Modular Protection System Conversion Kit - Rockwell...

Modular Protection System Conversion Kit

INSTALLATION MANUAL

GE Multilin to Bulletin 825 Plus

Important User Information

Read this document and the documents listed in the Additional Resources section about installation, configuration, and operation of this equipment before you install, configure, operate, or maintain this product. Users are required to familiarize themselves with installation and wiring instructions in addition to requirements of all applicable codes, laws, and standards.

Activities including installation, adjustments, putting into service, use, assembly, disassembly, and maintenance are required to be carried out by suitably trained personnel in accordance with applicable code of practice.

If this equipment is used in a manner not specified by the manufacturer, the protection provided by the equipment may be impaired.

In no event will Rockwell Automation, Inc. be responsible or liable for indirect or consequential damages resulting from the use or application of this equipment.

The examples and diagrams in this manual are included solely for illustrative purposes. Because of the many variables and requirements associated with any particular installation, Rockwell Automation, Inc. cannot assume responsibility or liability for actual use based on the examples and diagrams.

No patent liability is assumed by Rockwell Automation, Inc. with respect to use of information, circuits, equipment, or software described in this manual.

Reproduction of the contents of this manual, in whole or in part, without written permission of Rockwell Automation, Inc., is prohibited.

Throughout this manual, when necessary, we use notes to make you aware of safety considerations.

Labels may also be on or inside the equipment to provide specific precautions.

Allen-Bradley, Rockwell Software, Rockwell Automation, and TechConnect are trademarks of Rockwell Automation, Inc.

Trademarks not belonging to Rockwell Automation are property of their respective companies.

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.

IMPORTANT Identifies information that is critical for successful application and understanding of the product.

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.

ARC FLASH HAZARD: Labels may be on or inside the equipment, for example, a motor control center, to alert people to potential Arc Flash. Arc Flash will cause severe injury or death. Wear proper Personal Protective Equipment (PPE). Follow ALL Regulatory requirements for safe work practices and for Personal Protective Equipment (PPE).

1500-IN059C-EN-E – June 2013

Table Of Contents

Introduction Chapter 1 Page No.

Overview .................................................................................................... 1-1Kit Highlights and Limitations ................................................................... 1-2Personnel Safety ......................................................................................... 1-2

Equipment Description Chapter 2

Overview .................................................................................................... 2-1Operational Requirements .......................................................................... 2-1Ordering Information ................................................................................. 2-3

Conversion Kit Numbers (GE Multilin 169/269/269 Plus) ................. 2.3Conversion Kit Numbers (GE Multilin 369) ....................................... 2-5

Unpacking and Storage Chapter 3

Overview .................................................................................................... 3-1Unpacking Your Kit ................................................................................... 3-1Storage ........................................................................................................ 3-1

Installation Chapter 4

Overview ................................................................................................... 4-1Pre-Installation ........................................................................................... 4-1Removing Low Voltage Door Components ............................................... 4-2Removing Low Voltage Door .................................................................... 4-3Preparing Low Voltage Door for 825 Plus ................................................. 4-4825 Plus Installation ................................................................................... 4-5Re-Installing the Low Voltage Door .......................................................... 4-7Reconnecting Existing Control Circuit ...................................................... 4-8Post-Installation (Testing) ........................................................................ 4-10

Appendix A GE Multilin to Bulletin 825 Plus Conversion Kit

Wire Number Table (GE Multilin 169/269/269 Plus) .............................. A-1Wire Number Table (GE Multilin 369) .................................................... A-2Wire Number Table (MPM/MTM) ........................................................... A-3

Appendix B Technical Data

Conversion Kit Interface Panel ................................................................. B-1Converter Module ..................................................................................... B-1

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ii Table of Contents – Modular Protection System Conversion Kit • Installation Manual

Appendix C 825 Plus RTD Scanner • Installation Guide Page No.

Introduction ............................................................................................... C-1Installation Instructions ............................................................................. C-2Wire Number Cross-Reference Table ....................................................... C-3

Appendix D Bul. 825 Plus Kit • Component Configuration

Bulletin 825 Plus Kit Component Configuration (GE 169/269/269 Plus) ..... D-1Bulletin 825 Plus Kit Component Configuration (GE 369) ....................... D-2

Chapter 1

1500-IN059B-EN-E – June 2013

Introduction

Overview This manual describes the installation of the Bulletin 825 Plus Conversion Kitwithin a typical medium voltage (MV) controller. Simple troubleshooting isalso included.

Although this manual outlines the implementation within a medium voltagecontroller, the basic philosophy also applies for installation within a lowvoltage controller. To use this manual effectively, you must be familiar withelectrical procedures and terminology.

For setup, programming, and operation information on theBulletin 825-Plus Modular Protection System for motors,refer to Publication 825-UM004_-EN-P.

Rockwell Automation reserves the right to adapt theproducts described in this manual at any time to suit thelatest technical developments. Accordingly, attachedinformation is not an object of the contract and thus maychange without notification.

Prerequisite for proper operation is correct transport, proper and competentstorage and installation as well as careful operation and maintenance.

1. The power supply must be switched off prior to any intervention in theelectrical or mechanical part of the equipment.

2. In accordance with the applicable rules, work on electrical equipment ormeans of production may only be carried out by competent electricians orsuitably trained persons guided and supervised by a competent electrician.

3. The electrical equipment of a machine / plant must be inspected / tested.Deficiencies such as loose connections or scorched cables must beeliminated immediately.

4. The described control and protection system, 825 Plus provides startingand stopping functions for a motor.

In case of electrical or mecanical faults, the machine must beswitched off and protected immediately. The elimination ofdisturbances must be organized without delay. Failure to doso may result in personal injury and/or damage to theequipment.

A T T E N T I O NA T T E N T I O N

I M P O R T A N TI M P O R T A N T


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1-2 Introduction

The elimination of a disturbance may cause the motor to startrunning again by itself. This may endanger persons ordamage equipment. The user must take the necessary safetymeasures to protect against this type of occurrence so thatany danger is avoided.

Kit Highlights and Limitations The GE Multilin to Bulletin 825 Plus Conversion Kit provides equivalentfeatures and functionality of the GE Multilin 169/269/269 Plus and 369.However, the Conversion Kit also provides additional features and functionsnot provided/supported by these GE Multilin relays.

The Bulletin 825 Plus Conversion Kit provides:• easy installation• modular design• no additional wiring• uses existing low voltage door and panels• various communication methods:

– DeviceNet TM – Modbus TM

Option card required.

Personnel Safety Protection of personnel in the vicinity of control equipment is of primaryimportance. The corresponding requirements of regulatory agencies aretherefore becoming increasingly severe. The Bulletin 825 Plus reflects this byproviding the following protection:

• Equipment construction: – Touch protection– Insulated housing

• Motor protective functions: – Earth (ground) fault– High overload, stalling and jam– Phase reversal

Overview (cont.)A T T E N T I O NA T T E N T I O N

Chapter 2

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Equipment Description

Overview This chapter describes the features of the GE Multilin to Bulletin 825 PlusConversion Kit.

Operational Requirements Monitoring application parameters and process data of an installation is veryimportant. Even a slight change in the starting and operating behavior of themotor can indicate an impeding fault. The Bulletin 825 Plus helps eliminatethe potential trouble before major repairs are necessary and loss of productionoccurs.

The Bulletin 825 Plus fulfills these requirements by providing the followingprotective functions:• High overload, stalling• Underloading• Wrong direction of rotation

However, the Bulletin 825 Plus functionality does not directly correspond to theGE Multilin relays. Below is a summary of some of the features offered by theBulletin 825 Plus.

GE Multilin Function Description

169/269/269 Plus 369 Bul. 825 Plus Parameters

Current Transformer (Primary) 20A – 1500A 1A – 5000A 0.5 A – 5000 A Full Load Current (FLC) 10A – 1000A 1A – 5000A 0.5 A – 5000 A Thermal Overload Protection Yes Yes Yes Overcurrent Protection Yes Yes Yes Allowable Acceleration Time 0.5 – 125 s 1 – 250 s 1s – 240s

Allowable RTD types 10 Ω Cu, 100 Ω Ni, 120 Ω Ni, 100 Ω PI

10 Ω Cu, 100 Ω Ni, 120 Ω Ni, 100 Ω PI

10 Ω Cu, 100 Ω Ni, 120 Ω Ni, 100 Ω PI

Number of WindingRTDs 1 – 6 1 – 6 w/RTD option 1 – 12 Number of Bearing RTDs 1 – 2 1 – 4 w/RTD option 1 – 12 Allowable Number of Starts 1 – 5 (starts per hour) 1 – 5 (starts per hour) 1 – 15 (starts per hour) Phase Unbalance Trip Current 4 – 30 (percent of FLC) 4 – 30 (percent of FLC) 5 – 80 (percent of FLC) Phase Unbalance Alarm Current 4 – 30 (percent of FLC) 4 – 30 (percent of FLC) 5 – 80 (percent of FLC) Phase Reversal Protection Yes (w/metering option) Yes (w/metering option) Yes

Total of twelve (12) inputs for winding, bearing or other RTD.

2-2 Equipment Description

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Operational Requirements(cont.)

GE Multilin Function Description

169/269/269 Plus 369 Bul. 825 Plus Parameters

Jam Protection Yes Yes Yes Undervoltage Protection Yes (w/metering option) Yes (w/metering option) Yes Ground Fault Alarm Current 1 – 10 A 0.25 – 25 A 0.01 – 25 A Ground Fault Trip Current 1 – 10 A 0.25 – 25 A 0.01 – 25 A Ground Fault Trip Delay Time 1 – 255 s 0 – 255 s 0 s – 5 s Short Circuit Protection Yes Yes Yes Jam Circuit Current 1.5 – 6 (multiple of FLC) 1 – 6 (multiple of FLC) 1 – 6 (multiple of FLC) Underload Trip Current 1 – 1000 A 10 – 99 (percent of FLC) 10 – 100 (percent of FLC) Underload Trip Time Delay 1 – 255 s 1 – 255 s 1 – 120 s Ultimate Trip Current 4 – 12 (multiple of FLC) 2 – 20 (multiple of FLC) 4 – 12 (multiple of FLC) Winding Alarm Temperature 0 – 200°C 1 – 200°C 0°C – 200°C Winding Trip Temperature 0 – 200°C 1 – 200°C 0°C – 200°C Bearing Alarm Temperature 0 – 200°C 1 – 200°C 0°C – 200°C Bearing Trip Temperature 0 – 200°C 1 – 200°C 0°C – 200°C Ambient Temperature Sensor Input No Yes Yes Reset Condition Auto / Manual Auto / Manual Auto / Manual

Speed Switch Input 169/269 – No 269 Plus – Yes Yes Yes

Analog Output Yes Yes Yes Communication Modbus Modbus DeviceNet, Modbus Trip Contacts 1 form C 1 form C 1 form C Alarm Contacts 1 form C 1 form C 1 form A or B

The 825 Plus core balance/ground fault current transformer (GFCT) input has an operating range of 5 to 500 mA. Care is required to ensure this input range is not exceeded. When existing CT has a ratio of 50:0.025 (2000:1), the minimum trip level is 10A primary. For lower trip levels, the core balance/GFCT will need to be replaced with a 100:1 ratio CT. Refer to the catalog number breakdown for part numbers of various donut CT window sizes.

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Equipment Description 2-3

Ordering Information

Conversion Kit NumbersFor GE Multilin 169/269/269 Plus to Bulletin 825 Plus

Description Electrical Drawing Numbers Catalog Number

Standard Conversion Kit 80113-650-93 825PK2–BDXXXC

Standard Kit with DeviceNet 80113-650-94 825PK2–BDXDXC

Standard Kit with Modbus 80113-650-95 825PK2– BDXMXC

Standard Kit with RTDs 80113-650-96 825PK2– BDXXPC

Standard Kit with RTDs and DeviceNet 80113-650-97 825PK2– BDXDPC

Standard Kit with RTDs and Modbus 80113-650-98 825PK2– BDXMPC

Standard Conversion Kit with metering 80113-650-99 825PK2– BDVXXC

Standard Kit with DeviceNet and metering 80113-651-01 825PK2– BDVDXC

Standard Kit with Modbus and metering 80113-651-02 825PK2– BDVMXC

Standard Kit with RTDs and metering 80113-651-03 825PK2– BDVXPC

Standard Kit with RTD and DeviceNet and metering 80113-651-04 825PK2– BDVDPC

Standard Kit with RTD and Modbus and metering 80113-651-05 825PK2– BDVMPC

NOTE:• When ordering a conversion kit with the RTD option, refer to the 825 Plus RTD Scanner

Installation Guide (Appendix C) for additional information.• When ordering a conversion kit with the metering option, used to replace GE Multilin MTM/

MPM metering option, refer to Appendix A for additional information.


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Ordering Information (cont.)

Catalog Number BreakdownFor GE Multilin 169/269/369 Plus to Bulletin 825 Plus

Part Part Description Part Number Mounting Bezel (ANSI 49) 80158-905-04

Mounting Bezel (ANSI 61) 80158-905-05

Base 825 Plus Relay 825-PD Standard Conversion Kit

825 Plus I/O Card 825-PIOD

with DeviceNet 825 Plus DeviceNet Card 825-PDN

with Modbus 825 Plus Modbus RTU Card 825-PMB

825 Plus RTD Scanner 825-PR12D with RTDs

Fiber Optic Cable, 2 meters 80026-385-02

with Metering 825 Plus Voltage Card 825-PVS

3.25-inch Window 80022-030-03 Core Balance/GFCT (100:1) 5.5-inch Window 80022-030-04

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Equipment Description 2-5

Conversion Kit NumbersFor GE Multilin 369 to Bulletin 825 Plus

Description Electrical Drawing Numbers Catalog Number

Standard Conversion Kit 80113-650-87 825PK3–BDVXXC

Standard Kit with DeviceNet 80113-650-88 825PK3– BDVDXC

Standard Kit with Modbus 80113-650-89 825PK3– BDVMXC

Standard Kit with RTDs 80113-650-90 825PK3– BDVXPC

Standard Kit with RTDs and DeviceNet 80113-650-91 825PK3– BDVDPC

Standard Kit with RTDs and Modbus 80113-650-92 825PK3– BDVMPC

NOTE:• When ordering a conversion kit with the RTD option, refer to the 825 Plus RTD Scanner

Installation Guide (Appendix C) for additional information.


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Ordering Information (cont.)

Catalog Number breakdownFor GE Multilin 369 to Bulletin 825 Plus

Part Part Description Part Number Mounting Bezel (ANSI 49) 80158-906-03

Mounting Bezel (ANSI 61) 80158-906-04

Base 825 Plus Relay 825-PD

825 Plus I/O Card 825-PIOD

Standard Conversion Kit

825 Plus Voltage Card 825-PVS

with DeviceNet 825 Plus DeviceNet Card 825-PDN

with Modbus 825 Plus Modbus RTU Card 825-PMB

825 Plus RTD Scanner 825-PR12D with RTDs

Fiber Optic Cable, 2 m 80026-385-02

3.25-inch Window 80022-030-03 Core balance/GFCT (100:1) 5.5-inch Window 80022-030-04

Chapter 3

1500-IN059C-EN-E – June 2013

Unpacking and Storage

Overview This chapter describes the procedures for unpacking, inspecting, and storingthe GE Multilin to Bulletin 825 Plus Conversion Kit.

Unpacking Your Kit As you unpack the conversion kit, follow the steps listed below:

1. Handle each component carefully to avoid damage.

2. Unpack the box(es) enough to inspect the shipment for missing or damagedequipment.

3. In the event that a component is missing, damaged, or shows evidence ofrough handling, THE BUYER SHALL NOTE SUCH ON THECARRIER’S DELIVERY RECEIPT and immediately notify the carrier.

Save all packaging material for the insurance companyinspection.

4. If the above conditions are not complied with, any right to recovery formissing or damaged components as described above may be forfeited.

5. Make sure that the components received are correct based on what wasordered.

Storage If the Conversion Kit will be stored for any length of time, the followingprecautions should be taken:

1. The ambient temperature must be between -40oC to +60oC (-40°F to 140°F).

2. If the storage area is damp and/or cool, it is important to dry theConversion Kit out in a warm, dry environment before using. Also, cleanall terminals to help provide integrity of the electrical connections.

3. Cover the Conversion Kit with a heavy plastic or similar material to helpprevent the accumulation of dirt on the equipment.

For storage in harsh or caustic environments, consult aRockwell Automation representative.



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3-2 Unpacking and Storage

Installation

Overview This chapter describes the procedures for the installation of the GE Multilin to Bulletin 825 Plus Conversion Kit within a medium voltage controller.

Installation within other controller types can also be accomplished by following the principal philosophy of the retrofit described.

This manual is intended for use by personnel trained and familiar with medium voltage, solid-state power equipment, and general industrial controls.

Pre-Installation To avoid shock hazards, lock out incoming power before working on the equipment. Verify with a hot stick or appro-priate voltage measuring device that all circuits are voltage free. Failure to do so may result in severe burns, injury or death.

The National Electrical Code (NEC) and/or Canadian Elec-

trical Code (CEC) or other local codes outline provisions for safely installing electrical equipment Failure to follow locally applicable codes can result in hazards to personnel or a non-compliant installation.

Tools required: • Sheet metal cutting tools capable of cutting up to 12 gauge material • Hand drill, and drill bits • Screw drivers / Nut drivers • Drop sheets or tarp • Socket wrench with 3/8 socket • Marking device • Needle nose pliers • Wire cutters

Chapter 4

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Figure4.1–ToolsRequired

ATTENTIONATTENTION

IMPORTANT

ATTENTION

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4- Installation

Disconnect and lockout all sources of power entering the low voltage compartment where the GE Multilin relay is located. This may include opening the main disconnect of isolation switch. Failure to disconnect and lock out power can result in personal injury and/or damage to the equipment.

1. Disconnect the control wires connected to the GE Multilin relay. Using the wire number table in Appendix A, mark each wire with the corresponding GE Multilin relay terminal block number for reference later in the proce-dure.

2. Remove mounting hardware.

3. Remove the GE Multilin relay from the low voltage door. Save all the mounting hardware.

Figure4.–TypicalExistingLVdoorlayoutwith69PlusRelay

RemovingLowVoltageDoorComponents

ATTENTION

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Installation 4-

RemovingLowVoltageDoor

It is recommended to remove the low voltage doors to facilitate cutting the mounting hole for 825 Plus. The hole can be cut without removing the door if proper tools are used and blankets, drop sheets or tarps are used to prevent drill and saw chips from entering the controller.

Failure to check for clearance can result in damage to equip-ment and/or personal injury.

1. Remove all door-mounted devices. Note wire numbers and locations. It is recommended to create a sketch of the component layout and associ-ated wiring locations. (Figures 4.3)

2. Use nut driver to remove nut on grounding stud. This will facilitate removal of all wiring from the door.

3. Cut all remaining wire ties connecting wiring to the LV door.

4. Remove the low voltage door hinge pins. Caution must be taken when removing the door. It is recommended that two people remove the door – one person to hold the door and a second person to remove the hinge pins. (Figure 4.4)

Ensure sufficient personnel are present to safely remove the low voltage door. Failure to do so may result in personal injury and/or damage to the equipment.

Figure4.4

Figure4.

ATTENTION

ATTENTION

IMPORTANT

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4-4 Installation

PreparingLowVoltageDoorfor85Plus

1. Once the door has been removed, place the door on a level work surface.

2. Position an 825 Plus Mounting Collar squarely on the low voltage

door to align with the existing GE Multilin relay mounting notes. (Figure 4.5)

3. Using the collar as a template, lightly trace the cutout area on the inside and outside of the collar. This outline represents the minimum and maximum size required by the 825 Plus relay. (Figure 4.6)

4. Double-check the measurements before cutting. With a cutting tool, cut on the outside edge of the inside cutout trace. (Figure 4.7)

5. To ensure the hole is of the correct size, place a mounting collar over the hole. There should be no metal showing on the inside of the collar, and the collar should not pass through the cutout. (Figures 4.8 and 4.9)

Remove all metal-chips and splinters before mounting the 825 Plus relay.

Failure to remove all metal chips and splinters can result in equipment damage or hazardous operation.

Figure4.5

Figure4.6

Figure4.7

Figure4.8 Figure4.9

ATTENTION

IMPORTANT

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Installation 4-5

85PlusInstallation

1. Align the 825 Plus interface panel at the rear of the LV door with the existing mounting holes and cutout.

2. With the self tapping screws provided, mount the front cover and fasten the interface panel to the rear of LV door, which is located between the cutout cover and the interface panel. (Figures 4.10 and 4.11)

3. Ensure an extra long self-tapping screw is used in the top left, as viewed from the front of mounting hole. (Figure 4.11)

4. Mount the 825 Plus through the low voltage door cutout. (Figure 4.12)

5. Fasten the 825 Plus to the low voltage door using the four mounting screws provided with the 825 Plus. (Figure 4.13)

Tighten the screws with minimal force. Do not over tighten.

Self-tapping hardware is provided. However, pre-tapping the mounting plates will facilitate easier installation.

Figure4.10

Figure4.11

Figure4.1

Figure4.1

Figure4.14

IMPORTANT

IMPORTANT

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4-6 Installation

85PlusInstallation(cont.)

6. Before completely tightening the mounting hardware ensure the 825 Plus is mounted on a level plane both horizontally and vertically. (Figure 4.18)

7. Reconnect the various interface connectors on the back of the 825 Plus. (Figures 4.14, 4.16 and 4.17)

8. Ensure all ground wires are connected. (Figure 4.20)

Figure4.15

Figure4.18–FrontViewFigure4.16–CabletoConverterModule Figure4.17–RearView

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Installation 4-7

Re-InstallingtheLowVoltageDoor

1. Reinstall the low voltage door. Caution must be taken when re-installing the door. It is recommended that two people remount the door – one person to hold the door and a second person to replace the hinge pins. (Figure 4.19)

Ensure sufficient personnel are present to safely replace the low voltage door. Failure to do so may result in personal injury and/or damage to the equipment.

2. Remount all door-mounted devices that were removed. (Figure 4.20)

Figure4.19

Figure4.0

ATTENTION

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4-8 Installation

ReconnectingExistingControlCircuit

1. Using the provided spiral wrap, combine the existing and new door control wire bundle. (Figure 4.21)

2. Re-route the existing control wiring to the existing door components and through the 825 Plus interface panel. Care must be taken to ensure enough space to allow door closure. (Figures 4.21 and 4.22)

3. Secure the existing wiring to the door with provided sticky pads and tie wraps. The top right mounting tie wrap can be used to affix the existing wiring with the special tie wrap supplied. (Figures 4.23 and 4.24)

4. Reconnect the existing wires to the corresponding 825 Plus Interface Panel terminal blocks. These are located and numbered the same as those on the GE Multilin relays. Use the wire number table (created as part of the procedures in Appendix A) to verify the wire numbers and the terminal block location.

Figure4.1

Figure4. Figure4. Figure4.4

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Installation 4-9

If the RTD option is used, wire the RTDs to the 825 Plus RTD Scanner voltage panel. Refer to the RTD Interface Installation Guide (Appendix C) for additional information on RTD wiring.

Failure to reconnect all wires and cables correctly may result in equipment damage, personal injury and/or death.

5. Route the 825 Plus interface wire harness to the location of an existing GE MPM metering module or a blank space suitable to mount the supplied 825-MCM20 or 825-MCM5 converter module. (Figures 4.25 and 4.26)

Refer to Steps 8 to 11 for GE 169/269/269 Plus to 825 Plus kits with meter-ing option. Otherwise, use steps 6 to 7.

Important: Refer to the supplied wiring diagram during installation of 825 Plus Interface Panel. Refer to the Ordering Information section for Electrical Diagram (ED) drawing number.

6. Mount the 825-MCM20 or 825-MCM5 module on the LV panel with provided hardware. Note: drilling may be required.

Failure to remove all metal chips and splinters can result in equipment damage or hazardous operation.

7. Connect the corresponding wire harness to the 825 MCM module terminals. (Figure 4.26)

8. Remove the existing GE MPM/MTM metering module from LV panel. Using the wire number table in Appendix A, mark each wire with the corresponding GE MPM/MTM module terminal block number for refer-ence later in the procedure.

9. Remove the GE MPM/MTM module from the low voltage panel. Save all the mounting hardware.

10. Mount the 825 Plus MPM/MTM interfaced panel in the previous location used by the GE MPM/MTM metering module with the same mounting hardware.

11. Reconnect the existing wires to the corresponding 825 Plus MPM/MTM interface panel terminal blocks. These are located and numbered the same as those on the GE module. Use the wire number table in Appendix A to verify the wire numbers and the terminal block location.

Figure4.5

Figure4.6

Figure4.7

ATTENTION

ATTENTION

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4-10 Installation

PostInstallation(Testing)

Failure to follow these steps can result in damage to equipment and/or personal injury.

1. Inspect the interior of the enclosure for contamination, loose bolts, tools or metal chips, and vacuuming the enclosure is recommended.

2. Account for all the tools used. If a tool or hardware is unaccounted for, do not energize the equipment.

3. Inspect the wiring and the control scheme to ensure proper operation. Extra care should be taken when inspecting the connections for the cur-rent transformer and ground fault circuits, to ensure neither circuits are open or short-circuited during power-up.

4. For medium voltage controllers, follow items 5 though 7. For other styles of controllers, the intent of this section is to apply control voltage to the controller circuit, including the 825 Plus.

5. The medium voltage non-load break isolation switch must be in the fully opened position (the isolation switch handle moved to the OFF/down position).

6. Connect a remote 120VAC external power source to the ‘NORMAL-OFF-TEST’ (N-O-T) switch assembly test receptacle located in the low voltage compartment. (Figures 4.28 and 4.29)

7. Turn the N-O-T selector switch to the TEST position. (Figure 4.29)

With the selector switch in the test position, power will be applied to the control circuit. Additional caution must be taken to prevent accidental contact with the 120VAC.

Figure4.8

Figure4.9

ATTENTION

IMPORTANT

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Installation 4-11

8. Test the control circuit functionality by electrically operating the con-tactor (air or vacuum) in test mode. This may require the use of test jumpers depending on the control circuit. Refer to original drawings supplied with the equipment. (Figure 4.31)

9. Program the 825 Plus with the correct motor and protection parameters. (Figure 4.32) Refer to Publication 825-UM004B-EN-P, included with the 825 Plus, for programming instructions.

10. Turn test switch to OFF. Return the controller to service by removing any test voltage supply and turning the selector switch back to the "NORMAL" position.

11. Close the low voltage door and tighten down the door screws.

BEFORE:

AFTER:

Figure

Figure4.0

Figure4.1 Figure4.

Figure4. Figure4.4

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4-1 Installation

Appendix A

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GE Multilin 169/269/269 Plus to Bulletin 825 Plus Conversion KitWire Number Table

TB1

TB# 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43

Wire #

TB3

TB# 83 82 81 80 79 78 77 76 75 74 73 72

Wire #

TB2

TB# Wire #

44 45 84 85 – – – – – – – –

52 53

54 55 56 57 58 59 – – – – – – – –

Photocopy for multiple unit use.

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A-2

GE Multilin 369 to Bulletin 825 Plus Conversion KitWire Number Table

TB1

TB# 111 112 113 114 115 116 117 118 119 120 121 122 123 124 125 126

Wire #

TB2

TB# Wire # TB# Wire #

– – 72 51 73 52 74 53 75 54 76 55 77 56 78 57 79 58 80 59 81 60 82 61 83 62 84 – 85 – 71 86

TB3 – Upper Level

TB# 90 91 92 93 94 94 96 97 98 99 100

Wire #

TB3 – Lower Level

TB# 101 102 103 104 105 – 106 107 108 109 110

Wire #


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Technical Data A-3

GE Multilin MPM/MTM to Bulletin 825 Plus Conversion KitWire Number Table

TB1 – Upper Level TB# 9 10 11 12 13 14 15 16 17

Wire #

TB1 – Lower Level

TB# 1 2 3 4 5 6 7 8

Wire #


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A-4

Appendix B

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Technical Data

825 Plus Refer to Publication 825-UM004_-EN-P.

Conversion Kit Interface Panel

Converter Module Description Specification Terminals

• 0.5 to 1.5 mm2 (20 AWG to 14 AWG), single wire • 0.5 to 1.5 mm2 (20 AWG to 14 AWG), double wire • 0.5 to 1.5 mm2 (20 AWG to 14 AWG)

Bulletin 825 plug-in terminals (Range of cross-section)

• Nom inal 1.5 mm2 (.0023 in.2) • 2 x 2.5 mm2 / 1 x 4 mm2 (2 x .0039 in.2 / 1 x .006 in.2) Cat. No. 825-MCM20 /

825-MCM5 • 2 x 0.5 to 1.5 mm2 (20 AWG to 14 AWG) / 1 x 0.5 to 2.5 mm2 (20 AWG to 12 AWG)

Description Specification Terminals (TB1) Type 1492- CA3 Approvals CSA certified and UL listed Voltage Rating 600 V AC/DC Maximum Current 20 A Wire Range 0.5 to 1.5 mm2 (#22 – #14 AWG) Wire Strip Length Prepared conductors only Recommended Tightening Torque 12 lb.-in. (1.4 Nm) Insulation Temperature Range -40°C to +105°C (-40°F to +221°F) Terminals (TB2) Type P hoenix Connector Terminals (TB3) Type 1492- CD3 Approvals CSA certified and UL listed Voltage Rating 600 V AC/DC Maximum Current 35 A Wire Range 0.5 to 6 mm2 (#22 – #10 AWG) Wire Strip Length Prepared conductors only Recommended Tightening Torque 10 – 16 lb.-in. (1.1 – 1.8 Nm) Insulation Temperature Range -40°C to +105°C (-40°F to +221°F)

1500-IN059C-EN-E – June 2013

B-2 Technical Data

Appendix C

1500-IN059C-EN-E – June 2013

825PlusRTDScanner•InstallationGuide

Introduction The 825 Plus RTD scanner: • easy installation

• modular design

• (12)configurableRTDinputs • Fiber-opticcommunicationportto825Plus(max.length500m)

1500-IN059C-EN-E – June 2013

C-2 825 Plus RTD Scanner • Installation Guide

Failuretofollowthesestepscanresultindamagetotheequipmentand/orpersonalinjury.

1. EnsuretheRTDwiresaredisconnectedfromtheGEMultilinMPM/MTMmodule.UsingthewirenumbertableinAppendixC,markeachwirewiththecorrespondingGEMultilinrelayterminalblocknumber.

2. Mountthe825PlusRTDScannerinanappropriatelocationwithinthelowvoltagecompartment.The825PlusRTDscannermaybemountedremotefromthecontroller,i.e.nearthemotor.

3. Routeandconnectthesuppliedfibreopticcablebetweenthe825PlusRTDscannerandthe825Plusrelay.(Figure C.1)

4. RerouteandconnecttheRTDwirestothecorresponding825PlusRTDScannerterminalblocks.Usethewirenumbertablecreatedinstep1toverifythewirenumbersandtheterminalblocklocation.

5. RefertotheelectricaldiagramsandtheRTDwirenumbercross-referencetableprovidedtoensureproperconnections.

InstallationInstructions

FigureC.1


1500-IN059C-EN-E – June 2013

825 Plus RTD Scanner • Installation Guide C-

GEMultilinto825PlusRTDScanner WireNumberCross-ReferenceTable

Photocopyformultipleunituse.

1500-IN059C-EN-E – June 2013

C- 825 Plus RTD Scanner • Installation Guide

Appendix D

1500-IN059C-EN-E – June 2013

Bulletin 825 Plus Kit Component Configuration(GE 169 / 269 / 269 Plus)

825 PlusCommunication Card- DeviceNet- Modbus

825 Plus RTDScanner

825 Plus InterfacePanel

GE MTM/MPM to 825Plus Interface Panel(Standard Kits with

metering)

825-MCM CurrentConverter Module

(Standard Kits with nometering)

1500-IN059C-EN-E – June 2013

D-2 Bul. 825 Plus Kit • Component Configuration

Bulletin 825 Plus Kit Component Configuration(GE 369)


825 Plus RTDScanner



1 1500-IN059C-EN-E – June 2013

Installation 4-11

8. Test the control circuit functionality by electrically operating the con-tactor (air or vacuum) in test mode. This may require the use of test jumpers depending on the control circuit. Refer to original drawings supplied with the equipment. (Figure 4.31)

9. Program the 825 Plus with the correct motor and protection parameters. (Figure 4.32) Refer to Publication 825-UM004B-EN-P, included with the 825 Plus, for programming instructions.

10. Turn test switch to OFF. Return the controller to service by removing any test voltage supply and turning the selector switch back to the "NORMAL" position.

11. Close the low voltage door and tighten down the door screws.

BEFORE:

AFTER:

Figure

Figure4.0

Figure4.1 Figure4.

Figure4. Figure4.4

1500-IN059C-EN-E – June 2013

4-1 Installation

Appendix A

1500-IN059C-EN-E – June 2013

GE Multilin 169/269/269 Plus to Bulletin 825 Plus Conversion KitWire Number Table

TB1

TB# 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43

Wire #

TB3

TB# 83 82 81 80 79 78 77 76 75 74 73 72

Wire #

TB2

TB# Wire #

44 45 84 85 – – – – – – – –

52 53

54 55 56 57 58 59 – – – – – – – –


1500-IN059C-EN-E – June 2013

A-2

GE Multilin 369 to Bulletin 825 Plus Conversion KitWire Number Table

TB1

TB# 111 112 113 114 115 116 117 118 119 120 121 122 123 124 125 126

Wire #

TB2

TB# Wire # TB# Wire #

– – 72 51 73 52 74 53 75 54 76 55 77 56 78 57 79 58 80 59 81 60 82 61 83 62 84 – 85 – 71 86

TB3 – Upper Level

TB# 90 91 92 93 94 94 96 97 98 99 100

Wire #

TB3 – Lower Level

TB# 101 102 103 104 105 – 106 107 108 109 110

Wire #


1500-IN059C-EN-E – June 2013

Technical Data A-3

GE Multilin MPM/MTM to Bulletin 825 Plus Conversion KitWire Number Table

TB1 – Upper Level TB# 9 10 11 12 13 14 15 16 17

Wire #

TB1 – Lower Level

TB# 1 2 3 4 5 6 7 8

Wire #


1500-IN059C-EN-E – June 2013

A-4

Appendix B

1500-IN059C-EN-E – June 2013

Technical Data

825 Plus Refer to Publication 825-UM004_-EN-P.

Conversion Kit Interface Panel

Converter Module Description Specification Terminals

• 0.5 to 1.5 mm2 (20 AWG to 14 AWG), single wire • 0.5 to 1.5 mm2 (20 AWG to 14 AWG), double wire • 0.5 to 1.5 mm2 (20 AWG to 14 AWG)

Bulletin 825 plug-in terminals (Range of cross-section)

• Nom inal 1.5 mm2 (.0023 in.2) • 2 x 2.5 mm2 / 1 x 4 mm2 (2 x .0039 in.2 / 1 x .006 in.2) Cat. No. 825-MCM20 /

825-MCM5 • 2 x 0.5 to 1.5 mm2 (20 AWG to 14 AWG) / 1 x 0.5 to 2.5 mm2 (20 AWG to 12 AWG)

Description Specification Terminals (TB1) Type 1492- CA3 Approvals CSA certified and UL listed Voltage Rating 600 V AC/DC Maximum Current 20 A Wire Range 0.5 to 1.5 mm2 (#22 – #14 AWG) Wire Strip Length Prepared conductors only Recommended Tightening Torque 12 lb.-in. (1.4 Nm) Insulation Temperature Range -40°C to +105°C (-40°F to +221°F) Terminals (TB2) Type P hoenix Connector Terminals (TB3) Type 1492- CD3 Approvals CSA certified and UL listed Voltage Rating 600 V AC/DC Maximum Current 35 A Wire Range 0.5 to 6 mm2 (#22 – #10 AWG) Wire Strip Length Prepared conductors only Recommended Tightening Torque 10 – 16 lb.-in. (1.1 – 1.8 Nm) Insulation Temperature Range -40°C to +105°C (-40°F to +221°F)

1500-IN059C-EN-E – June 2013

B-2 Technical Data

Appendix C

1500-IN059C-EN-E – June 2013

825PlusRTDScanner•InstallationGuide

Introduction The 825 Plus RTD scanner: • easy installation

• modular design

• (12)configurableRTDinputs • Fiber-opticcommunicationportto825Plus(max.length500m)

1500-IN059C-EN-E – June 2013

C-2 825 Plus RTD Scanner • Installation Guide

Failuretofollowthesestepscanresultindamagetotheequipmentand/orpersonalinjury.

1. EnsuretheRTDwiresaredisconnectedfromtheGEMultilinMPM/MTMmodule.UsingthewirenumbertableinAppendixC,markeachwirewiththecorrespondingGEMultilinrelayterminalblocknumber.

2. Mountthe825PlusRTDScannerinanappropriatelocationwithinthelowvoltagecompartment.The825PlusRTDscannermaybemountedremotefromthecontroller,i.e.nearthemotor.

3. Routeandconnectthesuppliedfibreopticcablebetweenthe825PlusRTDscannerandthe825Plusrelay.(Figure C.1)

4. RerouteandconnecttheRTDwirestothecorresponding825PlusRTDScannerterminalblocks.Usethewirenumbertablecreatedinstep1toverifythewirenumbersandtheterminalblocklocation.

5. RefertotheelectricaldiagramsandtheRTDwirenumbercross-referencetableprovidedtoensureproperconnections.

InstallationInstructions

FigureC.1


1500-IN059C-EN-E – June 2013

825 Plus RTD Scanner • Installation Guide C-

GEMultilinto825PlusRTDScanner WireNumberCross-ReferenceTable

Photocopyformultipleunituse.

1500-IN059C-EN-E – June 2013

C- 825 Plus RTD Scanner • Installation Guide

Appendix D

1500-IN059C-EN-E – June 2013

Bulletin 825 Plus Kit Component Configuration(GE 169 / 269 / 269 Plus)


825 Plus RTDScanner


GE MTM/MPM to 825Plus Interface Panel(Standard Kits with

metering)


(Standard Kits with nometering)

1500-IN059C-EN-E – June 2013

D-2 Bul. 825 Plus Kit • Component Configuration

Bulletin 825 Plus Kit Component Configuration(GE 369)


825 Plus RTDScanner



Medium Voltage Products, 135 Dundas Street, Cambridge, ON, N1R 5X1 Canada, Tel: (1) 519.740.4100, Fax: (1) 519.623.8930, www.ab.com/mvb Publication 1500-IN059C-EN-E – June 2013 Supersedes Publication 1500-IN059B-EN-P – November 2006 Copyright © 2013 Rockwell Automation, Inc. All rights reserved. Printed in Canada.

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