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Reference ManualOriginal Instructions
Bulletin 857 Protection Relay Substitution GuidelinesBulletin Number 857
Topic PageSummary of Changes 2Overview 2Product Configuration 3Bulletin 857 Relay Catalog Number Explanation 4Hardware Interface Protocols 5Identify Installed Communication Interfaces 5Hardware Configuration Identification 7Recommended Spare Relays 10Cross Reference Matrix 11
This publication contains the following new or updated information. This list includes substantive updates only and is not intended to reflect all changes.
Overview
The Bulletin 857 Protection System is a highly configurable motor/feeder protection product and has served Rockwell Automation for over a decade. When used in medium voltage motor controllers as the primary motor protection device, it was supplied with a limited subset of the available configurations to simplify the user experience.
This document provides guidance for identifying specific products that are presently installed and the possible reconfiguration of any available stocked replacements of spare components to facilitate longer term support. The substitution uses a limited supply of available replacement parts may be required to support the installed base relay hardware. Some reconfigurations will not cover all possible Bulletin 857 relay configurations.
The following products or option characteristics are not supported through product substitution. • The low voltage DC control power supply option for 18…36V DC. An alternative 40…265V AC/DC supply voltage is required to support
replacement devices.• Dual fiber-optic Ethernet Connections• Arc Flash Detection (option card in position X6). Including the 857-VA1DA-6 and 857-VA1DA-02 individual Arc Flash Sensors• PROFIBUS Communications Adapters, 857-VPA3CG• Additional inputs and outputs that are supported by an option card (Option that is in position X8). This option card can be swapped
between devices if needed• Optional plug in communications modules connecting via the VCM232 communication option, catalog numbers
Relay configurations that contain these types of options require a complete engineered solution to provide support via alternative means, including alternative third-party devices.
Communication Options
The Bulletin 857 relay has up to four communications ports (software ports) supported by up to three hardware interfaces associated with the hardware platform. Only two of the three hardware interfaces are selectable at the time of order placement. The third hardware port is an RS-232 port that is on the front panel of the unit. This port is only used for data interactions for programming, diagnostics, and firmware updates. When an ethernet hardware interface is used, only one additional hardware interface is supported.
Topic PageUpdated graphics for 857-3xxxEL and 857-3xxxEM 9, 10
2 Rockwell Automation Publication 857-RM002B-EN-P - July 2021
A main aspect of the Bulletin 857 relay is around the communications capabilities. The relay also has additional features that surround the input/output configurations and arc flash option capabilities. The main selectivity comes from the two optional hardware interfaces, communication option 1 and communication option 2. The reference material below aids in identifying installed communication interfaces. Longer term support of the product may require the use of relays with alternative configurations to support your needs.
Figure 1 - Rear View of the Bulletin 857 Relay
Figure 2 - Typical Internal Communication Option Modules
The product catalog number defines the communication options. These were defined when the product was originally ordered. The fifth and sixth positions of the Bulletin 857 Relay Catalog Number Explanation on page 4 define the two communication hardware interfaces. Not all combinations are available. See Chapter 9 in Bulletin 857 Protection System for Feeder and Motor Protection, publication 857-UM001, for details that are related to pin assignments of the various communication options.
123456789101112131415161718
X3 X1
REMOTE
(TTL)
1
3
5
7
9
11
13
15
17
19
2
4
6
8
10
12
14
16
18
20
X6
X2
1234567
123456789101112131415161718
X7
+48V
DI2
DI1
DI3
DI4
DI5
DI6
--
A1 COM
A1 NO
A1 NC
T2
T2
T1
T1
----
Uaux
Uaux
BI
BO
COM
S1> +
S1> �
S2> +
S2> �
A5-
A5
A4
A4
A3
A3
A2
A2
IF COM
IF NC
IF NO
DI8
DI7
DI9
DI10
DI11
DI12
COM1
DI13
DI14
DI15
DI16
DI17
DI18
COM2
T4
T4
T3
T3
IL1 (S1)
IL2 (S1)
IL3 (S1)
Io1/1A(S1)
Io2/5A(S1)
Ua
Ub
--
Uc
--
IL1 (S2)
IL2 (S2)
IL3 (S2)
Io1/1A(S2)
Io2/5A(S2)
Ua
Ub
--
Uc
--
1234567891011
X8
Communication Option 1
Communication Option 2
Rockwell Automation Publication 857-RM002B-EN-P - July 2021 3
This matrix shows the physical interface characteristics and the associated communications protocols that are supported by those hardware interfaces.
Figure 3 - Hardware Interface and Protocols
Identify Installed Communication Interfaces
The protocol selection for a hardware interface is accomplished in the SetPointPS Software tool. See the examples below which illustrate the type and location of the hardware interfaces and the various protocol inclusions by port assignment.
Figure 4 - Installed Interface Configurations as shown in the SetPointPS Software
Figure 5 - Installed Interface Configurations as shown on the Bulletin 857
Installed Hardware Interfaces
Installed Hardware Interfaces
Rockwell Automation Publication 857-RM002B-EN-P - July 2021 5
See Hardware Interface Protocols on page 5 section for physical characteristics associated with the catalog number.
The 857 relay supports the hardware port via defined firmware and software identifications. There are four communication ports:• Local port• Extension port• Remote port• Ethernet port
Each of these ports has a specific purpose and use associated with various other options.
Figure 6 - Communication Ports
Table 1 - Hardware Interface by Catalog Code Letter
Hardware Interface shown in SetPointPS Option Code Letter in 5th and 6th position of the Catalog Number Explanation Notes
VCMTTL (RS-232) A or C Can be 9 pin D style or RJ45 connectionsVCMRS485 D Can be 2 or 4 wireVCMFIBER E Dual fiber-optic for connection to 857-RADVCMRTD N Single fiber-optic for connection to 857-RAAEthernet L or M RJ45 (copper) or Dual fiber-optic
6 Rockwell Automation Publication 857-RM002B-EN-P - July 2021
Shown below are physical illustrations of the rear panel of various Bulletin 857 relay models. These physically illustrate the various communication options modules. In many situations, the module type or style can be identified by the external connection plug that is used for the communication module. The one variant is the RS-232 option module that can use a similar RJ45 style of connector as used with copper Ethernet option configurations. See Recommended Spare Relays on page 10 for RTD Module support guidance.
Catalog Number Physical Configuration Replace With
(1) PROFIBUS is not supported.(2) Arc flash protection is not provided.(3) DC control power supply option for 18…36V DC is not supported.(4) Additional I/O in card slot X8 is not supported.(5) Optional plug in communications modules, connecting via the VCM232 communication option, is not supported.
Some Bulletin 857 base relays can support the features of other device configurations. For example, various protocols can be supported using the Ethernet hardware interface. It may be possible to support some auxiliary components, such as the 857 RTD scanners, using alternative configurations.
This table shows the most common product catalog numbers with a recommended alternative or substitution product that will aid in the longer term support capabilities.
System Security Design Guidelines Reference Manual, SECURE-RM001Provides guidance on how to conduct security assessments, implement Rockwell Automation products in a secure system, harden the control system, manage user access, and dispose of equipment.
Provides a quick reference tool for Allen-Bradley industrial automation controls and assemblies.
Safety Guidelines for the Application, Installation, and Maintenance of Solid-state Control, publication SGI-1.1
Designed to harmonize with NEMA Standards Publication No. ICS 1.1-1987 and provides general guidelines for the application, installation, and maintenance of solid-state control in the form of individual devices or packaged assemblies incorporating solid-state components.
Industrial Automation Wiring and Grounding Guidelines, publication 1770-4.1 Provides general guidelines for installing a Rockwell Automation industrial system.Product Certifications website, rok.auto/certifications. Provides declarations of conformity, certificates, and other certification details.
Use these resources to access support information.
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