Rockwell Automation Allen-Bradley 825-P User manual

Quick Start Guide
Bulletin 825-P Modular Protection System

Quick Start Guide —Allen-Bradley Bulletin 825-P Modular Protection System
2
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.
:
IMPORTANT This guide Does Not replace the User Manual, publication
825-UM004_-EN-P, and is intended for qualified service
personnel responsible for setting up and servicing these
devices. You must have previous experience with and a
basic understanding of electrical terminology, configuration
procedures, required equipment, and safety precautions.
ATTENTION
!
Identifies information about practices or circumstances
that can lead to personal injury or death, property damage
or economic loss.

Quick Start Guide —Allen-Bradley Bulletin 825-P Modular Protection System
33
Attention statements help you to:
• Identify a hazard
•Avoidahazard
• Recognize the consequences
Trademark List
DeviceNet and the DeviceNet logo are trademarks of the Open Device Vendors
Association (ODVA).
Microsoft Windows is a registered trademark of the Microsoft Corporation.
European
Communities (EC)
Directive Compliance
The 825-P Modular Protection System is CE marked for installation within the
European Union and EEA regions. It has been designed and tested to meet the
following directives.
EMC Directive
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.
IMPORTANT Identifies information that is critical for successful
application and understanding of the product.
TIP This product has been designed for environment A (heavy
industrial). Use of this product in environment B (light
industrial or domestic) can cause unwanted electromagnetic
disturbances in which case the user could be required to
take adequate mitigation measures.

Quick Start Guide —Allen-Bradley Bulletin 825-P Modular Protection System
4
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.
To obtain a copy of the 825-P’s Declaration of Conformity (DoC), contact your local
Allen-Bradley distributor or go to http://www.ab.com.certification/#CEmark.
Introduction
Follow these steps to successfully commission the 825-P Modular Protection System.
Table A: Commissioning Procedure
Step Description
1 General Precautions
2 Hardware Installation
3 Wiring Installation
4 Front Panel Operation
5 System Configuration
6 Port 4 Settings
7 Programming General Parameters
8 Programming Operational Parameters
9 Programming Protection Functions
10 Output Relay and Input Assignments

Quick Start Guide —Allen-Bradley Bulletin 825-P Modular Protection System
55
General
Precautions
Hardware
Installation
Relay Mounting
Figure 1 Mounting and Dimensions
ATTENTION
!
Have only qualified personnel service this equipment. If
you are not qualified to service this equipment, you can
injure yourself or others, or cause equipment damage.
ATTENTION
!
Equipment components are sensitive to electrostatic
discharge (ESD). Undetectable permanent damage can
result if you do not use proper ESD procedures. Ground
yourself, your work surface, and this equipment before
removing any cover from this equipment.
ATTENTION
!
Disconnect or de-energize all external connections before
opening this device. Contact with hazardous voltages and
currents inside this device can cause electrical shock
resulting in injury or death.
ATTENTION
!
To install an option card the relay must be de-energized and
then reenergized. When reenergized, the relay will reboot.
Therefore, de-energize the protected motor before
installing the option card to prevent damage to the motor.
IMPORTANT For complaince to IEC standards regarding thermal
overload protection, set the SERVICE FACTOR to a
value: 1.05…1.20.
IMPORTANT For a properly configured device, the settings in the Main
Settings and Overload Settings groups should be adjusted
according to the motor and system requirements. Settings
in other groups can be programmed as desired.

Quick Start Guide —Allen-Bradley Bulletin 825-P Modular Protection System
6
Option Cards
Figure 2 Inserting Option Cards
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)
➂
➀Mounting Panel–maximum thickness 6.5 mm
➁#8 x 1/2 inch mounting screw;
Torque specification = 0.9...1.3 N.m (8...12 Lb-in)
➂Gasket
➀
➁

Quick Start Guide —Allen-Bradley Bulletin 825-P Modular Protection System
77
Converter Modules and Optional Core Balance CT, RTD Scanner
Figure 3 Converter Module, CBCT, and RTD Scanner Connections
1. The 825-P relay is not EMC-Tested for converter module connecting cable
lengths greater than the 4-meter cable that is supplied.
2. Up to 12 RTDs can be monitored when an external 825-PR12D RTD Scanner
is used. There are separate trip and warning settings for each RTD.
3. A simplex 62.5/125 um fiber-optic cable with ST connector is needed for
connecting the external RTD module to the 825-P. (Fiber optic cable is not
supplied. Contact your local Allen-Bradley distributor.)
IMPORTANT Settings associated with options or accessories (converter
module, voltage input card, expansion I/O card, RTD
scanner) require their installation or connection prior to
being made available for configuration.

Quick Start Guide —Allen-Bradley Bulletin 825-P Modular Protection System
8
Wiring
Installation
Main Circuit
Figure 4 Relay with Phase CTs and CoreBalance CT
Figure 5 Relay without Phase CTs
K1
825-P825-MCM
L3L2L1
A1
13 5
642
A2
M
3 ~
Converter Module
Cat. No. 825-MCM2
Cat. No. 825-MCM20
Cat. No. 825-MCM180
Cat. No. 825-MCM630
Cat. No. 825-MCM630N

Quick Start Guide —Allen-Bradley Bulletin 825-P Modular Protection System
99
Figure 6 Voltage Connections (Optional Card Cat. No. 825-PVS required)
Figure 7 Input/Output
Slots C, D and E are for option cards. Rated supply voltage is 110...240V AC or 110...250V DC
IMPORTANT Be sure to properly label and connect the Trip relay
terminals according to the programmed behavior; factory
default setting is “Fail-Safe”.

Quick Start Guide —Allen-Bradley Bulletin 825-P Modular Protection System
10
Front Panel
Operation
Figure 8 Relay Front Panel
The following table provides a description for each programming key’s function.
Table B: Front Panel Programming Key Description

Quick Start Guide —Allen-Bradley Bulletin 825-P Modular Protection System
1111
Saving Settings
It is important to note that programmed values become operational only after they
have been saved to memory. The programming system will prompt to save settings
when the user navigates higher up in the programming menu by pressing the ESCape
key. The front panel display is as follows:
Save Changes?
Yes No
To save changes, place the cursor at “Yes” and press the Enter key.
System
Configuration
The 825-P displays “STATUS FAILURE” on initial start-up and after a hardware
configuration change. The second line of the display identifies the cause of failure; if
more than one configuration change is found, the highest priority error is identified.
To remove the failure, the new system hardware configuration must be manually
accepted. Use the following procedure with the front panel programming keys:
1. Select “Status” from the MAIN menu and press the Enter key. The front
panel displays the following:
Confirm Hardware
Config (Enter)
2. Press the Enter key. The front panel displays the following:
Accept Config?
Yes No
3. Position the cursor at “Yes” and press the Enter key. The 825-P
programming system checks parameter settings to ensure that no
interdependency setting errors exist. If none exist, the front panel displays the
following:
Config Accepted
Enter to Restart

Quick Start Guide —Allen-Bradley Bulletin 825-P Modular Protection System
12
4. Press the Enter key. The 825-P reboots and the “Enable” LED
illuminates with the following displayed on the front panel.
825-P MODULAR
PROT SYSTEM
If the LCD display COMMFLT WARNING, configuration of the Port 4 is
required. See next section.
IMPORTANT If the system check finds interdependency setting errors,
the front panel display:
Settings Mismatch
An example of mismatched settings is the correlation
between the Motor FLA and Phase CT Ratio settings.
Review setting values to determine where the mismatch
exists or, if little or no programming has been performed
yet, reset the 825-P relay to factory default values using the
following path:
MAIN > Reboot/Restore > Restore Defaults
The front panel then displays:
Restore Default?
No Yes
Position the cursor at “Yes” and press the Enter key.
The 825-P relay will reboot at this point.
Return to the first step of the System Configuration
process.

Quick Start Guide —Allen-Bradley Bulletin 825-P Modular Protection System
1313
Port 4 Settings
The Port 4 settings configure slot C for communications. Factory default settings are
for DeviceNet communications. Use the following path with the front panel
programming keys to access the Port 4 settings:
MAIN > Set/Show > Port > Port 4
The following table provides direction for the proper settings associated with each
communication option.
❶ A 232 setting is possible, although not typical.
Table C: Communication Settings
Setting Prompt Setting Range DeviceNet Modbus Empty
COMM INTERFACE ❶232, 485 232 485 232
PROTOCOL ASC, MOD MOD MOD MOD
SPEED 300 … 38,400 bps 19,200 19,200 19,200
PARITY O, E, N N N N
MODBUS SLAVE ID 1 … 248 248 1 to 247 1
IMPORTANT The 825-P displays “COMMFLT Warning” on initial
power-up with factory default settings when the hardware
installed in Slot C is as follows:
- Empty
- Modbus
- DeviceNet, but not powered

Quick Start Guide —Allen-Bradley Bulletin 825-P Modular Protection System
14
Programming
General
Parameters
Use the following path with the front panel programming keys to access the general
parameter settings:
MAIN > Set/Show > Port
MAIN > Set/Show > Date/Time
MAIN > Set/Show > Password
Port: In addition to configuring Slot C (Port 4) for communications as described in
Step 4, settings are available for configuring the Port F (front panel) RS 232
communications. Port F is available for computer connection.
Date/Time: Program the date (day, month, year) and time (hour, minutes, seconds)
with the settings available here.
Password: The 825-P provides the ability to set password protection to limit access
to the programmable settings from the front panel. Password protection is disabled
from the factory.
See Appendix A for more details.

Quick Start Guide —Allen-Bradley Bulletin 825-P Modular Protection System
1515
Programming
Operational
Parameters
Use the following path with the front panel programming keys to access the
operational parameter settings:
MAIN > Set/Show > Relay > [Group]
See Appendix A for more details
Table D: Operational Parameters
Group Description
Main Settings Basic system settings related to three-phase power source (e.g. line voltage
rating and frequency), motor rated current, and transformer (current and
voltage) data.
I/O Settings Settings related to configuration of the optional analog output.
Trip Inhibit Settings to configure the blocking of tripping functions. These settings
coordinate with assignment of a discrete input for “Block Protection”.
Relay Behavior Settings for configuring the output relays.
Timer Settings On-delay and off-delay timer settings for enhanced control capability of the
auxiliary output relays.
Front Panel Settings Settings for controlling the front panel LCD operation.
Display Settings Settings to select data that is displayed in the rotating status

Quick Start Guide —Allen-Bradley Bulletin 825-P Modular Protection System
16
Programming
Protection
Parameters
Use the following path with the front panel programming keys to access the
protection parameter settings:
MAIN > Set/Show > Relay > [Group]
See Appendix A for more details.
Output Relay and
Input Assignments
After the operational and protection parameter values are set, the next step is to
assign these functions to the relays.
Table E: Protection Parameters
Group Description
Overload Settings Thermal overload
Short Ckt Settings Short circuit
GF-CB Settings Ground/earth fault (core balance method)
GF-Res Settings Ground/earth fault (residual method)
Jam Settings Mechanical jam (overcurrent)
Undercurrent Settings Current-based underload detection
Current Imb Settings Current imbalance (asymmetry)
Prot. Disable Settings to disable protection elements during motor starting for a
user-specified time period
Start Monitoring Stall protection on motor start (current-time based)
Star-Delta Settings Settings for star-delta control
Start Inhibt Set Settings for starts/hour and antibackspin
Phase Rev Settings Phase reversal (sequence)
Speed Sw Set Stall protection on motor start (speed switch input monitoring)
PTC Settings Thermistor monitoring
RTD Settings RTD settings for use with optional RTD Scanner
Undervoltage Settings Voltage monitoring with optional voltage input card
Overvoltage Settings Voltage monitoring with optional voltage input card
VAR Settings Reactive power
Underpower Settings Power-based underload detection
Power Factor Settings Displacement power factor monitoring
Freq Settings Line frequency monitoring
Load Control Settings Settings for relay control based on motor loading

Quick Start Guide —Allen-Bradley Bulletin 825-P Modular Protection System
1717
To assign functions to the output relays and inputs, use the following path:
MAIN > Set/Show > IO Assign
ATTENTION
!
Protection elements have no effect until they are assigned
to the Trip relay or an auxiliary relay.
TIP The relay outputs will function as a N.C. contacts when the
relay behavior setting is Fail-Safe (Y), and will function as a
N.O. contacts when the relay behavior setting is Non-Fail-
Safe (N).

Quick Start Guide —Allen-Bradley Bulletin 825-P Modular Protection System
18
Trip Relay Assign
The 825-P allows mapping of only protection trip elements to the Trip output relay.
Settings are presented as bit-enumerated strings. The second line of the display
identifies a given bit’s associated function. To assign a function to the Trip relay,
simply program a value “1” in the bit location for each element you desire to assign
using the TRIP A through TRIP D settings. The front panel display appears as
follows:
TRIPA=10110000
OVERLOAD
Table F: Trip Relay Settings
Bit
01234567
TRIP A Overload Undercurrent Jam Current
Imbalance
Short Circuit RTD - W/B PTC Ground Fault
(Res)
TRIP B VAR Underpower Under-
voltage
Over-voltage Phase
Reversal
Power Factor Speed
Switch
Ground Fault
(CB)
TRIP C Start Time Freq 1 Freq 2 RTD (Other) RTD
(Ambient)
PTC Error RTD Error MCM Error
TRIP D Comm Idle Comm Loss Remote Trip Comm Fault Reserved Reserved Reserved Reserved
TIP Make sure the Trip relay terminals (95, 96 and 98) are
labeled to correspond with the relay behavior setting
(Fail-Safe or Non-Fail-Safe).

Quick Start Guide —Allen-Bradley Bulletin 825-P Modular Protection System
1919
AUX# Assign
The 825-P allows mapping of protection (trip and warning) and general-purpose
control elements to the auxiliary outputs. Assign functions to the auxiliary relays in
the same manner as performed with the Trip relay settings.
Table G: Auxiliary Relay Functions
Bit
01 234567
AUX# A Overload Undercurrent Jam Current
Imbalance
Short Circuit RTD - W/B PTC Ground Fault
(Res)
AUX# B VAR Underpower Under-voltage Over-voltage Phase
Reversal
Power Factor Speed
Switch
Ground Fault
(CB)
AUX# C Start Time Freq 1 Freq 2 RTD (Other) RTD
(Ambient)
PTC Error RTD Error MCM Error
AUX# D Comm Idle Comm Loss Remote Trip Comm Fault Reserved Reserved Reserved Reserved
AUX# E Overload
Warn
Undercurrent
Warn
Jam Warn Curr Imbal
Warn
RTD-W/B
Warn
Pwr Factr Warn Gnd Flt-CB
Warn
Gnd Flt-Res
Warn
AUX# F VAR Warn Underpwr Warn Undervolt Warn Overvolt Warn Speed Sw
Warn
Freq 1 Warn Freq 2 Warn RTD-Othr
Warn
AUX# G RTD-Amb
Warn
Setting Warn General Warn Load Ctl Upper Load Ctl
Lower
Timer 1 Timer 2 Short Ckt
Warn
AUX# H Stopped State Running State Starting State Star Starting
State
Delta
Starting
State
Start Command Network
Control
Reserved
TIP The AUX# A through AUX# D bytes are used to map trip
functions to the output. The AUX# E through AUX# H
bytes are used to map warning and status functions to the
output.

Quick Start Guide —Allen-Bradley Bulletin 825-P Modular Protection System
20
IN# Assign
The 825-P provides the ability to assign a control function to each discreet input.
Table H shows the available control functions and the method of assigning them.
Analog Output
The expansion I/O option provides an isolated 4…20mA DC analog current output
with a variety of output parameters. Use the Analog Output Select setting to select a
parameter from the list of available options. Table I shows description and scaling of
the output for different parameters selections.
Table I:
Table H: Input Function Assignment
IN#
0Emergency Start
1Disable Settings
2Trip Reset
3Timer 1
4Timer 2
5Speed Switch
6Block Protection
7Speed 2
0Breaker/Contactor Auxiliary
1Remote Trip
TIP The 825-P allows only one selection per input assignment.
Once a selection is assigned, it is not available to other
inputs.