mounted In a Panel
20.8
(0.82)
147.4
(5.80)
Legend
mm
(in)
192.0
(7.56)
186.0
(7.32)
138.0
(5.43)
144.0
(5.67)
Mounting Panel–maximum thickness 6.5 mm
#8 x 1/2 inch mounting screw;
Torque specication = 0.9...1.3 N.m (8...12 Lb-in)
Gasket

18 Rockwell Automation Publication 825-UM004D-EN-P - November 2012
Chapter 2 Installation
Rear-Panel Connections Rear-Panel Diagram
The physical layout of the connectors on the rear-panel of a fully configured
825-P is shown in Figure 3.
Figure 3 - Rear-Panel Layout
Converter
Module
Input
Core Balance
Current Transformer
Factory
Configured
Ground
Screw
Voltage Input
Card Expansion I/O
Incoming
Power
Communication
Card Temperature
Input
Factory
Configured
Current
Input
MCM / CWE DEVICENET
RTD
MODULE
PTC
RX
CBCT
S1
S2
BK
BU
SH
WH
RD
L1
L2
L3
N
157-0138
33
34
43
44
53
54
63
64
A1+
A2-
13
14
23
24
!
!
BUS
STATUS
NETWORK
STATUS
0.31 in
8.0 mm
WIRE STRIP GUIDE
T1
T2 95
98
96
95
96
98
NON- FAIL-SAFE
FAIL-SAFE
Y12
Y1-
Y14
190-3011-01
157-0136
PGM
MSD
MAC ID
LSD
DATA
RATE
0 = 125K
1 = 250K
2 = 500K
AUTO
BAUD
8 2
6 4
8 2
6 4
8 2
6 4
I+
I-
Y22
Y24
Y26
Y2-
A
B
C
D
E
Z
A
B
C
D
E
Z
!

Rockwell Automation Publication 825-UM004D-EN-P - November 2012 19
Installation Chapter 2
Top-Panel Diagram
The input and output designations for the rear-panel connectors of a fully
configured 825-P are shown in Figure 4. This diagram is located on the top panel
of the relay.
Figure 4 - Top-Panel Input and Output Designations
Power Connections
The power terminals on the rear panel (A1+ and A2-) must connect to
110…240V AC or 110…250V DC for the 825-PD and 24…48V DC for the 825-
PZ. For complete power input specifications, see Appendix:A Specifications.
The power terminals are isolated from the chassis ground. Use 16 AWG
(1.5 mm2) size or heavier wire to connect to the POWER terminals. Connection
to external power must comply with IEC 947-1 and IEC 947-3. Place an external
switch, circuit breaker, or overcurrent device in the power leads for the 825-P;
this device must interrupt both the positive (A1+)and neutral (A2-) power leads.
The maximum current rating for the power disconnect circuit breaker or
overcurrent device (fuse) must be 20 A. Be sure to locate this device within 3.0 m
(9.8 ft.) of the relay.
Operational power is internally fused by power supply fuse. See Field
Serviceability on page31 for details. Be sure to use fuses that comply with
IEC 127-2.
‡ See documentation for input voltage rating.

20 Rockwell Automation Publication 825-UM004D-EN-P - November 2012
Chapter 2 Installation
I/O Diagram
A more functional representation of the control (I/O) connections are shown
in Figure 5.
Figure 5 - Control I/O Connections in Powered-Down State
➊See Table 44 for control function assignment to the input IN1 and IN2. Connect the appropriate external contacts (#1 and #2) to the
inputs.
➋Inputs IN3, IN4, and IN5 are available when an optional I/O extension card is present. 825-PIOD inputs are rated 120V AC/DC. 825-PIOR
inputs are rated 24V AC/DC.
➌ See Table 42 for mapping protection elements to the Trip output. See Figure 7 and Figure 16 for typical control circuit connections.
➍ See Table 43 for mapping protection and/or control elements to the Aux outputs. Outputs Aux3 through Aux6 are available when an
optional I/O extension card is present.
➎ Analog Output is available when an optional I/O extension card is present.
➏You can connect up to six thermistors (PTC) in series. See Table 2 for PTC cable requirements.
➐ Use up to 500 meter long Simplex 62.5/125 mm fiber-optic cable (ST/ST).
➑Available when an optional DeviceNet Communications Protocol Card is present.
24V AC/+V DC24 or 120V AC/+V DC
24V AC/–V DC24 or 120V AC/–V DC
95
98 96
Trip
13
14
Aux1
Alarm
23
24
Aux2
33
34
Aux3
43
44
Aux4
53
Aux5
63
Aux6
RX
F/O Cable
to RTD Scanner
PS
A1
A2
110…240V AC, 24…48V DC
or 110…250 V DC
+ / H
– / N
825-P Relay
A
I +
Analog Out
T1 T2
PTC
I –
DeviceNet Cable
BK
V –
BU
CAN_L
SH
Drain
WH
CAN_H
RD
V +
Y1–
IN5
#1
IN4
#2
Y2–
IN3
#3
IN2
#4
IN1
Y26 Y24 Y22 Y14 Y12
#5
54 64
1
2
4
3
5
6
7
8