bulletin 857 protection relay substitution guidelines

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

Bulletin 857 Protection Relay Substitution Guidelines

Summary of Changes

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

- 857-VEA3CG: External EtherNet/IP™ plug on module- 857-VSE001: External dual fiber-optic interface module- 857-VSE002: External RS-485 interface module- 857-VSE006: External IEC 103 to 61850 converter module- 857-VSE010: External single optic interface module

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


Product Configuration

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

https://literature.rockwellautomation.com/idc/groups/literature/documents/um/857-um001_-en-p.pdf


Bulletin 857 Relay Catalog Number Explanation

a

Nom. Phase Current (A) / Nom. DI7-28 Activation Voltage

3 1 A / 5 A / 24V

6 1 A / 5 A / 110V

7 1 A / 5 A / 220V

b

Nom. Earth-fault Current I/O1 and I/O2 [A]

C 1 A and 5 A

D 0.2 A and 1 A

c

Additional I/O (X8 Terminal)

6 None

8 Ten outputs

9 Eight standard inputs and four outputs(1)

(1) Some options not UL Listed. Check with your Rockwell Automation® representative.

d

Supply Voltage [V]

A 40…265V AC/DC

B 18…36V DC

C 40…265V AC/DC, arc protection option

D 18…36V DC, arc protection option

E 40…265V AC/DC, DI19, DI20, arc channel, optional

F 18…36V DC+ DI19, DI20, arc channel, optional

e

Optional Hardware (Communication port 1)

Code Description

A TTL/RS-232 (VCM TTL)

B Plastic/Plastic serial fiber interface (VCM FIBRE PP)

C —

D RS-485 interface (4-wire, VCM 485-4)

E Glass/Glass dual serial fiber interface for 857-RAD (857-VCMFIBRE GG)(1)

(1) Required for connection to 857-RAD Enhanced RTD Scanner. Only available in this location.

F Rx Plastic/Tx Glass serial fiber interface (VCM FIBRE PG)

G Rx Glass/Tx Plastic serial fiber interface (VCM FIBRE GP)

I RJ45 connection (RS-232, VCM 232)

M ST 100-Mbps Ethernet dual fiber interface including IEC 61850

N RTD glass fiber interface for 857-RAA (857-VCMRTD)(2)

(2) Required for connection to the 857-RAA scanner only.

f

Optional Hardware (Communication port 2)

A None

C RJ45 connection (RS-232, 857-VCM232)

D RS-485 interface (2-wire, 857-VCM485-2)

L Built-in RJ45 10 Mbps Ethernet interface(1)

M Built in RJ45 10 Mbps interface inc. IEC 61850(1)

(1) Cannot order in combination with the following optional Communication PORT 1: (M) ST 100-Mbps EtherNet/IP fiber interface with IEC 61850

N RTD interface for 857-RAA (Glass fiber, 857-VCMRTD)(2)

(2) Required for connection to the 857-RAA scanner only.

g

Ingress Protection Rating

IP 30 (standard)

I IP 54 with conformal coating (optional)

C IP 30 with conformal coating (optional)

Position

1 2 3 4 5 6 7857 – 3 C 6 A A A –__

a b c d e f g



Hardware Interface Protocols

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



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



Hardware Configuration Identification

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

Bulletin 857-3xxxAA • Comm. option 1: A=VCM TTL Serial RS-232 • Comm. option 2: A=None

857-3C6AAM

Bulletin 857-3xxxAC • Comm. option 1: A = VCM TTL Serial RS-232 • Comm. option 2: C = VCM 232 Serial RS-232 via RJ45

857-3C6AAM If second RS-232 connection is not

required or a third partyEngineered Solution required

Bulletin 857-3xxxAD • Comm. option 1: A = VCM TTL Serial RS-232 • Comm. option 2: D = VCM 485-2 wire serial RS-485

PN-388317(857-3C6ADN)

No RS-232 support

Bulletin 857-3xxxAL Bulletin 857-3xxxAM• Comm. option 1: A = VCM TTL Serial RS-232• Comm. option 2: L = iEthernet, M = 61850 support

857-3C6AAM

Bulletin 857-3xxxAN • Comm. option 1: A = VCM TTL Serial RS-232 • Comm. option 2: N = VCM RTD, 857-RAA support

857-3C6ANMwith RS-232 to Ethernet converter

Bulletin 857-3xxxCA • Comm. option 1: C = None• Comm. option 2: A = None

857-3C6AAM

Bulletin 857-3xxxCL Bulletin 857-3xxxCM • Comm. option 1: C = None• Comm. option 2: L = iEthernet, M = 61850 support

857-3C6AAM



Bulletin 857-3xxxDA • Comm. option 1: D = VCM 485-4 wire serial RS-485 • Comm. option 2: A = None

PN-388316(857-3C6ADM)

Bulletin 857-3xxxDC • Comm. option 1: D = VCM 485-4 wire serial RS-485 • Comm. option 2: C = VCM 232 RS-232 via RJ45

PN-388316(857-3C6ADM)

with RS-232 to Ethernet converter

Bulletin 857-3xxxDD • Comm. option 1: D = VCM 485-4 wire serial RS-485 • Comm. option 2: D = VCM 485-2 wire serial RS-485

PN-388316(857-3C6ADM)

Bulletin 857-3xxxDL Bulletin 857-3xxxDM• Comm. option 1: D=VCM 485-4 wire serial RS-485 • Comm. option 2: L = iEthernet, M = 61850 support

PN-388316(857-3C6ADM)

Bulletin 857-3xxxDN • Comm. option 1: D = VCM 485-4 wire serial RS-485 • Comm. option 2: N = VCM RTD, 857-RAA Support

857-3C6ADN

Bulletin 857-3xxxEA • Comm. option 1: E = VCM FIBER, 857-RAD support• Comm. option 2: A = None

857-3C6AEM

Bulletin 857-3xxxEC • Comm. option 1: E = VCM FIBER, 857-RAD support• Comm. option 2: C = VCM 232 Serial RS-232 via RJ45

857-3C6AEMwith RS-232 to Ethernet converter

Bulletin 857-3xxxED • Comm. option 1: E = VCM FIBER, 857-RAD support• Comm. option 2: D = VCM 485-2 wire serial RS-485

PN-388317(857-3C6ADN)




Bulletin 857-3xxxELBulletin 857-3xxxEM• Comm. option 1: E = VCM FIBER, 857-RAD support• Comm. option 2: L = iEthernet, M = 61850 support

857-3C6AEM

Bulletin 857-3xxxILBulletin 857-3xxxIM• Comm. option 1: I = VCM 232 Serial RS-232 via RJ45• Comm. option 2: L = iEthernet, M = 61850 support

857-3C6AAM

Bulletin 857-3xxxMC• Comm. option 1: M = Dual Fiber Ethernet, 100 Mbps • Comm. option 2: C = VCM 232 RS-232 via RJ45

Third-party Engineered SolutionNo substitution for Dual Fiber Ethernet

Bulletin 857-3xxxMD• Comm. option 1: M = Dual Fiber Ethernet, 100 Mbps • Comm. option 2: D = VCM 485-2 wire serial RS-485


Bulletin 857-3xxxMN• Comm. option 1: M = Dual Fiber Ethernet, 100 Mbps • Comm. option 2: N = VCM RTD, 857-RAA support


Bulletin 857-3xxxNC • Comm. option 1: N = VCM RTD, 857-RAA support• Comm. option 2: C = VCM 232 RS-232 via RJ45

857-3C6ANMwith RS-232 to Ethernet converter

Bulletin 857-3xxxND• Comm. option 1: N = VCM RTD, 857-RAA support• Comm. option 2: D = VCM 485-2 wire serial RS-485

PN-388317(857-3C6ADN)

Bulletin 857-3xxxNLBulletin 857-3xxxNM• Comm. option 1: N=VCM RTD, 857-RAA support• Comm. option 2: L = iEthernet, M = 61850 support

857-3C6ANM




Recommended Spare Relays

The table below specifies recommended replacement relays, with associated communication ports and supported protocols.

RecommendedReplacement Comm. Port 1 Comm. Port 2 Protocols

SupportedRTD Scanner Support Rear View Notes

857-3C6AAM VCMTTL iEthernet

• Modbus• Ethernet/IP• Modbus TCP• IEC 61850• IEC 101• DNP 3• RS-232

None (1) (2) (3) (4) (5)

(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.

857-3C6ANM VCMRTD iEthernet

• Ethernet/IP• Modbus TCP• IEC 61850• IEC 101• DNP 3

857-RAA (1) (2) (3) (4) (5) (6)

(6) See Table 1 on page 6 for RTD Scanner supported models.

PN-388316 (857-3C6ADM) VCM485-4 wire iEthernet

• Modbus• Ethernet/IP• Modbus TCP• IEC 61850• IEC 101• DNP 3

None (1) (2) (3) (4) (5) (6)

857-3C6AEM VCMFIBER iEthernet

• Ethernet/IP• Modbus TCP• IEC 61850• IEC 101• DNP 3

857-RAD (1) (2) (3) (4) (5) (6)

PN-388317(857-3C6ADN) VCM485-4 wire VCMRTD • Modbus 857-RAA (1) (2) (3) (4) (5) (6)



Cross Reference Matrix

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.

Bulletin Number Recommended Substitution RTD Scanner Supported Comments857-3C6AAA 857-3C6AAM None —

857-3C6AAC Engineered solution or 857-3C6AAM None 857-3CAAM, if second RS-232 connection is not required.

857-3C6AAD PN-388316(1)

(1) PN-388316 = 857-3C6ADM.

None No RS-232 support.857-3C6AAL 857-3C6AAM None — 857-3C6AAM 857-3C6AAM None — 857-3C6AAN 857-3C6ANM 857-RAA For RS-232 support, requires an Ethernet converter857-3C6ACA 857-3C6AAM None — 857-3C6ACL 857-3C6AAM None — 857-3C6ADA PN-388316(1) None —

857-3C6ADC PN-388316(1) None PN-388316, with RS-232 to Ethernet converter.

857-3C6ADD PN-388316(1) None —

857-3C6ADL PN-388316(1) None —

857-3C6ADM PN-388316(1) None —

857-3C6ADN PN-388317(2)

(2) PN-388317 = 857-3C6ADN.

857-RAA — 857-3C6AEA 857-3C6AEM 857-RAD — 857-3C6AEC 857-3C6AEM 857-RAD No RS-232 support.857-3C6AED 857-3C6AEM 857-RAD — 857-3C6AEL 857-3C6AEM 857-RAD — 857-3C6AEM 857-3C6AEM 857-RAD — 857-3C6AIL 857-3C6AAM None — 857-3C6AMC No substitution available None Requires an engineered solution.857-3C6AMD No substitution available None Requires an engineered solution.857-3C6AMN No substitution available None Requires an engineered solution.857-3C6ANC 857-3C6ANM 857-RAA For RS-232 support, requires an Ethernet converter.857-3C6AND PN-388317(2) 857-RAA — 857-3C6ANL 857-3C6ANM 857-RAA — 857-3C6ANM 857-3C6ANM 857-RAA — 857-3C6BNL No substitution available None Requires an engineered solution.857-3C6CAD 857-3C6ADM None No Arc Flash or RS-232 option available.857-3C6CAL 857-3C6AAM None No Arc Flash option available.857-3C6CEL 857-3C6AEM 857-RAD No Arc Flash option available.857-3C6CEM 857-3C6AEM 857-RAD No Arc Flash option available.857-3C6CNL 857-3C6ANM 857-RAA No Arc Flash option available.857-3C6CNM 857-3C6ANM 857-RAA No Arc Flash option available.

857-RAA(3)

(3) RTD scanner options.

No substitution. See publication 857-RM001.

857-RAD(3) No substitution. See publication 857-RM001.


https://literature.rockwellautomation.com/idc/groups/literature/documents/rm/857-rm001_-en-p.pdf



Notes:



Bulletin 857 Protection Relay Substitution Guidelines Reference Manual

Additional ResourcesThese documents contain additional information concerning related products from Rockwell Automation.

You can view or download publications at rok.auto/literature.

Resource DescriptionBulletin 857 Protection Relay to E300 Electronic Overload Relay Migration Guide, 857-RM001

This document helps to select associated E300™ electronic overload relay components that can be used in a migration path from the Bulletin 857 relay.

EtherNet/IP Network Devices User Manual, ENET-UM006 Describes how to configure and use EtherNet/IP devices to communicate on the EtherNet/IP network.

Ethernet Reference Manual, ENET-RM002 Describes basic Ethernet concepts, infrastructure components, and infrastructure features.

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.

Industrial Components Preventive Maintenance, Enclosures, and Contact Ratings Specifications, publication IC-TD002

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.

https://literature.rockwellautomation.com/idc/groups/literature/documents/rm/secure-rm001_-en-p.pdf

https://literature.rockwellautomation.com/idc/groups/literature/documents/td/ic-td002_-en-p.pdf

https://literature.rockwellautomation.com/idc/groups/literature/documents/rm/enet-rm002_-en-p.pdf

http://literature.rockwellautomation.com/idc/groups/literature/documents/in/1770-in041_-en-p.pdf

https://rok.auto/certifications

https://literature.rockwellautomation.com/idc/groups/literature/documents/in/sgi-in001_-en-p.pdf

https://rok.auto/literature

https://literature.rockwellautomation.com/idc/groups/literature/documents/um/enet-um006_-en-p.pdf

https://literature.rockwellautomation.com/idc/groups/literature/documents/rm/enet-rm002_-en-p.pdf

https://literature.rockwellautomation.com/idc/groups/literature/documents/rm/secure-rm001_-en-p.pdf


Publication 857-RM002B-EN-P - July 2021Supersedes Publication 857-RM002A-EN-P - June 2021 Copyright © 2021 Rockwell Automation, Inc. All rights reserved. Printed in Canada.

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bulletin 857 protection relay substitution guidelines

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