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.

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.

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

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).

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.
 Table Of Contents

Introduction Chapter 1 Page No.

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

Equipment Description Chapter 2

Overview .................................................................................................... 2-1
Operational Requirements .......................................................................... 2-1
Ordering Information ................................................................................. 2-3
Conversion Kit Numbers (GE Multilin 169/269/269 Plus) ................. 2.3
Conversion Kit Numbers (GE Multilin 369) ....................................... 2-5

Unpacking and Storage Chapter 3

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

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

Appendix A GE Multilin to Bulletin 825 Plus Conversion Kit

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

Appendix B Technical Data

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

1500-IN059C-EN-E June 2013

ii Table of Contents Modular Protection System Conversion Kit Installation Manual

Appendix C 825 Plus RTD Scanner Installation Guide Page No.

Introduction ............................................................................................... C-1
Installation Instructions ............................................................................. C-2
Wire 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-1
Bulletin 825 Plus Kit Component Configuration (GE 369) ....................... D-2

1500-IN059C-EN-E June 2013

 Chapter 1
Introduction

Overview This manual describes the installation of the Bulletin 825 Plus Conversion Kit
within a typical medium voltage (MV) controller. Simple troubleshooting is
also included.

Although this manual outlines the implementation within a medium voltage

controller, the basic philosophy also applies for installation within a low
voltage controller. To use this manual effectively, you must be familiar with
electrical procedures and terminology.

IMPORT ANT For setup, programming, and operation information on the

Bulletin 825-Plus Modular Protection System for motors,
refer to Publication 825-UM004_-EN-P.

ATTENTION Rockwell Automation reserves the right to adapt the

products described in this manual at any time to suit the
latest technical developments. Accordingly, attached
information is not an object of the contract and thus may
change without notification.

Prerequisite for proper operation is correct transport, proper and competent

storage and installation as well as careful operation and maintenance.

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

2. In accordance with the applicable rules, work on electrical equipment or

means of production may only be carried out by competent electricians or
suitably 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 be
eliminated immediately.

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

ATTENTION In case of electrical or mecanical faults, the machine must be

switched off and protected immediately. The elimination of
disturbances must be organized without delay. Failure to do
so may result in personal injury and/or damage to the
equipment.

1500-IN059B-EN-E June 2013

1-2 Introduction

Overview (cont.) ATTENTION The elimination of a disturbance may cause the motor to start
running again by itself. This may endanger persons or
damage equipment. The user must take the necessary safety
measures to protect against this type of occurrence so that
any danger is avoided.

Kit Highlights and Limitations The GE Multilin to Bulletin 825 Plus Conversion Kit provides equivalent
features and functionality of the GE Multilin 169/269/269 Plus and 369.
However, the Conversion Kit also provides additional features and functions
not 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 X
Modbus TM X

X Option card required.

Personnel Safety Protection of personnel in the vicinity of control equipment is of primary

importance. The corresponding requirements of regulatory agencies are
therefore becoming increasingly severe. The Bulletin 825 Plus reflects this by
providing the following protection:

Equipment construction: Touch protection

Insulated housing

Motor protective functions: Earth (ground) fault

High overload, stalling and jam
Phase reversal

1500-IN059C-EN-E June 2013

 Chapter 2
Equipment Description

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

Operational Requirements
Monitoring application parameters and process data of an installation is very
important. Even a slight change in the starting and operating behavior of the
motor can indicate an impeding fault. The Bulletin 825 Plus helps eliminate
the potential trouble before major repairs are necessary and loss of production
occurs.

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

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

GE Multilin Bul. 825 Plus

Function Description
169/269/269 Plus 369 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
10 Cu, 100 Ni, 10 Cu, 100 Ni, 10 Cu, 100 Ni,
Allowable RTD types
120 Ni, 100 PI 120 Ni, 100 PI 120 Ni, 100 PI
Number of WindingRTDs 16 1 6 w/RTD option 1 12
Number of Bearing RTDs 12 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.

1500-IN059C-EN-E June 2013

2-2 Equipment Description

Operational Requirements
(cont.)
GE Multilin Bul. 825 Plus
Function Description
169/269/269 Plus 369 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 5s
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 200C 1 200C 0C 200C
Winding Trip Temperature 0 200C 1 200C 0C 200C
Bearing Alarm Temperature 0 200C 1 200C 0C 200C
Bearing Trip Temperature 0 200C 1 200C 0C 200C
Ambient Temperature Sensor Input No Yes Yes
Reset Condition Auto / Manual Auto / Manual Auto / Manual
169/269 No
Speed Switch Input Yes Yes
269 Plus 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.

1500-IN059C-EN-E June 2013

 Equipment Description 2-3

Ordering Information

Conversion Kit Numbers

For GE Multilin 169/269/269 Plus to Bulletin 825 Plus
Electrical Drawing
Description Catalog Number
Numbers
Standard Conversion Kit 80113-650-93 825PK2BDXXXC
Standard Kit with DeviceNet 80113-650-94 825PK2BDXDXC
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.

1500-IN059C-EN-E June 2013

2-4 Equipment Description

Ordering Information (cont.)

Catalog Number Breakdown

For 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
Standard Conversion Kit
Base 825 Plus Relay 825-PD
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

Core Balance/GFCT 3.25-inch Window 80022-030-03

(100:1) 5.5-inch Window 80022-030-04

1500-IN059C-EN-E June 2013

 Equipment Description 2-5

Conversion Kit Numbers

For GE Multilin 369 to Bulletin 825 Plus

Electrical Drawing
Description Catalog Number
Numbers
Standard Conversion Kit 80113-650-87 825PK3BDVXXC
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.

1500-IN059C-EN-E June 2013

2-6 Equipment Description

Ordering Information (cont.)

Catalog Number breakdown

For 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
Standard Conversion Kit Base 825 Plus Relay 825-PD
825 Plus I/O Card 825-PIOD
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

Core balance/GFCT 3.25-inch Window 80022-030-03

(100:1) 5.5-inch Window 80022-030-04

1500-IN059C-EN-E June 2013

 Chapter 3
Unpacking and Storage

Overview This chapter describes the procedures for unpacking, inspecting, and storing
the 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 damaged
equipment.

3. In the event that a component is missing, damaged, or shows evidence of

rough handling, THE BUYER SHALL NOTE SUCH ON THE
CARRIERS DELIVERY RECEIPT and immediately notify the carrier.

IMPORT ANT Save all packaging material for the insurance company
inspection.

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

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

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

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

2. If the storage area is damp and/or cool, it is important to dry the

Conversion Kit out in a warm, dry environment before using. Also, clean
all terminals to help provide integrity of the electrical connections.

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

IMPORT ANT For storage in harsh or caustic environments, consult a

Rockwell Automation representative.

1500-IN059C-EN-E June 2013

3-2 Unpacking and Storage

1500-IN059C-EN-E June 2013

 Chapter 4

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.

IMPORTANT This manual is intended for use by personnel trained and

familiar with medium voltage, solid-state power equipment,
and general industrial controls.

Pre-Installation ATTENTION
ATTENTION
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

Figure 4.1 Tools Required

1500-IN059C-EN-E June 2013

4- Installation

Removing
Low Voltage ATTENTION Disconnect and lockout all sources of power entering the low
Door Components 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.

Figure 4.2 Typical Existing LV door layout with 269 Plus Relay

1500-IN059C-EN-E June 2013

 Installation 4-

Removing Low Voltage Door

IMPORTANT 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.

ATTENTION 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)
Figure 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)

ATTENTION 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.

Figure 4.4

1500-IN059C-EN-E June 2013

4- Installation

Preparing Low Voltage Door

for 825 Plus

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)
Figure 4.5
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)

IMPORTANT Remove all metal-chips and splinters before mounting

the 825 Plus relay.

Figure 4.6 ATTENTION Failure to remove all metal chips and splinters can result
in equipment damage or hazardous operation.

Figure 4.7

Figure 4.8 Figure 4.9

1500-IN059C-EN-E June 2013

 Installation 4-

825 Plus Installation

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

Figure 4.10 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)

IMPORTANT Tighten the screws with minimal force. Do not over

tighten.

IMPORTANT Self-tapping hardware is provided. However, pre-tapping

the mounting plates will facilitate easier installation.
Figure 4.11

Figure 4.14

Figure 4.13

Figure 4.12

1500-IN059C-EN-E June 2013

4- Installation

825 Plus Installation (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)

Figure 4.15

Figure 4.16 Cable to Converter Module Figure 4.17 Rear View Figure 4.18 Front View

1500-IN059C-EN-E June 2013

 Installation 4-

Re-Installing the Low Voltage Door

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)

ATTENTION 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)

Figure 4.19

Figure 4.20

1500-IN059C-EN-E June 2013

4- Installation

Reconnecting Existing Control Circuit

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.
Figure 4.21

Figure 4.22 Figure 4.23 Figure 4.24

1500-IN059C-EN-E June 2013

 Installation 4-

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.

ATTENTION 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
Figure 4.25
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.

ATTENTION 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-
Figure 4.26 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.

Figure 4.27
1500-IN059C-EN-E June 2013
4-10 Installation

Post Installation (Testing)

ATTENTION 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

Figure 4.28 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)

IMPORTANT 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.

Figure 4.29

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.

Figure 4.30 BEFORE:

Figure 4.31 Figure 4.32

AFTER:

Figure 4.33 Figure 4.34

1500-IN059C-EN-E June 2013

4-12 Installation

1500-IN059C-EN-E June 2013

 Appendix A

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

Wire Number Table

TB1
TB# 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43

Wire #

TB2
TB# Wire #

44
45
84
85




52
53
54
55
56
57

TB3 58
59
TB# 83 82 81 80 79 78 77 76 75 74 73 72

Wire #

Photocopy for multiple unit use.

1500-IN059C-EN-E June 2013

A-2

GE Multilin 369 to Bulletin 825 Plus Conversion Kit

Wire 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 #

Photocopy for multiple unit use.

1500-IN059C-EN-E June 2013

 Technical Data A-3

GE Multilin MPM/MTM to Bulletin 825 Plus Conversion Kit

Wire 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 #

Photocopy for multiple unit use.

1500-IN059C-EN-E June 2013

A-4

1500-IN059C-EN-E June 2013

 Appendix B
Technical Data

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

Conversion Kit Interface Panel 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 -40C to +105C (-40F to +221F)
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 mm (#22 #10 AWG)
2

Wire Strip Length Prepared conductors only

Recommended Tightening Torque 10 16 lb.-in. (1.1 1.8 Nm)
Insulation Temperature Range -40C to +105C (-40F to +221F)

Converter Module Description Specification

Terminals
Bulletin 825 plug-in terminals
(Range of cross-section)
Cat. No. 825-MCM20 /
825-MCM5
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)
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)
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)

1500-IN059C-EN-E June 2013

B-2 Technical Data

1500-IN059C-EN-E June 2013

 Appendix C

825 Plus RTD Scanner Installation Guide

Introduction The 825 Plus RTD scanner:

easy installation
modular design
(12) configurable RTD inputs
Fiber-optic communication port to 825 Plus (max. length 500 m)

1500-IN059C-EN-E June 2013

C- 825 Plus RTD Scanner Installation Guide

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

1. Ensure the RTD wires are disconnected from the GE Multilin MPM/MTM
module. Using the wire number table in Appendix C, mark each wire with
the corresponding GE Multilin relay terminal block number.

2. Mount the 825 Plus RTD Scanner in an appropriate location within the low
voltage compartment. The 825 Plus RTD scanner may be mounted remote
from the controller, i.e. near the motor.

3. Route and connect the supplied fibre optic cable between the 825 Plus RTD
scanner and the 825 Plus relay. (Figure C.1)

4. Reroute and connect the RTD wires to the corresponding 825 Plus RTD
Scanner terminal blocks. Use the wire number table created in step 1 to
Figure C.1
verify the wire numbers and the terminal block location.

5. Refer to the electrical diagrams and the RTD wire number cross-reference
table provided to ensure proper connections.

1500-IN059C-EN-E June 2013

 825 Plus RTD Scanner Installation Guide C-

GE Multilin to 825 Plus RTD Scanner

Wire Number Cross-Reference Table

Photocopy for multiple unit use.

1500-IN059C-EN-E June 2013

C- 825 Plus RTD Scanner Installation Guide

1500-IN059C-EN-E June 2013

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

Communication Card
825 Plus
- DeviceNet
- Modbus

825-MCM Current
Converter Module
(Standard Kits with no
metering)

825 Plus Interface

Panel

825 Plus RTD

Scanner

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

1500-IN059C-EN-E June 2013

D-2 Bul. 825 Plus Kit Component Configuration

Bulletin 825 Plus Kit Component Configuration

(GE 369)

Communication Card
825 Plus
- DeviceNet
- Modbus

825-MCM Current
Converter Module

825 Plus Interface

Panel

825 Plus RTD

Scanner

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.

Figure 4.30 BEFORE:

Figure 4.31 Figure 4.32

AFTER:

Figure 4.33 Figure 4.34

1 1500-IN059C-EN-E June 2013

4-12 Installation

1500-IN059C-EN-E June 2013

 Appendix A

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

Wire Number Table

TB1
TB# 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43

Wire #

TB2
TB# Wire #

44
45
84
85




52
53
54
55
56
57

TB3 58
59
TB# 83 82 81 80 79 78 77 76 75 74 73 72

Wire #

Photocopy for multiple unit use.

1500-IN059C-EN-E June 2013

A-2

GE Multilin 369 to Bulletin 825 Plus Conversion Kit

Wire 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 #

Photocopy for multiple unit use.

1500-IN059C-EN-E June 2013

 Technical Data A-3

GE Multilin MPM/MTM to Bulletin 825 Plus Conversion Kit

Wire 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 #

Photocopy for multiple unit use.

1500-IN059C-EN-E June 2013

A-4

1500-IN059C-EN-E June 2013

 Appendix B
Technical Data

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

Conversion Kit Interface Panel 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 -40C to +105C (-40F to +221F)
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 mm (#22 #10 AWG)
2

Wire Strip Length Prepared conductors only

Recommended Tightening Torque 10 16 lb.-in. (1.1 1.8 Nm)
Insulation Temperature Range -40C to +105C (-40F to +221F)

Converter Module Description Specification

Terminals
Bulletin 825 plug-in terminals
(Range of cross-section)
Cat. No. 825-MCM20 /
825-MCM5
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)
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)
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)

1500-IN059C-EN-E June 2013

B-2 Technical Data

1500-IN059C-EN-E June 2013

 Appendix C

825 Plus RTD Scanner Installation Guide

Introduction The 825 Plus RTD scanner:

easy installation
modular design
(12) configurable RTD inputs
Fiber-optic communication port to 825 Plus (max. length 500 m)

1500-IN059C-EN-E June 2013

C- 825 Plus RTD Scanner Installation Guide

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

1. Ensure the RTD wires are disconnected from the GE Multilin MPM/MTM
module. Using the wire number table in Appendix C, mark each wire with
the corresponding GE Multilin relay terminal block number.

2. Mount the 825 Plus RTD Scanner in an appropriate location within the low
voltage compartment. The 825 Plus RTD scanner may be mounted remote
from the controller, i.e. near the motor.

3. Route and connect the supplied fibre optic cable between the 825 Plus RTD
scanner and the 825 Plus relay. (Figure C.1)

4. Reroute and connect the RTD wires to the corresponding 825 Plus RTD
Scanner terminal blocks. Use the wire number table created in step 1 to
Figure C.1
verify the wire numbers and the terminal block location.

5. Refer to the electrical diagrams and the RTD wire number cross-reference
table provided to ensure proper connections.

1500-IN059C-EN-E June 2013

 825 Plus RTD Scanner Installation Guide C-

GE Multilin to 825 Plus RTD Scanner

Wire Number Cross-Reference Table

Photocopy for multiple unit use.

1500-IN059C-EN-E June 2013

C- 825 Plus RTD Scanner Installation Guide

1500-IN059C-EN-E June 2013

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

Communication Card
825 Plus
- DeviceNet
- Modbus

825-MCM Current
Converter Module
(Standard Kits with no
metering)

825 Plus Interface

Panel

825 Plus RTD

Scanner

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

1500-IN059C-EN-E June 2013

D-2 Bul. 825 Plus Kit Component Configuration

Bulletin 825 Plus Kit Component Configuration

(GE 369)

Communication Card
825 Plus
- DeviceNet
- Modbus

825-MCM Current
Converter Module

825 Plus Interface

Panel

825 Plus RTD

Scanner

1500-IN059C-EN-E June 2013

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.