Wiring Man En

E-mail: [email protected] Internet: www.moeller.net www.eaton.com Issued by Moeller GmbH Hein-Moeller-Str. 7-11 D-53115 Bonn © 2008 by Moeller GmbH, Germany Subject to alterations FB0200-004EN_(02/08) ip/Ins/CPI Printed in Germany (11/08) Article No.: 119816

Eaton’s electrical business is a global leader in electrical control, power distribution, uninterruptible power supply and industrial automation products and services. Eaton’s global electrical brands, including Cutler-Hammer®, MGE Office Protection Systems™, Powerware®, Holec®, MEM®, Santak and Moeller, provide customer-driven PowerChain Management® solutions to serve the power system needs of the industrial, institutional, government, utility, commercial, residential, IT, mission critical and OEM markets worldwide. www.eaton.com

For service issues please contact your Moeller representative or the Moeller Field Service. Hotline +49(0)180 5 228322 (de, en) Tel. +49(0)228 602-3640 Fax +49(0)228 602-61400 E-Mail: [email protected] Internet: www.moeller.net/fieldservice

Wiring Manual | 2008

Moeller addresses worldwide: www.moeller.net/address

Wiring Manual | 2008 Automation and Power Distribution

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T1 T2

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SmartWire

SmartWire

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Vorsatz_en.fm Seite 1 Dienstag, 2. Dezember 2008 2:00 14

All brand and product names are trade marks or registered trademarks of the owner concerned

Updated edition 2008, publication date 02/08 © 2008 by Moeller GmbH, Bonn Editor: Heidrun Riege Translator: globaldocs GmbH All the circuits are designed according to our best expertise and have been carefully tested. They serve as practical examples. Moeller GmbH refuses to accept liability for any errors. All rights reserved, including those of the translation. No part of this manual may be reproduced in any form (printed, photocopy, microfilm or any other process) or processed, duplicated or distributed by means of electronic systems without the written permission of Moeller GmbH, Bonn, Germany. Subject to alterations without notice. Printed on bleached cellulose, 100 % free from chlorine and acid.

Moeller Wiring Manual 02/08

The Moeller Wiring Manual chapter The Moeller Wiring Manual

0

Switching, control, visualisation

1

Electronic motor starters and drives

2

Control circuit devices

3

Rotary switches

4

Contactors and relays

5

Motor-protective circuit-breakers

6

Circuit-breakers

7

All about Motors

8

Export to the world market and to North America

9

Standards, formulae, tables

10

Index

11

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0


The Moeller Wiring Manual Page

0

0-2

What's new in this edition?

0-3

Moeller – Competence and Experience from a Single Source

0-4

The Moeller Support Portal

0-5

Online Training Center

0-6

Electronic Catalogue

0-8

Moeller Field Service

0-9

Moeller Darwin technology

0-11

Moeller power distribution equipment

0-14


The Moeller Wiring Manual What's new in this edition? Export to the world market and to North America

The way to a safe machine

0

easySafety – Fulfills the highest safety demands. The safety of people and machines must be taken into account for the total lifecycle of a machine/system. For personnel protection safety components such as position switches, light curtains, two-hand control switches or emergency-stop pushbuttons come into use. The safety information is monitored and evaluated by the new easySafety control relay which complies to the highest safety requirements. a section "The way to the safe machine", page 1-10 The target markets of machine and system builders are international. Moeller knows these markets and is a competent partner worldwide in all issues relating to the export of switchgear and power distribution systems. The export of products to North America (USA and Canada) and the special requirements involved are taking on increasing importance. We have streamlined and expanded the existing content for you and collated it in a separate new chapter 9. The remaining content from the previous chapter 9 is now provided in chapter 10.

Always up-to-date We make every effort to adapt and update every new edition of the Wiring Manual according to the ever increasing requirements of the markets. The many example circuits in particular are continually being updated by our specialists to the best of their knowledge and carefully tested. They are provided solely as examples from practice. Moeller GmbH does not accept any liability for any errors.

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The Moeller Wiring Manual Moeller – Competence and Experience from a Single Source

0

www.moeller.net – The Moeller Home Page Moeller offers you a range of products and services that can be optimally combined with one another. Visit our site on the Internet. There you will find everything about Moeller, such as: • Up-to-date information about Moeller products • The addresses of the Moeller sales offices and representatives worldwide

• Information about the Moeller Company Group • Publications in the press, specialist press • References • Exhibition dates and events • Technical support in the Moeller Support Portal

www.moeller.net/en/support/ – The Moeller Support Portal You can receive technical support for all Moeller products just by a mouse click. And tips and tricks, Frequently Asked Questions (FAQs), updates, software modules, PDF downloads,

0-4

demo programs and much more. You can also subscribe to the Moeller Newsletters.


The Moeller Wiring Manual The Moeller Support Portal Uncomplicated and quick way of finding the information you need:

• Selection aids – Motor starters a section "Selection aids", page 8-3 – Frequency inverters a section "Selection aids", page 2-28

• PDF Downloads – Catalogues – Manuals and installation instructions – Product information, such as brochures, selection aids, technical essays, declarations of conformity and of course – The Moeller Wiring Manual

You can also find a link to the Moeller Field Service via the Support Portal (a section "Moeller Field Service", page 0-9).

• Software Downloads – Demo versions – Updates – Software and application modules

You can send your queries directly to the Technical Support/pre-sales service by e-mail. Simply select the e-mail form that meets your requirements to the -Moeller experts.

0-5

0


The Moeller Wiring Manual Online Training Center

0

http://trainingscenter.moeller.net

Moeller has now fully developed a web-based information and training platform for its well-known and successful easy control relay as well as the easyHMI multi-function display. This presents fully programmed and documented applications from a wide range of sectors.

The online training center is divided into the 6 areas “Products”, “Basics”, “Functions”, “Applications”, “References” and “Software”. The Products area provides:

Comprehensive information on all aspects of the easy and easyHMI is also provided with additional links to more in-depth topics.

• An overview of the device series and accessories, • mounting instructions, operating manuals and product information for download as PDF files.

Tips and tricks are presented in the FAQ area and you can share your experience with over 1,600 easy users in the easy forum (www.easy-forum.net). A full text search facility offers support in finding the information you are looking for.

The Basics area gives you the chance to learn about programming and networking devices at entry level. Special descriptions are provided depending on whether you wish to work with easySoft or with easySoft-CoDeSys.

0-6


The Moeller Wiring Manual Online Training Center The Programming section of the Basics area also explains how to use the programming system by means of example projects.

0

The "Networking" section provides examples on networking the devices. The Functions area provides 54 preprogrammed functions with: • a complete function description, • example program that you can load directly onto your easy or test beforehand with easySoft, and if necessary adapt it to your required application, • small Flash animations that illustrate how to create the function in easySoft, • sorted according to device class easy500/700/800 and easyHMI. The Applications area shows typical applications with easy such as temperature controls in greenhouses or stairway lighting controls as well as examples of graphic display applications with easyHMI. These applications are: • “ready to use”: simply load the completed programs onto your easy and put them into operation, • tested and fully documented.

The References area shows you that Moeller products are used in a wide range of areas and are in use worldwide. To obtain a short overview of their versatility look at some of the applications for the easy family on the page presented in PDF format. The Software area provides information and downloads for: • the easySoft operating and programming software, • the OPC server, supplied free-of-charge with easySoft • the Labeleditor for the customised labelling of the easyHMI, • Fieldbus interfaces with the necessary device master data, • CAD files for electrical engineering design.

0-7


The Moeller Wiring Manual Electronic Catalogue

0

The efficient way to detailed product information From detailed product information right up to the enquiry for your products by email or fax from your Moeller product supplier. All this and more you can find in the Electronic Catalogue.

Create a comprehensive data sheet for a product and save it as a PDF document or print it out. In product groups that contain a large number of products, special selection tools are provided in the ranges so that you can identify specifically a few products on the basis of the product features you require. A number of links to additional product information and all aspects of it enable you to ensure optimum use of the product: • Application examples and project design notes, • approvals • installation instructions, • manuals, • software, etc. Choose “Your” Electronic Catalogue on the Internet http://int.catalog.moeller.net/en. The Electronic Catalogue on the Internet is updated regularly.

This gives you fast access to new innovations as well as extensive information on the current Moeller ranges. • • • •

Industrial switchgear, Drives, Automation systems, drives, Power distribution systems.

0-8


The Moeller Wiring Manual Moeller Field Service Our services for your success. • • • •

Helpline Onsite Service Repairs Online Service

Moeller Helpline Break-Down Service You will receive competent and quick telephone assistance in the event of unscheduled machine stops and plant down-times, system faults and device break-downs around the clock. Consulting Service During business hours, you will receive support for commissioning, application queries right through to fault analysis, which can also be carried out by remote diagnosis. Specialists are available in the areas of automation, drives, low-voltage power distribution or switchgear. Moeller Onsite Service Troubleshooting onsite Qualified technicians and specialists can visit you in order to rectify faults quickly and reliably. Inspection and maintenance DIN VDE 0105 part 100 (clause 5.3) requires the recurrent testing of electrical equipment in order to ensure their proper condition. German work safety law A3 stipulates that repeat inspections on fixed electrical systems and equipment must be carried out at least every 4 years by electrical specialists.

Further information is available from our website.

0

The Field Service therefore offers appropriate services for circuit-breakers, distribution boards (xEnergy, MODAN, ID2000, other distribution boards etc.). We support you in the inspection and maintenance of the circuit-breakers and low-voltage distribution boards supplied by Moeller, determine the condition of your systems and carry out the necessary work. If required, thermography or network analysis are also carried out with this work. Mounting and commissioning support Contact us if you require fast and competent support in installing and commissioning tasks. Conversions and expansions Whether with controllers, circuit-breakers or other components, we can bring your machines and plants up to the latest state-of-the-art. Thermography Thermography gives us an efficient way of analysing your electrical systems and controls during operation. Network analysis Network analysis provides clear information about the specific state of your networks without the need for lengthy and expensive troubleshooting.

0-9


The Moeller Wiring Manual Moeller Field Service

0

Bus monitoring If required we can inspect the communication networks of your systems with the latest technical equipment. Moeller Repairs Direct exchange In the event of a fault, the direct exchange service for selective Moeller products considerably reduces the downtime of your production plant. Repairs The repair of Moeller products in our Service Center is an inexpensive alternative for fault rectification. Moeller Online Service Online troubleshooting We can provide special assistance if you wish to analyse and rectify faults on products. You can carry out interactive troubleshooting via the Internet with direct access to the Field Service database. FAQ - Frequently Asked Questions There are some questions about our products that our customers very often ask. You can benefit from the answers. You can read frequently asked questions with the corresponding answers on all aspects of automation. Downloads You're at the right place here if you require updates, software, documentation and declarations of conformity. Visit the Moeller Download Center to obtain all the information you require.

0-10

Contact • Faults hotline For field service contact your Moeller agent www.moeller.net/address or the Moeller Field Service directly Tel.: +49 (0) 180 522 3822 (de, en) (round the clock) • Consulting service Tel.: +49 (0) 228 602 3640 (Mo. - Fr. 08:00 - 16:00 CET) • Email [email protected] • Internet www.moeller.net/fieldservice


The Moeller Wiring Manual Moeller Darwin technology Darwin. The technological quantum spring.

0

Controlling

Protecting

HMI

Switching

The conventional switch cabinet is changing fundamentally. Darwin has established a bridge between the automation world and the world of switchgear. Switching devices are merging together with automation equipment and the conventional control wiring, such as between I/O modules and switching devices, is being replaced by a new, simple connection technology.

Drives

This project covers the entire Moeller product world for the switch cabinet in single evolutionary steps: • • • • •

Control, switching, contactors, operating and monitoring, Drives.

0-11


The Moeller Wiring Manual Moeller Darwin technology

0

Evolution of the control panel Before

Today

In the past each sensor and actuator was hardwired to an input and output of the main PLC. The result was a high wiring complexity, large control panels and a high potential for wiring errors.

This use of remote I/O and fieldbus technology significantly reduces wiring complexity.

Today sensors and actuators are wired to a remote preprocessing point and from there to the central PLC through a fieldbus.

0-12

The control system is distributed over several small control panels located in various positions on the machine. The number of hardwired inputs and outputs however, has remained the same; only the spaces between the control panels is bridged by fieldbus lines.


The Moeller Wiring Manual Moeller Darwin technology Today with SmartWire

Tomorrow with SmartWired

The current SmartWire technology lets you, for example, connect motor starters directly to the PLC. This intelligent wiring aid reduces both hard wiring and the number of central and remote I/Os as well as removing the potential for wiring errors.

SmartWire Darwin will completely replace the control wiring between PLC and switchgear.

The inputs and outputs are placed exactly where they are required – immediately next to the switching devices.

0

All devices connected with SmartWire Darwin operate as local or remote inputs/outputs of easyControl. The system is fully self-configuring. Further information a section "Connect, don't wire", page 5-8 and a section "SmartWire Gateway", page 1-43.

0-13


The Moeller Wiring Manual Moeller power distribution equipment

0

Low-voltage switchgear systems for infrastructure System range xEnergy xEnergy is a modular system range of power distribution boards designed specifically for infrastructures up to 4000 A. Moeller’s xEnergy products are optimized for safe and reliable power distribution.

The system range xEnergy integrates switching and protective devices, mounting and enclosure systems and control panel components into a coherent, cost-effective system.

0-14

It consists of: • Switching and protective devices, • the modular enclosure system, • the control panel complete with planning and calculation tools.

Being optimized for housing Moeller switchgear, the control panel components allow a flexible, time-saving installation.


The Moeller Wiring Manual Moeller power distribution equipment Type-testing of the complete switchgear–enclosure–control panel assemblies to IEC EN 60439 ensures a high safety level. xEnergy is a modular system consisting of matched function units that have been type-tested to IEC 60439. Available from Form 1 to Form 4, the system can be designed to conform to any applicable installation standard (DIN VDE, CEI, NF, UNE) and all relevant switchgear combinations to the respective protection type up to 4000 A have been type-tested.

Product features • Clear segregation into functional areas up to Form 4b • Enclosures for combination- and separate mounting, • Enclosure protection IP31 or IP55 • Main busbars at the rear up to 4000 A • Main busbars at the top up to 3200 A • All components fitted as TTA • Mains system types TN-C, TN-C-S, TN-S, TT, IT

Products XPower Panels • Incomers/feeders, outgoers or bus-couplers with circuit-breakers NZM4 or IZM up to 4000 A • Fixed mounted or withdrawable • 3 or 4 pole circuit-breakers • Cable or busbar trunking connection from top or bottom

0-15

0


The Moeller Wiring Manual Moeller power distribution equipment XFixed Panels

0

• Outgoers with circuit-breakers PKZ or NZM up to 630 A • Fixed mounted or withdrawable • 3 or 4 pole circuit-breakers • Cable connection from top or bottom

XFixed Panels • Outgoers with fuse combination units SASIL up to 630 A, plug-in units, vertically or horizontally fitted • Outgoers with fuse-strip units SL up to 630 A, fixed mounted, vertically fitted • 3 pole • Cable connection from top or bottom

0-16


The Moeller Wiring Manual Moeller power distribution equipment XGeneral Panels

0

• Mounting systems for rail-mounted service installation devices • Customized fixed mounted units on mounting plates up to 630 A, e.g. soft starters, frequency inverters, power factor correction • Automation engineering • Control technology adapter systems xStart • Incoming busbar 3, 4 pole and TP + N

0-17



0

Sheet steel wall-mounting enclosure CS With mounting plate

45 enclosure sizes are available for selection from 250 × 200 × 150 to 1200 × 1200 × 250 mm. The stable CS enclosure series made from solid sheet steel is used in applications wherever effective protection against the direct contact of live parts is required. The high IP55 degree of protection allows installed equipment to be protected from most harmful ambient conditions.

0-18

A continuous sponge polyurethane seal provides the necessary seal tightness. The surrounding rain channel profile offers protection against the ingress of liquid such as water or oil as well as dirt when the door is opened. The classification of impact resistance code IK10 to EN 62262 also protects the inside of the cabinet from mechanical damage. CS enclosures can be mounted as wall enclosures.


The Moeller Wiring Manual Moeller power distribution equipment Their powder coated surface provides an abrasion and corrosion resistant protection.

0

The enclosure door can be removed easily for other mechanical measures. Inside hinges that are covered can thus be undone simply and the door stop exchanged from right to left or vice versa. Moeller can also provide customised solutions on request. This includes for example: • other RAL colour tones, • other dimensions, • cutouts in doors and side panels, e.g. for mounting command and signalling devices, touch panels, meters and cable glands.

0-19



0

Terminal K

Copper conductors can be inserted easily and quickly into the box terminals from above without bending. The Moeller terminals are designed for copper strips or busbars as well as copper conductors. Each terminal pair is moulded in a plastic Duroplast shell. Each of the 6 sizes is available from stock as a 1-pole, 3-pole, 4-pole or 5-pole terminal combination.

The connection terminal consists of a combination of several very stable terminal blocks. It is used for connecting two or more conductors. A very wide range is available as standard with 6 sizes and terminal cross-sections from 16 to 3 x 240 mm² (160 to 1000 A).

0-20

Accessories such as the transparent plastic cover, auxiliary conductor terminals or conversion kits also enable the creation of your own terminal variants.


The Moeller Wiring Manual Moeller power distribution equipment CI insulated distribution boards, totally insulated

The assembly of the CI system demonstrates its flexibility. Whether as an individual enclosure, wall-mounted or free-standing distribution board of any size, the modular CI insulated distribution system up to 630 A always offers the right solution in harsh ambient conditions. The modular system makes it easy to adapt to a wide range of conditions. • IP65 protection ensures protection from dust, humidity and water jets, • pressure relief by means of liftable covers with spring-loaded locking bolts,

0

• "Total insulation" provides maximum personnel protection and operational safety. • Transparent neutral cover allows unrestricted view, • Floor-standing distribution boards with base covers for routing, fastening or covering large cable cross sections. Enclosed distribution boards are type-tested assemblies (TTA) in accordance with VDE 0660 part 500 or Type Tested Assemblies (TTA) to IEC 60 439.

0-21



0

SASY60i busbar system for the world market

The SASY60i modular busbar system from Moeller is designed for effective energy distribution in the control panel. Thanks to the innovative mounting technology feeder and outgoing circuit-breakers can be mounted quickly and compactly. SASY60i is safe and reliable. In conjunction with the latest generation of Moeller motor protective circuit-breakers and other circuit-breakers, the SASY 60i provides a universal, UL certified solution for switching, controlling, protecting and distributing energy. Together with the appropriate switching and protective devices, the busbar system is designed for worldwide use.

0-22

The larger air and creepage distances required in compliance with the UL 508A in America have been considered in the construction of the busbar components. When used in North America, the insulated bottom plate must be mounted under the system. Components approved for IEC such as h.b.c. fuse switch-disconnectors or D busbar mounting fuses can also suitable for perfectly matched fitting. As SASY60i requires few system components the new Moeller busbar system also reduces the stock-keeping and ordering required.


Notes

0

0-23


Notes

0

0-24


Switching, control, visualisation Page Timing relays

1-2

EMR4 measuring and monitoring relays

1-6

The way to the safe machine

1-10

System overview E

1-12

Engineering E

1-20

Programming E

1-50

Overview of automation products

1-67

Compact PLC, PS4

1-68

Modular PLC, XC100/XC200

1-70

HMI systems

1-72

Networking

1-73

Engineering PS4

1-75

Engineering EM4 and LE4

1-78

Engineering XC100, XC200

1-79

1-1

1


Switching, control, visualisation Timing relays

1

Electronic timing relays are used in contactor control systems which require short reset times, high repetition accuracy, high switching frequency, and a long component lifespan. Times between 0.05 s and 100 h can be easily selected and set. The switching capacity of electronic timing relays corresponds to the utilisation categories AC -15 and DC -13. In terms of the actuating voltages there are with timing relays the following differences : • Version A (DILET… and ETR4) Universal devices: DC 24 to 240 V AC 24 to 240 V, 50/60 Hz • Version W (DILET… and ETR4) AC devices: AC 346 to 440 V, 50/60 Hz • ETR2… (as row mounting device to DIN 43880) Universal device: DC 24 to 48 V AC 24 to 240 V, 50/60 Hz The functions of each of the timing relays are as follows: • DILET11, ETR4-11,ETR2-11 Function 11 (ondelayed) • ETR2-12 Function 12 (off-delayed) • ETR2-21 Function 21 (fleeting contact on energisation) • ETR2-42 Function 42 (flashing, pulse initiating)

1-2

• ETR2-44 Function 44 (flashing, two speeds; can be set to either pulse initiating or pause initiating) • Multifunction relays DILET70, ETR 4-69/70 Function 11 (on-delayed) Function 12 (off-delayed) Function 16 (on- and off-delayed) Function 21(fleeting contact on energisation) Function 22 (fleeting contact on deenergisation) Function 42 (flashing, pulse initiating) • Function 81 (pulse generating) Function 82 (pulse shaping) ON, OFF • Multifunction relays ETR2-69 Function 11 (on-delayed) Function 12 (off-delayed) Function 21 (fleeting contact on energisation) Function 22 (fleeting contact on deenergisation) Function 42 (flashing, pulse initiating) Function 43 (flashing, pause initiating) Function 82 (pulse shaping) • Star-delta timing relays ETR4-51 Function 51 (on-delayed) With both DILET70 and ETR4-70 an external potentiometer can be connected. Upon connection, both timing relays automatically recognize that a potentiometer is fitted. The ETR4-70 has a special feature. Equipped with two changeover contacts which can be converted to two timing contacts 15-18 and 2528 (A2-X1 bridged) or one timing contact 15-18 and a non-delayed contact 21-24 (A2-X1 not bridged). If the link A2–X1 is removed, only the timed contact 15–18 carries out the functions described below.


Switching, control, visualisation Timing relays Function 11

Function 16

On-delayed

On- and Off-delayed A1-A2 15-18

t

The control voltage Us is applied to terminals A1 and A2 through an actuating contact. After the set delay time the changeover contact of the output relay goes to position 15-18 (2528). Function 12 Off-delayed

t

A1-A2 Y1-Y2 B1 15-18 (25-28)

After the control voltage has been applied to terminals A1 and A2, the changeover contact of the output relay remains in the original position 15–16 (25–26). If terminals Y70 and Y1 in the DILET2 are linked with a floating NO contact or, in the case of the ETR4-69/70 or ETR2-69, a potential is applied to B1, the changeover contact changes to position 15-18 (15-28) immediately. If the connection between terminals Y1–Y1 is now interrupted or B2 is isolated from voltage, the changeover contact returns to its original position 1-1 (15-25) once the set time has elapsed.

t

t

1

A1-A2 Y1-Y2 B1 15-18 (25-28)

The control voltage Us is applied directly to terminals A1 and A2. If terminals Y1 and Y2 in the DILET70 are linked by a floating contact, or in the case of of the ETR4-69/70 a potential is applied to B1, the changeover contact goes to the position 15-18 (25-28) after a set time t. If connection Y1-Y1 is now interrupted or B2 is separated from the potential, the changeover contact goes back to its original position 1–1 (15–25) after the same time t. Function 21 Fleeting contact on energization A1-A2 t

15-18 (25-28)

After the voltage Us has been applied to A1 and A2, the changeover contact of the output relay goes to position 15–18 (25–28) and remains actuated for the set fleeting contact time. A fleeting pulse (terminals 1–2, 15–18) of defined duration is therefore produced from a two-wire control process (voltage on A25/A28) by this function.

1-3


Switching, control, visualisation Timing relays (16-25) after 26 s. This function is therefore a fleeting pulse with a time delay.

Function 82 Pulse forming

1

A1-A2 Y1-Y2 B1 15-18 (25-28)

t

After the control voltage has been applied to A1 and A2, the changeover contact of the output relay remains in the rest position 15–16 (25–26). If terminals Y70 and Y1 in the DILET2 are linked through a floating contact, or in the case of the ETR4-69/70 or ETR2-69, a potential is applied to B1, the changeover contact changes to the position 15–18 (25–28) immediately. If Y1–Y2 is now opened again or B1 is isolated from voltage, the changeover contact remains actuated until the set time has elapsed. If, instead, Y1–Y2 remain closed or B1 is separated from the potential for a longer period, the output relay likewise changes back to its rest position after the set time. An output pulse of precisely defined duration is thus produced in the pulse-forming function, irrespective of whether the input pulse via Y1–Y2 or B1 is shorter or longer than the set time. Function 81 Pulse generating with fixed pulse A1-A2 t

0.5 s

15-18 (25-28)

The actuating voltage is applied to terminals A1 and A2 via an actuating contact. After the set delay time has elapsed the changeover contact of the output relay goes to position 15-18 (2528) and returns to its original position 0.5-15 1-4

Function 22 Fleeting contact on de-energization

t

A1-A2 Y1-Y2 B1 15-18 (25-28)

The control voltage Us is applied directly to A1 and A2. If terminals Y1 and Y2 on DILET70 that are shorted at any time beforehand (DILET-70: floating) and then reopened (or for ETR4-69/70 or ETR2-69 contact B1 is floating), contact 1518 (25-28) closes for the duration of the set time. Function 42 Flashing, pulse initiating

t

t

t

t

A1-A2 15-18 (25-28)

After the voltage Us has been applied to A1 and A2, the changeover contact of the output relay changes to position 15–18 (25–28) and remains actuated for as long as the set flashing time. The subsequent pause duration corresponds to the flashing time.


Switching, control, visualisation Timing relays Function 43

Function 51 Star-delta

Flashing, pause initiated

On-delayed

t

t

t

t

1

A1-A2

A1-A2 15-18

t

t

tu

17-18 17-28

LED

After the voltage Us has been applied to A1 and A2 the changeover contact of the output relay stays in position 15-16 for the set flashing time and, after this time, goes to position 15-18 (the cycle begins with a pause phase).

If the control voltage Us is applied to A1 and A2, the instantaneous contact switches to position 17-18. After the set time the instantaneous contact opens; the timing contact 17-28 closes after a changeover time tu of 50 ms. On-Off Function

Function 44

A1-A2

Flashing, two speeds A1-A2

OFF

ON

OFF

A1-B1 15-18

t1

t2

t1

t2

t1

t2 Rel LED A1-B1 15-18

t1

t2

t1

t2

t1

t2 Rel LED

After the voltage Us has been applied to A1 and A2 the changeover contact of the output relay goes to position 15-18 (pulse begin). By bridging the contacts A1 and Y1 the relay can be switched to pause begin. The times t1 and t2 can be set to different times.

15-18 (25-28) LED

The On-Off function allows the operation of a control system to be tested and is an aid, for example, for commissioning. The Off function allows the output relay to be de-energized so that it no longer reacts to the functional sequence. The On function energizes the output relay. This function is dependent on the supply voltage being applied to the terminals A1/A2. The LED indicates the operational status. Further information sources Installation instructions • DILET…: AWA2527-1587 • ETR4…: AWA2527-1493, AWA2527-1485 • ETR2…: AWA2527-2372 Main catalogue for industrial switchgear, Section 4 “Timing relays”

1-5


Switching, control, visualisation EMR4 measuring and monitoring relays General

1

For the various applications measurement amd monitoring relays are necessary. With the new EMR4 range Moeller covers a large number of requirements: • general use, current monitor EMR4-I • space saving monitoring of the rotary field phase sequence relay EMR4-F • protection against destruction or damage of single system parts, phase monitoring relay EMR4-W • safe recognition of phase failure, phase imbalance monitoring relay EMR4-A • increased safety by motor current principle, level relay EMR4-N • increased operational safety, insulation monitoring relay EMR4-R

There are two versions, each with three measuring ranges (30/100/1000 mA, 1.5/5/15 A). The multi-voltage coil allows universal use of the relay. The two auxiliary changeover contacts allow a direct feedback. Selected bridging of short current peaks By using the selected time delay of between 0.05 and 30 s short current peaks can be bridged. EMR4-W phase monitoring relay

Current monitoring relay EMR4-I

The current monitoring relay EMR4-I is suitable for monitoring AC as well as DC current. With the definable low and high current limits, pumps and drill machines can be monitored. That is due to the selectable under or over limit.

1-6

The phase monitoring relay EMR4-W monitors the voltage height as well as the field rotation to provide protection against destruction or damage of single system parts. That means protection against destruction or damage of single system parts. Here the minimum low voltage and also the maximum overvoltage can be easily set to the required voltage within a defined range. An ON- or Off delay can be set. In the On-delay position short voltage breaks can be bridged. The off-delay position allows a failure storage for the set time.


Switching, control, visualisation EMR4 measuring and monitoring relays The delay time can be set between 0.1 and 10 s.

Phase imbalance relay EMR4-A

The relay activates with the correct rotation and voltage. After drop-out the device reactivates when a the voltage exceeds a 5 % hysteresis.

1

Phase sequence relay EMR4-F

The 22.4 mm wide EMR-4-A phase imbalance relay provides protection against phase to protect motors against destruction.

The phase sequence relay with a width of only 22.5 mm monitors the rotating field of portable motors for which the rotation direction is important (such as pumps, saws, drilling machines). This protects the motor from damage. The narrow mounting width saves space in the control panel.

Because the phase failure is determined through the phase shift, it can also be reliably detected to prevent motor overload in the event of a high motor feedback. The relay protects motors with a rated voltage of Un = 380 V, 50 Hz. Level monitoring relay EMR4-N

With a correctly rotating field the changeover contact switches the control voltage of the motor switching device. The EMR4-F500-2 covers the total voltage range from 200 to 500 V AC. The level monitoring relay EMR4-N is used mostly as dry running protection for pumps or for level regulation of liquids. It operates with sensors that measure conductivity. A sensor is required for the maximum and also a sensor for the minimum level. A third sensor is used for earth potential. The 22.5 mm wide device EMR4-N100 is suitable for conductive liquids. It can be switched from level regulation to dry running protection. The safety is increased as in both cases the motor current principle is used. 1-7


Switching, control, visualisation EMR4 measuring and monitoring relays An earth-fault is signalled via a changeover contact so that a fault can be cleared without expensive down time.

1

The device has a selectable fault memory so that the fault must be acknowledged after its removal. A Test button allows the device to be checked for correct operation at any time. The level monitoring relay EMR4-N500 has a higher sensitivity and is suitable for less conductive liquids. Due to an integrated rise and fall delay of between 0.1 and 10 s moving liquids can also be monitored. EMR4-R insulation monitoring relay

EN 60204 “Safety of machines” provides increased operational safety by monitoring the control voltage circuit for earth-fault using an insulation monitor. This is the main application for the EMR4-R. There are similar requirements in medical applications.

AC or DC control voltage Devices for AC and for DC are available, which cover the total control voltage range. The DC device has a multi-voltage source and can therefore also be used for AC. Multifunctional EMR4-AW(N) threephase monitors

The multifunctional three-phase monitors provide space saving monitoring of rotating fields. They feature a range of phase parameter measuring functions for phase sequence, phase failure, phase imbalance as well as undervoltage and overvoltage. Depending on device type, the threshold value for phase imbalance can be set between 2 and 15 %. The threshold values for undervoltage and overvoltage are fixed or adjustable.

1-8


Switching, control, visualisation EMR4 measuring and monitoring relays The different options and setting values are explained in the applicable installation instructions. The function “with neutral conductor monitoring” is a new feature of the EMR4-AWN... models.

1

Further information sources Installation instructions • Phase imbalance monitoring relay EMR4A400-1 AWA2431-1867 • Insulation monitoring relay EMR4-RAC-1-A AWA2431-1866 • Insulation monitoring relay EMR4-RDC-1-A AWA2431-1865 • Level monitoring relay EMR4-N100-1-B AWA2431-1864 • Phase sequence relay EMR4-F500-2 AWA2431-1863 • Phase monitoring relay EMR4-W… AWA2431-1863 • Current monitoring relay EMR4-I… AWA2431-1862 • Measuring/monitoring relays: 3-phase monitors EMR4-A…, EMR4-AW…, EMR4AWN…, EMR4-W… AWA2431-2271 Main catalogue Industrial Switchgear, Section 4 “monitoring relays”.

1-9


Switching, control, visualisation The way to the safe machine

1 The international standard EN ISO 12100-1 “Safety of machinery - Basic concepts, general principles for design” provide the design engineer with detailed assistance in the identification of hazards and the resulting risks to be assessed. This therefore lays down the technical measures for the reduction of hazards. The parts of machine control systems that handle safety tasks are defined as the “safetyrelated parts of control systems” (SRP/CS). Safety-related control systems comprise the entire safety function consisting of the input level (sensor), the logic (safety signal processing) and the output level (actuator). For reducing risks by means of SRP/CS, Moeller offers the right components with safety technology in accordance with the most stringent requirements stipulated in the safety standards EN 954-1, EN ISO 13849-1 and EN IEC 62061/61508. The appropriate safety functions are used according to the application field and the necessary hazard protection. Further information on the previous and the new international safety standards as well as circuit examples for a wide range of applications are provided in the latest version of the Moeller Safety Applications Technical Guide TB0200009.

1-10

The safety manual helps you by means of practical safety circuit examples and the associated calculations to determine safety performance in accordance with EN ISO 138491 and EN IEC 62061. Further technical information on the individual safety products is provided at www.moeller.net/Safety.


Switching, control, visualisation The way to the safe machine Fast and secure detection

Detecting hazards quickly with RMQ-Titan and FAK emergency-stop buttons. Motion safety under control with LS-Titan® position switches. Safe switching, disconnection and control with T rotary switches and P switch-disconnectors.

Input

Safe monitoring and processing

Safe monitoring and processing with ESR safety relays and easySafety control relay.

Logic

Reliable shutdown

Reliable disconnection with DILM contactors and CMD contactor monitoring relay.

Output

1-11

1


Switching, control, visualisation System overview E eRelay 2

2

1

1

3

5

4 4

6 6

5

ES C

ES C

9

10

11

ALT

L DE

OK

12

13

14

8 7

POW

ERR COM-ERR

ADR

9 8

1-12

MS

POWER BUS

NS


Switching, control, visualisation System overview E 1) Detachable display MFD-80… and MFD(AC)-CP4-500 2) Ethernet-Gateway EASY209-SE 3) Detachable display MFD-80… and MFD(AC)-CP4-800 4) Basic device easy500 5) Basic device easy700, expandable 6) Basic unit easy800, expandable, networkable via easyNet 7) EASY202-RE output expansion 8) easy410 I/O expansion 9) easy6… I/O expansion 10) Coupling unit EASY200-EASY for remote expansion of easy700, easy800 11) Expansion unit for networking PROFIBUSDP EASY204-DP 12) Expansion unit for networking AS-Interface EASY205-ASI 13) Expansion unit for networking CANopen EASY221-CO 14) Expansion unit for networking DeviceNet EASY222-DN

1

1-13


Switching, control, visualisation System overview E eHMI

1

1

2

3 4

7

8

6

9

10

11

12

5 POW

7

BUS

POWER COM-ERR

ERR MS

ADR

NS

6

1-14


Switching, control, visualisation System overview E 1) Ethernet gateway EASY209-SE 2) I/O module with or without temperature measuring for MFD-Titan 3) Power supply unit/CPU MFD(-AC)-CP8… 4) Display/operating unit MFD-80… 5) EASY202-RE output expansion 6) easy410 I/O expansion 7) easy6… I/O expansion 8) Coupling unit EASY200-EASY for remote expansion of MFD(-AC)-CP8… 9) Expansion unit for networking PROFIBUSDP EASY204-DP 10) Expansion unit for networking AS-Interface EASY205-ASI 11) Expansion unit for networking CANopen EASY221-CO 12) Expansion unit for networking DeviceNet EASY222-DN

1

1-15


Switching, control, visualisation System overview E eControl

1

1

1 2

2

3

3

5

6

7

ES

8

C

ALT

L DE

POW

BUS

POWER

ES C

COM-ERR

OK

ERR MS

ADR

NS

4 11 12

10 9

4

11 10

1-16


Switching, control, visualisation System overview E 1) CANopen connection for MFD-80… and MFD-CP4-CO 2) Detachable display MFD-80… and MFD(AC)-CP4-800 3) Basic device EC4P-200 4) CANopen I/O expansion EC4E… 5) Expansion unit for networking PROFIBUSDP EASY204-DP 6) Expansion unit for networking AS-Interface EASY205-ASI 7) Expansion unit for networking CANopen EASY221-CO 8) Expansion unit for networking DeviceNet EASY222-DN 9) EASY202-RE output expansion 10) easy410 I/O expansion 11) easy6… I/O expansion 12) Coupling unit EASY200-EASY for remote expansion of EC4P-200

1

1-17


Switching, control, visualisation System overview E Functions e

MFD(-AC)-CP8… and e800

e500 and e700

1

easy500 and easy700 have the same functions. easy700 offers more inputs and outputs, is expandable and can be connected to a standard bus system. The series and parallel linking of contacts and coils takes place in up to 128 current paths. The units have three contacts and a coil in series. The display of 16 operating and report texts is via an internal or external display. The main functions are: • Multi-function timing relay, • current impulse relay, • counters – forwards and backwards, – fast counter, – frequency counters, – operational time counter, • analog value comparator, • week and year time switch, • automatic summertime changeover, • retentive actual values of markers, numbers and timing relays. easy500 and easy700 can be custom-labelled.

1-18

MFD…CP8… and easy800 have the same functions. With its degree of protection MFD80...with IP65 can also be used in harsh environments. In addition for expansion and connection to standard bus systems eight easy800 or MFD-Titan units can be networked via easyNet. The series and parallel linking of contacts and coils takes place in up to 256 current paths. The units have four contacts and a coil in series. The display of 32 operating and report texts is via an internal or external display. In addition to the functions offered by easy700 the easy800 and the MFD-Titan feature: • PID controller, • arithmetic modules, • value scaling, • and much more. MDF-80 and easy800 can be custom-labelled.


Switching, control, visualisation System overview E eControl: EC4P-200

“Detachable” display – text display for eRelay, eSafety and eControl with IP65 protection

easy500

easy700 easy800 ES4P-200 EC4P-200

easyControl is the obvious successor to the easyRelay. The easyControl EC4P-200 can be used for implementing both small and mediumsized automation solutions. The easyControl can be combined with the standard easyRelaysystem as well as with virtually all automation devices via the integrated CANopen interface. With Ethernet on board, additional requirements such as OPC server and network programming are provided for. The easyControl EC4P-200 comes with a powerful CPU and an internal 256 KByte program memory. The EC4P-200 is programmed with easySoftCoDeSys (ECP-SOFT) based on IEC 61131-3.

The plug & play functionality allows you to connect the MFD-80.. display to the easyRelay, easySafety or easyControl via MFD-CP4.. power supply and communication module. The MFDCP4.. has an integrated 5 m connection cable which can be shortened as required. This has the advantage that no software or drivers are required for connection. The MFD-CP4.. offers genuine plug & play capabilities. The inputs and outputs are wired on the easyRelay, easySafety and easyControl. The MFD-80.. is mounted using 22.5 mm fixing holes. The IP65 display is backlit and offers a easy to read display. The display can be labelled to individual requirements.

1-19

1


Switching, control, visualisation Engineering E Power supply connection for AC devices

1

for DC devices

L

+

N

–

> 1A

L.1

L

N

N

Basic devices EASY512-AB-… EASY719-AB-… EASY512-AC-… EASY719-AC-… EASY819-AC-…

MFD-AC-CP8-…

1-20

+.1

+...V

0

0

Basic devices 24 V AC 24 V AC 115/230 V AC 115/230 V AC 115/230 V AC

115/230 V AC

Expansion devices EASY618-AC…

> 1A

EASY512-DA-… EASY719-DA-… EASY512-DC-… EASY7…-DC-… EASY819-DC-… EASY82.-DC-…

12 V DC 12 V DC 24 V DC 24 V DC 24 V DC 24 V DC

ES4P-…

24 V DC

EC4P-200

24 V DC

MFD-CP8-…

24 V DC

Expansion devices 115/230 V AC

EASY410-DC… EASY618-DC… EASY620-DC…

24 V DC 24 V DC 24 V DC


Switching, control, visualisation Engineering E Digital input connection of the AC devices L.1

1

N 100 nF /275 V h

1N4007

100 nF 1 kO

/275 V h

1

a a b c d

e f g h

b

c

d

e

Input signal via relay contact e.g. DILER Input signal via pushbutton RMQ Titan Input signal via position switch e.g. LS-Titan Conductor length 40 to 100 m for input without additional switching (e.g. easy700 I7, I8 already has addition switching, possible conductor length 100 m) Increased input current Limiting the input current Increasing the input current with EASY256HCI EASY256-HCI ballast device

f

g

N

h

Note • Due to the input circuitry the drop-out time of the input is increased. • Length of input conductor without additional circuit F 40 m, with additional circuit F 100 m.

1-21


Switching, control, visualisation Engineering E Digital input connection of the DC devices

1

+.1 –

p

a a b c d e

1-22

b

c

Input signal via relay contact e.g. DILER Input signal via pushbutton RMQ Titan Input signal via position switch e.g. LS-Titan Proximity switch, three-wire Proximity switch, four-wire

p

d

e

Note • Consider the voltage drop across the used conductor length. • Because of the high residual currents, twowire proximity switches should not be used.


Switching, control, visualisation Engineering E Analog inputs Depending upon the device two or four 0 to 10 V inputs are available. The resolution is 10-bit = 0 to 1023. The following applies: I7 = IA01 I8 = IA02

I11 = IA03 I12 = IA04

EASY512-AB/DA/DC… EASY719-AB/DA/DC… EASY721-DC… EASY819/820/821/822-DC… MFD-R16, MFD-R17, MFD-T16, MFD-TA17 EC4P-200

Caution! Analog signals are more sensitive to interference than digital signals so that more care must be taken when laying and connecting the signal cables. Incorrect switching states may occur if they are not connected correctly.

• With short cable lengths, ground the shield at both ends using a large contact area. If the cable length is more than around 30 m, grounding at both ends can result in equalisation currents between the two grounding points and thus in the interference of analog signals. In this case, only ground the cable at one end. • Do not lay signal lines parallel to power cables. • Connect inductive loads to be switched via the easy outputs to a separate power feed, or use a suppressor circuit for motors and valves. Supplying loads such as motors, solenoid valves or contactors and easy from the same power supply may cause interference of the analog input signal when switching.

• Use shielded twisted pair cables to prevent interference with the analog signals.

1-23

1


Switching, control, visualisation Engineering E Connecting power supply and analog inputs for e…AB device L

1

N

~ 0V

EASY200-POW +12 V

L01h

F1

N01 h

L

N

N

I1

I7

I8

Note With easy.... AB devices that process analog signals, the device power must be supplied through a transformer so that the device is isolated from the mains supply. The neutral conductor and the reference potential of DCsupplied analog sensors must be electrically connected.

1-24

Ensure that the common reference potential is earthed or monitored by an earth fault monitoring device. Observe the applicable regulations.


Switching, control, visualisation Engineering E Connecting analog inputs of e…DA/DC-… or MFD-R…/T… or EC4P-200 +

1

– +.1

a 4...20 mA (0...20 mA) +..V -0 V

h

Out 0...10 V -35...55 ˚C +12 V

+...V

0V

500 O

0V

0V

a a Setpoint potentiometer via separate power supply and potentiometer F1 kO, e.g. 1 kO, 0.25 W b Setpoint potentiometer with upstream resistor 1.3 kO, 0.25 W, potentiometer 1 kO, 0.25 W (values for 24 V DC) c Temperature monitoring via temperature sensor and transducer d Sensor 4 to 20 mA with resistor 500 O Note

b

c

d

• Connect the 0 V of the or the MFD-Titan with the 0 V of the power supply of the analogue encoder. • Sensor of 4(0) to 20 mA and a resistance of 500 O give the following approx. values: – 4 mA Q 1.9 V, – 10 mA Q 4.8 V, – 20 mA Q 9.5 V. • Analogue input 0 to 10 V, resolution 10-bit, 0 to 1023.

• Pay attention to the differing number and designation of the analogue inputs of each device type.

1-25


Switching, control, visualisation Engineering E Connecting Pt100/Ni1000 with MFD-T(A)P…

1

a

b

a Three wire connection b Two wire connection

MFD-TAP13-PT-A MFD-TP12-PT-A

-40 °C ... +90 °C 0 °C ... +250 °C 0 °C ... +400 °C

MFD-TAP13-NI-A MFD-TP12-NI-A

0 °C ... +250 °C

MFD-TAP13-PT-B MFD-TP12-PT-B

0 °C ... +850 °C

-40 °C ... +90 °C -200 °C ... +200 °C

Note Cable length, shielded < 10 m.

1-26


Switching, control, visualisation Engineering E Connecting “high-speed counters”, “frequency generators” and “incremental encoders” on e…DA/DC devices or MFD-R…/-T… or EC4P-200 +

+

–

–

+.1

+.1

1

p

A B

a

b

a High-speed counters, square wave signal via proximity switch, mark to space ratio should be 1:1 easy500/700 max. 1 kHz easy800 max. 5 kHz MFD-R/T… max. 3 kHz EC4P-200 max. 50 kHz b Square wave signal via frequency generator, mark to space ratio 1:1 easy500/700 max. 1 kHz easy800 max. 5 kHz MFD-R/T… max. 3 kHz EC4P-200 max. 50 kHz

c c Square wave signals via 24 V DC incremental encoder easy800-DC… and MFD-R/T… max. 3 kHz EC4P-200 max. 40 kHz Note Observe the different number and designation of the inputs of the “fast counter”, “frequency generator” and “incremental encoder” for each device type.

1-27


Switching, control, visualisation Engineering E Connecting relay outputs on EASY…R, MFD…R and EC4P-…MR, ES4P…

1

1

2

L…

1

2

L…

1

2

L…

1

2

L…

1

2

L…

M

a

b

Fuse protection switch potential L..

F 8 A/B16 Possible AC voltage range: 24 to 250 V, 50/60 Hz e.g. L1, L2, L3 phase to zero conductor Possible DC voltage range: 12 to 300 V DC

1-28

c

d

e

a Lamp, max. 1000 W at 230/240 V AC b Fluorescent tube, max. 10 x 28 W with electronic starter, 1 x 58 W with conventional starter at 230/240 V AC c AC motor d Valve e Coil


Switching, control, visualisation Engineering E Connecting transistor outputs on EASY…T, MFD-T… and EC4P…MT, ES4P…

1 + 24 V

0V

f 2.5 A F 10.0 A 24 V DC

a a

Contactor coil with zener diode as suppressor, 0.5 A at 24 V DC

b

Valve with diode as protective element, 0,5 A at 24 V DC

c

Resistor, 0.5 A at 24 V DC

d

Indicator lamp 3 or 5 W at 24 V DC, Output dependant upon device types and outputs

b

c

d

If inductive loads are not suppressed, the following applies: Several inductive loads should not be switched off simultaneously to avoid overheating the driver blocks in the worst possible case. If in the event of an emergency stop the +24 V DC power supply is to be switched off by means of a contact, and if this would mean switching off more than one controlled output with an inductive load, these inductive loads must be provided with a suppressor circuit.

Note Please note the following when switching off inductive loads: Suppressed inductive loads cause less interference in the entire electrical system. It is generally recommended that the suppressor is connected as close as possible to the inductive load. 1-29


Switching, control, visualisation Engineering E Parallel connection

Note The outputs must be connected only in parallel within a group (Q1 to Q4 or Q5 to Q8, S1 to S4 or S5 to S8); Q1 and Q3 or Q5, Q7 and Q8. Parallel outputs must be activated simultaneously.

1

if 4 outputs in parallel, max. 2 A at 24 V DC if 4 outputs in parallel, max. 2 A at 24 V DC Inductance without suppression max. 16 mH 12 or 20 W at 24 V DC Output dependant upon device types and outputs

0V

a a Resistor

1-30


Switching, control, visualisation Engineering E Connecting analog output on EASY820-DC-RC…, EASY822-DC-TC…, MFD-RA…, MFDTA…, EC4P…MTA, EC4P…MRA…

1

+ – +.1

+...V

0V

0V

0V

Q A1

a

0V

IA

0V

Q A1

b

a Servo valve control b Set value sekection for drive control Note • Analog signals are more sensitive to interference than digital signals, greater care must be therefore taken when routing signal cables. Incorrect switching states may occur if they are not connected correctly. • Analogue output 0 to 10 V, Resolution 10-bit, 0-1023.

1-31


Switching, control, visualisation Engineering E Input/output expansion e

1

Central expansion, up to 40 I/O easy700, easy800, MFD(-AC)-CP8… as well as EC4P-200 can be expanded with easy202, easy410, easy618 or easy620. This provides you with up to 24 inputs and 16 outputs. One expansion device per basic unit is possible, a section "Central and remote expansion e", page 1-33. Remote expansion, up to 40 I/O easy700, easy800, EC4P-200 and MFD-Titan are expanded with easy410, easy618 or easy620 using the EASY200-EASY coupling module. The expansion device can be operated up to 30 m from the basic device. There are a maximum of 24 inputs and 16 outputs available. One expansion device per basic unit is possible, a section "Central and remote expansion e", page 1-33. Networking via eNet, up to 320 I/O Up to eight stations can be interconnected by expanding the inputs and outputs via easyNet. An expansion device can be added to each easy800, MFD(-AC)-CP8… or EC4P-200. A network length of up to 1000 m is possible. There are two types of operation: • A master (position 1, station address 1) and up to 7 other stations. The program is contained in the master. • A master (space 1, station address 1) and up to 7 other “intelligent” or “dumb” stations. Each “intelligent” station has a program. a section "eNet, “loop through the device” network connection", page 1-34

1-32

Networking via CANopen (eControl) easyControl makes it possible to create networks via CANopen. For this the digital or analog I/O expansion modules EC4E… can be used. Another easy expansion module can be then connected to this (e.g. easy410, easy618, easy620). Observe the CANopen specification! a section "Network connection, CANopen", page 1-39


Switching, control, visualisation Engineering E Central and remote expansion e 1

I 1 - I...

2

R 1 - R...

Q 1 - Q...

S 1 - S...

easy700 easy800 EC4P-200 ES4P

easy202... easy410... easy618... easy620... 1

2

E+ E-

F 30 m

I 1 - I...

Q 1 - Q...

1

Central expansion

R 1 - R...

Remote expansion

S 1 - S... E+ E-

easy700 easy800 EC4P-200 ES4P

easy200

easy410... easy618... easy620...

Central expansion

R 1 - R...

MFD S 1 - S... MFD-AC-CP8... MFD-CP8...

easy202... easy410... easy618... easy620...

F 30 m

E+ E-

MFD E+ E-

MFD-AC-CP8... MFD-CP8... EASY-LINK-DS

easy200

Remote expansion

R 1 - R...

S 1 - S... easy410... easy618... easy620...

1-33


Switching, control, visualisation Engineering E eNet, “loop through the device” network connection

1

EASY-NT-R (124 O PIN1+2)

Geographic location, position1)

easyNet

Station Example 1

Example 2

1

1

1

2

2

3

3

3

8

8

8

2

easy800 EC4P-200 ES4P


easy410 easy618 easy620

MFD-AC-CP8 MFD-CP8

easy200

easy800

easy202


EASY-LINK-DS • Adressing the stations: – Automatic addressing of from station 1 or via easySoft… from the PC, physical location = station, – Single addressing on the corresponding device or via easySoft… on each station, geographic location and station can be different. 1-34

1) 1)The geographic location/place 1 always has the device address 1. • The maximum length easyNet is 1000 m. • Should easyNet be interrupted or a device is not operational, the network is no longer active from the interrupted point. • Unscreened 4-core cable, each two cores twisted. Characteristic impedance of the cable must be 120 O.


Switching, control, visualisation Engineering E eNet, network connection “T piece with spur cable” EASY-NT-R (124 O PIN1+2)

MFD-AC-CP8 MFD-CP8

easy800

Station Example 1

Example2

1

1

1

2

2

3

3

3

8

8

8

2

F 0.3 m



Geographic location, position1)

easyNet


easy200

F 0.3 m


easy202 EASY-LINK-DS

• Adressing the stations: – Single addressing on corresponding device or via easySoft… on every device. • The max. total length, including spur cables, with easyNet is 1000 m. • The max. length of T pieces for easy800 or for MFDTitan is 0,30 m.

1) The geographic location/place 1 always has the station address 1. • If easyNet is interrupted between the T piece and the device, or a device is not operational, the network is still active for the remaining devices. • Unscreened 4-core cable, each two cores twisted. Three cores are required. Characteristic impedance of the cable must be 120 O.

1-35

1


Switching, control, visualisation Engineering E Network connection eNet

1

RJ 45 sockets and plugs Connection layout of RJ45 socket on easy and MFD-Titan.

1 2 3 4 5 6 7 8

The network cable does not require a screen braid. If a network cable with shield braid is used, the braid does not have to be connected to PE. If a PE connection is required nevertheless, the screen braid must be connected to PE at only one end.

Connection layout of the RJ45 plug on the easy, MFD(-AC)-CP8…, EC4P-200 and ES4P.

1 2 3 4 5 6 7 8

Note Cable lengths and cross-sections a table, page 1-38. The minimum operation with easyNet functions with cables ECAN_H, ECAN_L, GND. The SEL_IN cable is used only for automatic addressing.

a

a Cable entry side 8-pole RJ45, EASY-NT-RJ45 Pin assignment for eNet PIN 1; ECAN_H; Data conductor; conductor pair A PIN 2; ECAN_L; Data conductor; conductor pair A PIN 3; GND; ground conductor; conductor pair B PIN 4; SEL_IN; Select conductor; conductor pair B

1-36

Assembly of the network cable for eNet The characteristic impedance of the cable must be 120 O.

A A B B

1 2 3 4

ECAN_H ECAN_L GND (Ground) SEL_IN

Bus terminating resistor A bus terminal resistor must be connected to the physically first and last device in the network: • Rating of the bus terminal resistor 124 O, • connect to PIN 1 and PIN 2 of the RJ-45 plug, • connection plug : EASY-NT-R.


Switching, control, visualisation Engineering E Prefabricated cables, RJ45 plug at both ends Cable length [cm]

Type designation

30

EASY-NT-30

80

EASY-NT-80

150

EASY-NT-150

User prepared cables 100 m 4 x 0.14 mm2; twisted pair: EASY-NT-CAB

Calculating length with known cable cross-section For a known conductor cross section the maximum conductor length is calculated.

1

lmax = Length of conductor in m S = Conductor cross-section in mm2 rcu = specific resistance of copper, when nothing else state 0.018 Omm2/m

lmax =

S x 12.4 rcu

RJ45 plug: EASY-NT-RJ45 Crimping tool for RJ45 plug: EASY-RJ45-TOOL. Calculating cross-section with known cable lengths The minimum cross-section is determined for the known maximum expansion of the network. l = Length of conductor in m Smin = minimum cross-section in mm2 rcu = specific resistance of copper, unless otherwise stated 0.018 Omm2/m

Smin =

l x rcu 12.4

Note If the result of the calculation is not a standard cross-section, use the next highest standard cross-section.

1-37


Switching, control, visualisation Engineering E Permissible network lengths with eNet

1

Total cable length of eNet

Transmission speed

m

Kbaud

mm2

F6

F1000

0.14

26

0.10

F 25

F 500

0.14

26

0.10

F 40

F 250

0.14

26

0.10

F 125

F 1251)

0.25

24

0.18

F 175

F 50

0.25

23

0.25

F 250

F 50

0.38

21

0.36

F 300

F 50

0.50

20

0.44

F 400

F 20

0.75

19

0.58

F 600

F 20

1.0

17

0.87

F 700

F 20

1.5

17

1.02

F 1 000

=10

1.5

15

1.45

1) Factory setting

1-38

Conductor cross-section, standardised EN

AWG

Bus conductor, minimum conductor cross-section mm2


Switching, control, visualisation Engineering E Network connection, CANopen Loop through the device

1

T piece with spur line

124 O

124 O

EC4P-200

EC4P-200

XC100/200

1 CAN-H 2 CAN-L 3 GND 4 5 6 7 8

XC100/200

6 5 4 3 2 1

GND CAN-L CAN-H GND CAN-L CAN-H

F 0.3 m 5 4

MFD

MFD

3 2 1

9 8 7 6

CAN-L

F 0.3 m

DF51/DV51 DE51NETCAN

DF51/DV51 DE51NETCAN

CAN-H GND

1 2 3 4 5

F 0.3 m CAN-H GND CAN-L

124 O

124 O

1-39


Switching, control, visualisation Engineering E

1

Bus terminating resistors The ends of the network link must be terminated with 120 O bus termination resistors.

6

6

6

5

5

4

4

3

3

3

2

2

2

1

1

1

5 4

120 O

CAN_L CAN_H

120 O

Terminals 1 and 4 , 2 and 5 , 3 and 6 are internally connected.

Properties of the CANopen cable Use only a cable that is approved for CANopen with the following characteristics: • Surge impedance 120 O • Capacitance per unit length < 60 pF/m The specifications for cable, connector and bus termination resistor are defined in ISO 11898. Some requirements and specifications for the CANopen network are listed below. The length of the CANopen bus cable depends on the conductor cross-section and the number of bus stations connected. The following table includes values for the bus length in relation to the cross-section and the connected bus stations, which guarantee a secure bus connection (table corresponds with the requirements of the ISO 11898).

1-40

Cable crosssection [mm]

Maximum length [m] n = 32

n = 64

n = 100

0.25

200

170

150

0.5

360

310

270

0.75

550

470

410

n = number of connected bus users

If the bus length is greater than 250 m and/or are more than 64 stations connected, the ISO 11898 demands a residual ripple of the supply voltage of F 5 %.


Switching, control, visualisation Engineering E Network connection with cable cross-sections > 0.14 mm2, AWG26 Network connect “through the device”. Example A, with terminals

Network connection “T piece with spur cable” Example A, with terminals 1

1

IN

2

2

3

IN

4

a RJ45

3

1 2

RJ45

3

c

4

RJ45

4

OUT

easy800 ES4P MFD-CP8 EC4P-200

OUT


b RJ45

RJ45

7 5 3 1

RJ45

RJ45

IN

8 6 4 2

RJ45

7 5 3 1

Example B, with interface element

8 6 4 2

Example B, with interface element

8 6 4 2

c F 0.3 m (3-core)

7 5 3 1

a Recommendation F 0.3 m

d

IN

OUT

RJ45

OUT


b Recommendation F 0.3 m (EASY-NT-30)


d F 0.3 m (EASY-NT-30)

Note Sreening is required for CANopen.

1-41

1


Switching, control, visualisation Engineering E Expansion units for networking

1

EASY204-DP

EASY221-C0

easy700, easy800

EC4P-200

MFD…CP8…

ES4P

A network module can be connected with easy700, easy800, MFD(-AC)-CP8… and EC4P200. The network module must be included as a slave in the configuration. The inputs and output points can be expanded via easyNet (a section "eNet, network connection “T piece with spur cable”", page 1-35 and a section "eNet, network connection “T piece with spur cable”", page 1-35).

1-42

EASY222-DN

EASY205-ASI

Further information can be found in the following manuals: • AWB2528-1508GB easy500, easy700 control relay, • AWB 2528-1423GB easy800, control relay, • GBAWB2528-1480GB MFD-Titan, multi-function display, • AWB2724-1584GB EC4-200, • AWB 2528-1401GB EASY204-DP, • AWB2528-1479GB EASY221-CO, • AWB2528-1427GB EASY222-DN.


Switching, control, visualisation Engineering E SmartWire Gateway The gateway allows the communication between 16 SmartWire modules and easy-NET compatible or CANopen compatible PLCs. It has a selector switch to select either easy-NET or CANopen operating mode. The gateway delivers the supply voltage for the electronic supply of the SmartWire modules and for the power element of the switchgear, e.g. the contactor coil actuation. The voltage is supplied to the modules via the SmartWire connection cable. Operating mode eNet In easyNET mode the gateway acts as a station on easyNET and the SmartWire master at the same time. Up to 8 stations on the easyNET can be intelligently connected with each other.

a

b

c

CANopen operating mode CANopen mode allows communication between SmartWire modules and controllers with CANopen interface such as EC4--200 or XC100/200. In addition to standard fieldbus modules such as remote I/O systems or visualisation devices, this allows a number of switchgear devices can be networked directly with the PLC. Up to 126 stations can be connected to a CANopen network, depending on the performance level of the CANopen fieldbus master.

a

b

CANopen

easy 800

easyNet

c f

EC4P

MFD Titan

easy 800

d g

1 2 3 4 5

1 2 3 4 5

d 16

SmartWire

e 16

e

SmartWire

f a Head-end controller (easy800, MFD-CP8NT, EC4P-200, ES4P, XC201) b SmartWire Gateway c easyNet d easyNet station, e.g. easy800, ES4P e easyNet station, e.g. MFD-CP8-NT f SmartWire module, e.g.: for xStart g SmartWire connection cable

a CANopen PLC e.g. EC4P-200, XC100/XC200 b SmartWire Gateway c CANopen PLC, e.g. EC4P-200 d CANopen station, e.g. MI4/MFD4 e SmartWire module, e.g.: for xStart f SmartWire connection cable

1-43

1


Switching, control, visualisation Engineering E Detachable display with protection type IP65 + –

L.1

ES4P

L.1

>1A

+ 24 V 0 V

L

N 115/230 V 50/60 Hz

easy800

m

>1A

L N

F5

1

MFD-CP4-800-CAB5

F5

EC4P-200

m

F5m easy700 MFD...CP4... DEL

easy500

DEL

ESC

ALT

OK

ALT

MFD-80... ESC

The display screen of the easyRelay or easyControl is shown on the MFD-80… “detachable display”. MFD-80-B can also be used to operate easyRelay and easyControl. No extra software or programming is necessary to operate the “remote display”. The connection cable MFD-CP4-…-CAB5 can be shortened.

1-44

OK

MFD-CP4-500-CAB5 F5m


Switching, control, visualisation Engineering E Communication connections e easy500

easy700

1

EASY-PC-CAB DEL

ESC

ALT

DEL

OK

ESC

ALT

EASY-USB-CAB

OK

abe MFD-CP4-500-CAB5 EASY209-SE

a EASY-SOFT-BASIC b EASY-SOFT-PRO c ESP-SOFT d ECP-SOFT(CoDeSys) e OPC

XT-CAT5-X...

MFD-CP4-800-CAB5

be easy800

MFD...CP8...

ES4P

c

EASY800-USB-CAB

EASY800-PC-CAB EASY800-MO-CAB 1)

d e

EC4P-200

XT-CAT5-X...1)

EU4A-RJ45-CAB1 EU4A-RJ45-USB-CAB

only EC4P-222… and XC200 1-45


Switching, control, visualisation Engineering E EASY209-SE standard connection

Ethernet connection

a

1

2

g

b c

1

1 2 3 4 5 6 7 8

TX+ TX– RX+

RX–

d f

a b c d e f g

e

3

Ethernet connection (RJ45 socket) Status LED (POW/RUN) COM terminal, cage clamp terminal 5-pole RESET button Device power supply 24 V DC V Device label Strain relief

2 1 2 3 4 5

1 press – 2 insert – 3 remove 1 = grey, 2 = brown, 3 = yellow, 4 = white,

24 V connection +24 V

5 = green

0V

>1A

+24 V 0 V

1-46

COM connection

1


Switching, control, visualisation Engineering E COM-LINK connection MFD-80…

MFD…CP8… MFD..T../R..

easy800

MFD…CP8… MFD..T../R..

1

POW-Side

The COM-LINK is a point-to-point connection that uses the serial interface. Via this interface the status of the inputs and outputs are read, and marker areas read and written. Twenty marker double words read or written are possible. Reading and writing are freely selectable. This data can be used for reference value input or for display functions. The stations of the COM-LINK have different functions. The active device is always a MFD…CP8… and controls the complete interface.

Remote stations can be easy800 or an MFD…CP8…. The remote station responds to the requests of the active station. It does not recognise the difference whether COM-LINK is active or a PC with EASY-SOFT-PRO is using the interface. The devices of the COM-LINK can be centralised or decentralised extended with easy expansion devices. The remote device can also be a device in the easyNet.

1-47


Switching, control, visualisation Engineering E Connecting and operating the e800 on the serial log printer

1

An SP (SP = serial protocol) function block can be used to send data directly via the serial PC interface on the front of the device. More information is provided in the EASY-SOFT-PRO help.

easy800

Serially controlled printer

EASY800-MO-CAB

Pin assignment of EASY800-MO-CAB:

1

2 6

3 7

4 8

5 9

2 white T x D 3 brown R x D 5 green GND

1

2 6

For information about EASY800-MO-CAB, see also AWA2528-2345.

1-48

3 7

4 8

5 9


Switching, control, visualisation Engineering E Connection and modem operation with e or MFD easy700

easy800

easy500

DEL

ESC

1

MFD...CP8... DEL

ALT

ESC

ALT

OK

OK

EASY800-PC-CAB EASY-PC-CAB

EASY800-MO-CAB

Modem 1

PC

Fax

e-mail

Modem 2

SMS

Pager

OPC

For information about EASY800-MO-CAB, see also AWA2528-2345.

1-49


Switching, control, visualisation Programming E Programming instead of wiring

1

Circuit diagramms are the basis of all electrotechnical applications. In practice electrical devices are wired to each other. With control relay easy this can be done simply. Simple menu operation in many languages simplify the input. That saves time and therefore costs. easy and MFD-Titan are the professional devices for the world market.

S1

S6

K1 S4 S5

K3

K3 K1

K2

K3

Contacts, coils, function modules, operands Operand

I

nI IA R

nR Q

nQ QA S

nS ID 1ID LE M 1M MB MD MW 1MB/1MW /1MD N P

1-50

Description

easy500, easy700

easy800

MFD(-AC)-CP8…

Bit input, basic unit Bit input, basic unit via easyNET Analogue input Bit input, expansion device1) Bit input, expansion device via easyNET Bit output, basic unit Bit output, basic unit via easyNET Analogue output Bit output, expansion device Bit output, expansion device via easyNET Diagnostic alarm COM-Link diagnostic alarm Bit output display backlight + Front LEDs Marker Marker COM-Link Marker Byte Marker double word Marker word Marker operand COM-Link

x – x x – x – – x – – – – x – – – – –

x x x x x x x X x x x – – x – x x x –

x x x x x x x x x x x x x x x x x x x

Marker

x x

– x

– x


Switching, control, visualisation Programming E Operand

Description

Jump Bit input via easyNET Bit output via easyNET easyNET Analog value comparator A Arithmetic AR Block comparison BC Block transfer BT Boolean sequence BV Counter relays C Frequency counters CF High-speed counters CH Incremental counters CI Comparators CP (reverse order) D Data function block DB PID controllers DC PT1 signal smoothing filter FT Get value from easyNet GT (clock)/Week time clock Ö H/HW Year time switch Y/HY Conditional jump JC Jump label LB Value scaling LS Master reset Z/MR Data multiplexer MX Numerical converters NC Operating hours counters O/OT Pulse output PO Pulse width modulation PW Sychronise clock via network SC Set cycle time ST Serial protocol SP Shift register SR Timing relays T Table function TB Value limitation VC 1) With easy700, easy800 and MFD…CP8… 2) With easy500 and easy700 programmable as operation type.

:

nRN nSN

easy500, easy700

easy800

x x – x – x x x – x – X – x – X X X X2) X X2) X – X – X x x – x – X – X – X X X X X – x – x – x x x – x – X X X – x – X – X – X – x – x X X – x – X n = NET station 1…8

MFD(-AC)-CP8…

x x x x X x x x x x x x x – x x x x x x x x x x – x x – x x x – x x x x

1

1-51


Switching, control, visualisation Programming E Coil functions

1

The switching behaviour of the relay coil is determined by the selected coil function. In the wiring diagram, the specified function should be used only once for each relay coil. Circuit diagram symbol

e Display

Coil function

Ä

Contactor function

Å

1-52

Unused outputs Q and S can also be used as markers like M and N.

Example

ÄQ1, ÄD2, ÄS4, Ä:1, ÄM7

Contactor function with negated result

ÅQ1, ÅD2, ÅS4

è

Cycle pulse on falling edge

èQ3, èM4, èD8, èS7

È

Cycle pulse on rising edge

ÈQ4, ÈM5, ÈD7, ÈS3

ä

Surge function

äQ3, äM4, äD8, äS7

S

Latch (set)

SQ8, SM2, SD3, SS4

R

Reset (unlatching)

RQ4, RM5, RD7, RS3


Switching, control, visualisation Programming E Parameter sets for times Example based on EASY512 Depending up on the programme the following parameters can be set: • • • • •

Switching function, Time range, Parameter display, Time 1 and Time 2.

T1 Relay no.

1

I1 Time setpoint 1 I2 Time setpoint 2

# Output switch status: # N/O contact open, â

N/C contact closed

ü Switching function

S Time range ü

T1 I1

+

30.000

I2

#

S

I7

+ Parameter display 30.000 constant as value, e. g. 30 s I7 Variable, e. g. Analoge value I7 T:00 clock time

T:00

Possible coil functions: • Trigger = TT.. • Reset = RT.. • Halt = HT.. Parameters

Switch function

X

Switch with on-delay

?X

Switch with on-delay and random time range

â

Switch with off-delay

?â

Switch with off-delay and random time range

Xâ

Switching with On-delay and Off-delay

?Xâ

Switching with On-delay and Off-delay with random time

ü

Single-pulse switching

Ü

Switching with flashing

1-53


Switching, control, visualisation Programming E Parameters

1

Time range and setpoint time

Resolution

Seconds: 0.000 to 99.999 s

easy500, easy700 10 ms easy800, MFD…CP8… 5 ms

M:S 00:00

Minutes: Seconds 00:00 to 99:59

1s

H:M 00:00

Hours: Minutes, 00:00 to 99:59

1 min.

S

00.000

Parameters

Displaying the parameter set via menu item “Parameter”

+

Call enabled

-

Access disabled

Basic circuits The easy circuit configuration is input in ladder diagram. This section includes a few circuit examples which are intended to demonstrate the possibilities for your own circuit diagrams. The values in the logic table have the following meanings for switching contacts: 0 = N/O contact open, N/C contact closed 1 = N/O contact closed, N/C contact open For relay coils Qx” 0 = Coil not energized 1 = Coil energized Note The examples shown are based on easy500 and easy700. easy800 and MFD…CP8… provide four contacts and one coil per rung.

1-54

Negation Negation means that the contact opens rather than closes when it is actuated (NOT circuit). In the easy circuit diagram, press the ALT button to toggle contact I1 between N/C and N/O contact. Logic table I1

Q1

1

0

0

1

I1-------ÄQ1


Switching, control, visualisation Programming E Parallel switching

Series connection Q1 is controlled by a series circuit consisting of three make contacts (AND circuit).

I1-I2-I3-ÄQ1 I1-I2-I3-ÄQ2

Q2” is actuated via three normally closed contacts connected in series (NAND circuit). In the easy circuit diagram, you can connect up to three make or break contacts in series within a rung. Use M marker relays if you need to connect more than three make contacts in series. Logic table I1

I2

I3

Q1

Q2

0

0

0

0

1

1

0

0

0

0

0

1

0

0

0

1

1

0

0

0

0

0

1

0

0

1

0

1

0

0

0

1

1

0

0

1

1

1

1

0

Q1 is controlled via a parallel circuit of several normally open contacts (OR circuit).

I1u------ÄQ1 I2s I3k

A parallel circuit of normally closed contacts controls Q2 (NOR circuit).

I1u------ÄQ2 I2s I3k

Logic table I1

I2

I3

Q1

Q2

0

0

0

0

1

1

0

0

1

1

0

1

0

1

1

1

1

0

1

1

0

0

1

1

1

1

0

1

1

1

0

1

1

1

1

1

1

1

1

0

1-55

1


Switching, control, visualisation Programming E Changeover circuit

1

A two-way circuit is made in easy using two series connections that are combined to form a parallel circuit (XOR).

Logic table

I1-I2k

An XOR circuit stands for an “Exclusive Or” circuit. Only when a contact is closed, is the coil energized. Logic table I1

I2

Q1

0

0

0

1

0

1

0

1

1

1

1

0

Self-latching A combination of a series and parallel connection is used to wire a latching circuit.

S1 normally open contact on I1 S2 normally closed contact on I2

Latching is I1uI2----ÄQ1 established by Q1k contact Q1 which is connected in parallel to I1. When I1 is actuated and reopened, the current flows via contact Q1 until I2 is actuated.

1-56

I1

I2

Contact Q1

Coil Q1

0

0

0

0

1

0

0

0

0

1

0

0

1

1

0

1

1

0

1

0

0

1

1

1

1

1

1

1

I1-I2u---ÄQ1

The hold-on (self-maintaining) circuit is used to switch machines on and off. The machine is switched on at the input terminals via normally open contact S1 and is switched off via normally closed contact S2. S2 breaks the connection to the control voltage in order to switch off the machine. This ensures that the machine can be switched off, even in the event of a wire break. I2 is always closed when not actuated. A self-latching circuit with wire break monitoring can alternatively be wired using the Set and Reset coil functions.

S1 normally open contact on I1 S2 normally closed contact on I2 I1-------SQ1 I2-------RQ1


Switching, control, visualisation Programming E Coil Q1 latches if I1 is activated. I2 inverts the break contact signal of S2 and only switches if S2 is activated in order to disconnect the machine or in the event of a wire break. Keep to the order that each coil is wired in the easy circuit diagram: first wire the “S”-coil, and then the“R”-coil. This will ensure that the machine will be switched off when I2 is actuated, even if I1 is switched on. Impulse relays An impulse relay is often used for controlling lighting such as for stairwell lighting.

On-delayed timing relays The on-delay can be used to override a short impulse or with a machine, to start a further operation after a time delay.

S1 normally open contact on I1 I1-------TT1 T1-------ÄM1

Permanent contact S1 normally open contact on I1 I1-------äQ1

To energize a relay coil continuously, make a connection of all contact fields from the coil to the leftmost position.

---------ÄQ1

Logic table Logic table I1

Status of Q1

Q1

0

0

0

1

0

1

0

1

1

1

1

0

---

Q1

1

1

1-57

1


Switching, control, visualisation Programming E Wiring of contacts and relays

1

Hardwired

Wiring with easy

t

t

S1

S1

S2

K1 K1

S2

P1

K1

P1

Star-delta starting You can implement two star-delta circuits with easy. The advantage of easy is that it is possible to select the changeover time between star and

delta contactors, and also the time delay between switching off the star contactor and switching on the delta contactor.

.

L S1 S2

Q11

Q12

Q11

K1 Q13

N 1-58

K1

Q11

Q12

Q12 Q13


Switching, control, visualisation Programming E L N S1

S2

1 Q11

K1 I1

L N

Q2

Q1 1

Q11

Q12

2

1

2

Q13

N

Function of the e circuit diagram Start/Stop of circuit with the external actuators S1 and S2. The mains contactor starts the timing relay in the logic relay.

I1u------TT1 dT1----ÄQ1

dT1----TT2

If your easy has an integral time switch, you can combine star-delta starting with the time switch function. In this case, use easy to also switch the mains contactor.

hT2----ÄQ2

I1: Mains contactor switched on Q1: Star contactor ON Q2: Delta contactor ON T1: Changeover time star/delta (10 to 30 s) T2: Wait time between star off, delta on (30, 40, 50, 60 ms) 1-59


Switching, control, visualisation Programming E Stairway lighting

1

easy requires only four space units. With five connections and the easy circuit the stairway lighting is operational.

For a conventional circuit a minimum of five elements are required. An impulse relay, two timing relays, two auxiliary relays. S1

S2

E1 E2

S3

E3 L N

K3

K1 K3

K1

K2

K3 5s

Q12

Q12

Q11 6 min

Important note Four such stairway circuits can be implemented with one easy device.

1-60

Q11

K2 Q12


Switching, control, visualisation Programming E S1

1

S2

E1 E2

S3

E3 L N K1 L N

I1

Q1 1

2

Button pressed briefly

Light On or Off, the impulse changeover relay function is able to switch off continuous lighting where required.

Light Off after 6 min.

Switched off automatically. With continuous lighting this function is not active.

Button pressed for more than 5 s

Continuous light

1-61


Switching, control, visualisation Programming E The easy circuit configuration for the function below looks like this:

1

I1-------TT2 T2-------SM1 I1u------äQ1 T3k Q1-M1----TT3

Q1-------RM1

The enhanced easy circuit diagram: after four hours, the continuous lighting is also switched off. I1------uTT1 hTT2

T2-------SM1 T1u------äQ1 T3s T4k Q1uM1----TT3

h------TT4

Q1-------RM1

1-62

Meaning of the contacts and relays used: I1: ON/OFF pushbutton Q1: Output relay for light ON/OFF M1:Marker relay.This is used to block the “switch off automatically after 6 minutes” function for continuous lighting. T1: Cyclical impulse for switching Q1 ON/OFF, (ü, impulse with value 00.00 s) T2: Scan to determine how long the button was pressed. When pressed for longer than 5 s, it changes to continuous lighting. ( X, ondelayed, value 5 s) T3: Switch off after the light has been on for von 6 min. ( X, on-delayed, value 6:00 min.) T4: Switch off after 4 hours continuously on. ( X, on-delayed, value 4:00 h)


Switching, control, visualisation Programming E 4-way shift register A shift register can be used for storing an item of information – e.g. sorting of items into “good” or “bad” – two, three or four transport steps further on. A shift pulse and the value (0” or 1”) to be shifted are required for the shift register.

Function: Pulse

Value

1

Storage position 1

2

3

4

1

1

1

0

0

0

Values which are no longer required are deleted via the reset input of the shift register. The values in the shift register pass through the register in the following order:

2

0

0

1

0

0

3

0

0

0

1

0

4

1

1

0

0

1

1st, 2nd, 3rd, 4th storage position.

5

0

0

1

0

0

0

0

0

0

Block diagram of the 4-way shift register

a

b c d

1 2 3 4 a b c d

Pulse Value Reset Storage position

Reset = 1

Allocate the value 0 with the information content bad. Should the shift register be accidently deleted, no bad parts will be reused. I1: Shift pulse (PULSE) I2: Information (good/bad) to be shifted (VALUE) I3: Clear content of the shift register (RESET) M1: 1st storage location M2: 2nd storage location M3: 3rd storage location M4: 4th storage location M7: Marker relay for cycle pulse M8: Cyclical pulse for shift pulse

1-63


Switching, control, visualisation Programming E

I1uM7----ÄM8

1

h------ÄM7

M8uM3----SM4

4th memory position, set

dM3----RM4

4th memory position, delete

dM2----RM3

3rd memory position, delete

dM1----RM2

2nd memory position, delete

hI2----RM1

1st memory position, delete

dM2----SM3

3rd memory position, set

dM1----SM2

2nd memory position, set

dI2----SM1

1st memory position, set

I3------uRM1 dRM2 dRM3 hRM4

1-64

Generate shift pulse

Delete all memory positions


Switching, control, visualisation Programming E Display text and actual values , display and edit set values easy500 and easy700 can display 16, easy800 can display 32 freely editable texts. These texts can be triggered by the actual values of function relays such as timing relays, counters, operating hours counters, analog value comparators, date, time or scaled analog values. The setpoints of timing relays, counters, operating hours counters, analog value comparators can be modified when the text is displayed.

1

SWITCHING; CONTROL; DISPLAY; ALL EASY!

Example of a text display: The text display can display the following:

RUNTIME M:S

Line 1, 12 characters

T1 :012:46

Line 2, 12 characters, a setpoint or actual value

C1 :0355

Line 3, 12 characters, a setpoint or actual value

PRODUCED

ST

Line 4, 12 characters

The text output unit D (D = Display) functions in the circuit diagram like a normal marker M. Should a text be attached to a marker this would be shown at condition 1 of the coil in the easy display. A precondition is that the easy is in RUN mode and before the texts are displayed the status display is shown. D1 is defined as alarm text and has therefore priority over other displays.

D2 to D16/D32 are displayed when activated. When several displays are activated they are shown one after the other every 4 seconds. When a set value is edited the corresponding display remains shown until the value transfer. Several values, such as actual and setpoint values from function relays, analog input values or time and date can be incorporated. The set values can be edited: • easy500 and easy700, two values, • easy800, four values.

1-65


Switching, control, visualisation Programming E Visualisation with eHMI

1

The visualisation with easyHMI is by “screens”, on which the display is shown. Example of a “screen”:

S1 S2 S3

M 3h

The following screen elements can be combined. • Graphic elements – Bit display – Bitmap – Bargraph – Message bitmap

1-66

• Pushbutton elements – Latching button – Button field • Text elements – Static text – Message text – Screen menu – Running text – Rolling text • Value display elements – Date and time display – Numerical value – Timing relay value display • Value entry elements – Value entry – Timing relay value entry – Date and time entry – 7-day time switch input – Year time switch entry


Switching, control, visualisation Overview of automation products The requirements placed on automation systems today range from the special manufacturing of single units up to the series production of millions of units. These call for flexible, open and modular automation products which meet these requirements. Moeller can offer an optimum range of products and services that can be combined for your control and visualization tasks. This allows us to provide more efficient solutions and optimise the efficiency of your machines and electrical systems. Moeller offers worldwide economical solutions for the automation of production processes and machines. Compact PLC, PS4 series

Modular PLC, XC100/XC200

1

The outstanding feature of modular PLCs is their scalable design. This offers a high level of flexibility for designing individual automation systems. Another benefit is their ability to be integrated in modern communication concepts. Access via Ethernet is indispensable for many applications. Firstly to enable efficient communication between controllers and secondly for data exchange with higher-level control systems using communication standards such as OPC. HMI systems

Compact PLCs are programmable logic controllers which offer outstanding basic features by means of the large number of hardware and software functions. They can be used for many applications for regulating, controlling and measuring. If the integrated functions are insufficient, the devices can be expanded locally or via networks.

Moeller offers a wide range of products for communication between human and machine, allowing you to implement optimum solutions quickly. The offer range includes graphical text operator panels (a section "MFD4-5-XRC30", page 1-72) and touch operator panels.

1-67


Switching, control, visualisation Compact PLC, PS4

1

Compact PLCs are devices which offer outstanding basic features by means of the large number of hardware and software functions and can be used for many applications involving regulating, controlling and measuring tasks. If additional functions are required the devices can easily be expanded locally or via networks. The PS4 compact PLCs have the following system characteristics: • • • • •

Standard programming, Remote and local expansion options, Integrated fieldbus interface (Suconet), Plug-in screw terminals, Small, compact in size.

The controllers in this range are very versatile with a wide range of features, such as integrated setpoint potentiometers, analog inputs/outputs and memory expansion modules (from PS4-150). The range consists of: • Compact PLC PS4, • LE4 local expansion modules, • EM4 remote expansion modules. All compact PLCs are networkable and can be networked and programmed via the integrated fieldbus. The common programming software is Sucosoft S40, a user-friendly programming package conforming to IEC 61131-3.

PS4C Compact PLC LE4L ocal expansion module

EM4 Expansion module

1-68


Switching, control, visualisation Compact PLC, PS4 PS4-141/151 – the universal genius Universal use, outstanding series features. • Inputs/outputs – 16 digital inputs – 14 (PS4-151: 8)digital outputs – 2 analog inputs – 1 analog output • Program memory – 24 kByte (+32 kByte optional) – Recipe memory (optional): 32 KByte • Expandable by – Remote with EM4 modules – Networking: Suconet, Ethernet PS4-201 – the adaptable PLC Flexible for standard solutions, locally and remotely expandable for a wide range of configuration options. • Inputs/outputs – 8 digital inputs – 6 digital outputs – 2 analog inputs – 1 analog output • Program memory – 24 kByte (+32 kByte optional) – Recipe memory (optional): 32 KByte • Expandable by – Local with LE4 modules – Remote with EM4 modules – Networking: Suconet , PROFIBUS-D, Ethernet

PS4-271 – The building services specialist Locally and remotely expandable for AC applications.

1

• Inputs/outputs – 12 digital inputs – 8 digital outputs (12 A) – 8 analog inputs, of which 2 for PT1000/Ni1000) – 2 analog outputs • Program memory (+optional expansion) – 24 kByte (+32 kByte) – Recipe memory (optional): 32 KByte • Expandable by – Local with LE4 modules – Remote with EM4 modules – Networking: Suconet, PROFIBUS-DP, Ethernet PS4-341 – the high-speed PLC Even more speed and larger program and data memory. • Inputs/outputs – 16 digital inputs – 14 digital outputs – 2 analog inputs – 1 analog output • Program memory (+optional expansion) – 512 kByte – Recipe memory (optional): 512 KByte • Expandable by – Local with LE4 modules – Remote with EM4 modules – Networking: Suconet, PROFIBUS-DP, Ethernet

1-69


Switching, control, visualisation Modular PLC, XC100/XC200 XC100

1

XC200

The modular PLC of the XC100 series is a powerful automation system for small and medium-sized applications. Locally expandable by up to 15 XI/OC modules. The integrated CANopen fieldbus interface provides the interface to the remote periphery. The OPC server also simplifies the connection with standard OPC client applications.

The modular PLCs of the XC200 series offer a high processing performance and outstanding communications capabilities. This includes the integrated Ethernet interface in addition to an RS 232 interface and a CANopen fieldbus interface. The OPC server also supplies the connection with standard OPC client applications. All XC201..-XV devices also feature an integrated WEB server as a technological highlight.

1

0 1 2 3 4 5 6 0 1 2 7 3 4 5 14 15 XC-CPU101

2 0 1 2 3 4 5 6 8 9 10 7 11 12 13 14 15

DC INPUT

EH-XD16

0 1 2 3 4 5 6 8 9 10 7 11 12 13 14 15

DC INPUT

EH-XD16

0 1 2 3 4 5 6 8 9 10 7 11 12 13 14 15

DC INPUT

EH-XD16

0 1 2 3 4 5 6 8 9 10 7 11 12 13 14 15

DC INPUT

0 1 2 3 4 5 6 0 1 2 7 3 4 5 14 15 XC-CPU201

1-70

EH-XD16

3


Switching, control, visualisation Modular PLC, XC100/XC200 System components • Modular PLCs – XC100 a 8 DI, 6 DO, CANopen, RS 232, 4 interrupt inputs Slot for multimedia memory card, 64 – 256 KByte program/data memory, 4/8 KByte for retentive data, 0.5 ms/1000 instructions – XC200 b 8 DI, 6 DO, CANopen, RS 232, Ethernet, 2 counters, 2 interrupt inputs, WEB/OPC server, USB, locally expandable with XI/OC I/O modules, 256 – 512 KByte program/data memory, 0.05 ms/1000 instructions • XI/OC input/output modules c – Can be fitted to the XC100/200 (max. 15 modules) – Plug-in terminals with screw or springloaded terminal • easySoft-CoDeSys – Programming, configuring, testing/commissioning in a single tool

For further information see the following product overview and manuals: – XC100 hardware and engineering (AWB2724-1453) – XC200 hardware and engineering (AWB2724-1491) – XI/OC hardware and engineering (AWB2725-1452) – XV100 hardware and engineering (AWB2726-1461) – easySoft-CoDeSys PLC program development (AWB2700-1437) – Function blocks for easySoft-CoDeSys (AWB2786-1456); including data handling function blocks for text display PLCs The latest version can be found at: www.moeller.net/support. Enter the numbers shown in brackets as the search criterion e.g. “AWB2725-1453”.

1-71

1


Switching, control, visualisation HMI systems Text operator panel MI4

1

The MI4 text operator panels are designed for simple and economical machine operation. The high contrast LCD displays come with a durable LED backlight. All displays have graphics capability. This enables the display of different character sets, graphics and bargraphs. All buttons can be configured by project. Insert labels can be provided for function buttons for individual labelling.

1-72

MFD4-5-XRC-30 The 5.7" touch panel is a colour STN device based on resistive touch technology. It can be used solely as an HMI or also as an HMI with integrated PLC functionality and integrated web server. The display screens are created with the easySoft-CoDeSys programming software. A separate design tool is therefore unnecessary. The Ethernet, CANopen and RS232 interfaces are integrated on the touch panel.


Switching, control, visualisation Networking

Networking PS40 series

Modbus Ethernet CANopen PROFIBUS Suconet

PS40 Series

Part no.

Interfaces

PS4-141-MM1 PS4-151-MM1

Suconet K + RS 232 Suconet K + RS 232

PS4-201-MM1 PS4-271-MM1 PS4-341-MM1

Suconet K + RS 232 Suconet K + RS 232 Suconet K + RS 232

LE4-501-BS1 LE4-504-BS1 LE4-504-BT1 COBOX

Suconet K, master or slave PROFIBUS-DP, master PROFIBUS-DP, slave Ethernet

EM4-101-... EM4-111-...

Suconet K/K1 Suconet K/K1

EM4-201-DX2 EM4-204-DX1

Suconet K PROFIBUS-DP

1

max. 6 LE4

Networking XC series

Modbus Ethernet CANopen PROFIBUS Suconet

XC series

Part no.

Interfaces

XC-CPU101-xx XIOC-SER

RS232, CANopen 1 serial interface with RS232C, 485, 422 Suconet K slave Modbus master, slave

XIOC-NET-SK-M XIOC-NET-DP-M XIOC-NET-DP-S

Suconet K master PROFIBUS DP master PROFIBUS DP slave

XC-CPU201-xx XIOC-SER

Ethernet, RS232, CANopen, USB 1 serial interface with RS232C, 485, 422 Suconet K slave Modbus master, slave

XIOC-NET-SK-M XIOC-NET-DP-M XIOC-NET-DP-S

Suconet K master PROFIBUS DP master PROFIBUS DP slave

1-73


Switching, control, visualisation Networking CANopen PROFIBUS MPI Suconet

Display and operator panels

1

Part no.

Resolution

Touch operator panel MI4

MI4-130-TA1 MI4-137-KD1

MFD4-5-XRC-30

1-74

120 X 32 120 X 32 120 X 32 120 X 32 120 X 32

MI4-110-KC1 MI4-110-KD1 MI4-110-KG1/2 MI4-117-KC1 MI4-117-KD1

3,8” 3,8”

320 X 240 320 X 240

STN mono STN mono

320 X 240

STN color

Ethernet CANopen easyNet serial

Display and operator units

Text operator panel MI4

5,7”


Switching, control, visualisation Engineering PS4 Compact PLC PS4-151-MM1 • Wiring for a 230 V AC supply circuit • Relay contacts with different potentials: 230 V AC and 24 V DC

• 24 V DC inputs from an external power supply unit, earthed operation

Q1 L1 L2 L3 N PE

1

Q2

3

5

1

F2 I> I> I> 2 4 6

T1

**

2 L1 N

*

MM

PE

*

T2

1

F1

+24 V

0V

+24 V

0V

2 +24 V

0V

B1

2.5 mm 2

B2 A

A

.0 .1 .2 .3 .4 .5 .6 .7 24 V 0V .0 .1 .2 .3 .4 .5 .6 .7 24 V 0V

L1 N

X1

I

PRG Suconet K

1

R

U0 U1 U10 0V

.0

2

I

IA/QA

R .1

.2 .3

.4 .5

.6

.7

A1 A1

F3

F4

F5

F6

F7

M1 A2

X1

A1

P1 A1

P2 Q12

A2

*

A1

X2

Q11

Insulation monitoring must be provided where the control circuits are not earthed (EN 60204-1 and VDE 0100-725).

A2

A1

Q13 A2

A1

Q14 A2

A2

** IEC/EN 60204-1 specifies that a control transformer is required.

1-75

1


Switching, control, visualisation Engineering PS4 PS4-201-MM1 compact PLC

L1 L2 L3 N PE

1

Q1

3

• Non-earthed operation with insulation monitoring

1

5

F2

1 I> I> I> 2 4 6 13 23 33

C1

F1 2

+24 V

13

S2

PE

P1

14

A2

Q11

0V

A2

+24 V

0V

1

1

F5 2

2

13

+24 V 0 V

13

S3

B4 14

14

.0 .1 .2 .3 .4 .5 .6 .7 24 V 0V

A

A1

I

PRG Suconet K .0 .1 .2 .3 .4 .5 U0 U1 U10 0V

Q

1

2 A1

Q12

1-76

A1

A1

Q13 A2

*

*

P1

A1

+24 V

F4

A1

12 14

11

T2 0V

2

22

44 L1 N

3

F3

S1

Q11 14 24 34 L1 L2 L3 PE

T1

21

43

Q11

1 2

C1

24 V 0V

1

• Shared power supply for PLC and inputs/outputs

For operation without insulation monitoring, 0 V must be linked with the PE potential in the control circuits.

M1 A2

A2


Switching, control, visualisation Engineering PS4 PS4-341-MM1 compact PLC • Shared power supply for PLC and inputs/outputs

1

3

1

5

Q1

F2

1 I> I> I> 2 4 6 13 23 33

C1

F1

21

2

44 L1 N

13 PE

S2

P1

T2

+24 V

+24 V

F4

11

A2 A2

0V

Digital Input

Digital Input

Digital Input Digital Output

.0 .1 .2 .3 .4 .5 U0 U1 U10 0 VA .0 .1 .2 .3 .4 .5 .6 .7 24 V 0 VQ

Digital Output

0 VI .0 .1 .2 .3 .4 .5 .6 .7

F6

.0 .1 .2 .3 .4 .5 .6 .7

24 V 0V

*

P1

Q11

0V

F5

PRG Suconet K

A1

12 14

A1

+24 V

0V

2

22

14

3

F3

S1

Q11 14 24 34 L1 L2 L3 PE

1 2

C1 43

Q11

T1

1

0 VI

L1 L2 L3 N PE

• Non-earthed operation with insulation monitoring

1

*

2

For operation without insulation monitoring, 0 V must be linked with the PE potential in the control circuits.

1-77


Switching, control, visualisation Engineering EM4 and LE4 EM4-201-DX2 expansion module and LE4-116-XD1 local expansion module • Earthed operation

Q1 L1 L2 L3 N PE

1

Q2

5

3

1

Q3

I> I> I> 2 4 6 L1

N

L1

*

+24 V

0V

0V

2 1

F1 2 15

K1

11

13 11

A1

K1

Q15 Q16 Q17 12

.0 .1 .2 .3 .4 .5 .6 .7

14 12

I .8 .9 .10 .11 .12 .13 .14 .15

.8 .9 .10 .11 .12 .13 .14 .15 24 V 0V

Q

2 13

13

Q19 14

1-78

A2

Q

I

Q18

*

A1

Q12 A2

0V .0 .1 .2 .3 .4 .5 .6 .7 24 V 0V

18

Suconet K1/K

N

Insulation monitoring must be provided where the control circuits are not earthed.

A1

Q14 14

X1

P1 A2

X2

PE

*

+24 V 1

1

5

T2

F2

A1

3

I> I> I> 2 4 6 PE

T1

24 V 0V

1

• Inputs and outputs have a separate power supply


Switching, control, visualisation Engineering XC100, XC200 Device arrangement Install the rack and the PLC horizontally in the control cabinet as shown in the following figure.

1 a Kerning > 50 mm b Kerning > 75 mm to active elements c Cable duct

c a b

a b

a b a b

Terminal assignments

Example of power supply wiring

The terminals for the power supply and the local I/O have the following assignment:

The voltage terminal 0VQ/24VQ is only used for the power supply of the local 8 inputs and 6 outputs, and is potentially isolated from the bus. Outputs 0 to 3 can be loaded with 500 mA and outputs 4 and 5 with 1 A, each with a 100 % duty factor (DF) and a simultaneity factor of 1.

%IX 0.0 %IX 0.2 %IX 0.4 %IX 0.6 %QX 0.0 %QX 0.2 %QX 0.4 24 VQ 24 V

%IX 0.1 %IX 0.3 %IX 0.5 %IX 0.7 %QX 0.1

The wiring example shows the wiring with a separate power supply for the PLC and the IO terminals. If only one supply is used, then the following terminals must be connected together: 24 V to 24VQ and 0 V to 0VQ.

%QX 0.3 %QX 0.5 0 VQ 0V

1-79


Switching, control, visualisation Engineering XC100, XC200 You use the XT-SUB-D/RJ45 programming cable for the physical connection. 1 3 5 7 1 3 5

CANopen interface Assignment of the 6-pole Combicon connector:

8 7 6 5 4 3 2 1

ETH

(XC-CPU101/ 201)

(XC-CPU201)

8

RxD

–

7

GND

–

6

–

Rx–

5

TxD

–

4

GND

–

3

–

Rx+

2

–

Tx–

1

–

Tx+

You can use the COM1 or COM2 interface on the PC. 1-80

4

CAN_H

3

GND

2

CAN_L

1

CAN_H

Use only a cable that is permissible for CANopen with the following properties: • Surge impedance 108 to 132 O • Capacitance per unit length < 50 pF/m CAN_H

CAN_H

120 O

RS232

CAN_L

CAN_L CAN_GND

CAN_L CAN_GND

Loop resistance [O/km]

Pin

GND

5

Core crosssection [mm2]

This interface is used by the XC100/XC200 to communicate with the PC. The physical connection is implemented via an RJ -45 interface. The interface is not electrically isolated. The connector has the following assignment:

6

120 O

Serial interface RS 232

6 5 4 3 2 1

Signal

Length [m]

+ 24 V H 0VH + 24 VQ H 0 VQ H

Terminal

Baud rate [Kbit/s]

0 2 4 6 0 2 4

1

20

1000

0.75 – 0.80

16

125

500

0.50 – 0.60

40

250

250

0.50 – 0.60

40

500

100

0.34 – 0.60

60

1000

40

0.25 – 0.34

70


Notes

1

1-81


Notes

1

1-82


Electronic motor starters and drives Page General Basics of drives engineering

2-2 2-7

DS soft starters

2-29

DM soft starters

2-33

DS6 connection examples

2-37

DS4 connection examples

2-40

Connection examples, DM4

2-56

Frequency inverters DF, DV

2-70

DF51, DV51 connecting examples

2-74

DF6 connecting examples

2-80

DV6 connecting examples

2-82

Rapid Link system

2-88

2-1

2


Electronic motor starters and drives General The complete power supply and control programme for motors As the applications differ, so do the requirements made of the electric drives:

2

• In the simplest case, the motor is switched with an electromechanical contactor. Combinations consisting of motor protection and line protection are termed motor starter. • If frequent and/or silent switching is required, contactless semiconductor contactors are used. In addition to conventional line, short-circuit and overload protection, superfast semiconductor fuses are required for type “1” coordination and may be needed for type “2” coordination. Switching

• During DOL starting (star-delta, reversing starter or pole-switching), unwanted current and torque peaks occur. Soft starters eliminate these to ensure gentle starting and prevent an excessive burden on the power source. • Where an infinitely adjustable speed or a torque adjustment is necessary, frequency inverters (U/f inverters, vector frequency inverters, servo) are used today. As a general rule, the application determines the drive.

Frequent and silent switching

Soft starting

Speed control

Power distribution

Protection

Short-circuit, overload

Short-circiuit, overload, semi-conductor

Short-circiuit, overload, semi-conductor

Short-circuit, semi-conductor

Switching

Electro mechanical

Electronic

Electro mechanical

Electro mechanical

Electronic starter

Frequencyinverter Motor protection

M 3~

M 3~

Control

M 3~

M 3~

M 3~

Three-phase asynchronous motor A drive task first requires a drive motor whose characteristics with regard to speed, torque and control options are in accord with the set task. 2-2

The three-phase asynchronous motor is the world’s most common electric motor. Its popularity is the result of a rugged, simple construction, high degrees of protection, standardized sizes and low cost.


Electronic motor starters and drives General pole pairs and the frequency of the supply voltage. The direction of rotation can be reversed by swapping over two of the supply phases: Three-phase motors have typical starting characteristics, with starting torque MA, pullup torque MS, pull-out torque MK and rated load torque MN. M, I I A

ns =

Example: 4-pole motor (number of pole pairs = 2), mains frequency = 50 Hz, n = 1500 r.p.m. (synchronous speed, speed of rotating field)

Ms

MN MM

MB

Because of the induction effect, the asynchronous motor’s rotor can not reach the rotating field’s synchronous speed even at idle. The difference between synchronous speed and rotor speed is termed slip.

ML

IN 0

n N nS n

Slip speed: ns – n s = ns

The three-phase motor contains three phase windings that are offset from one another by 120 °/p (p = number of pole pairs). To generate a rotating field in the motor, an alternating voltage is applied to each phase in turn at a time delay of 120 °. L1

L2

L3

Speed of an asynchronous machine: f x 60 n = (1 – s) p L1

The output power is as follows: P2 =

0

90°

180°

360°

120°

Mxn 9550

h =

P2 P1

P1 = U x I xW3 x cos v

270°

120°

p

ns = Revolutions per minute f = Frequency of voltage in Hz p = Number of pole pairs

Mk

MA

2

f x 60

120°

The effect of induction produces the rotating field and a torque in the rotor winding. The motor speed is determined by the number of

P1 = Electrical rating in kW P2 = Mechanical shaft rating in kW M = Torque in Nm n = Speed in rpm h = Efficiency

The motor’s electrical and mechanical rating are recorded on its nameplate. 2-3


Electronic motor starters and drives General terminal bolts. There are basically two connection configurations: star and delta.

Motor & Co GmbH Typ 160 l Nr. 12345-88 3 ~ Mot.

W2

U2

V2

U1

V1

W1

Dy S1

400/690 V 29/17 A 15 kW y 0,85 1430 U/min 50 Hz Iso.-Kl. F IP 54 t IEC34-1/VDE 0530

2

As a rule, three-phase asynchronous motors are connected to their power supply with six Star connection

Delta connection

W1

L3

L3 V2

L2

V1

W2 V2 U2

ULN

ULN

L1

U1

W1

U2

W2

L1

ILN

U1

ILN

ULN = W3 x UW

ILN = IW

ULN = UW

ILN = W3 x IW

U1

V1

W1

U1

V1

W1

W2

U2

V2

W2

U2

V2

Notes In continuous operation, the mains voltage must be the same as the motor’s rated voltage.

2-4

V1 L2


Electronic motor starters and drives General Starting and operating methods The most important starting and operating methods for three-phase asynchronous motors include: DOL starters (electromechanical)

2

Star-delta circuit (electromechanical)

D

y

M 3h

M 3h

M ~ I, n = constant

My ~ l Md, n = constant

D IN

IN MN

MN y

nN

nN U 100 %

U 100 %

58 %

t

D

y

t

2-5


Electronic motor starters and drives General Soft starter and solid state contactor (electronic)

Frequency inverter (electronic)

2

POWER ALARM

Hz A RUN

I

O

PRG

PRG ENTER

M 3h

M 3h

M ~ U2, n = constant

M ~ U/f, n = variable

IN

IN MN

MN

n0 n1 n2 ...

nN

nN ...

nmax

U

U 100 %

100 % U2

U Boost

U Boost

30 % t Ramp

UBoost = Start pedestal (adjustable) tRamp = Ramp time (adjustable)

t

t Ramp

U2 = Output voltage (adjustable) UBoost = Start pedestal (adjustable) tRamp = Ramp time (adjustable)

2-6

t


Electronic motor starters and drives Basics of drives engineering Power electronics devices The power electronics devices provide infinitely variable adjustment of physical variables – such as speed or torque – to the application process. The power is drawn from the electrical mains, converted in the power electronics apparatus and fed to the consumer (i.e. the motor). Semiconductor contactors Semiconductor contactor allow fast, silent switching of three-phase motors and resistive loads. Switching takes place automatically at the ideal point in time and suppresses unwanted current and voltage peaks. Soft starters Soft starters ramp the voltage fed to the motor up to 100% of the mains voltage. The motor starts virtually jerk-free. The voltage reduction causes a quadratic torque reduction in relation to the motor's normal starting torque. Soft starters are therefore especially well suited to starting loads with a quadratic speed or torque characteristic (e.g. pumps or fans).

Frequency inverters Frequency inverters convert the AC or threephase system with its constant voltage and frequency into a new, three-phase system with variable voltage and frequency. This voltage/frequency control enables stepless speed control of three-phase motors. The controlled drive can be operated at rated-load torque even at low speeds. Vector frequency inverters While conventional frequency inverters control three-phase motors using a charactieristiccontrolled U/f (voltage/frequency) relationship, vector frequency inverters work using a sensorless, flow-oriented control of the motor’s magnetic field. The controlled variable is the motor current. This allows an opimized control of the torque for demanding applications (mixers and agitators, extruders, transport and conveying installations).

2-7

2


Electronic motor starters and drives Basics of drives engineering Moeller drives Designation

Part no.

Rated operational current [A]

Mains supply voltage

Assigned motor rating

[V]

[kW]

DS4-340-M

11–41

3AC 110–500

–

DS4-340-M DS4-340-MR

6–23 6–23

3 AC 110 – 500 3 AC 110 – 500

2.2 –11 (400 V) 2.2 –11 (400 V)

DS4-340-MX DS6-340-MX DS4-340-MXR

16–23 41–200 16–31

3 AC 110 – 500 3 AC 230 – 460 3 AC 110 – 500

7.5 – 15 (400 V) 18.5–110 (400 V) 7.5 – 15 (400 V)

DM4-340

16–900

3 AC 230 – 460

7.5 – 500 (400 V)

DM4-340

16–900

3 AC 230 – 460

11–900 (400 V)

DF51-322 DF51-320 DF51-340 DF6-340 DV51-322... DV51-320... DV51-340... DV6-340...

1.4–10 15.9–32 1.5–16 22–230 1.6–11 17.5–32 1.5–16 2.5–260

1/3 AC 230 3 AC 230 3 AC 400 3 AC 400 1/3 AC 230 3 AC 230 3 AC 400 3 AC 400

0.25–2.2 (230 V) 4–7.5 (230 V) 0.37–7.5 (400 V) 11–132 (400 V) 0.18–2.2 (230 V) 4–7.5 (230 V) 0.37–7.5 (400 V) 0.75 – 132 (400 V)

2 Semiconductor contactor for resistive and inductive load Soft starters Soft starter with bidirectional operation Soft starter with internal bypass relay Soft starter with bypass relay and bidirectional operation Soft starters (in-line connection type) Soft starters (delta connection type) Frequency inverters

Vector frequency inverters

2-8


Electronic motor starters and drives Basics of drives engineering

POWER ALARM

Hz A

2

RUN

I

O

PRG

PRG ENTER

DS4 soft starters

DF frequency inverters

DM soft starter

DV vector frequency inverters

2-9


Electronic motor starters and drives Basics of drives engineering DOL start

2

In the simplest case, and especially at low rated output (up to about 2.2 kW), the threephase motor is connected directly to mains voltage. In most applications, the connection is made with an electromechanical contactor. In this control mode – on the mains at fixed voltage and frequency – the speed of the asynchronous motor is only slightly below the

I Ie

synchronous speed ns ~ f. Due to rotor slippage, the operating speed [n] deviates from this value in relation to the rotating field: n = ns x (1 – s), slippage being s = (ns – n)/ns. On starting (s = 1) a high starting current occurs, reaching up to ten times the rated current Ie.

M2 MN

7 6 5 4

ML

1 3 2 1

0.25

0.5

0.75

1

0.25

0.5

0.75

1

n/nN

n/nN I/Ie: 6...10

M/MN: 0.25...2.5

Features of DOL starting • For low- and medium-power three-phase motors • Three connection lines (circuit layout: star or delta) • High starting torque • Very high mechanical load • High current peaks • Voltage dips • Simple switching devices If an application demands frequent and/or silent switching, or if adverse environmental

conditions prevent the effective use of electromechanical switching elements, electronic semiconductor contactors are required. In addition to short-circuit and overload protection, the semiconductor contactor must be protected with a superfast fuse. According to IEC/EN 60947, type “2” coordination requires the use of a superfast semiconductor fuse. For type “1” coordination, – the majority of cases – a superfast semiconductor fuse is not necessary.

2-10


Electronic motor starters and drives Basics of drives engineering – Controlling pumps in paint processing plants. • Other applications: Non-motor-driven loads, such as – Heater elements in extruders – Heater elements in kilns – Controlling lighting systems.

Here are a few examples: • Building services management: – Reversing drive for lift doors – Starting heat-exchanger units – Starting conveyor belts • In critical atmospheres: – Controlling filling station petrol pump motors Motor start in star-delta configuration Most commonly used for starting three-phase motors in the star-delta circuit layout. The completely factory prewired SDAINL stardelta combination from Moeller provides .

I Ie

convenient motor control. The customer saves on expensive wiring and installation time and reduces the likelihood of faults.

M2 MN

7 6 5 4

ML

1 3 2 1

0.25

0.5

0.75

1

0.25

0.5

I/Ie: 1.5...2.5 Features of star-delta starting • For low- to high-power three-phase motors • Reduced starting current • Six connection cables

0.75

1

n/nN

n/nN M/MN: 0.5

• Reduced starting torque • Current peak on changeover from star to delta • Mechanical load on changeover from star to delta

2-11

2


Electronic motor starters and drives Basics of drives engineering Soft starters (electronic motor start)

2

The characteristic curves for DOL and stardelta starting show sudden current and torque changes, which have a number of negative effects, especially at medium and high motor ratings: • • • •

High mechanical machine loads Rapid wear Increased servicing costs High supply costs from the power supply companies (peak current calculation) • High mains and generator load • Voltage dips with a negative effect in other consumers

I Ie

7

The ideal scenario of a smooth torque build-up and a controlled current reduction in the starting phase is made possible by the electronic soft starter. Providing infinitely variable control of the three-phase motor’s supply voltage in the starting phase, it matches the motor to the load behaviour of the driven machine and accelerates it smoothly. This avoids mechanical jolting and suppresses current peaks. Soft starters present an electronic alternative to the conventional star-delta switch.

M2 MN

6 5 4

ML

1

3 2 1

0.25

0.5

0.75

1

0.25

0.5

0.75

n/nN I/Ie: 1...5 Features of the soft starters • For low- to high-power three-phase motors • No current peaks • Zero maintenance • Reduced adjustable starting torque

2-12

1

n/nN M/MN: 0.15...1


Electronic motor starters and drives Basics of drives engineering Parallel connection of several motors to a single soft starter You can also use soft starters to start several motors connected in parallel. This does not, however, allow the behaviour of the individual motors to be controlled. Each motor must be separately fitted with suitable overload protection.

L1 L2 L3

2

F1 Q1

Note The total current consumption of the connected motors must not exceed the soft starter’s rated operational current Ie.

Q11

Note You must, however, protect each motor with thermistors and/or overload relays.

Q21

L1 L2 L3

T1 T2 T3

Caution! Switching must not take place in the soft starter’s output as the resulting voltage peaks can damage the thyristors in the power section. Problems may arise during starting if there are significant differences in the connected motors' ratings (e.g. 1.5 kW and 11 kW) which are connected in parallel to the output of a soft starter. The lower-rated motors may not be able to reach the required torque due to the relatively large ohmic resistance of these motors’ stators, requiring a higher voltage during starting.

F11

M1

F12

M 3

M2

M 3

It is advisable to use this circuit type only with motors of a similar rating.

2-13


Electronic motor starters and drives Basics of drives engineering Using a soft starter with pole-changing motors

2

Using soft starters for motors with power-factor correction

Soft starters can be connected in the supply line before pole-changing, a section "Polechanging motors", page 8-53.

Caution!

Note

Power-factor corrected motors or motor groups must not be started with soft starters. Mains-side compensation is permissible when the ramp time (starting phase) has completed (i.e. the TOR (Top of Ramp) signal has been issued) and the capacitors exhibit a series inductance.

All changeovers (high/low speed) must take place at standstill. The start signal must be issued only when a contact sequence has been selected and a start signal for pole-changing was set. Control is comparable to cascade control with the difference that the changeover is made not to the next motor but to the other winding (TOR = top-of-ramp signal). Using soft starters with three-phase slipring motors When upgrading or modernizing older installations, contactors and rotor resistors of multistage three-phase stator automatic starters can be replaced with soft starters. This is done by removing the rotor resistors and assigned contactors and short-circuiting the sliprings of the motor’s rotor. The soft starter is then connected into the incomer and provides stepless starting of the motor. a figure, page 2-15

2-14

No capacitive loads must be connected at the soft starter’s output.

Note If electronic devices (such as, soft starters, frequency inverters or UPS), use capacitors and correction circuits only with a choke fitted upstream. a figure, page 2-16

Q11

Q1

3 5

4 6

2

M1

M 3 L M

K

U V W PE

3 5

1

I> I> I> 2 4 6

1

L1 L2 L3 13 14

U3

Q43

W3

4 6

2

V3

3 5

1

F1

R3 U2

Q42

V2 W2

6

3 5

2 4

1

R2 U1

Q41

W2

6

4

2

V1

5

3

1

R1

Q21

Q11

Q1

3 5

M1

M 3

U V W

T1 T2 T3

L1 L2 L3

2 4 6

1

I> I> I> 2 4 6

1 3 5

L1 L2 L3

K L M

13 14

F1

Electronic motor starters and drives Basics of drives engineering Moeller Wiring Manual 02/08

2

2-15

2-16

Q11

M 3

Q11

M1

Q21

Q1

L1 L2 L3

M 3

T1 T2 T3

L1 L2 L3

Not permissible

Caution!

Q11

M1

Q21

Q1

L1 L2 L3

M 3

T1 T2 T3

L1 L2 L3

TOR

2

M1

Q1

L1 L2 L3

Q12

Electronic motor starters and drives Basics of drives engineering Moeller Wiring Manual 02/08


Electronic motor starters and drives Basics of drives engineering Type 2 coordination In type “2” coordination, the contactor or soft starter must not endanger persons or the installation in the event of a short-circuit and must be capable of continued use without repairs or parts replacements. For hybrid control devices and contactors, there is a risk of contact welding. In this case the manufacturer must provide appropriate maintenance instructions.

Soft starters and classification type to IEC/EN 60947-4-3 The following classification types are defined in IEC/EN 60947-4-3, 8.2.5.1: Type 1 coordination In type “1” coordination, the contactor or soft starter must not endanger persons or the installation in the event of a short-circuit and does not have to be capable of continued use without repairs or parts replacements.

L1 L2 L3 PE

The coordinated short-circuit protection device (SCPD) must trip in the event of a short-circuit. Blown fuses must be replaced. This is part of normal operation (for the fuse), also for type “2” coordination.

L1 L2 L3 PE

Q1

I> I> I>

F3

Q1

I> I> I>

F3

L1 L2 L3 Q21

L1 L2 L3 Q21

T1 T2 T3

M1

M 3

T1 T2 T3

M1

M 3

F3: Superfast semiconductor fuse 2-17

2


Electronic motor starters and drives Basics of drives engineering Design and mode of operation of frequency inverters Frequency inverters provide variable, stepless speed control of three-phase motors. Driving

2

Braking

Energy flow

Variable

Constant Mains

F

U, f, I

U, f, (I)

M, n

m

I ~ M f ~ n

Pel = U x I x √3 x y

Frequency inverters convert constant mains voltage and frequency into a DC voltage. from which they generate a new three-phase supply with variable voltage and frequency for the three-phase motor. The frequency inverter

b

v J

Motor

Electronic actuator

a

M 3~

Load PL =

Mxn 9550

draws almost only active power (p.f. ~ 1) from the supplying mains. The reactive power needed for motor operation is supplied by the DC link. This eliminates the need for p.f. correction on the mains side.

c

IGBT

L1, L1 M 3~

L2, N L3

d a Rectifier b DC link

2-18

c Inverter with IGBT d Open-/closed-loop control


Electronic motor starters and drives Basics of drives engineering The frequency-controlled three-phase motor is today a standard component for infinitely variable speed and torque regulation, providing efficient, energy-saving power either as an individual drive or as part of an automated installation.

I Ie

7

The possibilities for individual or plant-specific coordination are determined by the specific features of the inverters and by the modulation procedure used.

2 M MN

6

2

5

M MN

4 1 3 2

ML

I IN

1

0.25

0.5

0.75

1

0.25

0.5

0.75

n/nN I/Ie: 0...1.8

1

n/nN M/MN: 0.1...1.5

Modulation procedure of inverters An inverter basically consists of six electronic switches and is today usually made with IGBTs (insulated gate bipolar transistors). The control circuit switches the IGBTs on and off

according to various principles (modulation procedures) to change the frequency inverter’s output frequency.

Sensorless vector control The switching patterns for the inverter are calculated with the PWM (pulse width modulation) switching patterns. In voltage vector control mode, the amplitude and frequency of the voltage vector are controlled in relation to slippage and load current. This allows large speed ranges and highly accurate speeds to be achieved without speed

feedback. This control method (U/f control) is the preferred method on a frequency inverter with the parallel operation of several motors. In flow-regulated vector control, the active and reactive current components are calculated from the measured motor currents, compared with the values from the motor model and, if necessary, corrected. The 2-19



2

amplitude, frequency and inclination of the voltage vector are controlled directly. This allows operation at the current limit and the achievement of large speed ranges and highly accurate speeds. Especially noteworthy is the drive’s dynamic output at low speeds, for example in lifting and winding applications. The key advantage of sensorless vector technology is that the motor current can be X1

R1

i1

The following illustration shows a simplified equivalent circuit diagram for the asynchronous motor and associated current vectors:

b

iw

im

u1

R'2 s

X'2

regulated to match the motor’s rated current. This allows dynamic torque regulation to be implemented for three-phase asynchronous motors.

im~ V

Xh

o i1

iw

d

ib im

a

a b c d e

b

c

Stator Air gap Rotor Rotor flow-oriented Stator-oriented

In sensorless vector control, the fluxgenerating current iµ and the torquegenerating current iw are calculated from the measured stator voltage u1 and stator current i1. The calculation is performed with a dynamic motor model (electrical equivalent circuit of the three-phase motor) with adaptive current regulators, taking into account the saturation of the main field and the iron loss. The two current components are set according to their value and phase in a rotating coordinate system (o to the stator reference system (a, b).

2-20

e

ia

i1 = Stator current (phase current) iµ = Flux-generating current component iw = Torque-generating current component R’2 /s = Slip-dependent rotor resistance

The physical motor data required for the model is formed from the entered and measured (self-tuning) parameters.


Electronic motor starters and drives Basics of drives engineering EMC-compliant connection of frequency inverters

Network Cable protection

F

Switching

Q

Main choke

R

2

Interference filters K

Frequency inverters T

3~

O ENTER

3

Motor cable

Motor M

I PRG

M 3~

The EMC-compliant mounting and connection is described in detail in the respective devices’ manuals (AWB). 2-21


Electronic motor starters and drives Basics of drives engineering Notes about correct installation of frequency inverters

2

Measures for EMC-compliant installation are:

For an EMC-compliant installation, observe the following information. Electrical and magnetic disturbance fields can be limited to the required levels. The necessary measures work only in combination and should be taken into consideration at the engineering stage. To subsequently modify an installation to meet EMC requirements is possible only at considerable additional cost.

• Earthing measures • Screening measures • Filtering measures • Chokes They are described in more detail below. Earthing measures These must be implemented to comply with the legal standards and are a prerequisite for the effective use of further measures such as filters and screening. All conducting metallic enclosure sections must be electrically connected to the earth potential. For EMC, the important factor is not the cable’s crosssection, but its surface, since this is where high frequency current flows to earth. All earthing points must be low-impedance, highly conductive and routed directly to the central earthing point (potential equalization bar or star earth). The contact points must be free from paint and rust. Use galvanized mounting plates and materials.

EMC compliance The EMC (electromagnetic compatibility) of a device is its ability to withstand electrical interference (i.e. its immunity) while itself not emitting excessive electromagnetic interference into the environment. The IEC/EN 61800-3 standard describes the limit values and test methods for emitted interference and noise immunity for variablespeed electrical drives (PDS = Power Drives System). The tests and values are based not on individual components but on a typical complete drive system.

T1

K1

Tn

Kn

M1

Mn

M 3h

M 3h

PE K1 = Radio interference filter T1 = Frequency inverter

PE

PE

PE e

2-22

PE


Electronic motor starters and drives Basics of drives engineering Screening measures

L1 L2 L3 PE

M 3

2

F 300 mm

a

b Four-core screened motor supply cable: a Copper screen braid, earth at both ends with large-area connections b PVC outer sheath c Drain wire (copper, U, V, W, PE) d PVC cable insulation 3 x black, 1 x green/yellow e Textile and PVC fillers

e

d

c 2-23



2

Screening reduces emitted interference (noise immunity of neighbouring systems and devices against external influences). Cables laid between the frequency inverter and the motor must be screened, but the screen must not be considered a replacement for the PE cable. Four-wire motor cables are recommended (three phases plus PE). The screen must be connected to earth (PES) at both ends with a large-area connection. Do not connect the screen with pigtails. Interruptions in the screen, such as terminals, contactors, chokes, etc., must have a low impedance and be bridged with a large contact area.

Note

To do this, sever the screen near the module and establish a large-area contact with earth potential (PES, screen terminal). Free, unscreened cables should not be longer than about 100 mm.

b

Maintenance switches at of frequency inverter outputs must be operated only at zero current. Control and signal lines must be twisted and can be double-screened, the inner screen being connected to the voltage source at one end and the outer screen at both ends. The motor cable must be laid separately from the control and signal lines (>10 cm) and must not run parallel to any power cables.

a

Example: Screen attachment for maintenance switch MBS-I2

f 100 a Power cables: mains, motor, internal DC link, braking resistance b Signal cables: analog and digital control signals Inside control panels, too, cables should be screened if they are more than 30 cm long.

4.2 x 8.2 e

o 4.1

2-24

o 3.5


Electronic motor starters and drives Basics of drives engineering Example for screen earth kit and signal cables:

1 O

L

2

1

P24 15

H

PES

F 20 m

2

2

3 2

Cu 2.5 mm M4 PE

ZB4-102-KS1

PES 4K7 R1

M

M

REV

FWD

Example for a standard connection of frequency inverter DF5, with reference value potentiometer R1 (M22-4K7) and mounting accessories ZB4-102-KS1 Filtering measures Radio interference filters and line filters (combinations of radio interference filter and mains choke) protect against conducted highfrequency interference (noise immunity) and reduce the frequency inverter’s high-frequency interference, which is transmitted through or emitted from the mains cable, and which must be limited to a prescribed level (emitted interference). Filters should be installed as closely as possible to the frequency inverter to keep the length of the connecting cable between frequency inverter and filter short.

Note The mounting surfaces of frequency inverters and radio interference filters must be free from paint and must have good HF conductivity.

I

O

2-25



2

Filters produce leakage currents which, in the event of a fault (such as phase failure or load unbalance), can be much larger than the rated values. To prevent dangerous voltages, the filters must be earthed. As the leakage currents are high-frequency interference sources, the earthing connections and cables must have a low resistance and large contact surfaces. Z1 L1 L2 L3

G1

L1 L2 L3

R2 S2 T2

L/L1 L2 N/L3

U V W

e

e

E

E

M 3h

E

Chokes Fitted on the frequency inverter’s input side, chokes reduce the current-dependent phase effect and improve the power factor. This reduces the current harmonics and improves the mains quality. The use of mains chokes is especially recommended where several frequency inverters are connected to a single mains supply point when other electronic devices are also connected to the same supply network. A reduction of the mains current interference is also achieved by installing DC chokes in the frequency inverter’s DC link.

PE

E

With leakage currents f 3.5 mA, EN 60335 states that one of the following conditions must be fulfilled: • the protective conductor must have a crosssection f 10 mm2, or • the protective conductor must be opencircuit monitored, or • an additional conductor must be fitted.

2-26

At the frequency inverter’s output, chokes are used if the motor cables are long and if multiple motors are connected in parallel to the output. They also enhance the protection of the power semiconductors in the event of an earth fault or short-circuit, and protect the motors from excessive rates of voltage rise (> 500 V/µs) resulting from high pulse frequencies.


Electronic motor starters and drives Basics of drives engineering Example: EMC-compliant mounting and connection

15

2

PES

PE

PES

a PES

b PES

c

PES W2 U2 V2 U1 V1 W1 PE

a Metal plate, e. g. MSB-I2 b Earthing terminal c Maintenance switches

2-27


Electronic motor starters and drives Basics of drives engineering Mounting instructions

Selection aids

Electronic devices such as soft starters and frequency inverters must normally be fitted vertically.

°

0°

F 30° F

30

F3

30°

F

f 100

To ensure adequate air circulation for cooling, a clear space of at least 100 mm should be maintained both above and below the device.

a

a f 100

2

a Free space at the sides depends on the device series. Detailed information on the individual device series is provided in the installation instructions (AWA) and manuals (AWB).

2-28

The selector slide allows a fast and clear configuration of the individual drive solution components required without the need for a PC or any other tool. The slide shows immediately the components of a complete drive train, from the mains supply to the motor feeder. This includes the mains fuse and mains contactor, as well as the mains choke, suppressor, frequency inverter, motor choke and sinusoidal filter. Once the required motor rating is set, the assigned products are shown immediately. A range of different mains voltages as well as open-loop and closed-loop control of frequency inverters are shown. All information is available in German and English so that the slide can be used internationally. The selector slide can be obtained free of charge. If you prefer to use the selection tool online, this is available at: www.moeller.net/en/support/slider/index.jsp


Electronic motor starters and drives DS soft starters DS6 product features

DS4 product features • Construction, mounting and connection as for contactor • Automatic control voltage detection – 24 V DC g 15 % – 110 to 240 V AC g 15 % – safe starting at 85 % Umin • Operation indication by LED • Individually adjustable start and stop ramps (0.5 to 10 s) • Adjustable start pedestal (30 to 100 %) • Relay contact (N/O contact): operating signal, TOR (top of ramp)

• Design and terminals in power section as per circuit-breaker (NZM) • External control voltage – 24 V DC g 15 %; 0.5 A – safe starting at 85 % Umin • Operation indication by LED • Individually adjustable start and stop ramps (1 to 30 s) • Adjustable start pedestal (30 to 100 %) • Two relays (NO contact): Ready and TOR (top of ramp)

2 1

U

5

t-Start (s)

0,5 0

60

10

50

U-Start

80 40

U-Start (%)

30

2

100

1

t

5 0,5

t-Stop (s)

0

10

t-Start

t-Stop

2-29

2


Electronic motor starters and drives DS soft starters Example: Setting values and applications

t-Start, t-Stop l 10 s

2

l1s U-Start

l 30 %

Jl0

l 60 – 90 % JlL

Power section versions L1 L2 L3 L1 L2 L3 DS T1 T2 T3

M 3

2-30

DOL Starters

DOL starter with bypass

Reversing starters

DS4-340-...-M DS4-340-...-MX DS4-340-...-MR DS6-340-...-MX

Reversing starter with internal bypass DS4-340-...-MXR


Electronic motor starters and drives DS soft starters Connecting star points when using soft starters or semiconductor contactors Note

The connection of a three-phase load in the star point at PE or the N conductor is not permissible.

DS4 and DS6 soft starters are two-phase controlled.

Example DS4:

2

L1 L2 L3

L1

L2

L3

L1

L2

L3

L1 L2 L3

L1

L2

L3

L1

L2

L3

T1 T2 T3

T1

T2

T3

T1

T2

T3

Q21

M1

M 3

R1

Caution! Not permissible: Danger! 1L1

3L2

5L3 PE

Dangerous voltage. Risk of death or serious injury. When the power supply (ULN) is switched on, a dangerous voltage is also present in the OFF/STOP state.

2T1

4T2

6T3

PE

M 3~

2-31


Electronic motor starters and drives DS soft starters LED displays Example DS4:

2

Red LED

Green LED

Function

Lit

Lit

Init, LEDs lit only briefly, Init itself takes about 2 seconds Depending on device: – All devices: LED briefly lit once – DC devices: after a brief pause, the LEDs briefly light up again

OFF

OFF

Device is off

OFF

Flashing at 2 s intervals

Ready for operation, power supply OK, but no start signal

OFF

Flashing at 0.5 s interval

Device in operation, ramp is active (soft start or soft stop); on M(X)R the current rotating field direction is also indicated.

OFF

Lit

Device in operation, top-of-ramp reached; on M(X)R the current rotating field direction is also indicated.

Flashing at 0.5 s interval

OFF

Error

U Ue

A1, A2 FWD, REV, 0

Uout = 100 %

Run(FWD/REV-) LED

Error-LED

Initialization

2-32

Fault

Ready for operation

In ramp

Top of ramp


Electronic motor starters and drives DM soft starters Product features • DM4 is a three-phase controlled soft starter • Configurable, communications-capable soft starter with plug-in control signal terminals and interface for optional units: – Operator control and programming unit – Serial interface – Fieldbus connection • Application selector switch with userprogrammable parameter sets for 10 standard applications • I2t controller – Current limitation – Overload protection – Idle/undercurrent detection (e.g. belt breakage) • Kickstarting and heavy starting • Automatic control voltage detection • 3 relays, e.g. fault signal, TOR (top of ramp) Ten preprogrammed parameter sets for typical applications can be simply called up with a selector switch. Additional plant-specific settings can be defined with an optional keypad. In three-phase regulator control mode, for example, three-phase resistive and inductive loads – heaters, lighting systems, transformers – can be controlled with the DM4. Both openloop and – with measured value feedback – closed-loop control are possible.

Instead of the keypad, intelligent interfaces can also be used: • Serial RS 232/RS 485 interface (configuration through PC software) • Suconet K fieldbus module (interface on every Moeller PLC) • PROFIBUS DP fieldbus module The DM4 soft starters provide the most convenient method of implementing soft starting. In addition to phase failure and motor current monitoring, the motor winding temperature is signalled through the built-in thermistor input, so that the soft starters do not require additional, external components, such as motor protective relays. DM4 complies with the IEC/EN 60947-4-2 standard. With the soft starter, reducing the voltage results in a reduction of the high starting currents of the three-phase motor, although the torque is also reduced [Istartup ~ U] and [M ~ U2]. After starting, the motor reaches its rated speed with all of the solutions described above. For starting motors at rated-load torque and/or for motor operation at a motor speed that is independent of the supply frequency, a frequency inverter is required.

2-33

2


Electronic motor starters and drives DM soft starters The application selector switch enables direct assignment without parameter entry.

2

2-34

n

a

ru

c/l

flash 0 - standard 1 - high torque on 2 - pump 3 - pump kickstart 4 - light conveyor 5 - heavy conveyor 6 - low inertia fan 7 - high inertia fan 8 - recip compressor 9 - screw compressor

fa ult su pp ly

0 - standard 1 - high torque 2 - pump 3 - pump kickstart 4 - light conveyor 5 - heavy conveyor 6 - low inertia fan 7 - high inertia fan 8 - recip compressor 9 - screw compressor

b


Electronic motor starters and drives DM soft starters Standard applications (selector switch) Labelling on device

Indication on keypad

Meaning

Notes

Standard

Standard

Standard

Default settings, suitable without adaptation for most applications

High torque1)

High Torque

High breakaway torque

Drives with higher friction torque at standstill

Pump

Small pump

Small pump

Pump drives up to 15 kW

Pump Kickstart

Large pump

Large pump

Pump drives over 15 kW longer startup times

Light conveyor

LightConvey

Light conveyor

Heavy conveyor

HeavyConvey

Heavy-duty conveyor

Low inertia fan

LowInert.fan

Low-inertia fan

Fan drive with relatively small mass inertia moment of up to 15 times the motor’s inertia moment

High inertia fan

HighInertfan

High-inertia fan

Fan drive with relatively large mass inertia moment of over 15 times the motor’s inertia moment. Longer ramp-up times.

Recip compressor

RecipCompres

Reciprocal compressor

Higher start pedestal, p.f. optimization matched

Screw compressor

ScrewCompres

Screw compressor

Increased current consumption, no current limitation

1) For the “High Torque” setting, the soft starter must be able to supply 1.5 times the motor’s rated current.

In-delta circuit As a rule, soft starters are connected directly in series with the motor (in line). The DM4 soft starters also allow a delta connection. Advantage: • This circuit is cheaper because the soft starter has to be laid out for only 58 % of the motor full load current. Disadvantages over in-line connection:

• The DM4’s overload protection is active only in one line. so that additional motor protection must be fitted in the parallel phase or in the supply cable. Note The delta connection is more cost-effective at motor ratings over 30 kW and when replacing star-delta switches.

• As in a star-delta circuit, the motor must be connected with six conductors. 2-35

2

2-36

W2

U1

U2

V1

V2

W1

In-Line

I

M

I

55 kW 400 V

3~

I

400 S1

DM4-340-55K (105 A)

/ 690 V 55 kW 1410 rpm 50 Hz

100 / 59 A cos ϕ 0.86

DM4-340-30K (59 A)

100 A 3

DILM115

DILM115

100 A

NZM7-125N

400 V

NZM7-125N-OBI

ULN

I

I

I

M

55 kW 400 V

3~

In-Delta

W2

U1

U2

V1

V2

W1

Electronic motor starters and drives DM soft starters Moeller Wiring Manual 02/08

2


Electronic motor starters and drives DS6 connection examples Compact motor starter The devices of the DS6 series in conjunction with the mounting and connection accessories of the NZM circuit-breaker series offer the features of the compact electronic motor starters up to 110 kW.

The terminals of NZM can be optimally adapted to those of the DS6 by using NZM1/2XAB spacers.

2

Standard connection of the DS6-340-MX

L1 L2 L3 PE Q1

I> I> I>

PE

5L3

3L2

1L1

F3

TOR

Ready

PE

4T2

M1

M 3~

6T3

2T1

Q21

0 V + 24 - A2 EN + A1

13

14

23

24

Q1 + 24 V 0V 2-37


Electronic motor starters and drives DS6 connection examples Compact motor starter DS6 soft starter, NZM circuit-breaker and P3 maintenance switch

L1 L2 L3 PE

2 Q1

ON

Trip

OFF

I> I> I>

NZM1

PE

5L3

1L1

3L2

F3

TOR Ready

PE

6T3

4T2

2T1

Q21 0 V +24 -A2 EN +A1 13 14 23 24

DS6 + 24 V 0V 1

3

5

7

2

4

6

8

U

V

W

Start/Stopp

Q32

P3

2-38

M1

M 3~


Electronic motor starters and drives DS6 connection examples DS6-340-…-MX and NZM circuit-breaker with emergency-stop function to IEC/EN 60204 and VDE 0113 Part 1 L1 L2 L3 PE

2

a D2 U>

b

D1 3.13

Q1 3.14 I> I> I>

PE

5L3

3L2

1L1

F3

TOR

Ready

PE

6T3

4T2

2T1

Q21

0 V +24 -A2 EN +A1

13 14 23 24 S3

M1

Q1

M 3~

+ 24 V 0V

n Emergency-Stop Q1: Power and motor protection (NZM1, NZM2) Q21:DS6 soft starters M1:motor F3: Superfast semiconductor fuses (optional)

a Control circuit terminal b Undervoltage release with early-make auxiliary contact 3 AC, 230 V

NZM1-XUHIV208-240AC NZM2/3-XUHIV208-240AC

3 AC, 400 V

NZM1-XUHIV380-440AC NZM2/3-XUHIV380-440AC 2-39


Electronic motor starters and drives DS4 connection examples Linking the overload relay into the control system

Note: Connecting the motor directly to mains power can cause overvoltage and destruction of the soft starter’s semiconductors. Note: The overload relay’s signalling contacts are linked into the On/Off circuit.

In the event of a fault, the soft starter decelerates for the set ramp time and stops. Standard connection, unidirectional rotation In standard operation the soft starter is connected into the motor supply line. A central switching element (contactor or main switch) with isolating properties to isolate the mains according to EN 60947-1 section 7.1.6 and for working on the motor is required according to EN 60204-1 section 5.3. No contactors are required to operate individual motor feeders.

Minimum connection of DS4-340-M(X)

L1 L2 L3 PE Q1

F2 I I I

01

F2

S3 1L1 3L2 5L3

F3 TOR Q21 2T1 4T2 6T3

2

We recommend using an external overload relay instead of a motor-protective circuitbreaker with built-in overload relay. This allows controlled ramping down of the soft starter through the control section in the event of an overload.

M1

M 3~

13

14

Q21

A1 A2

0: Off/soft stop, 1: Start/soft start n Emergency-Stop 2-40

M1

Q21

F3

F2

Q11

I I I

M 3~

13

14

Ready

Q1: Line protection Q11:Mains contactor (optional) F2: Motor-protective relay

Q1

1L1 3L2 5L3 2T1 4T2 6T3

L1 L2 L3 PE

K1

S2

S1

F2

Q11

K2t

K1 K2t

b

Q11

t > tStop + 150 ms

Q21

Soft Start Soft Stop

K1

A2

A1

Softstarter DS4-340-M

F3: Semiconductor fuse for type 2 coordination S1: Q11 off (unguided deceleration) Additional to Q1 S2: Q11 on Q21: Soft starter b: Activation withQ11/K2t optional M1: Motor

L00/L–

L01/L+

Electronic motor starters and drives DS4 connection examples Moeller Wiring Manual 02/08

2-41

2


Electronic motor starters and drives DS4 connection examples Soft starter without mains contactor

L1 L2 L3 PE

L01/L+ K1

2 Q1 I I I

F2 S1

F2 1L1 3L2 5L3

F3 TOR

S2

2T1 4T2 6T3

Q21

M1

13

14

M 3~

Q1:Line protection F2: Overload relays F3: Semiconductor fuse for type 2 coordination, in addition to Q1 (optional) Q21: Soft starters M1: Motor

2-42

K1

K1 L00/L– n Emergency-Stop S1: Soft stop S2: Soft start

Q21

A1 A2

F3

F2

Q11

I I I

M 3~

13

14

TOR

Line protection Mains contactor (optional) Soft starters Overload relays

M1

Q21

Q1

Q1: Q11: Q21: F2:

L1 L2 L3 PE

1L1 3L2 5L3 2T1 4T2 6T3

K1

S2

S1

F2

K2t

K1

Q11

K1

F3: Semiconductor fuse for type 2 coordination, in addition to Q1 (optional) n Emergency-stop M1: Motor

L00/L–

L01/L+

K3

K3

Q21

K1, K3: contactor relays K2t: Timing relay (off-delayed) S1: Q11 off S2: Q11 on

K3

K2t t = 10 s Soft Start

Soft Stop

K1

A2

A1

Connection of soft starter with mains contactor


2

2-43


Electronic motor starters and drives DS4 connection examples Reversing circuit standard connection, bidirectional rotation Note: The device of the DS4-...-M(X)R series have a built-in electronic reversing contactor Minimum connection of DS4-340-M(X)R

L1 L2 L3 PE F2

Q1 I I I

F2

S3

102

1L1 3L2 5L3

F3 TOR Q21 2T1 4T2 6T3

2

function. You need to only specify the required direction of rotation. The DS4 then internally ensures the correct control sequence.

13

14

FWD

Q21

M1

M 3~

Q1:Line protection Q21: Soft starters F2: Overload relays F3: Semiconductor fuse for type 2 coordination, in addition to Q1

2-44

0V

M1: Motor n: Emergency-Stop 0: Off/Soft stop 1: FWD 2: REV

REV

F3

F2

Q11

M1

Q21

Q1 I I I

M 3~

13

14

TOR

Q1:Line protection F2: Overload relays F3: Semiconductor fuse for type 2 coordination, in addition to Q1

L1 L2 L3 PE

1L1 3L2 5L3 2T1 4T2 6T3

K1

K2

S2

S1

F2

K1

K2

K1

S3 K2

n: Emergency-Stop Q21: Soft starters S1: Soft stop M1: Motor K1, K2: Contactor relays S2: Soft start FWD S2: Soft start REV

L00/L–

L01/L+

Q21

K1

0V

FWD

K2

REV

Reversing starter without mains contactor


2

2-45


Electronic motor starters and drives DS4 connection examples Reversing soft starter with mains contactor

Q1 I I I

Q11 F2 1L1 3L2 5L3

F3 TOR Q21 2T1 4T2 6T3

2

L1 L2 L3 PE

M1

13

14

M 3~

Q1:Line protection Q11:Mains contactor (optional) Q21:Soft starters F2: Overload relays F3: Semiconductor fuse for type 2 coordination, in addition to Q1 (optional) M1:Motor

2-46

L00/L–

L01/L+

K1

S2

S1

F2

K2t

K1

Q11

K1

K2t t = 10 s

K3

K3

K4

K3

Soft Start REV K4

Q21

K3

n: Emergency-Stop S1: Q11 Off (unguided deceleration) S2: Q11 On FWD: Clockwise rotation REV: Anticlockwise rotating field

K4

Soft Start FWD

Soft Stop

K1

0V

FWD

K4

REV


2

2-47


Electronic motor starters and drives DS4 connection examples External bypass, one direction of rotation Caution!

2

The DS4-...-MX(R) devices have built-in bypass contacts. The following types therefore only apply to DS4-...-M. If an external bypass for devices with reversing function (DS 4 -...-MR) is to be fitted, you must include an additional bypass contactor for the second direction of rotation as well as additional interlocks to prevent a short-circuit through the bypass contactors! The bypass connection allows a direct connection of the motor to the mains to suppress heat dissipation through the soft starter. The bypass contactor is actuated once

2-48

the soft starter has completed the acceleration phase (i.e. once mains voltage is reached). By default, the Top-of-Ramp function is mapped to relay 13/14. The soft starter controls the bypass contactor so that no further user action is required. Because the bypass contactor is switched only at zero current and does not, therefore, have to switch the motor load, an AC1 layout can be used. If an Emergency-Stop requires an immediate disconnection of the voltage, the bypass may have to switch under AC3 conditions (for example if the Enable signal is removed with a command or the soft stop ramp time is 0). In this case, the circuit must be laid out so that either a higher-priority isolating element trips first or the bypass must be laid out to AC3.


Electronic motor starters and drives DS4 connection examples L1 L2 L3 PE

Q1

2

F2

I< I< I<

F2 F3

01

1L1 3L2 5L3

S3 TOR

Q21 2T1 4T2 6T3

Q22

M M1 3~ S3: Q1: Q21: Q22: F2:

Soft start/stop Cable protection Soft starters Bypass contactor Overload relays

Q21 TOR

13 14

Q21

A1 A2

Q22

13 14 A1 A2

F3: Semiconductor fuse for Additional type 2 coordination in addition to Q1 M1: (optional) Motor

2-49


Electronic motor starters and drives DS4 connection examples Pump control, single direction of rotation, continuous operation

Note In contrast to simple bypass operation, the bypass contactor must be laid out to AC3 here.

Pump Q1:Line protection Q11:Mains contactor (optional) Q21:Soft starters Q22:Bypass contactor Q31:Motor contactor F2: Overload relays F3: Semiconductor fuse for type 2 coordination, in addition to Q1 (optional) M1:Motor

L1 L2 L3 PE Q1 I I I

F2 F3

1L1 3L2 5L3

Q11 TOR Q22

Q21 2T1 4T2 6T3

2

In pump applications the bypass contactor is often required to provide emergency operation capability. This is achieved with a service switch that allows a changeover from soft starter operation to DOL starting through the bypass contactor. In the latter setting the soft

starter is fully bypassed. But because the output circuit must not be opened during operation, the interlocks ensure that changeovers take place only after a stop.

Q31

M1

2-50

M 3~

13

14

Q21

K1

E2

b

39

K2

Q22

n Emergency-Stop a t > t-Stop + 150 ms b Enable

K1

K1

S3

S2

S1

K2

c

K4

K3

K1

d

Q31

K3

Q11

Q31

K4

c Hand d Auto e Soft start/soft stop

K3

K2

K5

S5

S4

K5

e

K6t

A1 A2

f RUN g Bypass

Q21

K5

f

K4

a

K6t

Q22

Q21 TOR

K2

g

14

13

Pump control, single direction of rotation, continuous operation


2

2-51


Electronic motor starters and drives DS4 connection examples Starting several motors sequentially with a soft starter (cascaded control)

2

When starting several motors one after the other using a soft starter, keep to the following changeover sequence: • • • • •

Start using soft starter Switch on bypass contactor Disable soft starter Switch soft starter output to the next motor Restart

a section "Soft starter with motor cascade, control section part 1", page 2-54 n Emergency-Stop S1: Q11 Off S2: Q11 On a Soft start/soft stop b Simulation of RUN relay Timing relay K2T simulates the RUN signal of the DS4. The set off-delay time must be greater than the ramp time. To be on the safe side, use 15 s. c RUN

d Off-time monitoring Set the timing relay K1T so that the soft starter is not thermally overloaded: calculate the time from the soft starter’s permissible operating frequency or select a soft starter that allows the required time to be reached. e Changeover monitoring Set the timing relay to a return time of about 2 s. This ensures that the next motor branch can not be connected as long as the soft starter is running. a section "Soft starter with motor cascade, control section part 2", page 2-55 a Motor 1 b Motor 2 c Motor n i Switching off individual motors The Off switch results in all motors being switched off at the same time. To switch off individual motors, you need to make use of N/C contact i. Observe the thermal load on the soft starter (starting frequency, current load). If motors are to be started at short intervals, you may have to select a soft starter with a higher load cycle.

2-52

Q13

L1 L2 L3 N PE

M1

Q14

Q21

F3

Q11

1L1 2L2 3L3

M 3~

M2

M 3~

Q23

Q24

I> I> I>

Q15

14

TOR 13

I> I> I>

2T1 4T2 6T3

Soft starter with motor cascade

Q25

Qn3

Mn

Qn

M 3~

I> I> I>

Qm

Q11: Mains contactor (optional) F3: Semiconductor fuse for type 2 coordination (optional) Q21: Soft starters M1, 2,...: Motor


2

2-53

2-54

K1

Q11

K1

K4

K2

K12

Q14

K22

Q24

K4

Kn2

Qn1

Q21

K2

a

K2T

A1 A2

b

K3

Q21 TOR 14

13

K4

K2T

c

a section "Starting several motors sequentially with a soft starter (cascaded control)", page 2-52

K1

S2

S1

Q1

K1T

2 K1T

K4

d

K4T

K4

e

Soft starter with motor cascade, control section part 1


K3

Q15

K12

Q14

a

Q15

K12

Q15

Q24

K4T

Q14

K22

K12

Q41 Q25

K3

Q24

Q25

b

i

K22

Q25

Qn

K4T

Q(n-1)1

Kn2

K(n-1)2

Qn


Q14

Q11

i

Qm

K3

Qn

c

i

Qm

Kn2

Qm

Soft starter with motor cascade, control section part 2


2

2-55


Electronic motor starters and drives Connection examples, DM4 Enable/immediate stop without ramp function (e.g. for Emergency-Stop)

2

The digital input E2 is programmed in the factory so that it has the "Enable" function. The soft starter is enabled only when a High signal is applied to the terminal. The soft starter cannot be operated without enabling signal. In the event of wire breakage or interruption of the signal by an Emergency-Stop circuit, the regulator in the soft starter is immediately blocked and the power circuit disconnected, and after that the "Run“ relay drops out.

require an immediate de-energization, this is effected via the enabling signal. Caution! You must in all operating conditions always first stop the soft starter ("Run“ relay scanning), before you mechanically interrupt the power conductors. Otherwise a flowing current is interrupted – thus resulting in voltage peaks, which in rare cases may destroy the thyristors of the soft starter.

Normally the drive is always stopped via a ramp function. When the operating conditions n Emergency-Stop S1: Off S2: On Q21:Soft starters (E2 = 1 a enabled)

S1

S2

K1

2-56

K1

K1

Q21

E2 39


Electronic motor starters and drives Connection examples, DM4 Linking the overload relay into the control system We recommend using an external overload relay instead of a motor-protective circuitbreaker with built-in overload relay. This allows controlled ramping down of the soft starter through the control section in the event of an overload.

Caution! Connecting the motor directly to mains power can cause overvoltage and destruction of the soft starter’s semiconductors. There are two options, which are shown in the following diagram: n Emergency-Stop S1: Off

F1

a

S2: On

K1

b

S1

S2

K1

K1

Q21

E2

Q21:Soft starters, enablr (E2 = 1 h enabled) a The overload relay’s signalling contacts are incorporated in the On/Off circuit. In the event of a fault, the soft starter decelerates for the set ramp time and stops. b The signalling contacts of the overload relay are linked into the enabling circuit. In the event of a fault, the soft starter’s output is immediately de-energized. The soft starter switches off but the mains contactor remains on. To de-energize the mains contactor as well, include a second contact of the overload relay in the On/Off circuit.

39

2-57

2


Electronic motor starters and drives Connection examples, DM4 With separate contactor and overload relay

Actuation Q1

K1

I> I> I>

S2

Q11

S1

K1

F2 E2

K1

F3

Q21

39

3L3

2L2

1L1

a L

~

N

=

M 3~

2-58

6T3

4T2

T1

– Thermistor

+ Thermistor

Q21

2T1

2

L1 L2 L3 N PE

Standard connection For isolation from the mains, either a mains contactor upstream of the soft starter or a central switching device (contactor or main switch) is necessary.

T2

E1

Q21

39

b

S1: Soft start S2: Soft stop F3: Superfast semiconductor fuses (optional) a Enable b Soft start/soft stop


Electronic motor starters and drives Connection examples, DM4 Without mains contactor L1 L2 L3 N PE

2 Q1

Q2 I> I> I>

I> I> I>

a F1

b

Q21

13

14

23

24

33

~

K4

34

43

= Analog Out 2

T2

K3

Analog Out 1

T1

K2;TOR

7

62

63

I mot M 3~

1

0 V Analog

- Thermistor

6T3

4T2

2T1

PE

+ Thermistor

K1;RUN

8 REF 1: 0–10 V

+12

REF 2: 4–20 mA

7

39

+12 V DC

E2

0 V Analog

=

E1

Enable

~

N

0 V (E1;E2)

L

Start/Stop

5L3

3L2

1L1

⎧ ⎪ ⎨ ⎪ ⎩

F2

c

M1

F3: Superfast semiconductor fuses (optional) a Control voltage through Q1 and F11 or separately via Q2 b See Control section c Motor current indication

2-59


Electronic motor starters and drives Connection examples, DM4 Soft starters with separate mains contactor

Q1

Q2 I> I> I>

I> I> I>

b Q11

F11

a

Q21

13

14

23

24

33

~

K4

34

43

= Analog Out 2

T2

K3

Analog Out 1

T1

K2;TOR

1

0 V Analog

- Thermistor

6T3

4T2

PE

+ Thermistor

K1;RUN

8 REF 1: 0–10 V

+12

REF 2: 4–20 mA

7

39

+12 V DC

E2

0 V Analog

=

E1

Freigabe

~

N

0 V (E1;E2)

L

Start/Stop

5L3

3L2

1L1

⎧ ⎪ ⎨ ⎪ ⎩

F3

2T1

2

L1 L2 L3 N PE

7

62

63

I mot M 3~

T1: + Thermistor T2: – Thermistor E1: Start/stop E2: Enable

2-60

M1

a See Control section b Control voltage through Q1 and F11 or through Q2 c Motor current indication

c


Electronic motor starters and drives Connection examples, DM4 Soft starters with separate mains contactor Actuation

2 K1 S3

Q1

Q11

S1

K1

13

S2 Q21 OK (no error) K1

S4

K2

K1 Q21 RUN

K2

14

K1 33 34 E2

Q21

39

a

K2

Q21

E1 39

Q11

b

n Emergency-Stop S1: Off (unguided deceleration) S2: On S3: Soft start S4: Soft stop (deceleration ramp) a Enable b Soft start/soft stop

2-61


Electronic motor starters and drives Connection examples, DM4 Bypass circuit

Q1

Q1 I> I> I>

I> I> I>

Q11

b F11

a +12

T2

13

14

23

24

K3

33

~

K4

34

43

=

7

62

63

I mot M1

T1: + Thermistor T2: – Thermistor E1: Start/stop E2: Enable

2-62

PE

Analog Out 2

- Thermistor

T1

K2;TOR

1

Analog Out 1

+ Thermistor 6T3

4T2

K1;RUN

REF 1: 0–10 V

+12 V DC

Q21

8 REF 2: 4–20 mA

7

39 0 V Analog

=

E2

0 V Analog

Q22

E1

Freigabe

~

N

0 V (E1;E2)

L

Start/Stop

5L3

3L2

1L1

⎧ ⎪ ⎨ ⎪ ⎩

F3

2T1

2

L1 L2 L3 N PE

c

M 3~

a See Control section b Control voltage through Q1 and F11 or through Q2 c Motor current indication


Electronic motor starters and drives Connection examples, DM4 Bypass circuit After completion of the acceleration phase (full mains voltage reached), the soft starter M4 actuates the bypass contactor. Thus, the motor is directly connected with the mains. Advantage: • The soft starter’s heat dissipation is reduced to the no-load dissipation. • The limit values of radio interference class

"B“ are adhered to. The bypass contactor is now switched to a noload state and can therefore be AC-1 rated. If an immediate voltage switch-off is required due to an emergency stop the bypass contactor must also switch the motor load. In this case it must be AC-3 rated.

Actuation

K1 S3 S1

S4 K2

K2

K1 Q21 RUN

13 14

Q21 TOR

23 24

K1

S2 Q21 OK (no error) K1

Q22

K1

33 34

Q21

E2 39

a n Emergency-Stop S1: Off (unguided deceleration) S2: On a Enable b Soft start/soft stop

K2

Q21

E1 39

Q11

Q22

b

2-63

2


Electronic motor starters and drives Connection examples, DM4 In-delta circuit

Q1

Q2 I> I> I>

I> I> I>

Q11

a F11

b

M1

REF 1: 0–10 V

Analog Out 1

d

=

0 V Analog

T1

~

K3 K4

– Thermistor

W1 2T1 V1 4T2 U1 6T3

+ Thermistor

K1;RUN K2;TOR

T2 13 14 23 24 33 34 43

7

62 63

I mot

M 3~

a Control voltage through Q1 and F11 or through Q2 b See Control section

2-64

PE

Analog Out 2

Q21

8 1 REF 2: 4–20 mA

+12 V DC

+12

0 V Analog

=

7

E1 E2 39 Enable

~

N

0 V (E1;E2)

L

Start/Stop

1L1 3L2 5L3

F3

W2 V2 U2

2

L1 L2 L3 N PE

c Motor current indication d Thermistor connection

c


Electronic motor starters and drives Connection examples, DM4 A delta connection allows the use of a soft starter with a lower rating than the motor it is used to control. Connected in series with each motor winding, the current the soft starter needs to supply is reduced by a factor of W3. This layout has the drawback that six motor supply cables are needed. Apart from that

there are no restrictions. All soft starter functions remain available. For this you have to connect the motor in delta and the voltage in this connection method must agree with the mains voltage. For 400 V mains voltage the motor must therefore be marked with 400 V/690 V.

Actuation

K1 S3

Q1 S1

13

K2

K2

Q21 RUN

14

K1

S2

Q21 OK (no error)

S4

K1

33 34

K1

E2

Q21

39

a

K2

E1

Q21

39

Q11

b

n Emergency-Stop S1: OFF S2: ON a Enable b Soft start/soft stop E2: Enable

2-65

2


Electronic motor starters and drives Connection examples, DM4 Starting several motors sequentially with a soft starter (cascaded control)

2

When starting several motors one after the other using a soft starter, keep to the following sequence when changing over: • • • • •

Start using soft starter Switch on bypass contactor Block soft starter Switch soft starter output to the next motor Restart

a section "Control section part 1", page 2-68 n Emergency-Stop S1: Q11 Off S2: Q11 On a Soft start/soft stop b RUN c Off-time monitoring Set the timing relay K1T so that the soft starter is not thermally overloaded: calculate the time from the soft starter’s permissible operating frequency or select a soft starter that allows the required time to be reached. d Changeover monitoring Set the timing relay to a return time of about 2 s. This ensures that the next motor branch can not be connected as long as the soft starter is running.

2-66

a section "Control section part 2", page 2-69 a Motor 1 b Motor 2 c Motor n i Switching off individual motors The Off switch results in all motors being switched off at the same time. To switch off individual motors, you need to make use of N/C contact i. Observe the thermal load on the soft starter (starting frequency, current load). If motors are to be started at short intervals, you may have to select a soft starter with a higher load cycle.

Q13

M1

Q14

Q21

~

L N

Q23

M2

Q24 Q25

Qn3

Mn

Qn4

M 3~

Q15

F11

I> I> I>

T2

PE

I> I> I>

M 3~

T1

=

Q2

I> I> I>

1L1 2T1

M 3~

2L2 4T2

I> I> I>

3L3 6T3

F3

– Thermistor

Q1

+ Thermistor

L1 L2 L3 N PE

Qn5

Cascade

Electronic motor starters and drives Connection examples, DM4 Moeller Wiring Manual 02/08

2

2-67

2-68

K1

Q21

E2

a

39

Q11

K4

K2

K12

Q14

K22

Q24

K4

Kn2

Qn

Q21

K2

E1

b

39

K3

Q21 23 TOR 24


K1

K1

K1

S2

33

Q21 OK (no error) 34

S1

Q1

K1T

2 K4

K1T

Q21 13 K4 RUN 14

c

K4T

K4

d

Control section part 1


Q15

K3

Q14

a

Q15

K12

Q15

b

K22

Kn2

K(n-1)2

Q24

Q25

Qn

K4T

Q24

Q25

K4T

Q25

Q(n-1)1

K3

Q24

Q14

K22

K12

i

K3

Qn

i

Qm

Qn


Q14

K12

Q11

i

c

Qm

Kn2

Qm

Control section part 2


2

2-69


Electronic motor starters and drives Frequency inverters DF, DV Features of DF frequency inverters

2

• Infinitely variable speed control through voltage/frequency control (U/f) • High starting and acceleration torque • Constant torque in motor’s rated range • EMC measures (optional: radio interference filter, screened motor cable) Additional features of sensorless vector control for frequency inverters DV51 and DV6 • Infinitely variable torque control, also at zero speed • Low torque control time • Increased concentricity and constancy of speed • Internal brake chopper • Speed control (options for DV6: control module, pulse generator) General The DF and DV frequency inverters are factorypreset for their assigned motor rating, allowing drives to be started immediately after installation.

2-70

Individual settings can be made with an optional keypad. Various control modes can be selected and configured in a number of layers. For applications with pressure and flow control, all devices contain a built-in PID controller that can be matched to any system. A further advantage of the frequency inverters is that they eliminate the need for external components for monitoring and motor protection. On the mains side, only a fuse or circuit-breaker (PHKZ) is needed for line and short-circuit protection. The frequency inverter’s inputs and outputs are monitored internally by measurement and control circuits, such as overtemperature, earth fault, shortcircuit, motor overload, motor blockage and drive belt monitoring. Temperature measurement in the motor winding can also be incorporated in the frequency inverter’s control circuit through a thermistor input.


Electronic motor starters and drives Frequency inverters DF, DV

b a POWER ALARM RUN

1 2

2

OPE RBUS POWER

OFF

ALARM

Hz A RUN

I

O

PRG

PRG ENTER

Hz A

I

O

POWER ALARM

RUN PRG

PRG ENTER

g

c

h

e

f

a b c d e

DV51 vector frequency inverter DEX-L2… EMC filter DF51 frequency inverters DF6 frequency inverters DEX-BR1... braking resistors

d

f DEX-LN… mains choke, DEX-LM… motor choke, SFB… sinusoidal filter g DEX-CBL-… connection cables h Keypads DEX-KEY-…

2-71

BR* 6* 5*

RBr

U

M 3~

V

W

DV51 only DV51 only Input RST for DF51

BR

DC–

DC+

L+

L3

L2

L1

e i

* PNU C005 = 19 (PTC)

L

5

PE K12 K14 K11

2

3

4

6

3

FF2

2CH *

PE

FF1

PE

AM

1

FWD 0...10 V

N

O

H

– +

+10 V

L

0...10 V

OI

P24

+24 V

0V

1

L

11

12

RJ 45 ModBus

CM2

RUN

REV

0V

RST

FA1

– +

2-72 4...20 mA

2 Block diagram, DF51, DV51

Electronic motor starters and drives Frequency inverters DF, DV Moeller Wiring Manual 02/08

BR*

DC–

U

M 3~

V

RST FF2 K2

REV

AT

K3

e

W PE K12 K14 K11 K23 K24 K33 K34

K1

FF1

BR* DF6-320-11K, DF6-340-11K and DF6-340-15K only

RBr

L+ DC+

FWD

5 FW

P24

PLC CM1

TH

i

PTC

4

FM 10 V (PWM)

3

AM 0...+10 V

AMI 4...20 mA

2

OI

O

H

– +

+10 V

1

0...10 V

3

SP

SN

RP

RS 485 SN

RJ 45 RS 422

L O2 0V

– +

L1 L2 L3 PE

–10 V...+10 V

+24 V

4...20 mA

Block diagram DF6

Electronic motor starters and drives Frequency inverters DF, DV Moeller Wiring Manual 02/08

2

2-73


Electronic motor starters and drives DF51, DV51 connecting examples Basic control Example 1Reference input through potentiometer R1 Enable (START/STOP) and direction control through terminals 1 and 2 with internal control voltage

2

n Emergency-Stop circuit S1: OFF S2: ON Q11: Mains contactor F1: Line protection PES:Cable screen PE connection M1:230 V 3-phase motor

S1

S2

Note: For EMC-conformant mains connection, suitable radio interference suppression measures must be implemented according to product standard IEC/EN 61800-3.

Q11

Q11

DILM12-XP1

(4th pole can be broken off) DILM

A1 1

3

5

13

2

4

6

14

A2

2-74


Electronic motor starters and drives DF51, DV51 connecting examples Wiring f

1 h 230 V, 50/60 Hz

L N PE

M t

F1

2

M

PE FWD

Q11 REV

L

T1

N

PE

L+ DC+ DC– U

V

H

W PE

O

L

2

1 P24 PES

PES PES X1 PES PES

M1

M 3~

PE 4K7

e – Single-phase frequency inverter DF51-322-... – Directional control through terminals 1 and 2 – External reference input from potentiometer R1

M M REV FWD R11 FWD: Clockwise rotating field enable REV: Anticlockwise rotating field enable

2-75


Electronic motor starters and drives DF51, DV51 connecting examples DF5-340-... frequency inverters with EMC-conformant connection Actuation Example 2 Setpoint entry via potentiometer R11 (fs) and fixed frequency (f1, f2, f3) via terminal 3 and 4 with internal control voltage Enable (START/STOP) and rotation direction selection via terminal 1

2

Q1

S1

S2

Q11

n Emergency-Stop circuit S1: OFF S2: ON Q11:Mains contactor R1: Main choke K1: RFI filter Q1:Line protection PES: Cable screen PE connection M1:400 V 3-phase motor FWD: Clockwise rotating field enable, reference frequency fS FF1: Fixed frequency f1 FF2: Fixed frequency f2 FF1+ FF2: Fixed frequency f3

Q11

2-76


Electronic motor starters and drives DF51, DV51 connecting examples Wiring f

3 h 400 V, 50/60 Hz

L1 L2 L3 PE

f1

f2

f3

fs = fmax

2

Q1 PE I

I

FF1

I FF2

Q11

FWD U1

V1

W1 PE

R1 U2

V2

W2

L1

L2

L3 PE

L1 L2 L3

L+ DC+ DC– U

V

H

W PE

O

L

4

3

FWD

FF1

T1

PE

FF2

K1

1 P24

PES PES X1

R11 PES PES

M1

PE

M 3~

e 2-77


Electronic motor starters and drives DF51, DV51 connecting examples Version A: Motor in delta circuit Motor: P = 0.75 kW Mains: 3/N/PE 400 V 50/60 Hz

2

1 h 230 V, 50/60 Hz L N PE

The 0.75 kW motor described below can be delta-connected FAZ-1N-B16 to a single-phase 230 V mains (version A) or star-connected to a 3-phase 400 V mains. Select the appropriate frequency inverter for your mains voltage:

F1

Q11 DILM7 +DILM12-XP1 1 PE

R1

• DF51-322 for 1 AC 230 V DEX-LN1-009 • DF51-340 for 3 AC 400 V • Model-specific accessories for EMC-complaint connection.

2 L

N PE

K1 DE51-LZ1-012-V2 L

DF51-322-075 DV51-322-075 T1

N

PE

L+ DC+ DC– U

V

W PE PES

230 S1

/ 400 V 0,75 kW 1410 rpm

PES

4.0 / 2.3 A cos ϕ 0.67 50 Hz

X1 PES PES

230 V 4A 0.75 kW

2-78

U1

V1 W1

M1 W2 U2 V2

M 3~

e


Electronic motor starters and drives DF51, DV51 connecting examples Version B: Motor in star circuit 3 h 400 V, 50/60 Hz

L1 L2 L3 PE PKM0-10

2

Q1 I

DILM7

I

I

Q11 U1

V1

W1 PE

R1 DEX-LN3-004

U2

V2

W2

L1

L2

L3 PE

K1 DE51-LZ3-007-V4 L1 L2 L3

DF51-340-075 DV51-340-075

L+ DC+ DC– U

T1

PE

V

W PE PES PES

X1 PES PES 400 V 2.3 A 0.75 kW

U1

V1 W1

M1 W2 U2 V2

M 3~ e

2-79


Electronic motor starters and drives DF6 connecting examples DF6-340-... frequency inverters

2

Actuation Example: Temperature regulation for ventillation system. When the room temperature rises, the fan speed must increase. The target temperature can be set with potentiometer R11 (e.g. 20 °C)

Q1

S1

S2

Q11

Q11

n Emergency-Stop circuit S1: OFF S2: ON Q1: Line protection Q11: Mains contactor PES: Cable screen PE connection K1: Radio interference suppression filter 2-80


Electronic motor starters and drives DF6 connecting examples Wiring 3 h 400 V, 50/60 Hz

50 ˚C 100 %

L1 L2 L3 PE

20 ˚C

40 % 4 mA

10.4 mA

2

20 mA

Q1 PE I

I

I

Q11 L1

L2

L3 PE

K1 L1 L2 L3

PE PID

L+ DC+ DC– U

V

W PE

T1

OI

H

O

L

FW P24

PES

PES

PES X1 PES

M1

PE 4...20 mA

PES M 3~

4K7 R11

e

i

M FWD

B1

2-81

U

W PE K12 K14 K11

e

V

M 3~

11 12 13 14 15

FF1 7

+24 V

BR* DV6-340-075, DV6-340-11K and DV6-320-11K only

BR*

AT FA1

K1

4

OL

DC–

RUN

RBr

6

5

FRS

IP

L+

FF2

2CH QTQ

DC+

JOG 3

FWD

REV P24

CM2

8 FW

P24

PLC CM1

TH

i

PTC

2

AM

AMI

FM 10 V (PWM)

RST 1

0...+10 V

J51

O2

L

OI

O

H

– +

SP

SN

RP

RS 485 SN

RJ 45 RS 422

+10 V

RO TO

0...10 V

3

4...20 mA

L1 L2 L3 PE

0V

+24 V

–10 V...+10 V

– +

2-82 4...20 mA

2 Block diagram DV6

Electronic motor starters and drives DV6 connecting examples Moeller Wiring Manual 02/08

v' KREF

+ – v KFB

VF

VG G

+

+

APR

FFWG

o' + – o

e

FB

ASR

Vn

i'

+ i

–

ACR

Vi

u'

PWM

M 3h

Block diagram: speed control circuit, vector frequency inverter DV6 with encoder interface module DE6-IOM-ENC


2

2-83


Electronic motor starters and drives DV6 connecting examples DV6-340-... vector frequency inverters with built-in encoder module (DE6-IOM-ENC) and external DE4-BR1-... braking resistor Actuation

2

Q1 TI

S1

RB

T2 K11

S2

Q11

K3 Q11

Q11

G1

PLC

K2

Enable K2

Example: Hoisting gear with speed regulation, control and monitoring through PLC Motor with thermistor (PTC resistor) n Emergency-Stop circuit S1: OFF S2: ON Q1:Line protection Q11:mains contactor K2: Control contactor enable RB: Braking resistance B1: Encoder, 3 channels 2-84

K12

M11

PES:Cable screen PE connectionirmes M11:Holding brake

RB

i

L1 L2 L3 PE

1 2

PES

DE4-BR1...

T1 T2 PE

T1

K1

Q11

Q1

L1

I

L2

I

L3 PE

PES

e

L+ DC+ DC– BR U

L1 L2 L3

I

3 h 400 V, 50/60 Hz

V

M 3~ M1

W PE

PE

Th CM1

i

PES

PES

B1

M11

I..

b

Encoder

CM2 I.. I..

CM2 11 12 13

EP5 EG5 EAPEAN EBP EBN EZP EZN

DE6-IOM-ENC

2

3

8 FW P24

m

a

n1 n2 n3 REV FWD

Q.. Q.. Q.. Q.. Q.. P24

1

Wiring


2-85

2


Electronic motor starters and drives DV6 connecting examples Installing encoder interface module DE6-IOM-ENC

2

1

2

4

3

M3 x 8 mm

0.4 – 0.6 Nm 1

2-86


Electronic motor starters and drives DV6 connecting examples EG5

F 20 m

2

EG5

15

1

2

3

M4

Order ZB4-102-KS1 separately!

ZB4-102-KS1

TTL (RS 422) A A B B C C EP5 EG5 EAP EAN EBP EBN EZP EZN

– +

5VH

M 3h

2-87


Electronic motor starters and drives Rapid Link system System Rapid Link

2

the aid of a power and data bus in which the rapid link modules are installed.

Rapid Link is a modern automation system for material handling systems. Because the Rapid Link modules can be simply fitted into a power and data bus, it allows electrical drives to be installed and taken into operation much more quickly than with conventional methods. A time-saving installation is implemented with

Note The Rapid Link system must not be commissioned without referring to the manual AWB2190-1430. This publication is available for download as PDF file from the Moeller Support Portal.

.

a

b

c

d

e f g h j

i

k

i

k

Function modules: a Interface control unit r the interface to the open field bus b Disconnect control unit r power infeed with lockable rotary handle; r circuit-breaker to protect from overload and short-circuits

2-88

c Motor control unit r 3-phase electronic overload protection with DOL starter, expandable DOL starter or reversing starter function d Speed control unitr controls three-phase asynchronous motors with four fixed speeds, bidirectional operation and soft starting


Electronic motor starters and drives Rapid Link system Power and data bus: e AS interface® flat cable

Engineering The Rapid Link function modules are installed immediately adjacent to the drives. They can be connected to the power and data bus at any point without having to interrupt the bus. The AS-Interface® data bus is a system solution for networking different modules. ASInterface® networks are quick and easy to implement. AS-Interface® uses a geometrically coded, unscreened flat cable with a cross-section of 2 x 1.5 mm2. It is used to transfer both power and all data traffic between the PLC and I/O and also supplies the connected devices with energy to a certain extent. The installation meets the usual requirements. Engineering is simplified by full flexibility in system layout and mounting. When a link is connected to the flat cable, two metal pins pierce through the cable’s jacket and into the two cores to establish a contact with the AS-Interface® cable. There is no need to cut and strip cables, apply ferrules or connect individual cores.

6.5

b

a

a

+

–

4

Link for M12 connector cables Flexible busbar for 400 V h and 24 V Power feed for flexible busbar Plug-in power link for flexible busbar Round cable for 400 V h and 24 V Plug-in power link for round cable

2

f g h i j k

2

10 a Piercing pins b Flat cable, protected against polarity reversal The power bus supplies the Rapid Link function modules with main and auxiliary power. Plug-in tap-off points can be quickly and safely connected at any point along the bus. The power bus can consist either of a flexible busbar (flat cable) or standard round cables: • The flexible busbar RA-C1 is a 7-core flat cable (cross-section 4 mm2) and has the following structure:

M L+ PE N L3 L2 L1 • For the power bus you can also use conventional round cables (cross-section 7 x 2.5 mm2 or 7 x 4 mm2, outer core diameter < 5 mm, flexible copper conductor to IEC/EN 60228) with round cable feeders

2-89


Electronic motor starters and drives Rapid Link system safe isolation according to IEC/EN 60947-1 Annex N or IEC/EN 60950. The 24 V DC power supply unit must be earthed on the secondary side. The 30 V DC PSU for the ASInterface®-/RA-IN-power supply must meet the safe isolation requirements according to SELV. The power sections are supplied through disconnect control unit RA-DI (see illustration below) with:

RA-C2. The cable can have an external diameter of 10 to 16 mm.

2 Danger! • Rapid Link must be operated only on threephase systems with earthed star point and separate N and PE conductors (TN-S network). It must not be operated unearthed. • All devices connected to the power and data bus must also meet the requirements for

• Ie = 20 A/400 V at 2.5 mm2 • Ie = 20 to 25 A/400 V at 4 mm2. Round cables up to 6 mm2 can be used to feed power to disconnect control unit RA-DI.

⎧ ⎨ ⎩

3 AC 400 Vh, 24 V H 50/60 Hz F 6 mm2 RA-DI Disconnect Control Unit RA-DI Q1 2.5 mm2 / 4 mm2 1.5 mm2 RA-MO RA-SP

1.5 mm2 1.5 mm2 RA-SP RA-MO

1.5 mm2 Motor/Speed Control Units

1.5 mm2

1.5 mm2

1.5 mm2

1.5 mm2

PES

PES

PES

e

M 3h

e

M 3h

Disconnect control unit RA-DI protects the cable from overload and provides short-circuit protection for the cable as well as all connected RA-MO motor control units. The combination of RA-DI and RA-MO fulfills the requirements of IEC/EN 60947-4-1 as 2-90

PES

e

M 3h

e

M 3h

starter with type “1” coordination. That means that the contactor’s contacts in the RAMO are allowed to weld in the event of a short-circuit in the motor terminal strip or the motor supply cable. This arrangement also conforms to IEE wiring regulations.


Electronic motor starters and drives Rapid Link system The affected RA-MO motor control unit must be replaced after a short-circuit! When you configure a power bus with a disconnect control unit, observe the following: • Even in the event of a 1-pole short-circuit at the line end, the short-circuit current must exceed 150 A. • The total current of all running and simultaneously starting motors must not exceed 110 A. • The total load current (about 6 x mains current) of all connected speed control units must not exceed 110 A. 2

Z i dt2

[A s]

105 8 6

• Observe the voltage drop in your specific application. Instead of the disconnect control unit, you can use a 3-pole miniature circuit-breaker In F 20 A and B or C characteristic. Here, you must observe the following: • The let-through energy J in the event of a short-circuit must not exceed 29800 A2s. • Therefore the short-circuit current Icc at the mounting location must not exceed 10 kA a characteristic curve.

63 A 50 A

FAZ-B FAZ-C

40 A 32 A 25 A 20 A 16 A 13 A 10 A

4

2 1.5

6A 4A

104

3A

8 6 2A

4

FAZ-...-B4HI

2 1.5 1A

103

0.5 A

8 6 4 3 0.5

1

1.5

2

3

4

5

6 7 8 9 10

15

Icc rms [kA]

2-91

2


Electronic motor starters and drives Rapid Link system Motor Control Unit

2

Motor control unit RA-MO allows the direct bidirectional operation of three-phase motors. The rated current is adjustable from 0.3 to 6.6 A (0.09 to 3 kW).

The unit is connected to AS-Interface® through an M12 plug with the following PIN assignment: M12 plug

Connections Motor control unit RA-MO is supplied ready for installation. The connection to the ASInterface® data bus and the motor is described below. The connection to the power bus is described in the earlier general section “Rapid Link system”.

PIN

Function

1

ASi+

2

–

3

ASi–

4

–

External sensors are connected through an M12 socket.

400 V F 2.2 kW M 3h

3 h 400 V PE 50/60 Hz 24 V H

PIN

Function

1

L+

2

I

3

L–

4

I

On the RA-MO the motor feeder features a plastic-encapsulated socket. The length of the motor cable is limited to 10 m. The motor is connected through a halogenfree, 8 x 1.5 mm2, unscreened, DESINAconformant motor supply cable with a length of 2 m (SET-M3/2-HF) or 5 m (SET-M3/5-HF). Alternatively you can assemble your own motor supply cable with plug SET-M3-A with 8 x 1,5 mm2

1

3

2-92

4

6

PE

7

5

8


Electronic motor starters and drives Rapid Link system i

M 3h SET-M3/... 1

1

U

–

–

•

–

–

–

–

3

3

W

–

–

4

5

–

–

B1 (h/–)

5

6

–

T1

–

6

4

–

–

B2 (h/+)

7

2

V

–

–

8

7

–

T2

–

PE

PE

PE

–

–

Motor connection without thermistor

Motor connection with thermistor

:

:

5

8

1

7

3

5

PE

6

7

1

2

3

*

T1

T2

U

V

W

PE

e

8

1

7

3

2

PE

6

7

1

2

3

*

T1

T2

U

V

W

PE

e M3h

M 3h

i

If motors are connected without PTC thermistor (thermoclick), cables 6 and 7 must be linked at the motor; otherwise the RA-MO issues a fault message.

2-93


Electronic motor starters and drives Rapid Link system Note The two connections illustrated below apply only for motor control unit RA-MO.

Connecting a 400 V AC brake with rapid braking: 4

6

1

7

3

PE

Connecting a 400 V AC brake:

2

:

1

7

1

3

2

PE

3

*

5

4

1

2

3

*

B1

B2

U

V

W

PE

e PE

e M 3h

2-94

M 3h

For controlling braking motors, their manufacturers provide braking rectifiers, which are fitted in the motor terminal strip. If the DC circuit is opened at the same time, the voltage at the braking coil drops off much quicker, causing the motor to also brake more quickly.


Electronic motor starters and drives Rapid Link system Speed Control Unit RA-SP Speed control unit RA-SP is used for electronic variable speed control of three-phase motors. Notes Unlike the other Rapid Link system devices, the RA-SP speed control unit’s enclosure is fitted with a heat sink and requires an EMC-conformant mounting and connection. Connections Speed control unit RA-SP is supplied ready for connection. The connection to the ASInterface® data bus and the motor is described below. The connection to the power bus is described in the earlier general section “Rapid Link system”. .

400 V M 3h

3 h 400 V PE 50/60 Hz

The unit is connected to AS-Interface® through an M12 plug with the following PIN assignment: M12 plug

PIN

Function

1

ASi+

2

–

3

ASi–

4

–

2

On the RA-SP the motor feeder features a metal-encapsulated socket. To meet EMC requirements, this is connected with PE and heat sink over a large area. The matching plug is also metal-encapsulated and the motor cable is screened. The length of the motor cable is limited to 10 m. The motor cable’s screen must have a large-area connection with PE at both ends, and the motor connection terminals must also, therefore, meet EMC requirements. The motor is connected through a halogenfree 4 x 1.5 mm2 + 2 x (2 x 0.75 mm2), screened, DESINA-conformant motor supply cable with a length of 2 m, (SET-M4/2-HF) or 5 m, (SET-M4/5-HF). Alternatively you can assemble your own motor supply cable with plug SET-M4-A, with 4 x 1.5 mm2 + 4 x 0.75 mm2 contact.

1

3

4

6

PE

7

5

8

2-95


Electronic motor starters and drives Rapid Link system RA-SP2-...

2

341-...

341(230)-...

400 V AC

230 V AC

i

M 3h Servo cable SETM4/... 1

1

U

–

–

–

•

–

–

–

–

–

3

3

W

–

–

–

4

5

–

–

B1 (h)

B1 (h)

5

7

–

T1

–

–

6

6

–

–

B2 (h)

B2 (h)

7

2

V

–

–

–

8

8

–

T2

–

–

PE

PE

PE

–

–

–

EMC correct installation of motor conductors SET-M4/...

1

3

U1, V1, W1, PE

2 B1/B2

2-96

T1/T2

4


Electronic motor starters and drives Rapid Link system 8

7

1

T1 T2 U

3

PE

S1

5

8

3

3

PE

PES

PES

PES

T1 T2 U

3.2 / 1.9 A cos ϕ 0.79 50 Hz

7

7

1

e

/ 400 V 0.75 kW 1430 rpm

1

8

PES

W PE

V

M3h i

230

5

V

U1

V1

W1

U2

V2

400

PE

S1

4

/ 690 V 0.75 kW 1430 rpm

6

5

8

e

1.9 / 1.1 A cos ϕ 0.79 50 Hz

7

1

3

U1

V1

W1

W2

U2

V2

PE

PES

PES

PES

T1 T2 U

V

W PE

e

2

W PE

M3h i

W2

F 10 m

5

PES

B1 B2

T1 T2 U

V

W PE

e M3h i

M 3h

RA-SP2-341-... RA-SP2-341(230)-... For controlling braking motors, their manufacturers provide braking rectifiers, which are fitted in the motor terminal strip.

Notes When using speed control unit RA-SP, do not connect the braking rectifier directly to the motor terminals (U/V/W)! 2-97


Electronic motor starters and drives Rapid Link system EMC correct assembly of speed control unit RA-SP

2

PE

PES e

2-98


Notes

2

2-99


Notes

2

2-100


Control circuit devices Page RMQ

3-2

Signal Towers SL

3-11

LS-Titan® position switches

3-13

Electronic position switches LSE-Titan®

3-24

Analog electronic position switches

3-25

Inductive proximity switches LSI

3-27

Optical proximity switches LSO

3-29

Capacitive proximity switches LSC

3-30

3-1

3


Control circuit devices RMQ Commands and signals are the fundamental functions for controlling machines and processes. The required control signals are produced either manually by control circuit devices or mechanically by position switches. The respective application governs the degree of protection, the shape and colour.

3

Advanced technology has been used consistently in the development of the new control circuit devices RMQ-Titan®. The use of LED elements and laser inscription throughout offer maximum reliability, efficiency and flexibility. In detail, this means: • High-quality optics for a uniform appearance, • Highest degree of protection up to IP67 and IP69K (suitable for steam-jet cleaning), • Clear contrast using LED element lighting, even in daylight, • 100,000 h, i.e.machine lifespan, • Impact and vibration resistant, • LED operating voltage from 12 to 500 V, • Low power consumption – only 1/6 of filament lamps, • Expanded operating temperature range 25 to +70 °C, • Light testing circuit, • Built-in safety circuits for highest operational reliability and accessibility, • Abrasion-proof and clearly contrasting laser inscription, • Customer-specific symbols and inscriptions from 1 off, • Text and symbols can be freely combined, • Terminations using screws and Cage Clamp1) throughout, • Spring-loaded Cage Clamp terminals for reliable and maintenance free contact, • Switching contacts suitable for use with electronic devices to EN 61131-2: 5 V/1 mA, 3-2

• Freely programmable switching behaviour on all selector switch actuators: springreturn/stay-put, • All actuators in illuminated and nonilluminated version, • Emergency-Stop actuators with pull and turnto-release function, • Emergency-Stop buttons with lighting option for active safety, • Contacts switch differing potentials, • For use also in safety-related circuits using positive operation and positively opening contacts, • Complying with industry Standard IEC/EN60947. 1)

Cage Clamp is a registered trade mark of Messrs. WAGO Kontakttechnik GmbH, Minden.

RMQ16


Control circuit devices RMQ RMQ-Titan® system overview

3

ATEX

ATEX

3-3


Control circuit devices RMQ RMQ-Titan®

3

Four-way pushbutton Moeller has added more operator elements to its highly successful range of control circuit devices RMQ-Titan. It has a modular design. Contact elements from the RMQ-Titan range are used. The front rings and front frames are of the familiar RMQ-Titan format and colour. Four-way pushbutton The four-way pushbuttons enable users to control machines and systems in four directions of movement, with each direction of movement being assigned one contact element. The actuator has four individual button plates. They can be specifically selected for various applications and can be laser-inscribed to suit the customer's requirements.

0

0

1

1

2

Selector switch actuators The selector switch actuators have four positions. The actuator is available either as a rotary button or as a thumb-grip. One contact element is assigned to each On and each Off position.

Labels Moeller offers various types of labels for all operating elements. Versions available are: Joystick with double contact The joystick allows the control of up to four directions of movement on machines. Different variants of the joystick have 2/4 positions and other variants have 2 settings for each position. This allows for example two speed settings for each direction. For this a standard make open contact and an early-make contact are fitted in series. Momentary contact and latching contact versions are available.

3-4

• Blank, • With direction arrows, • With inscription 0–1–0–2–0–3–0–4. Customised inscriptions are also possible. The Labeleditor software enables customized inscriptions to be designed and these can subsequently be permanently applied to the labels by laser and are wipe-proof..


Control circuit devices RMQ Contact versions Screw terminals

Springloaded terminals

Front fixing

Base fixing

x

x

x

x

Contact

Contact travel diagram1)

.3

0

2.8

5.5

3

.4

M22-(C)K(C)10 x

x

x

–

.1

0 1.2

5.5

.2

M22-(C)K(C)01 x

x

x

x

.5

0

2.8

5.5

.6

M22-(C)K01D2) x

–

x

–

.7

0

1.8

5.5

.8

M22-K10P –

x

x

–

.3

.3

.4

.4

0

3.6

5.5

M22-CK20 –

x

x

–

.1

.1

.2

.2

0 1.2

5.5

M22-CK02 –

x

x

–

.1

.3

.2

.4

0 1.2 3.6

5.5

M22-CK112) 1) Stroke in connection with front element. 2) N/C: Positive opening safety function according to IEC/EN 60947-5-1.

3-5


Control circuit devices RMQ Terminal markings and function numbers (conventional number/circuit symbol), EN 50013 10

01

13

21

14

3

22

20

13

23

14

24

30

13

23

33

14

24

34

11

13

21

14

22

21

13

21

33

14

22

34

12

13

21

31

14

22

32

02

11

21

12

22

03

11

21

31

12

22

32

Voltage versions with series elements

Ue h/H 12 – 30 V h/H 1

2

1

2

1

2

X1

X2

M22-(C)LED(C)-...

M22-XLED60/ M22-XLED220

M22-XLED601)

Ue FAC/DC

1x

60 V

2x

90 V

3x

120 V

...

...

7x

240 V

M22-XLED220

Ue F

1x

220 VDC

1) For increasing the voltage AC/DC.

Ue h 85 – 264 V h, 50 – 60 Hz 1

2

1

2

M22-XLED230-T 3-6

X1

X2

M22-(C)LED(C)230-...

M22-XLED230-T1)

Ue F

1x

400 V~

2x

500 V~

1) AC– for increasing the voltage 50/60 Hz.


Control circuit devices RMQ Circuit for light test The test button is used to check operation of the indicator lights independently of the respective control state. Decoupling elements prevent voltage feedback.

13

13

13

14

14

14

2

12 – 240 V h/H

M22-XLED-T for Ue = 12 to 240 V AC/DC (also for light test with signal towers SL)

a

4

1 2

1 2

1

2 1

3

3

1


2 1


2 1

1

M22-XLED-T

1


2

2

2

X1

X1

X1

X2

X2

X2

M22-(C)LED(C)-... 1)

a Test button 1) Only for elements 12 to 30 V.

3-7


Control circuit devices RMQ M22-XLED230-T for Ue = 85 to 264 V AC/50 – 60 Hz

3

85 – 264 V h/50 – 60 Hz

L1 13

13

13

14

14

14

2

3

1

4

2

1

2

1

2 X1

X1

X1

X2

X2

X2

N a Test button 1) For elements 85 to 264 V.

3-8

a

1

M22-XLED230-T M22-(C)LED(C)230-... 1)


Control circuit devices RMQ Labeleditor 1. * = Colour (here "G" for green), 2.* = File name generated by Labeleditor Please order: 1 x M22-XDH-G-RMQ_Titan_xxxxx.zip • Double pushbutton actuator with white button plates and special symbols Basic type: M22-DDL-*-*-* Customised inscription of devices using the Labeleditor software You can label your device to your individual requirements in four simple steps: • Download the inscription software: www.moeller.net/support, keyword: “Labeleditor” • Creation of label template (menu-guided in the software) • Send the label template to the factory by email. The email address is automatically set for the selected product by the program. When your template is sent, the Labeleditor issues a file name such as “RMQ_Titan_12345.zip”. This file name is part of the article to be ordered (see Ordering examples). • Send order to the Moeller sales office or the electrical wholesalers.

3

1. * = Colour (here "W" for white), 2. and 3. * = File name assigned by Labeleditor; must be stated here 2 x Please order: 1 x M22-DDL-W-RMQ_Titan_xx xxx.zip-RMQ_Titan_xxxxx.zip • Key-operated button, 2 positions, individual lock mechanism no. MS1, individual symbol Basic type: M22-WRS*-MS*-* WRS*: * = Number of positions, MS*: * = Number of individual lock mechanism, -*: * = File number assigned in Labeleditor Please order: 1 x M22-WRS2-MS1-RMQ_Titan_xxxxxx.zip

Ordering examples • M22-XST insert plate for M22S-ST-X legend plate mount with special inscription Basic type: M22-XST-* * = File name generated by Labelditor Please order: 1 x M22-XST-RMQ_Titan_xxxxxx.zip • Button plate in green with special inscription Basic type: M22-XDH-* 3-9


Control circuit devices RMQ ATEX approval Surface-mounted devices with ATEX approval are used for example in areas laden with explosive dust such as in milling facilities, metal and wood processing plants, cement works, in the aluminium industry, animal feed industry, grain storage and preparation, agriculture and the pharmaceutical industry.

3

The basic devices listed in our Main Catalogue can be ordered with approval in accordance with the ATEX directive 94/9/EC. a ATEX equipment code Note What does ATEX stand for? a section, page 4-17. Moeller supplies devices from the RMQ-Titan and FAK range in compliance with the ATEX directive for manufacturers: 94/9/EC (binding from 06/2003). The switches are approved for device group II, the application “everything, except for mining” and for category 3 (normal safety). The approval has the test number BVS 06 ATEX E023U and BVS 06 ATEX E024X. The housings, pushbutton actuators, indicator lights, and foot and palm switches etc. have the equipment code Ex II3D IP5X T85°C. ATEX directive for operators 1999/92/EC (binding from 06/2006) allows approved devices with the above test number to be used in dust environments, zone 22, category 3.

• • • • • • • • • • • • •

Pushbutton actuators, flush and extended Mushroom-headed pushbutton Selector switch actuators Keyswitches Illuminated pushbuttons Indicator light lens assemblies, conical Double actuators Illuminated selector switch actuators Joystick 4-way pushbuttons Emergency-Stop pushbuttons Foot and palm switches Potentiometer

Order Order with the designation M22COMBINATION-* with the suffix M22-ATEX or FAK-COMBINATION-* with the suffix FAKATEX. * User-definable customer code, max. 10 characters. Further information is provided in the Main Catalogue for Industrial Switchgear. www.moeller.net/en/support/pdf_katalog.jsp

3-10


Control circuit devices Signal Towers SL Signal Towers SL – everything under visual control at all times Signal towers SL indicate machine states using visible and acoustic signals. Mounted on control panels or on machines, they can be reliably recognized as continuous light, flashing light, strobe light or acoustic indicator even from a distance, and dealt with as necessary.

Product features • Continuous light, flashing light, strobe light and acoustic indicator can be combined as required. • Free programmability permits the actuation of five addresses. • Simple assembly without tools by bayonet fitting. • Automatic contacting by built-in contact pins. • Excellent illumination by specially shaped lenses with Fresnel effect. • Use of filament bulbs or LEDs as required. • A large number of complete units simplifies selection, ordering and stock holding for standard applications. The various colours of the light elements indicate the operating status in each case to IEC/EN 60204-1 an: RED:

Dangerous state – immediate action necessary YELLOW:

Abnormal status – monitor or -action GREEN:

Normal status – no action necessary BLUE:

Discontinuity – action mandatory WHITE:

Other status – can be used as required.

3-11

3


Control circuit devices Signal Towers SL Programmability 2 1

3 4

3

0

5

5Ⳏ

5

BA15d F 7 W 4Ⳏ

4

3Ⳏ

3

2Ⳏ

1Ⳏ

054321

N

1...5 Ue = 24 – 230 Vh/Hⵑ

Five signal lines from a terminal strip in the basic module run through each module. The module is addressed via a wire link (jumper) on each printed circuit board. Five different addresses can also be allocated several times. Thus, for example, a red strobe light and in parallel with it an acoustic indicator can indicate and announce the dangerous status of a machine. Insert both jumpers into the same position on the pcb – and it's done! (a section "Circuit for light test", page 3-7.)

3-12

2

1


Control circuit devices LS-Titan® position switches New combinations for your solutions with LS-Titan®

a

3

LS-Titan

RMQ-Titan a Operating heads in four positions, each turned by 90°, can be fitted subsequently. Actuating devices RMQ-Titan® simply snap fitted Another unique feature is the possibility to combine control circuit devices from the RMQTitan range with the position switches LS-Titan. Pushbuttons, selector switches or EmergencyStop buttons can all be directly snapped on to any position switch as operating head. The complete unit then has at least the high degree of protection IP66 at front and rear.

In addition, all the operating heads and the adapter for accepting the RMQ-Titan actuators have a bayonet fitting that enables quick and secure fitting. Using the bayonet fitting, the heads can be attached in any of the four directions (4 x 90°).

3-13


Control circuit devices LS-Titan® position switches Overview

3 LS, LSM

LSR…

3-14

LS4…ZB

LS…ZB

LS…ZBZ


Control circuit devices LS-Titan® position switches Safety position switches LS4…ZB, LS…ZB Moeller safety position switches have been specially designed for monitoring the position of protective guards such as doors, flaps, hoods and grilles. They meet the requirements of the German Trade Association for the testing of positively opening position switches for safety functions (GS-ET-15). These reqquirements include:

Positive opening is an opening movement by which it is ensured that the main contacts of a switch have attained the open position at the same time as the actuating element assumes the Off position. Moeller position switches all meet these requirements.

“Position switches for safety functions must be designed so that the safety function cannot be bypassed manually or with simple tools.” Simple tools are: pliers, screwdrivers, pins, nails, wire, scissors, penknives etc.

All Moeller safety position switches are certified by the German employers liability insurance association or by the Technical Monitoring Service (TÜV), Rheinland, and the Swiss accident prevention authority (SUVA). BG

BG

BG

PRÜFZ

ERT

PRÜFZ

ERT

ET 06183

BGIA 0603010

ET 07014

Sicherheit geprüft tested safety



LS4…ZB

LS…ZBZ

LS…ZB

PRÜFZ

ERT

BG

Positive opening Mechanically operated position switches in safety circuits must have positively opening contacts (see EN 60947-5-1/10.91). Here, the term positive opening is defined as follows: “The execution of a contact separation as the direct result of a predetermined motion of the actuating element of the switch via non-spring operated parts (e.g. not dependent on a spring)“.

PRÜFZ

ERT

In addition to these requirements, LS...ZB position switches offer additional manipulation safety by means of an operating head which can rotate but cannot be removed.

3 Certification

ET 06165 Sicherheit geprüft tested safety

LSR-ZB…

3-15


Control circuit devices LS-Titan® position switches “Personnel protection” by monitoring the protective device LS…ZB

LS4…ZB STOP

• Door open • LS...ZB disconnects power • No danger

3

LS…ZB closed

open a Safety contact b Signalling contact

a b

21

22

21

22

13

14

13

14

Door closed

a Safety contact (21 – 22) closed Signalling contact (13-14) open

Door open

a Safety contact (21 – 22) open Signalling contact (13-14) closed

3-16


Control circuit devices LS-Titan® position switches "Enhanced personnel protection" with separate signal for door position LS…ZBZ • • • • •

STOP

Stop signal Waiting time Machine is stopped Protective device open No danger

3 LS…FT-ZBZ, spring-powered interlock (closed-circuit current principle) LS-S02-…FT-ZBZ c

a b

d

a b c d e

e

A1 US

A1

A1 US

A2 21

22

A2 21

22

A2 21

22

11

12

11

12

11

12

Safety contact Signalling contact Interlocked Released open

Door closed and a Coil at (A1, A2) de-energized also Door open interlocked with mains failure or wire break: Door interlocked = safe state Safety contact (21-22) closed Signalling contact (11-12) closed

a Both contacts in the open position tamperproof against simple tools

Door released

a Apply voltage to coil (A1, A2) e.g. via zero-speed monitor Safety contact (21 – 22) opens Signalling contact (11 - 12) remains closed

Close door

a Signalling contact (11 – 12) closes

Door open

a Only possible once it is released Signalling contact (11 - 12) opens.

Interlock door

a Disconnect the voltage from coil (A1, A2) 1st actuator interlocked 2nd safety contact (21-22) closes

3-17


Control circuit devices LS-Titan® position switches LS-S11-…FT-ZBZ c

d

A1

A1

A1

A2 21

22

A2 21

22

A2 21

3

22

13

14

13

14

13

14


US

US

a b

a b c d e

e

Door closed and a Coil de-energised (A1, A2) interlocked even with mains failure or wire breakage: Door interlocked = safe state Safety contact (21-22) closed Signalling contact (13-14) open

Door open

a Safety contact (21 - 22) open Signalling contact (13-14) closed

Door released

a Apply voltage to coil (A1, A2) Close door e.g. via zero-speed monitor Safety contact (21 – 22) opens Signalling contact (13-14) remains open

a Signalling contact (13 - 14) opens.

Door open

a Only possible once it is released Signalling contact (13 - 14) closes.

a Disconnect the voltage from coil (A1, A2) 1st actuator interlocked 2nd safety contact (21-22) closes

3-18

Interlock door


Control circuit devices LS-Titan® position switches "Process protection and enhanced personnel protection" with separate signal for door position LS…ZBZ • • • • •

STOP

Stop signal Waiting time Process sequence halted Protective device open Product OK

3

LS…MT-ZBZ, magnet-powered interlock (operating current principle) LS-S02-…MT-ZBZ c

a b

d

a b c d e

e

A1 US

A1

A1

A2

A2

A2

21

22

21

22

21

22

11

12

11

12

11

12


Door closed and a Voltage on coil (A1, A2) interlocked Safety contact (21-22) closed Signalling contact (11 - 12) closed

Door open

a Both contacts in the open position tamperproof against simple tools

Door released

a Coil de-energised (A1, A2) e.g. via zero-speed monitor, Safety contact (21 – 22) opens Signalling contact (11 - 12) remains closed

Close door

a Signalling contact (11 – 12) closes

Door open

a Only possible once it is released Signalling contact (11 - 12) opens.

Interlock door

a Apply voltage to coil (A1, A2) 1st actuator interlocked 2nd safety contact (21-22) closes

3-19


Control circuit devices LS-Titan® position switches LS-S11-…MT-ZBZ c

3

a b

d

A1 US

A1

A2

A2

a b c d e

e

A1 A2

21

22

21

22

21

22

13

14

13

14

13

14


Door closed and a Voltage on coil (A1, A2) interlocked Safety contact (21-22) closed Signalling contact (13-14) open

Door open

a Safety contact (21 - 22) open Signalling contact (13-14) closed

Releasing of doora Coil de-energised (A1, A2) e.g. via zero-speed monitor, Safety contact (21 – 22) opens

Close door

a Signalling contact (13 - 14) opens.

Door open

Interlock door

a Apply voltage to coil (A1, A2) 1st actuator interlocked 2nd safety contact (21-22) closes

3-20

a Only possible once it is released Signalling contact (13 - 14) closes.


Control circuit devices LS-Titan® position switches “Personnel protection” by monitoring of the protective mechanism LSR…I(A) /TKG LSR…I(A)/TS STOP

• Hinged protective cover open • LSR... disconnects power • No danger

3

LSR…TKG, LSR…TS Closed

open a Safety contact b Signalling contact

a b

21

22

21

22

13

14

13

14

Hinged a Safety contact (21 – 22) closed protective cover Signalling contact (13-14) open closed Hinged a Safety contact (21 – 22) open protective cover Signalling contact (13-14) closed open

3-21


Control circuit devices LS-Titan® position switches LS, LSM

LS4…ZB

Standards

• IEC 60947, EN 60947, VDE 0660 a EN 50047 • Dimensions • Fixing dimensions • Switching points • Minimum IP65

• IEC 60947, EN 60947, VDE 0660 a EN 50041 • Dimensions • Fixing dimensions • Switching points • IP65

Suitable applications

• Also for use in safety circuits, by positive operation and positively opening contacts

• Safety position switches for protection of personnel • With separate actuating element for protective guards • Positive operation and positively opening contacts • Approval of German Trade Association

Actuation

• • • • • • • •

• Coded actuating element • Operating head: – Can be rotated by 90° – Can be actuated from both sides • Actuating element – Convertible for vertical and horizontal fixing • With triple coding

3

3-22

Plunger (centre fixing) Plunger head (centre fixing) Rotary lever Angled roller lever Adjustable roller lever Actuating rod Spring-rod Operating heads adjustable in 90° steps


Control circuit devices LS-Titan® position switches LS…ZB

LS…ZBZ

Standards

• IEC 60947, EN 60947, VDE 0660 • IP65

• IEC 60947, EN 60947, VDE 0660 • IP65

Suitable applications

• Safety position switches for protection of personnel • With separate actuating element for protective guards • Positive operation and positively opening contacts • Approval of German Trade Association

• Safety position switches for protection of personnel • With separate actuating element for protective guards • Positive operation and positively opening contacts • Electromagnetic interlocking • Approval of German Trade Association

Actuation

• Coded actuating element • Operating head: – Can be rotated by 90° – Can be actuated from four sides and from above

• Coded actuating element • Operating head: – Can be rotated by 90° – Can be actuated from four sides

3

3-23


Control circuit devices Electronic position switches LSE-Titan® Switching point variably adjustable The switching point on electronic position switches LSE-Titan is adjustable and variable. Two high-speed and bounce-free PNP switching outputs enable high switching frequencies.

3

The position switch is overload as well as conditionally short-circuit proof and has snapaction switching behaviour. This ensures a defined and reproduceable switching point. The switching point lies in the range from 0.5 to 5.5 mm (supplied as = 3 mm). Adjustment to a new switching point is carried out as follows: Move the plunger from the original to the new switch position. For this purpose, press the setting button for 1 s. The LED now flashes with a high pulse frequency and the new switching point is retentively set. The LSE-11 and LSE-02 devices can be used in safety-oriented circuits. They have the same function as electromechanical position switches.

adjust fasten

1s

LED adjust

fmax F 2 N

Note

This means that all the devices are also suitable for safety applications designed for personnel or process protection.

adjust Bauart geprüft Functional

TÜV Rheinland

Safety Type approved

Contact travel diagram LSE-11

+Ue

0 0.5

5.5 6.1

Q1 electron. Q1

Q2

Q2

default = 3.0

0V

LSE-02

+Ue

0 0.5

Q1 electron. Q1 0V

3-24

Q2

Q2 default = 3.0

5.5 6.1


Control circuit devices Analog electronic position switches Analog electronic position switches material wear. The analog position switches also have a diagnosis output for further processing of data. This means that the safe status can be monitored and analysed at all times. The position switch also has a self-test function. The outputs Q1 and Q2 are constantly scanned for overload, short circuit against 0 V and short circuit against +Ue.

Two types are available: • LSE-AI with current output, • LSE-AU with voltage output. Analog, mechanically actuated position switches directly linked with the world of automation Analog position switches LSE-AI (4 to 20 mA) and LSE-AU (0 to 10 V) represent another innovation in electronic position switches. Using them, it is now possible for the first time to monitor the actual position of a flue gas valve or an actuator continuously. The actual position is converted in analog fashion into voltage (0 to 10 V) or current (4 to 20 mA) and then continuously signalled to the electronics. Even objects of varying sizes or thicknesses, such as brake shoes, can be scanned and the results processed further.

Contact travel diagram LSE-AI I [mA] 20

4

S [%]

0

100

LSE-AU U [V]

Simple rotational-speed dependent control systems of fan motors or smoke-venting blowers signal the opening angle of the air damper (e.g. 25, 50 or 75 %) and thus save power and

10

S [%] 0

100

Connection diagram +24 V (–15 / +20 %) LSE-AI +Ue

F 200 mA

diagnosis +Q2

4 – 20 mA

analog +Q1 0V

A < 400 O

Q Ue

0V

3-25

3


Control circuit devices Analog electronic position switches +24 V (–15 / +20 %) LSE-AU +Ue diagnosis +Q2 analog +Q1

F 200 mA F 10 mA

0V

3

V

0 V – 10 V

Q Ue

0V

Contact diagram

Normal scenario LSE-AI

LSE-AU

Q1

4 – 20 mA

0 – 10 V

Q2

Q Ue

Q Ue

LED

LED

LED

t

t

Fault scenario LSE-AI

LSE-AU

Q1

0 mA

0V

Q2

0V

0V

LED

LED

LED t

Reset

+Ue

t +Ue

t >1s

3-26

t >1s


Control circuit devices Inductive proximity switches LSI The inductive proximity switch operates on the principle of the attenuated LC oscillator: When metal enters the response range of the proximity switch, power is withdrawn from the system. The metal part causes an energy loss, which is caused by the formation of eddy currents. The eddy current losses are related to the size and nature of the metal part. The change in the oscillation amplitude of the oscillator results in a current change, which is evaluated in the downstream electronics and is converted into a defined switching signal. A steady-state signal is available at the output of the unit, for the duration of the attenuation.

a

b

c

d

e a b c d e

Oscillator Rectifier Amplifier Output Power supply

Properties of inductive proximity switches The following details apply to all inductive proximity switches: • Protective insulation to IEC 346/VDE 0100 or IEC 536, • Protection type IP67, • High operating frequency or switching frequency, • Maintenance and wear-free (long service life),

• Resistant to vibration, • Any required mounting position • LED display indicates the switching or output status and simplifies adjustment during installation, • Operational temperature range –25 to +70 °C • Oscillating load: Cycle time 5 minutes, amplitude 1 mm in the frequency range 10 to 55 Hz, • Comply with IEC 60947-5-2, • Have a steady-state output which remains activated as long as the unit is being attenuated • Bounce-free switching behaviour in the microseconds-range (10–6 s). Switching interval S The switching distance is the distance at which a metal part approaching the active surface effects a signal change at the output. The switching distance depends on: • Approach direction • Size • Material of the metal part The following correction factors must be used for different materials: Steel (St 37)

1,00 x Sn

Brass

0.35 – 0.50 x Sn

Copper

0.25 – 0.45 x Sn

Aluminium

0.35 – 0.50 x Sn

Stainless steel

0.60 – 1.00 x Sn

Sn = Rated switching distance

3-27

3


Control circuit devices Inductive proximity switches LSI AC operating mode AC inductive proximity switches have two terminals. The load is connected in series with the sensor.

L1

Sensor

U Sensor

3

U Supply

R Load U, I Load

N

DC voltage mode DC inductive proximity switches have three terminals and are operated with a protective low voltage. The switching behaviour can be determined more precisely, because the load is actuated via a separate output, and is independent of the load.

+

R U, I Load

3-28

Sensor

U Sensor

U Supply

Load

–


Control circuit devices Optical proximity switches LSO Working principle The optoelectronic sensors in the switch operate using modulated infrared light. Visible light therefore cannot affect their operation. Infrared light can penetrate even severe dirt on the optics, and thus ensures reliable operation. Proximity switch transmitters and receivers are matched to one another. The sensor receiver has an integral bandpass filter to amplify primarily the transmitted frequency. All other frequencies are attenuated. This gives the units good resistance to extraneous light. Precision plastic optics ensure long range and long sensing distances. There are two types of optical proximity switch, distinguished by their function. Reflected-light beam

Material

Factor app.

Paper, white, matt, 200 g/m2 Metal, gloss Aluminium, black, anodized Polystyrene, white Cotton, white PVC, grey Wood, untreated Card, black, gloss Card, black, matt

1 x Sd 1.2 – 1.6 x Sd 1.1 – 1.8 x Sd

3

1 x Sd 0.6 x Sd 0.5 x Sd 0.4 x Sd 0.3 x Sd 0.1 x Sd

Sd = Operating range Reflected-light barrier

b

a Object

a

The reflected-light beam transmits infrared light to the object being scanned, which reflects this light in all directions. The portion of this light which strikes the receiver ensures a switching signal is produced, assuming adequate intensity. Evaluation takes place of “Reflection“ and “No reflection“. These states mean the same as presence or absence of an object in the sensing range. The degree of reflection of the object surface to be monitored affects the operating range Sd. The following correction factors apply to different reflecting material characteristics.

a Object b Reflector

a

The unit transmits a pulsed infrared light beam, which is reflected by a triple reflector or mirror. The interruption in the light beam causes the unit to switch. Light barriers identify objects irrespective of their surface, as long as they do not have a gloss finish. The reflector size must be chosen such that the object to be detected virtually completely interrupts the light beam. Reliable detection is always achieved if the object is the same size as the reflector. The unit can also be set to detect transparent objects.

3-29


Control circuit devices Capacitive proximity switches LSC Working principle

3

The active area of a capacitive proximity switch LSC is formed by two concentrically arranged metal electrodes. You can imagine these as the electrodes of a capacitor that are opened up. The electrode surfaces of this capacitor are arranged in the feed-back branch of a highfrequency oscillator circuit. This is adjusted such that it will not oscillate when the surface is clear. When an object approaches the active surface of the proximity switch, it enters the electric field in front of the electrode surfaces. This effects a rise in the coupling capacitance between the plates and the oscillator begins to respond. The oscillation amplitude is monitored via an evaluation circuit and converted into a switching command.

Metals achieve the greatest switching distances due to their high conductivity. Reduction factors for various metals, such as are necessary with inductive proximity switches, need not be taken into account. Actuation by objects made of non-conductive materials (insulators): When an insulator is brought between the electrodes of a capacitor, the capacitance rises relative to the dielectric constant e of the insulator. The dielectric constant for all solid and liquid materials is greater than that for air.

A+

Objects made of non-conductive materials affect the active surface of a capacitive proximity switch in the same way. The coupling capacitance is increased. Materials with a high dielectric constant achieve great switching distances.

B–

Note

C B A

a

b

B C

e a Oscillator b Evaluation circuit c Amplifier d Output e Power supply A, BMain electrodes C Auxiliary electrodes

3-30

Effects Capacitive proximity switches are activated both by conductive as well as non-conductive objects.

c

d

When scanninng organic materials (wood, grain, etc.) it must be noted that the attainable switching distance is greatly dependent on their water content. (eWater = 80!) Influence of environmental conditions As can be seen from the following diagram, the switching distance Sr is dependent on the dielectric constant er of the object to be monitored. Metal objects produce the maximum switching distance (100 %). With other materials, it is reduced relative to the dielectric constant of the object to be monitored.


Control circuit devices Capacitive proximity switches LSC

80

er

60

30 10 1

10 20

40

60

80

100 sr [%]

The following table lists the dielectric constants er of some important materials. Due to the high dielectric value of water, the fluctuations with wood can be significant. Damp wood therefore is registered much more effectively by capacitive proximity switches than dry wood.

Material

er

Air, vacuum Teflon Wood Paraffin Kerosene Oil of terpentine Transformer oil Paper Polyethylene Polypropylene Cable insulation Soft rubber Silicone rubber Polyvinyl chloride Polystyrene Celluloid Perspex Araldite Bakelite Silica glass Hard rubber Oil-impregnated paper Chipboard Porcelain Laminated paper Quartz sand Glass Polyamide Mica Marble Alcohol Water

1 2 2 to 7 2.2 2.2 2.2 2.2 2.3 2.3 2.3 2.5 2.5 2.8 2.9 3 3 3.2 3.6 3.6 3.7 4 4 4 4.4 4.5 4.5 5 5 6 8 25.8 80

3

3-31


Notes

3

3-32


Rotary switches Page Overview

4-2

ON-Off switches, main switches, maintenance switches

4-3

Changeover switches, reversing switches

4-5

(Reversing) star-delta switches

4-6

Multi-Speed Switches

4-7

Interlock circuits

4-11

Single-phase starting switches

4-12

Meter selector switches

4-13

Heater switches

4-14

Step switches

4-15

Rotary switches and switch-disconnectors with ATEX approval

4-17

4-1

4


Rotary switches Overview Use and mounting forms The following mounting forms are available:

Moeller rotary switches and switch-disconnectors are used as:

4

g h i j k

a Main switches, main switches used as Emergency-Stop devices, b ON-OFF switches, c Safety switches, d Changeover switches, e Reversing switches, star-delta switches, multi-speed switches, f Step switches, control switches, coding switches, meter selector switches.

Basic type

ATEX

TM

Flush mounting, Centre mounting, Surface mounting, Service distribution board mounting, Rear mounting.

Refer to the latest issue of our Main Catalogue for “Industrial Switchgear”. Other contact arrangements are listed in the K115D/F/GB specialist catalogue (order no. 077643) in addition to the switches listed in the Main Catalogue.

Iu

Use as

[A]

a

b

c

d

e

f

g

h

i

j

k

–

10

–

x

–

x

–

x

k

k

–

k

–

T0

j

20

x

x

–

x

x

x

+

k

k

k

+

T3

j

32

x

x

–

x

x

–

+

k

k

k

+

T5b

j

63

x

x

x

x

x

–

+

–

k

–

+

T5

j

100

x

–

x

x

–

–

+

–

k

–

+

T6

–

160

x

–

–

x

–

–

–

–

+

–

+

T8

–

3151

x

–

–

x

–

–

–

–

+

–

+

)

Mounting form

P1-25

j

25

x

x

x

–

–

–

+

k

+

k

+

P1-32

j

32

x

x

x

–

–

–

+

k

+

k

+

P3-63

j

63

x

x

x

–

–

–

+

–

+

k

+

P3-100

j

100

x

x

x

–

–

–

+

–

+

k

+

P5-125

–

125

x

x

–

–

–

–

+

–

–

–

+

P5-160

–

160

x

x

–

–

–

–

+

–

–

–

+

P5-250

–

250

x

x

–

–

–

–

+

–

–

–

+

P5-315

–

315

x

x

–

–

–

–

+

–

–

–

+

Iu = max. rated uninterrupted current 1) In enclosed version (surface mounting), max. 275 A. k Dependent on the number of contact units, function and contact sequence. + Irrespective of the number of contact units, function and contact sequence.

4-2


Rotary switches ON-Off switches, main switches, maintenance switches On-Off switchs, main switches T0-2-1 P1-25 P1-32 P3-63 P3-100 P5-125 P5-160 P5-250 P5-315

These switches can also be used as switch-disconnectors for lighting, heating or combined loads.

0 1

L1

1 2 3 4 5 6

L2 L3

Main switches to IEC/EN 60 204 for rear mounting switches with door interlock, padlocking feature, finger-proof incoming terminals, N and PE terminal, red thumb-grip handle (black, if required), warning label. If it is not clear which drive is associated with which main switch, an additional maintenance switch is required close to each drive.

ON OFF

FS 908

Maintenance switches (safety switches) with auxiliary contacts T0-3-15680 0 1

ON

L1 OFF

L2 FS 908

L3 N N

P1-25/.../ P1-32/.../ P3-63/.../ P3-100/.../ ...N/NHI11

L2 L3 N

ON

FS 908 1)

Load shedding contact

1)

Maintenance switches are fitted to electrical machines or installations to provide safe working conditions in accordance with the safety regulations.

0 1

L1

OFF

1 2 3 4 5 6 7 8 9 10 11 12

N

1 2 3 4 5 6 N N 13 14 21 22

1)

By attaching their own padlock to the SVB padlocking feature, electricians can protect himself against anyone switching on without authorization (a section "Circuit diagram example for maintenance switches with a load shedding contact and (or) switch position indicator", page 4-4).

4-3

4


Rotary switches ON-Off switches, main switches, maintenance switches T0(3)-3-15683 maintenance switch

Circuit diagram example for maintenance switches with a load shedding contact and (or) switch position indicator

Function

L1 L2 L3 N F1

4

F0

1

3

FAZB4/1-HS 95

5

F2

Q11 2

4

96

6

21

F2

O 22 13

I

14

1

3

5

7

9

11

8

10

12

Q1 2

4

6

U

V

W

A1

M 3

P1

P1: On P2: Off Q11: Load shedding T0(3)-3-15683 circuit diagram 1-2,3-4,5-6 7-8,11-12 9-10

4-4

P2

13

Q11

Q11 A2

14

Load shedding: When switching on, the main current contacts close first, then the contactor is activated via the late-make N/O contact. When switching off, the contactor is first disconnected by opening the early-break contact, then the main contacts isolate the motor supply. Switch position indication: The position of the switch can be signalled to the control panel or mimic diagram panel via additional make and NC contacts.


Rotary switches Changeover switches, reversing switches Changeover switches T0-3-8212 T3-3-8212 T5B-3-8212 T5-3-8212 T6-3-8212 T8-3-8212

L1 L2

10 2 1 2 3 4 5 6 7 8 9 10 11 12

0 1

L3

2

4

FS 684

Reversing switches T0-3-8401 T3-3-8401 T5B-3-8401 T5-3-8401 0 1

2

L1 L2 L3

1 0 2 1 2 3 4 5 6 7 8 9 10

FS 684

4-5


Rotary switches (Reversing) star-delta switches Star-delta switches T0-4-8410 T3-4-8410

L1

L2

L3

0

T5B-4-8410 T5-4-8410

FS 635

4

W2

U1

W1

0 YΔ 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

Y

U2 V2

V1

Reversing star-delta switches T0-6-15877 T3-6-15877

L1L2L3 SOND 28 1 )

0 Y

Y

FS 638

W2

U1

W1

U2

V2

V1

Y 0 Y 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24

1) Standard contactor interlock a section "Interlock circuits", page 4-11

4-6


Rotary switches Multi-Speed Switches 2 speeds, non-reversing Tapped winding T0-4-8440 T3-4-8440 T5B-4-8440 T5-4-8440

L1 L2L3

0 1 2 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

1 2

0

FS 644 1U 2W

2V

4

2U 1W

1V

햲

a without connections 2 separate windings T0-3-8451 T3-3-8451 T5B-3-8451 T5-3-8451

L1L2L3

0 1 2 1 2 3 4 5 6 7 8 9 10 11 12

1 0

2

FS 644 1U

1W

2U

1V

2W

2V

4-7


Rotary switches Multi-Speed Switches 2 speeds, reversing Tapped winding T0-6-15866 T3-6-15866

L1 L2 L3 2 1 0 1 2 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24

0 1 2

1 2

FS 629

4 1U 2W

2V 2U

1W

2 separate windings, reversing T0-5-8453 T3-5-8453

1V

L1 L2L3

0 1 2

1 2

FS 629

2U

1U

1W

4-8

1V

2W

2V

2 1 0 1 2 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20


Rotary switches Multi-Speed Switches 3 speeds, non-reversing Tapped winding arrangement, single winding for low speed T0-6-8455 T3-6-8455 T5B-6-8455 T5-6-8455 1

L1 L2 L3 0 1 2 3 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24

2

0

3

FS 616

4

1U

1U 2W

2V 2U

1W

1V A

1W

1V B

0-(A)y- (B)d = (B)y y

4-9


Rotary switches Multi-Speed Switches 3 speeds, non-reversing Tapped winding arrangement, single winding for high speed T0-6-8459 T3-6-8459 1

L1 L2 L3 0 1 2 3 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24

2 3

0

FS 616

4

T5B-6-8459 T5-6-8459 1 0

2

3

FS 420 1U

1U 2W

2V 2U

1W

1V A

1W

1V B

0-(B)d- (B)y y -(A)y

4-10


Rotary switches Interlock circuits Interlock circuits between rotary switches and contactors with overload relays provide neat and economical solutions for many switching drive tasks. The following points are common to all interlock circuits:

• Protection against automatic restarting after a motor overload or power failure • The facility for remote disconnection (e.g. emergency-stop) can be provided by one or more Off pushbuttons.

Without mains disconnection (SOND 27) Mains disconnection only by contactor primarily for star-delta circuit

With mains disconnection (SOND 28) Mains disconnection by contactor and switch

4 F0

Q11

F0

Q11

F2

F2 Q1 01 2

S0

Q11

Q11

Circuit as required

Circuit as required M 3~

M 3~

Interlock with contactor (SOND 29) Contactor can be energized only when switch is in an operating position F0

Q11

Interlock with contactor (SOND 30) Contactor can be energized only when switch is in an operating position F0

Q11

F2

F2 Q1 01 2

S0 S1 Q11

Q1 01 2

S0

Control section SOND 29

S1

Power section

Q11

Control section SOND 30 Power section

Q11

Q11

Circuit as required

Circuit as required M 3~

Control section SOND 28 Power section without mains disconnection

Q11

Power section without mains disconnection

Q11

Q1 01 2

S0

Control section SOND 27

M 3~

4-11


Rotary switches Single-phase starting switches Meter selector switches enable you to measure currents, voltages and power in three-phase systems with only one measuring device.

Numerous circuits are possible for the different measurements. Some of the most common ones are shown below.

Voltmeter changeover switch

L1-L2

0

L1L2L3 N

L1-N

L2-L3

L2-N

L3-L1

L3-N

1 2 3 4 5 6 7 8 9 10 11 12

FS 1410759

V

L1 L2 L3 0 L1L2L3 0

L1

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18

L2

FS 9440

A

L1 L2 L3

4-12

L1L2 L3

V

Ammeter selector switches

0

L2-L3 L1-L2 L3-L1

FS 164854

T0-5-15925 T3-5-15925 For direct measurement L3

T0-2-15922 3 x phase to neutral without “0” position L1-L2 L2-L3 L3-L1

4

L3-L1 L2-L3 L1-L2 0 L1-N L2-N L3-N

T0-3-8007 3 x phase to phase 3 x phase to neutral with “0” position

1 2 3 4 5 6 7 8


Rotary switches Meter selector switches Ammeter changeover switch T0-3-8048 T3-3-8048 For measurement via transformers, complete rotation possible 0 L1

L3 L2

L1 L2 L3

0 L1L2L3 0

FS 9440

1 2 3 4 5 6 7 8 9 10 11 12

A

4

Wattmeter selector switches T0-5-8043 T3-5-8043 Two-phase method (Aron circuit) for three-cable installations loaded as required. The total wattage is calculated by adding together the two wattages. 0 1

FS 953

2

The Aron circuit will give a correct result for four-cable systems only when the sum of the currents equals zero, i.e. only when the four-cable system is balanced. L1 L2 L3 W 1 2 3 11

10 2 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18

4-13


Rotary switches Heater switches 1-pole disconnection, 3 steps T0-2-8316 T3-2-8316 T5B-2-8316 1 0

2

3

L1 L2 L3

FS 420 I

4

I

0 1 2 3

II

III

1 2 3 4 5 6 7 8

II III

1 2 3

T0-2-15114, complete rotation possible 1

0 1 1+2 2 0 1+2

0 2

FS 193840

1 2 3 4 5 6 7 8

Further heater switches, 2- and 3-pole, with alternative circuitry, output stages, and number of steps are described in the Moeller Main Catalogue, Industrial Switchgear and in the catalogue K 115.

4-14


Rotary switches Step switches One step closed in each position, complete rotation possible T0-6-8239 T3-6-8239 345 2 6 1 7 12 8 1110 9

FS 301

1 2 3 4 5 6 7 8 9 10 11 12 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24

4

4-15


Rotary switches Step switches Stay-put switches On-Off stay-put switch 1-pole: T0-1-15401 2-pole: T0-1-15402 3-pole: T0-2-15403 0

0 1 1 2 3 4 5 6

1

FS 415

4 Changeover switches 1-pole: T0-1-15431 2-pole: T0-2-15432 3-pole: T0-3-15433

1-pole: T0-1-15421 2-pole: T0-2-15422 3-pole: T0-3-15423 2

0

20 1

1

FS 429

1 2 3 4 5 6 7 8 9 10 11 12

HAND

0

HAND 0 AUTO

AUTO

1 2 3 4 5 6 7 8 9 10 11 12

FS 1401

On-Off stay-put switches 1-pole: T0-1-15521 2-pole: T0-2-15522 3-pole: T0-3-15523 With pulsed contact in the intermediate position ON OFF

FS 908

4-16

0 1 2 3 4 5 6 7 8 9 10 11 12

1


Rotary switches Rotary switches and switch-disconnectors with ATEX approval What does ATEX stand for? ATmosphéres EXplosibles = ATEX Explosive atmospheres Dust

Gas

Two standards For operators: 1999/92/EC (binding from 06/2006)

For manufacturers: 94/9/EC (binding from 06/2003)

Explosion risk assessment

Device groups

Gas, steam, mist Zone 0 Zone 1 Zone 2

Group I II

Dust

Ex risk

Zone 20 permanent, frequent, long periods Zone 21 occasional Zone 22 normally not, but then for short time

Application Mining Everything, except mining

Selection of devices and protective systems by categories

Selection of devices by device groups

Gas, steam, mist Zone 0, 1, 2 Zone 1, 2 Zone 2

Group I I II II II

Dust

Category

Zone 20, 21, 22 Zone 21, 22 Zone 22

1 1, 2 1, 2, 3

4

Category M1 M2 1 2 3

Safety Very high High Very high High Normal

4-17


Rotary switches Rotary switches and switch-disconnectors with ATEX approval ATEX approval for Moeller Moeller offers T rotary switches (from 20 to 100 A) and P switch-disconnectors (from 25 to 100 A) in accordance with the binding ATEX Directive 94/6 EC (binding from 06/2006). The switches are provided with the equipment marking Ex II3D IP5X T90°C and are approved for the Ex zone 22 in explosive dust atmospheres.

4

Explosive dust atmospheres are present in: • • • • • • • • •

Mills, Metal polishing workshops, Woodworking facilities, Cement industry, Aluminium industry, Animal feed industry, Grain storage and preparation, Agriculture, Pharmacy etc.

The ATEX switches are used as: • Main switches • Maintenance switches • Repair switches,

• ON-OFF switches or, • Changeover switches. The following ATEX switches are available: Current range

T rotary switches

P switch-disconnectors

20 A

T0-…/I1

–

25 A

–

P1-25/I2

32 A

T3-.../I2

P1-32/I2

63 A

T5B-.../I4

P3-63/I4

100 A

T5-.../I5

P3-100/I5

Note Moeller ATEX switches have passed the EC prototype test for main, maintenance and manual override switches for the current ranges from 20 to 100 A. They are approved for explosive dust atmospheres in accordance with category II 3D, with the test number: BVS 04E 106X. For further information see installation instructions AWA1150-2141.

General installation and application notes • Only suitable cable glands may be used for category 3D! • Use only temperature resistant cables (> 90°C)! • The maximum surface temperature is 90°C! • Operation only permissible at an ambient temperature between –20 and +40°C! • Observe the technical data of the switch used!

4-18

• Never open the device in dust explosive atmospheres! • Observe the requirements of EN 50281-1-2! • Check that the device is free of dust prior to assembly! • Do not open the device while it is energized!


Contactors and relays Page Contactor relays SmartWire Contactors DIL, overload relays Z

5-2 5-8 5-24

Contactors DIL

5-30

Overload relays Z

5-35

ZEV electronic motor-protective system

5-38

Thermistor machine protection device EMT6

5-45

CMD contactor monitoring device

5-48

5-1

5


Contactors and relays Contactor relays Contactor relays Contactor relays are often used in control and regulating functions. They are used in large numbers for the indirect control of motors, valves, clutches and heating equipment. In addition to the simplicity which they offer in project engineering, panel building, commissioning and maintenance, the high level of safety which they afford is a major factor in their favour.

5

Safety The contactor relay contacts themselves constitute a considerable safety feature. By design and construction they ensure electrical isolation between the actuating circuit and the operating circuit, in the de-energized state,

between the contact input and output. All Moeller contactor relays have double-break contacts. The German Trade Associations demand that, for control systems of power-driven metalwork presses, the contacts of contactors must be interlocked and opposing. Interlocking means that the contacts are mechanically connected to one another such that N/C contacts and N/O contacts can never be closed simultaneously. At the same time, it is necessary to ensure that the contact gaps are at least 0.5 mm over the entire life, even when defective (e.g. when a contact is welded). The contactor relays DILER and DILA fulfil this requirement.

Moeller contactor relays Moeller offers two ranges of contactor relays as a modular system: • Contactor relays DILER, • Contactor relays DILA. and the modules are described on the following pages. Modular system The modular system has many advantages for the user. The system is formed around basic units, which are equipped with additional functions by means of modules. Basic units are intrinsically functional units, consisting of an AC or DC drive and four auxiliary contacts.

5-2

Modules with auxiliary functions Auxiliary contact modules have 2 or 4 contacts. The combination of normally open contacts and normally closed contacts comply with EN 50011. The auxiliary contact modules of the contactors DILEM and DILM cannot be snapped onto the basic device to prevent duplication of terminal markings e.g. contact 21/22 on the basic unit and 21/22 on the add-on auxiliary contact module. The DILA and DILM7 to DILM32 contactors of the DILA-XHIR11 auxilary contact are available specially for switching very low signals for electronic applications.


Contactors and relays Contactor relays The system and the Standard European Standard EN 50011 “Terminal markings, reference numbers and reference letters for certain contactor relays” has a direct bearing on the use and application of the modular system. There are various types, which the Standard differentiates between by means of reference numbers and reference letters, depending on the number and position of the make and N/C contacts in the device, and their terminal markings. Ideally devices with the reference letter E should be used. The basic devices DILA-40, DILA-31, DILA-22 as well as DILER-40, DILER-31 and DILER-22 comply with the E version. Example 1 DILA-XHI04

Example 2 DILA-XHI13

For 6 and 8 pole contactor relays, the “E” version means that four make contacts must be arranged in the lower/rear contact level. If, for example, the available auxiliary contact modules are used in the DILA-22 and DILA-31, they result in contact combinations with reference letters X and Y. Below are 3 examples of contactors with 4 normally open and 4 normally closed contacts with different reference letters. Version E is to be preferred.

Example 3 DILA-XHI22

51 61 71 81

53 61 71 81

53 61 71

83

52 62 72 82

54 62 72 82

54 62 72

84

+ DILA-40

+ DILA-31

A1 13 23 33 43

A1 13 21 33 43

A2 14 24 34 44

A2 14 22 34 44

q 44 E DILA40/04

q 44 X DILA31/13

+ DILA-22 A1 13 21 31 43

A2 14 22 32 44

q 44 Y DILA22/22

5-3

5


Contactors and relays Contactor relays Coil connections A1

On the contactor relay DILA the coil connection A1 is at the top and A2 at the bottom. As suppressor circuits the following are connected on the front: • RC suppressors • Varistor suppressors

A1 A2 A2 DILER

5

The DC operated contactors DILER and DILA have an integrated suppressor circuit.

DILA

On the top positioned terminals A1–A2 of the contactor DILER the following accessories are connected to limit the relay coil switch off voltage peaks: • RC suppressors • Diode suppressors • Varistor suppressors Suppressor circuit Electronic equipment is today being increasingly used in combination with conventional switching devices such as contactors. This equipment includes programmable logic controllers (PLCs), timing relays and coupling modules, whose operation can be adversely affected by disturbances from interactions between all the components. One of the disturbance factors occurs when inductive loads, such as coils of electromagnetic switching devices, are switched off. High cut-off induction voltages can be produced when such devices are switched off and, under some circumstances, can destroy adjacent electronic devices or, via capacitive coupling mechanisms, can generate interference voltage pulses and thus cause disruptions in operation.

5-4

Since interference-free disconnection is impossible without an accessory, the coils may be connected to a suppressor module, depending on the application. The advantages and disadvantages of the various suppressor circuits are explained in the following table.


Notes

5

5-5


Contactors and relays Contactor relays Circuit diagram

Load current and voltage responses

+

i

t0

u U 0

–

0

+

0

ZD

t1

–

Very long

1V

–

Medium

UZD

yes

Short

UVDR

yes

Short

–

t2 t

I0 t

t0

u U0

–

Induction voltage limiting defined

t

U

i D

Additional dropout delay

I0

0

D

5

Proof against incorrect connection also for AC

t1 t2

0

t U

i I0 0 VDR

t

u U0 0

t1 t2 t

U

R

i I0 0

C

u U0 0

5-6

t0

t

T1

t


Contactors and relays Contactor relays Circuit diagram

+

Damping also below ULIMIT

Increased rating with circuitry

Notes

–

–

Advantages:

D

Dimensioning uncritical, minimum possible induction voltage, very simple and reliable

–

–

+

–

D

Disadvantage:

Long drop-out delay

Advantages:

Very short drop-out delay. Dimensioning uncritical. Simple construction

Disadvantage:

No damping below UZD

Advantages:

Dimensioning uncritical. High energy absorption. Very simple construction

Disadvantage:

No damping below UVDR

Advantages:

HF damping due to stored energy, immediate de-energisation, highly suitable for AC.

Disadvantage:

Precise dimensioning required

ZD –

–

–

VDR

yes R

yes

C

5-7

5


Contactors and relays SmartWire Connect, don't wire The heart of a modern machine control system is the PLC (programmable logic controller). Typically the PLC is mounted in a control panel in a central position of the system. The switchgear is connected with special cables to the input and output terminals of the PLC for the control and return signals. In a distributed system the connections between the switchgear and the remote input/output system are of a similar type.

5

5-8

The system SmartWire system is used for the connection between the switchgear and the PLC. The inputs/outputs of the PLC are relocated to the switchgear and connected with a plug-in cable. The switchgear is supplied, as much as possible, by the connection cable. This saves time with control wiring, saves space in the control panel (because cable trunking is no longer requiered) and reduces the necessary inputs/outputs on the PLC.


Contactors and relays SmartWire Overview SmartWire The SmartWire system consists of the following components:

1 2

6

XI/ON

3

5

10 6

5

7 4

8

1 2 3 4 5 6 7 8 9 10

Gateway for easyNet and CANopen Gateway for PROFIBUS-DP XI/ON gateway SmartWire-I/O module DOL starter MSC-D up to 32 A DOL starter MSC-D up to 15.5 A SmartWire power module SmartWire connection cable SmartWire module for DILM Reversing starter MSC-R up to 12 A

9

The SmartWire system connects the switching device with the PLC. SmartWire modules for DILM are mounted directly on relays, contactors or the contactors of the motor starters. The SmartWire module for DILM takes over the functions of several inputs/outputs. The SmartWire module is connected with a gateway via a SmartWire connection cable. The gateway then connects the SmartWire system with the superimposed field bus and therefore 5-9


Contactors and relays SmartWire allows communication with various field bus systems. The SmartWire system can consist of a line with up to 16 slaves. The slaves can be eithar SmartWire modules for DILM or SmartWire I/O modules. SmartWire module for DILM

5

The SmartWire I/O module provides digital inputs and outputs in the SmartWire system. Via the 4 inputs various sensors can be integrated into the SmartWire system via floating contacts. Both digital relay outputs Q1 c and Q2 g can be used in the actuation of actuators up to a rated current of AC-15, 3 A at 250 V. SmartWire power module

The SmartWire module for DILM is fixed directly onto a contactor DILM7 to DILM32, a relay DILA or a motor starter MSC. The SmartWire module for DILM allows a contactor or a motor starter to be directly controlled from a PLC and the return signals to be monitored. For this purpose the 6 pole SmartWire connection cable is connected via the sockets IN and OUT. As well as the communication signals a 24 V supply for the contactor coil is also transmitted via the SmartWire connection cable. SmartWire-I/O module

5-10

With a SmartWire power module a second connection for the contactor coil control voltage can be made at another position in the SmartWire chain. The power module has two applications: • Exceeding the power capacity of the contactors in the total SmartWire chain of 72 W/3 A, • Requirement of selective safety switch-off of individual contactor groups or motor starter groups.


Contactors and relays SmartWire Assembly SmartWire system

24 V 0V

24 V DC

h

f

Gate- Aux way

j

b

24 V 0V

g

24 V 0V 24 V 0V

24 V 0V

i c

5

d

d

a M

a b c d e f g h i j

M

M

M

M

M

M

M

M

e

SmartWire module for DILM: SWIRE-DIL Gateway SmartWire power module: SWIRE-PF SmartWire connection cable: SWIRE-CAB-… SmartWire end plug: SWIRE-CAB-000 Field bus Programmable logic controller Earth Fuse SmartWire I/O module: SWIRE-4DI-2DO-R

5-11


Contactors and relays SmartWire DOL starters The SmartWire module for DILM controls the contactor so the terminals A1-A2 must not be wired. Also a return signal is fed back to the SmartWire system via the SmartWire module for DILM. The terminals X3-X4 are supplied with a bridging connection. If in the application electrical interlocking is required the bridge can be removed and the floating contacts connected.

5

A return signal to the PLC is available at terminals X1-X2. When required, a floating auxiliary contact of the PKZ motor-protective circuit-breaker can be connected here. a figure, page 5-13 Reversing starters The reversing starter is assembled from a PKZM0 and two contactors DILM7 to DILM32. A SmartWire module for DILM is mounted on each contactor. The SmartWire module for DILM controls the contactors so the terminals A1-A2 of the contactors must not be wired. Also a return signal will be given back for each to the system SmartWire via the SmartWire module for DILM. Terminals X3-X4 are supplied with a bridging connection. For the electrical interlocking of both contactors this bridge is removed and the auxiliary break contact (21-22) of the other contactor is connected as floating contact. a figure, page 5-14 and a figure, page 5-15

5-12

Star-delta starters with 3 SmartWire modules for DILM They control the contactors so the terminals A1-A2 of the contactors do not have to be wired. Also a return signal to the system is fed for each of the SmartWire system modules for DILM. The terminals X3-X4 are supplied with a bridging connection. For the electrical interlocking of both contactors this bridge is removed and the normally closed auxiliary contact (21-22) of the other contactor is connected as floating contact. a figure, page 5-16 with SmartWire-I/O module The SmartWire I/O module actuates contactor Q11 via digital relay output Q1. The further operation is the same as that of a conventional star-delta starter. The inputs of the SmartWire I/O module are used to implement return signals to the SmartWire system. a figure, page 5-17 With SmartWire module for DILM and ETR4-51 timing relay The SmartWire module for DILM controls mains contactor Q11 so that terminals A1-A2 do not have to be wired. A return signal is also fed back to the SmartWire system via the SmartWire module for DILM. The PLC and the changeover between star contactor and delta contactor have the same wiring and function as the conventional star-delta starter assembly. a figure, page 5-18

PE

-Q1

L3

L2

L1

X1

-Q11

3 5

V

-M1

3~

M

U

4

2

V

3

1

U

4

2

W PE

W PE

6

5

6

I> I> I>

1 1.14

1.13 1.22

1.21

-Q11 A2

A1

-Q1

6

X1 X2 X3 X4 24V 0V DC

1.14

1.13

SmartWire

SmartWire

IN OUT

6

Circuit diagram DOL starters

Contactors and relays SmartWire Moeller Wiring Manual 02/08

5

5-13

5-14

PE

-Q1

L3

L2

L1

X1

-Q11

3 5

V

-M1

3~

M

U

4

2

V

3

1

U

4

2

W PE

W PE

6

5

6

I> I> I>

1

-Q12

1.14

1.13

5

2

1 4

3

1.21 1.22

6

5

-Q11 A2

A1

-Q1

6

22

21

X1 X2 X3 X4 24V 0V DC

1.14

1.13

-Q11

SmartWire

IN OUT

-Q12 A2

A1

6

22

21

X1 X2 X3 X4 24V 0V DC

-Q12

SmartWire

SmartWire

IN OUT

6

Circuit diagram for reversing starter with DILM7 to DILM12 with electrical interlock bridge


PE

-Q1

L3

L2

L1

X1

-Q11

3 5

V

-M1

3~

M

U

4

2

V

3

1

U

4

2

W PE

W PE

6

5

6

I> I> I>

1

-Q12

1.14

1.13

2

1 4

3

1.21 1.22

6

5

-Q11 A2

A1

-Q1

6

22

21

X1 X2 X3 X4 24V 0V DC

1.14

1.13

-Q12

SmartWire

IN OUT

-Q12 A2

A1

6

22

21

X1 X2 X3 X4 24V 0V DC

-Q11

SmartWire

IN OUT

6

SmartWire

Circuit diagram for reversing starter with DILM17 to DILM32


5

5-15

5-16

PE

-Q1

L3

L2

L1

-M1

X1

-Q11

3 5

V2

-Q12

W1 PE

W1 PE

6

5

6

W2 U2

3~

M

V1

U1

4

2

V1

3

1

U1

4

2

I> I> I>

1

V2

2

1

1.54

1.53

6

5

W2 U2

4

3

-Q13 2

1 4

3 6

5

5

-Q11

X1

1.54

1.53

6

-Q1

SmartWire

-Q12

X2 X3 X4 24V 0V DC

IN OUT

6

22

21

-Q13

X1 X2 X3 X4 24V 0V DC

-Q13

SmartWire

-Q12

22

21

SmartWire

X1 X2 X3 X4 24V 0V DC

IN OUT

6

SmartWire

IN OUT

6

Circuit diagram for star-delta starter with 3 SmartWire modules for DILM


PE

-Q1

L3

L2

L1

-M1

X1

-Q11

3 5

V2

-Q12

W1 PE

W1 PE

6

5

6

W2 U2

3~

M

V1

U1

4

2

V1

3

1

U1

4

2

I> I> I>

1

3

V2

2

6

W2 U2

4

5

1.54

1

1.61 1.62

1.53

-Q13 2

1 4

3 6

5

L02

-Q11 A2

A1

-K2

-Q1

L01

14

13

1.54

1.53

-K1

-Q13 A2

A1

-Q12

-K1

21

22

58

57

-Q12 A2

A1

-Q13

-K1

21

22

68

67

-K2

1.61 1.62

Q1

Q2

I2 I3 I4 V+

14

13

SmartWire

13 14

V+ I1

-Q1

-Q11

6

SmartWire

23 24

IN OUT

6

Circuit diagram for star-delta starter with SmartWire I/O module


5

5-17

5-18

PE

-Q1

L3

L2

L1

-M1

X1

-Q11

3 5

V2

-Q12

W1 PE

W1 PE

6

5

6

W2 U2

3~

M

V1

U1

4

2

V1

3

1

U1

4

2

I> I> I>

1

5

3

V2

2

6

W2 U2

4

5

1.54

1

1.61 1.62

1.53

-Q13 2

1 4

3 6

5

L02

-Q11

L01

-Q1

X1

1.62

1.61

6

SmartWire

X2 X3 X4 24V 0V DC

IN OUT

6

-K1

A2

A1

SmartWire

-Q11

-Q1

14

13

1.54

1.53

-Q13 A2

A1

-Q12

-K1

21

22

18

17

-Q12 A2

A1

-Q13

-K1

21

22

28

17

Circuit diagram for star-delta starter with SmartWire I/O module for DILM and ETR4-51 timing relay



Contactors and relays SmartWire SmartWire system for safety-relevant applications In most applications an emergency stop function and power-off when a guard or protective door is opened is required in addition to normal operational switching. Although the SmartWire system is not designed for transmitting safety-relevant signals, it can be laid out to provide safety shutdown functionality using the configuration described below. In an emergency, the control voltage for the contactor coils can be switched off through the safety relay’s Enable circuit. Additional SmartWire power modules can be combined into contactor groups that can be switched off together in an emergency. With this circuit layout, controllers up to EN 954-1 safety category 1 can be set up.

Measures to achieve a higher safety category In many applications PLCs with safety category 3 or 4 according to EN 954-1 are required. Category 3 controllers can be built with an additional series-connected group contactor upstream of the motor outgoers. In an emergency, the safety relay isolates the control voltages for both the group contactor and the motor contactors. With this redundant isolation the circuit fulfills the requirements for category 3 PLCs. a figure, page 5-22 and a figure, page 5-23

a figure, page 5-20 and a figure, page 5-21

5-19

5

5-20 -F01

-T01

-K01

POWER

Y1

22

21

Y2 Y3

CONTROL-LOGIC

RESET

-S02 RESET

22

21

I> I> I>

A1 A2

-S01 NOT AUS

-Q01

PE

L3

L1 L2

K1

K1

14 24 34 42

13 23 33 41

-F02

6

A2

X3 X4

0

-Q11

14 24V 0V

13

Out

SmartWire NET U Aux Ready

-K01

-F03

0

H

A2

X3 X4

-Q12

A1 X1 X2 IN OUT

6

SmartWire

In NET Out

24V 0V

24

2h

400

I> I> I>

A1 X1 X2 IN OUT

-K02 Gateway

-Q02

6

5 A2

X3 X4

-Q13

A1 X1 X2 IN OUT

6

-K03 Power-Module

-K01

-F04

6

Out

A2

X3 X4

-Q14

A1 X1 X2 IN OUT

In

SmartWire

Power-Aux

24V 0V Aux

24

23

6

A2

X3 X4

-Q15

A1 X1 X2 IN OUT

Circuit diagram for safety power-off


PE

PE

L3

L1 L2

-Q1

3 5

-M1 -M1

M 3~

V

3

U

-M2

U

-M1

M 3~

V

V

4

3

1

-Q12 2

4

2

W PE

W PE

6

5

6

5

I> I> I>

1

W PE

-Q2

W PE

4

V

5 6

3

U

6

4

U

-Q11 2

1

2

I> I> I>

1

-Q3

-M3

U

U

1

-Q13 2

2

-M1

M 3~

V

V

4

3

4

3

W PE

W PE

6

5

6

5

I> I> I>

1

-Q4

-M4

U

U

1

-Q14 2

2

3 5

U

W PE V

-M1

-M5

U

W PE

V

-M1

M 3~

V

V

4

3

1

5

-Q15 2

4

2

6

M 3~

3

W PE

W PE

6

5

6

5

I> I> I>

1

4

-Q5

3

6

4

I> I> I>

1

Mains circuit for safety relevant switch-offs


5

5-21

5-22

POWER

-S01 NOT AUS 1.32 1.22

CH2 + –

S12 S33 S31 S22

CH1 +

1.31 1.21

S21 S12

-Q13

-Q14

S34 S35

14

22 13

22 21

21

CONTROL-LOGIC

RESET

-S02 RESET

-Q16

-Q15

I> I> I>

A1 A2

-F01

-T01

– +

-Q01

PE

L3

L1 L2

K1

22

22 21

21

14 24 34

A2

A1

-K01

-Q16

13 23 33

-Q12

-Q11

K1

21

21 22

22

-F02

6

A2

X3 X4

0

-Q11

24 24V 0V

23

Out

SmartWire NET U Aux Ready

-K01

-F03

0

H

A2

X3 X4

-Q12

A1 X1 X2 IN OUT

6

SmartWire

In NET Out

24V 0V

24

2h

400

I> I> I>

A1 X1 X2 IN OUT

-K02 Gateway

14

13

-Q02

6

A2

X3 X4

-Q13

A1 X1 X2 IN OUT

6

-K03 Power-Module

-K01

-F04

6

Out

A2

X3 X4

-Q14

A1 X1 X2 IN OUT

In

SmartWire

Power-Aux

24V 0V Aux

34

33

5 6

A2

X3 X4

-Q15

A1 X1 X2 IN OUT

Control circuit for redundant switch-offs


1

PE

-Q16 2

-F1

PE

L3

L1 L2

5 6

3 4

-Q1

3 5

-M1

V

U

-M1

M 3~

V

U

4

3

1

-Q11 2

4

2

U

-M2

U

1

-Q12 2

2

-M1

M 3~

V

V

4

3

4

3

-Q3

W PE

W PE

6

5

6

5

I> I> I>

1

W PE

-Q2

W PE

6

5

6

I> I> I>

1

-M3

-Q13

U

U

2

1

2

-M1

M 3~

V

V

4

3

4

3

-Q4

W PE

W PE

6

5

6

5

I> I> I>

1 5

-M4

-M1

M 3~

-M5

U

V

U

-M1

M 3~

V

V

4

3

1

-Q15 2

4

2

U

V

U

3

W PE

W PE

6

5

6

5

I> I> I>

1

W PE

4

-Q5

W PE

5 6

3

6

4

-Q14 2

1

2

3

I> I> I>

1

Main circuit for redundant switch-offs


5

5-23


Contactors and relays Contactors DIL, overload relays Z Overview of DIL contactors, 3-pole

5 DILM7 … DILM15

DILM17 … DILM38

DILM40 …DILM72

DILM185 … DILM250

DILM300 … DILM500

DILM580 … DILM1000 DILH1400

DILM1600 DILH2000 DILH2200

5-24

DILM80 … DILM170


Contactors and relays Contactors DIL, overload relays Z Overview DILP contactors, 4 pole

DILEM4

5 DILMP20

Part no.

DILMP32 … DILMP45

DILMP63 … DILMP80 DILMP125 … DILMP200

Rated operational current 50 – 60 Hz open

conventional free air thermal current Ith = Ie AC-1

AC-1

open

40 °C

50 °C

60 °C

Ith = Ie

A

A

A

A

DILEM4

22

20

191)

20

DILMP20

22

21

20

20

DILMP32-10

32

30

28

32

DILMP45-10

45

41

39

45

DILMP63

63

60

54

63

DILMP80

80

76

69

80

DILMP125

125

116

108

125

DILMP160

160

150

138

160

DILMP200

200

188

172

200

1) At 55 °C

5-25


Contactors and relays Contactors DIL, overload relays Z Rated operating current Ie [A] At 400 V

5

380 V, 400 V

660 V, 690 V

1000 V

Conventional free air thermal current Ith = Ie [A] AC-1 at 60 °C

Part no.

220 V, 230 V

6.6

1.5

3

3

–

20

DILEEM

DILEEM

9

2.2

4

4

–

20

DILEM

DILEM

7

2.2

3

3.5

–

20

DILM7

DILM7

9

2.5

4

4.5

–

20

DILM9

DILM9

12

3.5

5.5

6.5

–

20

DILM12

DILM12

15.5

4

7.5

7

–

20

DILM15

DILM15

17

5

7.5

11

–

35

DILM17

DILM17

25

7.5

11

14

–

40

DILM25

DILM25

32

10

15

17

–

40

DILM32

DILM32

38

11

18.5

17

–

40

DILM38

DILM32

40

12.5

18.5

23

–

50

DILM40

DILM40

50

15.5

22

30

–

65

DILM50

DILM50

65

20

30

35

–

80

DILM65

DILM65

72

25

37

35

–

80

DILM72

DILM72

80

25

37

63

–

90

DILM80

DILM80

95

30

45

75

–

110

DILM95

DILM95

115

37

55

90

–

130

DILM115

DILM115

150

48

75

96

–

160

DILM150

DILM150

170

52

90

140

–

185

DILM170

DILM170

5-26

max. rating [kW] AC-3

Part no.

Auxiliary contact blocks For surface mounting

For side mounting

02DILEM 11DILEM 22DILEM

–

DILA-XHI(V)… DILM32-XHI…

–

DILM32-XHI11-S

DILM150-XHI(V) …

DILM1000-XHI(V)…

V,


Contactors and relays Contactors DIL, overload relays Z Conventional free air thermal current Ith = Ie [A] AC-1 at 60 °C

Part no.

1000 V

Part no.

–

20

DILEEM

DILEEM

–

20

DILEM

DILEM

–

20

DILM7

DILM7

–

20

DILM9

DILM9

–

20

DILM12

DILM12

–

20

DILM15

DILM15

–

35

DILM17

DILM17

–

40

DILM25

DILM25

–

40

DILM32

DILM32

–

40

DILM32

DILM38

–

50

DILM40

DILM40

–

65

DILM50

DILM50

–

80

DILM65

DILM65

–

80

DILM72

DILM72

–

90

DILM80

DILM80

–

110

DILM95

DILM95

–

130

DILM115

DILM115

–

160

DILM150

DILM150

–

185

DILM170

DILM170

Auxiliary contact blocks

Motor overload relay

For surface mounting

For side mounting

02DILEM 11DILEM 22DILEM

–

ZE-0.16 up to ZE-9

DILA-XHI(V)… DILM32-XHI…

–

ZB12-0.16 up to ZB12-16

DILM32-XHI11-S

ZB32-0.16 up to ZB32-38

DILM1000-XHI(V)…

ZB65-10 up to ZB65-75

DILM150-XHI(V)…

Electronic motor protection system ZEV

ZEV + ZEV-XSW-25 ZEV-XSW-65 ZEV-XSW-145 ZEV-XSW-820

5

ZB150-35 up to ZB150-175

5-27


Contactors and relays Contactors DIL, overload relays Z Rated operating current Ie [A] At 400 V

5

380 V, 400 V

660 V, 690 V

1000 V


Part no.

220 V, 230 V

185

55

90

175

108

275

DILM185

DILM185

225

70

110

215

108

315

DILM225

DILM225

250

75

132

240

108

350

DILM250

DILM250

300

90

160

286

132

400

DILM300

DILM300

400

125

200

344

132

500

DILM400

DILM400

500

155

250

344

132

700

DILM500

DILM500

580

185

315

560

600

800

DILM580

DILM580

650

205

355

630

600

850

DILM650

DILM650

750

240

400

720

800

900

DILM750

DILM750

820

260

450

750

800

1000

DILM820

DILM820

1000

315

560

1000

1100

1000

DILM1000

DILM1000

1600

500

900

1600

1)

1800

DILM1600

DILM1600

1400

–

–

–

–

1400

DILH1400

DILH1400

2000

–

–

–

–

2000

DILH2000

DILH2000

2200

–

–

–

–

2200

DILH2200

DILH2200

1) Please enquire

5-28

max. rating [kW] AC-3

Part no.


For side mounting

–

DILM1000-XHI…

V,


Contactors and relays Contactors DIL, overload relays Z

1000 V


Part no.

Part no.

108

275

DILM185

DILM185

108

315

DILM225

DILM225

108

350

DILM250

DILM250

132

400

DILM300

DILM300

132

500

DILM400

DILM400

132

700

DILM500

DILM500

600

800

DILM580

DILM580

600

850

DILM650

DILM650

800

900

DILM750

DILM750

800

1000

DILM820

DILM820

1100

1000

DILM1000

DILM1000

1)

1800

DILM1600

DILM1600

–

1400

DILH1400

DILH1400

–

2000

DILH2000

DILH2000

–

2200

DILH2200

DILH2200


For side mounting

–

DILM1000-XHI…

Motor overload relay

Electronic motor protection system ZEV

Z5-70/FF250 up to Z5-250/FF250 ZW7-63 up to ZW7-630

–

ZEV + ZEV-XSW-25 ZEV-XSW-65 ZEV-XSW-145 ZEV-XSW-820

–

–

–

–

–

–

5

5-29


Contactors and relays Contactors DIL Accessories Device

5

DILE(E)M

DIL7 to DILM170 AC

DC

DILM185 to DILM500

DILM580 to DILM2000

Suppressor circuit

–

–

j

j

j

RC suppressors

j

j

–

–

–

Varistor suppressors

j

j

–

–

–

Motor suppressor module

–

to DILM15

to DILM15

–

–

Star-point bridge

j

j

j

j

–

Paralleling link

j

j

j

to DILM185

–

Mechanical interlock

j

j

j

j

j

Sealable shroud

j

–

–

–

–

Cable terminals

–

–

–

j

to DILM820

Individual coils

–

from DILM17

from DILM17

j

j

Electronic modules

–

–

–

j

j

Electronic modules including coils

–

–

–

j

j

Terminal cover

–

–

–

j

j 1)

to DILM32

to DILM32

Timer module 1) Terminal cover to DILM1000.

5-30


Contactors and relays Contactors DIL Contactors DILM These are designed and tested to IEC/EN 60 947. For every motor rating between 3 kW and 900 kW there is a suitable contactor available. Equipment features • Magnet system Due to the new electronic operation the DC contactors from 17 to 72 A have a sealing power of only 0.5 W. Even for 170 A is only 2.1 W necessary. • Accessible control voltage connections The coil connections are on the front of the contactor. They are not covered by the main current wiring. • Can be controlled directly from the PLC The contactors DILA and DILM to 32 A can be controlled directly from the PLC. • Intergrated suppressor DC With all DC contactors DILM a suppressor is integrated in the electronics. • Plug-in suppressors AC With all AC contactors DILM up to 170 A a suppressor can be simply plugged in on the front when required. • Control of the contactors DILM185 to DILM2000 by three different methods: – Conventionally via coil terminals A1-A2 – Directly from a PLC via terminals A3-A4 – By a low power contact via terminals A10-A11. • Conventional control of contactors DILM185-S to DILM500-S via coil terminals A1-A2. There are two coil terminals (110 to 120 V 50/60 Hz and 220 to 240 V 50/60 Hz). • All contactors up to DILM170 are finger and back-of-hand proof to IEC 536 (VDE 0160 part 100). Additional terminal covers are available from DILM185 onwards.

• Double-frame terminal for contactors DILM7 to DILM170 With the new double frame-clamp the connection area is not limited by the screw. They give total security with varying cross sections and have protection against incorrect insertion to ensure safe connection. • Integrated auxiliary contact The contactors up to DILM32 have an integrated auxiliary contact as N/O or N/C contact. • Screw or spring terminals The contactors DILE(E)M and DILA/DILM12, including the corresponding auxiliary contacts, up to 2000 A, are available with screw or spring terminals. • Contactors with screwless terminals They have spring terminals in the mains current circuit as well as for the coil terminals and auxiliary contacts. The shake proof and maintenance free spring terminals can terminate two conductors each of 0.75 to 2.5 mm2 with or without ferrules. • Terminals Up to DILM72 the connection terminals for all auxiliary contacts and coils as well as for main conductors can be tightened with a Pozidriv screwdriver size 2. For contactors DILM80 to DILM170 Allen screws are used. • Mounting All contactors can be fitted on to a mounting plate with fixing screws. DILE(E)M and DILM up to 72 A can also be snapped on to a 35 mm top-hat rail to IEC/EN 60715. • Mechanical interlock With two connectors and a mechanical interlock an interlocked contactor combination up to 150 A can be achieved 5-31

5


Contactors and relays Contactors DIL without extra space requirement. The mechanical interlock ensures that both connected contactors cannot be similtaneously be operated. Even with a mechanical shock the contacts of both contactors cannot close similtaneously. In addition to individual contactors, complete contactor combinations are also available from Moeller:

5

• DIUL reversing contactors from 3 to 75 kW/400 V • SDAINL star-delta starters from 5.5 to 132 kW/400 V xStart DC-actuated contactors The market for DC actuated contactors is growing due to the increasing use of electronics. Whilst AC contactors were used 20 years ago with additional resistors and specially wound DC coils with a lot of copper were used till recently, the next quantum leap has started. Electronic components are now in use for the drives of DC actuated contactors. The xStart contactor series DILM7 to DILM170 has been particularly optimized in the development of DC actuated contactors. The DILM17 to DILM170 DC contactors are no longer switched on or off in the conventional way using a coil but by means of an electronic unit. The integration of electronics in the contactor drives makes different technical features possible which enable the contactors to offer outstanding performance in their daily use.

5-32

Universal voltage coils The DILM17 to DILM170 DC actuated contactors cover the entire DC control voltage range with only 4 control voltage variants. Rated actuation voltage RDC24

24…27 V DC

RDC60

48…60 V DC

RDC130

110…130 V DC

RDC240

200…240 V DC

Voltage tolerance Contactors are built in compliance with the IEC/EN 60947-4-1 standard. The requirement for operational safety even with small mains supply fluctuations is implemented with the reliable switching of contactors at between 85 to 110 % of the rated actuation voltage. The DC actuated DILM17 to DILM170 contactors now cover an even wider range in which they switch reliably. They allow reliable operation between 0.7 x Ucmin and 1.2 x Ucmax of the rated actuation voltage. The greater voltage tolerance than stipulated by the standard increases operating safety even with less stable mains conditions.


Contactors and relays Contactors DIL Integrated suppressor Conventionally operated contactors generate voltage peaks at the coil to current change dI/dt which can have a negative effect on other components in the same control circuit. To prevent damage, contactor coils are often connected in parallel with additional suppressor circuits (RC elements, varistors or diodes). Thanks to their electronics, the DC actuated contactors DILM17 to DILM170 switch without any effect on the network. An additional suppressor is therefore unnecessary since the coils do not generate any external overvoltages. The otherDILM7 to DILM15 DC operated contactors have a built-in suppressor circuit. When using DC operated contactors from Moeller in the project design, the issue of overvoltage protection in control circuits is therefore unnecessary since all DC operated contactors are free of system disturbance or are provided with a suppressor circuit. Contactor dimensions The electronic circuit provides the coil with a high making capacity, which it reduces to the required holding power after startup. This allows the design of AC- and DC-operated contactors with the same physical dimensions, which can then also be used with the same accessories.

Rated power 1)

Contactor

Power consumption Pick-up

Holding

7.5… 15 kW

DILM17 DILM25 DILM32 DILM38

12 W

0.5 W

18.5… 37 kW

DILM40 DILM50 DILM65 DILM72

24 W

0.5 W

37… 45 kW

DILM80 DILM95

90 W

1.3 W

55… 90 kW

DILM115 DILM150 DILM170

149 W

2.1 W

1) AC-3

5

at 400 V

For project design, the reduced sealing power also means a considerable reduction in the heat dissipation in the control panel. This allows side by side mounting of the contactors in the control panel.

Pick-up and holding power The pickup of DC-operated contactors DILM17 to DILM170 is electronically controlled. A sufficiently high power is provided for the pickup to ensure that the contactor switches reliably. The low power needed to hold the contactor is also controlled by the electronics.

5-33


Contactors and relays Contactors DIL Applications The three-phase motor dominates the electric motor sector. Apart from individual low-power drives, which are often switched directly by hand, most motors are controlled using contactors and contactor combinations. The power rating in kilowatts (kW) or the current rating in amperes (A) is therefore the critical feature for correct contactor selection.

5

Physical motor design means that rated currents for the same rating sometimes differ widely. Furthermore it determines the ratio of the transient peak current and the locked-rotor current to the rated operational current (Ie). Switching electrical heating installations, lighting fittings, transformers and power factor correction installations, with their typical individual characteristics, increases the wide range of different uses for contactors. The switching frequency can vary greatly in every application. The difference can be, for example, from less than one operation per day up to a thousand operations or more per hour. Quite often, in the case of motors, a high switching frequency coincides with inching and plugging duty. Contactors are actuated manually or automatically, using various types of command devices, depending on the travel, time, pressure or temperature. Any interrelationships required between a number of contactors can easily be produced by means of interlocks via their auxiliary contacts.

5-34

The auxiliary contact of the contactor DILM can be used as mirror contact to IEC/EN 60947-4-1 Appendix F to show the condition of the main contacts. A mirror contact is a normally closed contact that cannot be similtaneously closed with the normally open main contacts. Other applications • Capacitor contactors for power factor compensation DILK for 12.5 to 50 kvar/400 V. • Lighting contactors DILL for 12 to 20 A/400 V (AC-5a) or 14 to 27 A/400 V (AC-5b).


Contactors and relays Overload relays Z Motor protection using Z thermal overload relays Overload relays are included in the group of current-dependent protective devices. They monitor the temperature of the motor winding indirectly via the current flowing in the supply cables, and offer proven and cost-efficient protection from destruction as a result of: • Non starting, • Overload, • Phase-failure. Overload relays operate by using the characteristic changes of shape and state of the bimetal when subjected to heating. When a specific temperature is reached, they operate an auxiliary switch. The heating is caused by resistances through which the motor current flows. The equilibrium between the reference

S

and actual value occurs at various temperatures depending on the magnitude of the current. Tripping occurs when the reference temperature is reached. The tripping delay depends on the magnitude of the current and preloading of the relay. Whatever the current, the relay must trip out before the motor insulation is endangered, which is why EN 60947 states maximum response times. To prevent nuisance tripping, minimum times are also given for the limit current and locked-rotor current. Phase-failure sensitivity Overload relays Z offer, due to their design, an effective protection against phase failure. They have phase failure sensitivity to IEC 947-4-1 and VDE 0660 part 102 and therefore can also provide protection for EEx e motors (a following diagramms).

햴 97 95

97 95

97 95

98 96

98 96

98 96

햲 햳

Normal operation (no fault) a Trip bridge b Differential bar c Differential travel

Three phase overload

One phase drops out

5-35

5


Contactors and relays Overload relays Z When the bimetallic strips in the main current section of the relay deflect as a result of three-phase motor overloading, all three act on a trip bar and a differential bar. A shared trip lever switches over the auxiliary contact when the limits are reached. The trip and differential bars lie against the bimetallic strips with uniform pressure. If, in the event of phase failure for instance, one bimetallic strip does not deflect (or recover) as strongly as the other two, then the trip and differential bars will cover different

Design note a section "Motor protection in special applications", page 8-8; Further information to motor protection a section "All about Motors", page 8-1.

Tripping characteristics The overload relays ZE, ZB12, ZB32, ZB65 and the ZB150 up to 150 A are, due to the German Physical/Technical Bureau (PTB), suitable for protection of EEx e-motors to the ATEX-Guidelines 94/9 EG. In the relevant manual all tripping characteristics are printed for all currents. ZB12, ZB32, ZB65, ZE

5-36

These tripping characteristics are mean values of the scatter bands at an ambient temperature of 20 °C from cold. The tripping time is dependant upon the current. When units are warm, the tripping delay of the overload relay drops to about a quarter of the value shown. 2h 100 60 40 20 10 6 4 2 1 40 20 10 6 4 2 1 0.6

ZB150

3-phase

2-phase

1 1.5 2 3 4 6 8 10 15 20 x Setting current

Seconds

Minutes

Minutes

2h 100 60 40 20 10 6 4 2 1 40 20 10 6 4 2 1 0.6

Seconds

5

distances. This differential movement is converted in the device by a step-up mechanism into a supplementary tripping movement, and thus accelerates the tripping action.

3-phase

2-phase

1 1.5 2 3 4 6 8 1015 20 x Setting current


Contactors and relays Overload relays Z ZW7

Seconds

Minutes

2h 100 60 40 20 10 6 4 2 1 40 20 10 6 4 2 1 0.6

Maximum Minimum

5 1 1.5 2 3 4 6 8 10 15 20 x Setting current

5-37


Contactors and relays ZEV electronic motor-protective system Operating principle and control Like overload relays operating on the bimetallic strip principle, electronic motor-protective relays are current-dependent protective devices.

5

The acquisition of the actual flowing motor current in the three external conductors of the motor connections is with motor protection system ZEV with seperate push-through sensors or a sensor belt. These are combined with an evaluation unit so that seperate arrangement of the current sensor and the evaluation unit is possible. The current sensor is based on the Rogowski principle from the measurement technology. The sensor belt has no iron core, unlike a current transformer, therefore it doesn´t become saturated and can measure a very wide current range. Due to this inductive current detection, the conductor cross-sections used in the load circuit have no influence on the tripping accuracy. With electronic motor-protective relays, it is possible to set higher current ranges than is possible with electromechanical thermal overload relays. In the ZEV System, the entire protected range from 1 to 820 A is covered using only an evaluator. The ZEV electronic motor-protective system carries out motor protection both by means of indirect temperature measurement via the current and also by means of direct temperature measurement in motors with thermistors. Indirectly, the motor is monitored for overload, phase failure and unbalanced current consumption.

5-38

With direct measurement, the temperature in the motor winding is detected by means of one or more PTC thermistors. In the event of excessive temperature rise, the signal is passed to the tripping unit and the auxiliary contacts are actuated. A reset is not possible until the thermistors cool to less than the response temperature. The built-in thermistor connection allows the relay to be used as complete motor protection. In addition, the relay protects the motor against earth faults. Small currents flow out even in the event of minor damage to the motor winding insulation. These earth faults currents are registered on an external summation current transformer, which adds together the currents in the phases, evaluats them and reports earth-fault currents to the microprocessor in the relay. Selecting one of the eight tripping classes (CLASS) allows the motor to be protected to be adapted from normal to extended starting conditions. This allows the thermal reserves of the motor to be used safely. The motor-protective relay is supplied with an auxiliary voltage. The evaluator has a multi-voltage version, which enables all voltages between 24 V and 240 V AC or DC to be applied as supply voltage. The devices have monostable behaviour; they trip out as soon as the supply voltage fails.


Contactors and relays ZEV electronic motor-protective system In addition to the usual N/C contact (95-96) and the N/O contact (97-98) for overload relays the motor protection relay ZEV is equipped with a programmable N/O contact (07-08) and a programmable N/C contact (05-06). The above mentioned, usual contacts react directly via thermistors or indirectly via the current, to the detected temperature rise of the motor, including phase-failure sensitivity. The programmable contacts can be assigned to various signals, such as • Earth-fault, • Pre-warning at 105 % thermal overload, • Separate indication of thermistor tripping • Internal device fault The function assignment is menu-guided using a display. The motor current is entered without tools using the keypad, and can be clearly verified on the display. In addition the display allows a differential diagnosis of tripping causes, and therefore a faster error handling is possible.

Tripping in the event of a 3 pole balanced overload at x-times the set current takes place within the time specified by the tripping class. The tripping delay in comparison with the cold state is reduced as a function of the preloading of the motor. Very good tripping accuracy is achieved and the tripping delays are constant over the entire setting range. If the motor current imbalance exceeds 50 %, the relay trips after 2.5 s. The accredition exists for overload protection of explosion proof motors of the explosion protection “increased safety” EEx e to Directive 94/9/EC as well as the report of the German Physical/Technical Bureaux (PTB report ) (EG-Prototype test certificate number PTB 01 ATEX 3233). Further information can be found in the manual AWB2300-1433G “Motor protection system ZEV, overload monitoring of motors in EEx e areas”.

ZEV electronic motor-protective system

Evaluation device 1 to 820 A

Current sensors 1 to 25 A 3 to 65 A 10 to 145 A

Sensor belt 40 to 820 A

5-39

5


Contactors and relays ZEV electronic motor-protective system Tripping characteristics

Tripping characteristics for 3 phase loads ZEV

100

tA Minutes

50 20 10

CLASS 40 35 30 25 20

5 2 1 20

Seconds

5

15 10 CLASS 5

10 5 2 1

0.7 1

2

5

8

x Ie

Tripping limits for 3 pole balanced load Response time < 30 min. at up to 115 % of the set current > 2 h at up to 105 % of the set current from cold

5-40

These tripping characteristics show the relationship between the tripping time from cold to the current (multiples of set current IE ). After preloading with 100 % of the set current and the temperature rise to the operational warm state associated with it, the stated tripping delays tA are reduced to approx. 15 %.


Contactors and relays ZEV electronic motor-protective system Electronic motor-protective system ZEV with earth-fault protection and thermistor monitored motor L1 L2 L3 N PE

f Z1

e

S1 S2

Z2

Q11

C1 C2

Y1 Y2

~

95 97 05 07

PE

A1 A2

Reset

Q11

=

5

a L1 L2 L3

A

d

I

µP %

D Class

T1 T2

<

M 3~

>

b c

Mode

Up

Test Reset

Down

96

98 06 08

Q11

Fault Programmable contact 1 Programmable contact 2 Current sensor with A/D transducer Self hold-in of the contactor prevents an automatic re-start after the control voltage has failed and then returned (important for EEx e applications, a AWB2300-1433G) f Remote reset a b c d e

5-41


Contactors and relays ZEV electronic motor-protective system Thermistor protection With thermistor motor protection, to DIN 44081 and DIN 44082, up to six PTC thermistor

temperature sensors with a thermistor resistance of RK F 250 O or nine with a RK F 100 O can be connected to terminals T1-T2.

R[ ] 12000

5

4000

a

c

1650

d

b 750

TNF –20°

TNF –5°

TNF

TNF= Nominal response temperature a b c d

Tripping range IEC 60947-8 Re-switch on range IEC 60947-8 Tripping at 3200 O g 5 % Re-switch on at 1500 O +10 %

The ZEV switches off at R = 3200 O g15 % and switches on again at R = 1500 O +10 %. With switch off due to thermistor

5-42

TNF +5°

TNF +15°

i [°C]

input contacts 95-96 and 97-98 switch over. Additionally, the thermistor tripping can be programmed to different trip messages on contacts 05-06 or 07-08. With temperature monitoring with thermistors, no dangerous condition can occur should a sensor fail as the device would directly switch off.


Contactors and relays ZEV electronic motor-protective system Electronic motor-protective system ZEV with short-circuit monitoring at the thermistor input L1 L2 L3 N PE

a Z1

S1 S2

Z2

Q11

C1 C2

Y1 Y2

PE

A1 A2 ~

Reset

Q11

S3

95 97 05 07

=

5

L1 L2 L3

A

I

µP %

D Class

<

T2

M 3~

T1

>

Mode

Up

Test Reset

Down

96 IN1 IN2 IN3 11

K1

98 06 08

Q11

M A1

A2 12 14

Short-circuits in the thermistor circuit can be detected if required by the additional use of a current monitor K1 (e.g. type EIL 230 V AC from Crouzet). Basic data • Short-circuit current in the sensor circuit F 2.5 mA, • max. cable length to sensor 250 m (unscreened),

• Total PTC thermistor sensor resistance F 1500 O • Programming ZEV: “Auto reset”, • Setting current monitor: – Device to lowest current level, – Overload tripping, – Store the tripping, • Confirmation of the short-circuit after clearing with pushbutton S3.

5-43


Contactors and relays ZEV electronic motor-protective system Device mounting The mounting of the device is very simple due to the clip-on and the push-through mounting. Mounting details of every device can be found in the mounting instructions AWA2300-1694 or the manual AWB2300-1433D.

3

2

1

ZEV mounting and current sensor

1 Wrap the band around the current conductors.

5

2 Engage the fixing pin. 3 Pull the fixing band tight and close with the velcro fastener.

Attaching the sensor coils a following diagram. • Place the ZEV in the desired mounting position. • Click the ZEV on the current sensor. • Position motor conductors through the current sensor. Mounting on the current conductors Due to the fixing band the Rogowski sensor ZEV-XSW-820 is particularly easy to mount. And this saves the user time and money.

5-44


Contactors and relays Thermistor machine protection device EMT6 EMT6 for positive temperature coefficient thermistor output relay to drop out. The defect is indicated by an LED. As soon as the sensors have cooled enough so that the respective smaller resistance is reached the EMT6-(K) switches automatically on again. With the EMT6-(K)DB(K) the automatic re-switch on can be defeated by switching the device to “Hand”. The unit is reset using the reset button.

L

21

A1 Power

13

Tripped

US

22

T1 T2

A2

The EMT6-K(DB) and EMT6-DBK are fitted with a short-cicuit in sensor circuit monitor. Should the resistance in the sensor circuit fall below 20 ohms it trips. The EMT6-DBK also has a zero voltage safe, re-switch on lock-out and stores the fault by a loss of voltage. Switching on again is possible only after the fault has been rectified and the control voltage is present again.

14

PTC N L

Since all the units use the closed-circuit principle, they also respond to a broken wire in the sensor circuit.

Power

Tripped

T1 T2

A2

Y2

21

13

22

14

Reset

US

+24 V

Y1

A1

PTC

The thermistor machine protection relays EMT6… are accredited for protection of EEx e motors to ATEX Directive 94/9 EG by the German Physical/Technical Bureaux. For protection of EEx e motors the ATEX Directives require short-circuit monitoring in the sensor circuit. Because of their integrated short-circuit monitoring the EMT6-K(DB) and EMT6-DBK are especially suitable for this application.

N

Method of operation The output relay is actuated when the control voltage is switched on and the resistance of the PTC thermistor temperature sensor is low. The auxiliary contacts operate. On reaching the nominal actuation temperature (NAT), the sensor resistance becomes high and causes the 5-45

5


Contactors and relays Thermistor machine protection device EMT6 EMT6 as contact protection relay 3

L1 L2 L3 N

Application example

400 V 50 Hz

Control of a storage tank heater a Control circuit b Heater Q11: Heater protection

-Q1 I> I> I>

L1

5

A1

1

3

5

A2

2

4

6

U

V

W

a

-Q11

b

400 V 50 Hz

Functional description For this see circuit page 5-47. Switching on the heater The heater can be switched on provided main switch Q1 is switched on, the safety thermostat F4 has not tripped and the condition T F Tmin is satisfied. When S1 is actuated, the control voltage is applied to contactor relay K1, which maintains itself via a N/O contact. The changeover contact of the contact thermometer has the position I-II. The low resistance sensor circuit of the EMT6 guarantees that Q11 is actuated via K2 N/O contact 13-14; Q11 goes to self-maintain.

5-46

Switching off the heater The heater circuit-breaker Q11 stays in self maintain until main switch Q1 is switched off, the pushbutton S0 is pressed, the thermostat trips or T = Tmax. When T = Tmax the changeover contact of the contact thermometer has the position I-III. The sensor circuit of the EMT6 (K3) is low resistance, the N/C contact K3/21-22 open. Main circuit-breaker Q11 drops out.


Contactors and relays Thermistor machine protection device EMT6

-K1

13

230 V 50 Hz -F1 4AF

L1

K3. If, for example, limit value Tmax is not detected, the thermostat’s N/C contact F4 opens to switch off the power.

14

Open-circuit protection A safety thermostat ensures fault isolation in the event of an open circuit in the sensor circuit of

-S0

-K2

-S1

13 14

-Q11

13 14

-K1

a

-F4

5 II III

21

-K3 X1

A1

-K2

- H1 X2

N

a Contact thermometer changeover contact I-II position at T F Tmin I-III position at T F Tmax S0: Off

-K3 EMT6

23

A2

A2

22 A1

T2 T1 A1

-Q11 EMT6 A2

A2

24

-K1

T1 T2 A1

K1: Control voltage "On" K2: Switch-on at T F Tmin K3: Switch-off at Tmax

S1: Start F4: Safety thermostat

5-47


Contactors and relays CMD contactor monitoring device can be used for monitoring tasks. The PKZ2 motor-protective circuit-breakers can be used as backup motor-protective circuit-breakers or switch-disconnectors when fitted with a U-PKZ2 (18VDC) undervoltage release. This also applies to NZM1 to NZM4 circuit-breakers or N1 to N4 switch-disconnectors with an NZM..-XUV undervoltage release. Applications Operating principle

5

The CMD (Contactor Monitoring Device) monitors the main contacts of a contactor for welding. It compares the contactor control voltage with the state of the main contactors and indicates this reliably with a mirror contact (IEC EN 60947-4-1 Ann. F). If the contactor coil is de-energized and the contactor does not drop out, the CMD trips the backup circuit-breaker, motor-protective circuit-breaker or switch-disconnector via an undervoltage release. The CMD also monitors the functioning of the internal relay using an additional auxiliary make contact of the monitored contactor. For this the auxiliary make and break contact is positively driven. The break contact is designed as a mirror contact. Approved switchgear combinations To ensure the functional reliability of the entire unit, consisting of contactor, circuit-breaker and CMD, the CMD is only approved for use with specific Moeller contactors as well as motor-protective circuit-breakers or switch-disconnectors. CMD can be used for monitoring the welding of all DILEM, S(E)-(A)-PKZ2 and DILM7 to DILH2000 contactors. All auxiliary break contacts of these contactors are designed as mirror contacts and 5-48

These combinations are used in safety-oriented applications. Previously the series connection of two contactors was recommended for circuits of safety category 3. Now one contactor and Moeller's CMD is enough. The CMD contactor monitoring relay is used for Emergency-stop applications in compliance with EN 60204-1. It can also be used in the US automotive industry where solutions are required that can reliably detect the welding of the motor starters and safely disconnect the motor feeder. The CMD is approved as a safety module by the German employers' liability association. It also has UL and CSA approval for the North American market. Further information can be found in the manuals • CMD(24VDC) AWB2441-1595 • CMD(110-120VAC), CMD(220-240VAC) AWB2441-1600

˜

W

PE

PE

L1 L2 L3

L02

L01

14

A2

A1

-Q11

-S2

13

22

21

-K

-S1

a

1.13

1.14

-Q1

-F1

a Switching by safety relay or safety PLC b Signal contact to PLC evaluation

M 3

V

PE U -X1

-M1

4

2

6

5

1

3

T3

T1 T2

I> I> I>

L1 L2 L3

-Q11

-Q1

L1 L2 L3

14

-Q11

13

-F2 CMD A2

A1 L

14

-Q1

U<

D2

D1 D2

L02

13

b

22

TEST 21

S21 S22 S13 S14 S31 S32

-S3

34

33

-Q11

22

21

-Q11

L01

Circuit for DOL starters

Contactors and relays CMD contactor monitoring device Moeller Wiring Manual 02/08

5

5-49

5-50

˜

M 3

2

-Q12

1

PE

4

3

31

31 32

A1

A2

A2

-Q12

32

A1

-Q11

22

22

13 14 21

14

13

-Q11

14 21

-Q12

-S3

-S2

-Q11 L02

6

5

13

22

-S1

21

a -K

1.14

1.13

-Q1

-F1

a Switching by safety relay or safety PLC b Signal contact to PLC evaluation

-M1

PE U -X1

6

5

V W PE

4

2

-Q11

3

1

I> I> I> T1 T2 T3

L1 L2 L3

L1 L01 L2 L3

-F2 CMD

14

13

-Q12

A2

A1 L

U<

D2

D1 D2

-Q1

S21 S22 S13 S14 S31 S32

22

21

-S4

44

-Q11

43

22

21

-Q11

5

-Q1

L1 L2 L3

-F3 CMD

14

13

TEST

b

A2

A1 L

L02

D1 D2

S21 S22 S13 S14 S31 S32

44

43

-Q12

22

21

-Q12

L01

Circuit for reversing starters

Contactors and relays CMD contactor monitoring device Moeller Wiring Manual 02/08


Notes

5

5-51


Notes

5

5-52


Motor-protective circuit-breakers Page Overview

6-2

PKZM01, PKZM0 and PKZM4

6-4

PKZM01, PKZM0 and PKZM4 – auxiliary contacts

6-7

PKZM01, PKZM0 and PKZM4 – releases

6-8

PKZM01, PKZM0 and PKZM4 – operating principle schematics

6-9

PKZ2 – overview

6-12

PKZ2 – remote operator

6-14

PKZ2 – release

6-16

PKZ2 – auxiliary switches, trip-indicating auxiliary contacts

6-17

PKZ2 – operating principle schematics

6-18

6-1

6


Motor-protective circuit-breakers Overview Definition Motor-protective circuit-breakers are circuit-breakers used for switching, protection and isolation of circuits primarily associated with motor loads. At the same time, they protect these motors against destruction from locked-motor starting, overload, short-circuit and phase-failure in three-phase power supplies. They have a thermal release for protection of the motor winding (overload

protection) and an electromagnetic release (short-circuit protection). The following accessories can be fitted to motor-protective circuit-breakers: • • • •

undervoltage releases, Shunt release, Auxiliary contact, Trip-indicating auxiliary contact.

Moeller motor-protective circuit-breakers

6

PKZM01 The motor-protective circuit-breaker PKZM01 reintroduces the pushbutton actuation up to 16 A which was very popular with customers. The mushroom actuator for Emergency-Stop operation on simple machines is also being reintroduced. The PKZM01 is preferably installed in surface-mount or flush-mount enclosures. Many accessory parts from the PKZM0 can be used. Major system module: motor-protective circuit-breaker PKZM4 The PKZM4 system is a modular and efficient system for switching and protecting motor loads up to 63 A. It is the “big brother” of the PKZM0 and can be used with almost all PKZM0 accessory parts. Major system modules: motor-protective circuit-breakers PKZM0 The PKZM0 motor-protective circuit-breaker is a modular and efficient system for switching and protecting motor loads up to 32 A and transformers up to 25 A.

6-2

The major system modules are: • Motor-protective circuit-breakers • Transformer-protective circuit-breaker • (High-capacity) contact modules Description a section "The motor-protective circuit-breakers PKZM01, PKZM0 and PKZM4", page 6-4. PKZ2 PKZ2 for motor and distribution circuit protection The PKZ2 is a modular and efficient system for protecting, switching, signalling and remote operation of motors and systems in low-voltage switchgear systems up to 40 A. The major system modules are: • Motor-protective circuit-breakers • System-protective circuit-breakers • (High-capacity) contact modules Description a section "Motor and system protection", page 6-12.


Motor-protective circuit-breakers Overview PKZM01 Circuit-breaker in surface mounting enclosure

PKZM0 Circuit-breaker

PKZM4 Circuit-breaker

PKZ2 Circuit-breaker

6 PKZ2 Compact starter

MSC-D DOL Starters

MSC-R Reversing starters

6-3


Motor-protective circuit-breakers PKZM01, PKZM0 and PKZM4 The motor-protective circuit-breakers PKZM01, PKZM0 and PKZM4

6

PKZM01, PKZM0 and PKZM4 use bimetallic releases which are delayed depending on the magnitude of the current to offer a proven, technical solution for motor protection. The releases are sensitive to phase failure and are temperature-compensated. The rated current with the PKZM0 up to 32 A is split into 15 ranges, for the PKZM01 it is split into 12 ranges and for the PKZM4 up to 63 A into 7 ranges. The installation (motor) and the supply cable are reliably protected by short-circuit releases, permanently set to 14 x Iu. The motor start is also guaranteed in every operational situation. The phase-failure sensitivity of PKZM0

and PKZM4 can be used to protect EEx e motors. An ATEX certificate has been awarded. The motor-protective circuit-breakers are set to the rated motor current in order to protect the motors. The following accessories complement the motor-protective circuit-breaker for the various secondary functions: • • • •

Undervoltage release U, Shunt release A, Standard auxiliary contact NHI, Trip-indicating auxiliary contact AGM.

Motor starter combinations The motor-starter combinations MSC are available up to 32 A. Motor starters up to 16 A consist of a motor-protective circuit-breaker PKZM0 and a contactor DILM. Both can be mechanically connected without the use of tools. Furthermore, a plug-in electrical connector is used to establish the connection with the main circuit wiring. The motor-protective circuit-breaker PKZM0 and the contactor DILM up to 16 A feature the respective interfaces for this purpose. The motor-starter combination MSC from 16 A consists of a motor-protective circuit-breaker PKZM0 and a contactor DILM. Both are fitted to a top-hat rail and mechanically and electrically interconnected by a connector element.

6-4

The MSC is available as direct-on-line starter MSC-D and as reversing starter MSC-R. The compact starters and high-capacity compact starters with the PKZ2 (up to 18.5 kW/400 V) are available for motor ratings of more than 5.5 kW/400 V or the combination of PKZM4 with the proven contactor DILM.


Motor-protective circuit-breakers PKZM01, PKZM0 and PKZM4 Motor-protective circuit-breakers for starter combinations PKM0 The PKM0 motor-protective circuit-breaker is a protective switch for starter combinations or for use as a basic unit in a short-circuit protective switch in the range 0.16 A to 32 A. The basic unit is without overload release, but equipped with short-circuit release. This circuit-breaker is

used for protection of resistive loads where no overloading is to be expected. These protective switches are also used in motor-starter combinations with and without automatic reset, where an overload relay or a thermistor overload relay is used as well.

Transformer-protective circuit-breakers and current limiters PKZM0-T The transformer-protective circuit-breaker is designed for protecting transformer primaries. The short-circuit releases in the types from 0.16 A to 25 A are permanently set to 20 x Iu. The response ranges of the short-circuit releases are higher here than with motor-protective circuit-breakers in order to cope with the even higher inrush currents of idling transformers without tripping. The overload release in the PKZM0-T is set to the rated current of the transformer primary. All the PKZM0 system accessories can be combined with the PKZM0-T. PKZM0-...-C The PKZM0 features a version with springloaded terminals. A version with springloaded terminals on both sides, and a combined version which features springloaded terminals on the outgoer side only can be chosen. The conductors can be connected here without ferrules. The connections are maintenance-free.

CL-PKZ0 The current limiter module CL-PKZ0 is a short-circuit protective device specially developed for the PKZM0 and PKZM4 for non-intrinsically-safe areas. The CL module has the same base area and uses the same terminations as the PKZM0. When they are mounted on a top-hat rail alongside one another, it is possible to connect them using B3...-PKZ0 three-phase commoning links. The switching capacity of the series connected PKZM0 or PKZM4 + CL is 100 kA at 400 V. In the event of a short-circuit, the contacts of the motor-protective circuit-breaker and CL will open. While the current limiter returns for the closed rest position, the motor protective-circuit breaker trips via the instantaneous release and produces a permanent isolating gap. The system is ready to operate again, once any defect has been rectified. The current limiter can conduct an uninterrupted current of 63 A. The module may be used for individual or group protection. Any feed direction may be used.

6-5

6


Motor-protective circuit-breakers PKZM01, PKZM0 and PKZM4 Individual and group protection with CL-PKZ0

l> l> l>

l> l> l>

6

Use the BK25/3-PKZ0 for terminals > 6/4 mm2

Iu = 63 A

l> l> l>

l> l> l>

For grouped connection with three-phase commoning link B3...PKZ0. Note utilization factors to IEC/EN 0660 500.

Examples: PKZM0-16, PKZM4-16 or

PKZM0-16/20, PKZM4-16/20 or

PKZM0-20, PKZM4-20 or

PKZM0-25, PKZM4-25

4 x 16 A x 0.8 = 51.2 A

2 x (16 A + 20 A) x 0.8 = 57.6 A

3 x 20 A x 0.8 = 50 A

3 x 25 A x 0.8 = 60 A

6-6


Motor-protective circuit-breakers PKZM01, PKZM0 and PKZM4 – auxiliary contacts Auxiliary switches and standard auxiliary contacts NHI for PKZM01, PKZM0 and PKZM4 They switch at the same time as the main contacts. They are used for remote indication of the operating state, and interlocking of switches

against one another. They are available with screw terminals or springloaded terminals.

Side mounted: 1.13

1.21

1.13 1.21 1.31

1.13 1.21 1.33

1.14

1.22

1.14 1.22 1.32

1.14 1.22 1.34

I>

Integrated: 1.53 1.61

6

1.53

I > 1.54

1.54 1.62

Trip-indicating auxiliary contacts AGM for PKZM01, PKZM0 and PKZM4 These provide information about the reason for the circuit-breaker having tripped. In the event of a voltage/overload release (contact 4.43-4.44 or 4.31-4.32) or short-circuit release (contact

4.13-4.14 or 4.21-4.22) two potential-free contacts are actuated independently of one another. It is thus possible to indicate the difference between short-circuit and overload.

"+" 4.43

"I >" 4.13

"+" 4.31

"I >" 4.21

4.44

4.14

4.32

4.22

I>

6-7


Motor-protective circuit-breakers PKZM01, PKZM0 and PKZM4 – releases Voltage releases These operate according to the electromagnetic principle and act on the switch mechanism of the circuit-breaker. Undervoltage releases

6

These switch the circuit-breaker off when no voltage is present. They are used for safety tasks. The undervoltage release U-PKZ20, which is connected to voltage via the early-make auxiliary contacts VHI20-PKZ0 or VHI20-PKZ01, allows the circuit-breaker to be switched on. In the event of power failure, the undervoltage release switches the circuit-breaker off via the switch mechanism. Uncontrolled restarting of machines is thus reliably prevented. The safety circuits are proof against wire breaks. The VHI-PKZ0 can be used together with the PKZM4! D1

U<

D2

6-8

Shunt releases These switch the circuit-breaker off when they are connected to voltage. Shunt releases can be provided in interlock circuits or for remote releases where voltage dips or interruptions are not to lead to unintentional switch off. C1

C2


Motor-protective circuit-breakers PKZM01, PKZM0 and PKZM4 – operating principle schematics Motor-protective circuit-breakers PKZM01, PKZM0 and PKZM4 Manually operated motor-starter L1 L2

L3

-Q1

I> I> I>

T1

T2 T3

6

6-9


Motor-protective circuit-breakers PKZM01, PKZM0 and PKZM4 – operating principle schematics Motor-protective circuit-breakers with auxiliary switches and trip-indicating auxiliary contacts PKZM01(PKZM0-...)(PKZM4...) + NHI11-PKZ0 + AGM2-10-PKZ0 L1 L2

L3 1.13 1.21

-Q1 1.14 1.22 4.43

4.31

4.21

4.13

4.44

4.32

4.22

4.14

I> I> I>

T1 T2

6

T3

For differential fault message (Overload or short-circuit) L1

-X1

1

X1 -E1

-X1

2

3

-X1

X1 -E3

X2

4.14

4.44

-X1

X1 -E2

X2

-Q1

1.22

1.14

-X1

-Q1

-Q1

4.13

4.43

1.21

1.13

-Q1

4

X1 -E4

X2

X2

5

N

E1: circuit-breaker ON E2: circuit-breaker OFF

6-10

E3: general fault, overload release E4: short-circuit release


Motor-protective circuit-breakers PKZM01, PKZM0 and PKZM4 – operating principle schematics Remote switch off via shunt release High-capacity compact starter with auxiliary contact and shunt release PKZM0-.../S00-.. + A-PKZ0 Q11: Contact module

L1 L2 L3 1.13 1.21

-Q1 1.14 1.22

C1

I> I> I> C2

-Q11

A1

13

A2

14

21 22 I>> I>> I>> T1 T2 T3

-X1

1

2

3

6

PE

U1 V1 W1

M 3 -M1 L1

S1: Off S2: On S3: Circuit-breaker On

1.13

-Q1 1.14 21

-S1 22

13

-S3 14 13

13

-K1

-S2 14

14

C1

-Q1 A1

-Q11 A2

N

C2

6-11


Motor-protective circuit-breakers PKZ2 – overview Motor and system protection The PKZ2 achieves its modularity by combining the motor or system-protective circuit-breaker with various accessories. This results in numerous application options and adaptation to widely differing requirements. The circuit-breaker The circuit-breaker PKZ2/ZM... consists of: • Basic device, • Plug-in trip block. There is a choice of trip blocks:

6

• Motor-protective trip blocks (11 versions for the range from 0.6 to 40 A) • System-protective trip blocks (5 versions for the range from 10 to 40 A) All trip blocks are equipped with adjustable overload and short-circuit releases. Overload from ... to...: • Motor-protective trip blocks: 8.5 to 14 x Ie • Motor-protective trip blocks: 5 to 8.5 x Ie

In the event of an overload, the circuit-breaker does not trip. Instead, a normally closed contact (95–96) is actuated which switches off the contactor in the control circuit (contactors up to 18.5 kW, AC-3). At the same time, a normally open contact (97–98) is actuated, which ensures remote indication. The normally closed contact and normally open contact are suitable for carrying two different potentials. The trip block has a manual and an automatic position: • Automatic position: The normally closed contact and normally open contact automatically return to the original position after the bimetallic strips have cooled down. The contact can be actuated again by actuation, for example, of a pushbutton. • Manual position: An acknowledgement locally, at the unit, moves the contacts back to the original position after tripping. Important note!

Standards The PKZ2 motor-protective circuit-breaker complies with the IEC 947, EN 60947 and EN 60947 standards. The circuit-breaker has a switching capacity of 30 kA/400 V. It is inherently short-circuit proof up to a rated operational current of 16 A. The PKZ2 also complies with the requirements stipulated in EN 60204 for disconnectors and main switches. Special motor-protective trip block ZMR-...-PKZ2 This trip block features an overload relay function which allows the following interesting application: 6-12

For an EEx e application, the normally closed contact 95–96 must be used to shed the contact module or contactor, to achieve disconnection.


Motor-protective circuit-breakers PKZ2 – overview

• Switch + standard contact module SE1A-...-PKZ2. The contact module features the same functions and properties of a standard contactor. It can be used for operational switching of 1 x 106 AC-3 operations. A1

A2 2 T1

4 T2

13

14

4 T2

An actuating voltage of 1 V DC can be used with the contact module SE2A-G-PKZ24 (2 V DC) and the high-capacity contact module S-G-PKZ24 (24 V DC). It is necessary to take account of: • • • •

Pick-up capacity: 150 VA, Pick-up current 6.3 A (16 – 22 ms) Holding power: 2.7 W, Holding current: 113 mA.

21

22

6 T3

• Switch + S-PKZ2... high-capacity contact module. A high-capacity compact starter is obtained by using a motor-protective circuit-breaker (PKZ2/ZM...) as the switch, and a combination circuit-breaker is produced by using a circuit-breaker (PKZ2/ZM-...-8) as the switch. The high-capacity contact module increases the switching capacity of the combination to 100 kA/400 V, and is suitable for 1 x 106 AC-3 operations.

2 T1

(High-capacity) contact module for 24 V DC control voltage

A1

13

21

A2

14

22

2 T1

A1

13

A2

14

+24 V

(High-capacity) contact module S-...-PKZ2 A compact starter combination is produced by combining a contact module S-...-PKZ2 (contactor) featuring the same contours with the PKZ2:

6

6 T3

4 T2

Current limiters CL-PKZ2 A specially developed current-limiter module which can be attached and featuring the same contours is available to increase the switching capacity of the circuit-breaker to 100 kA/400 V. In the event of a short-circuit the contacts of the PKZ2 and CL-PKZ2 will open. The PKZ2 trips via the magnetic release and remains in this position. The CL-PKZ2 returns to the rest position after the short-circuit. Both units are ready for operation again after the fault.

6 T3

I >>

I >>

I >>

2 T1

4 T2

6 T3

6-13


Motor-protective circuit-breakers PKZ2 – remote operator The remote operator allows the PKZ2 to be switched on and off remotely during operation. After tripping, it can be reset to 0 by the remote operator. The PKZ2 system has two remote operators:

6

• In the RE-PKZ2 – the electronic remote operator for standard applications – both CONTROL and LINE are separate inputs, but with the same reference potential. This allows actuation using low current units, e.g. control circuit devices. • The electronic remote operator RS-PKZ2 can be actuated directly, without any coupling elements, from the semiconductor outputs of a PLC (24 V DC). Electrical isolation between the CONTROL and LINE allows it to take power for the switching

process from a separate power supply (e.g. 230 V 50 Hz). Both remote operators must be supplied with the mains supply of 72 W/VA for 74 ms at the terminals 700–30 during the switching operation (On/Off/Reset). Twelve voltage versions are available per remote operator. These cover a wide application range. The remote operators can optionally be set for manual or automatic operation. • Manual position: remote switching on is reliably electrically interlocked. • Automatic position: remote switching is possible. An integrated normally open contact (33–34) when closed indicates the automatic position of the remote operator.

Minimum command time for the remote operators RE-PKZ2 and RS-PKZ2 CONTROL

ON I

ON

0 f 15 CONTROL

OFF/RESET

I

OFF/RESET

t (ms)

0 f 15 t (ms) f 300

LINE

CONTROL

I

ON

0

OFF F 30

6-14

Main contact F 30

t (ms)


Motor-protective circuit-breakers PKZ2 – remote operator Remote operator RE-PKZ2 Off and Reset separate 72

L

74 L(+)

N(-)

72

L(+)

74

CONTROL

I>

A20 A40 B20

I

A20 0

A40

ON

OFF

RESET

N(-)

72

LINE

T

Off equals Reset

74

33

LINE

33

34

CONTROL

34

B20

I

A20 0

A40

ON

OFF

RESET

B20

6

Remote operator RS-PKZ2 Off equals Reset L

72

74 L(+)

N(-)

72

I>

T

A20 A30 A0

N(-) 74

72

LINE

33

LINE

33

CONTROL

34

CONTROL

34

A20 ON

L(+)

74

A30

A0

–

OFF/ RESET

I 24 V

ON

A20 0

A30 OFF/ RESET

A0 24 V~/

+

6-15


Motor-protective circuit-breakers PKZ2 – release Voltage releases Undervoltage release U Undervoltage releases trip the circuit-breaker in the event of a power failure and prevent restarting when the power returns. Three versions are available: • Non-delayed, • With/without early-make auxiliary contact, • With 200 ms dropout delay. D1

6

2.13

2.23

Undervoltage releases which switch off without delay are suitable for Emergency-Stop circuits. The undervoltage release can be energized early by an additional link (see circuit diagram). Undervoltage release with a 200 ms dropout delay.

D1

2.13

U< U< D2

D2

2.14

2.24

Shunt release A Shunt releases trip the circuit-breaker when a voltage is applied. These are an economic option for switching off remotely.

C1

Shunt releases are suitable for AC and DC, and one version covers a wide voltage range.

C2

6-16

2.14


Motor-protective circuit-breakers PKZ2 – auxiliary switches, trip-indicating auxiliary contacts NHI standard auxiliary contacts NHI ... S for the starter combination, featuring the same contours, for indication of the position of the main contacts of the contactor and/or those of the circuit-breaker.

The NHI is available in two versions. NHI for circuit-breakers, fitted and featuring the same contours, for indicating the position of the main contacts of the switch. 1.13 1.21

1.13 1.21

1.21 1.43 1.13 1.31

1.21 43 1.13 31

NHI11

1.14 1.22

I>

PKZ 2(4)/ZM...

I>

1.31 1.43

or

1.13 1.21

13

NHI22 1.14 1.22

1.32 1.44

14

21

6

A1 A2

22

I >> 1.14 1.22 PKZ 2(4)/ZM.../S NHI 11S

1.14 1.32 1.22 1.44 NHI 22S

1.14 32 1.22 44 NHI 2-11S

Trip-indicating auxiliary contact AGM The trip-indicating auxiliary contact is of particular importance. Two separate contact pairs signal that the circuit-breaker is in the tripped position. One contact pair (normally open & normally closed) signals general tripping and one pair signals tripping in the event of a short circuit. If the normally open contact 4.43/4.44 and the normally closed contact 4.21/4.22 are connected in series, then it is also possible to indicate overload tripping differentially.

"+"

"I >"

4.43 4.31

4.21

4.13

4.44 4.32 AGM 2-11

4.22

4.14

I>

PKZ 2(4)/ZM...

6-17


Motor-protective circuit-breakers PKZ2 – operating principle schematics Motor-protective circuit-breaker consisting of: • PKZ2 basic unit • Plug-in trip block Z L1

L2

L3

I>

I>

I>

High-capacity compact starter, consisting of: • Basic device • Trip block • High-capacity contact module fitted with same contour profile

-Q1

L1

L2

L3

-Q1 T1

T2

T3

I >> I >> I >>

6

Compact starter, consisting of: • Basic device • Trip block • Contact module SE1A...-PKZ2, which can be attached and has the same contours, for operational switching L1

L2

L3

A1

13

21

A2

14

22 I >> I >> I >> T1

L1

L2

L3

I>

I>

I>

-Q1

A1

13

21

A2

14

22 T1

I>

T2

I>

T3

I >> I >> I >> T1

6-18

T3

Circuit-breaker with current limiter fitted

–Q1

I>

T2

T2

T3


Motor-protective circuit-breakers PKZ2 – operating principle schematics On-off switching with remote operator Separate actuation of OFF and RESET

Circuit-breaker with remote operator, standard version. Example 1: PKZ2/ZM-.../RE(...)

L1

72

A20

74

A40

33

B20

N

34

L1 L2

L3

-Q1 1

2

-X1 I> I> I>

72

6

T1 T2 T3

74

-Q1

-X1

3

A20

A40

B20

4

5

6

-X1

햲 -X1 7

13

-S11 14

햵

13

13

-S21

-S01 14

햴

a Separate actuation of OFF and Reset b Reset c OFF d ON Actuation by control circuit devices (for example pushbuttons NHI, AGM, VS3, EK...SPS with floating contacts).

33

-Q1 14

햳

34

-X1

8

Auxiliary switch for signalling the manual/automatic position of the remote operator. Indicates the automatic position when closed.

6-19


Motor-protective circuit-breakers PKZ2 – operating principle schematics Common actuation of OFF and RESET Circuit-breaker with remote operator, standard version.

Example 2: PKZ2/ZM-.../RS(...)

L1

72

A20

74

A40

33

B20

34

N L1 L2

L3

-Q2 9

10

-X1 I> I> I>

6

72

74

T1 T2 T3

-Q2

11

-X1

A20

A40

12

13

B20

햲 -X1

-X1

13

13

-S02

-S12 14

33

-Q2 14

34

-X1

햴

15

햳

a Off = Reset b Off/Reset c ON Actuation by control circuit devices (for example pushbuttons NHI, AGM, VS3, EK...SPS with floating contacts).

6-20

14

Auxiliary switch for signalling the manual/automatic position of the remote operator. Indicates the automatic position when closed.


Motor-protective circuit-breakers PKZ2 – operating principle schematics Circuit-breaker with remote operator, 24 V DC version with electronic outputs For direct actuation by a programmable logic controller (PLC).


L1

72

33

74

A40

A20

B20 34

N

L1

L2

L3

-Q3 2

1

-X2 I> I> I>

6

74

72

-Q3

ON

A20

A30

3

4

B20

OFF/ RESET

-X2

24 V

-X2

T1 T2 T3

33

-Q3 34

-X2

Actuation by PLC with 24 V DC electronic outputs. Auxiliary switch for signalling the manual/automatic position of the remote operator.

5

6

Indicates the automatic position when closed.

6-21


Motor-protective circuit-breakers PKZ2 – operating principle schematics Circuit-breaker with remote operator Actuation by control circuit devices.


L1

72

A20

33

74

A40

B20

N

34

L1 L2

L3

-Q4 8

7

-X2 I> I> I>

72

6

74 T1 T2 T3

-Q4

9

10

-X2

13

A0

13

-S23

-S22 14

-X1

11

~

A30

24 V /

A20

33

-Q1

14

34

12

-X2

S22: On S23: Off/Reset Actuation by control circuit devices via 24 V AC/DC. Auxiliary switch for signalling the manual/automatic position of the remote operator. Indicates the automatic position when closed.

6-22


Motor-protective circuit-breakers PKZ2 – operating principle schematics Indication by auxiliary switches Circuit-breaker with auxiliary contact and trip-indicating auxiliary contact. L1 L2 L3 1.13

Example: PKZ2/ZM-... + NHI11-PKZ2 + AGM2-11-PKZ2

1.21

-Q1 1.14 1.22 4.43

4.31

4.21 4.13

4.44

4.32

4.22

I> I> I>

T1 T2

4.14

T3

For differential fault indication.

6

L1

1.13

1.21

-Q1

-Q1 1.14 1

-X1 X1

-E1

N

-X1

4

-X1 X1

X1

-E3 X2

4.14

3

-X1

-E2 X2

-Q1 4.44

2

-X1

4.13

4.43

-Q1 1.22

X1

-E4 X2

X2

5

E1: Circuit-breaker On E2: Circuit-breaker Off E3: General fault, Overload tripping E4: Short-circuit tripping

6-23


Motor-protective circuit-breakers PKZ2 – operating principle schematics Use of the undervoltage release in the Emergency-Stop circuit Motor-protective circuit-breaker with auxiliary contact and undervoltage release. L1 L2 L3 1.13 1.21

1.31

1.43

1.14 1.22

1.32

1.44

All poles of the Emergency-Stop circuit are isolated from the mains supply in the event of a power failure.

-Q1 D1

2.13

I> I> I>

U> D2

Example: PKZ2/ZM... + NHI22-PKZ2 + UHI-PKZ2

2.14 T1 T2 1

6

2

T3 3

PE

-X1 U1 V1

W1

M 3 -M1

S1: Emergency-Stop S2: Emergency-Stop

L1 2.13

-Q1 2.14

21

-S1 22

21

D1

-S2 22

-Q1 U<

D2

N

6-24


Motor-protective circuit-breakers PKZ2 – operating principle schematics Remote switch off via shunt release High-capacity compact starter with auxiliary contact and shunt release

Example: PKZ2/ZM-.../S-PKZ2 + A-PKZ2

Q11: High-capacity contact module

L1 L2 L3 1.13 1.21

-Q1 1.14 1.22

C1

I>I> I> C2

-Q11

21

A1

13

A2

14 22 I>> I>> I>> T1 T2 T3

-X1

1

2

6

PE

3

U1 V1 W1

M 3 -M1

S1: Off S2: On S3: Circuit-breaker Off

L1 -Q1

1.13 1.14 21

-S1 22

13

-S3 14

-S2 C1

-Q1 A1

-Q11 A2

C2

N

6-25


Motor-protective circuit-breakers PKZ2 – operating principle schematics High-capacity compact starter with maximum number of auxiliary contacts fitted Example: PKZ2/ZM.../S-PKZ2 + NHI2-11S-PKZ2 1.13 1.21 31

43

T1 T2 T3 1.14 1.22 32

44

L1 L2 L3

-Q1

I> I> I> 13 21

-Q11

A1 A2 14 22

I>> I>> I>>

1 2

6

-X1

PE

3

U1 V1 W1

M 3 -M1 L1

-Q1

-K1

A1

-K2

A2

-Q1 1.22

1.14

A1

-K3

A2

A1

A1

A1

A1

-K4

22

14

44

A2

-Q11

-Q11

-Q1 32

21

13

43

31

1.21

1.13

-Q1

-K5

A2

-K6

A2

A2

N 13 21 31 43

14 22 32 44

13 21 31 43

K1: Circuit-breaker On K2: Circuit-breaker Off K3: Contact module Off

6-26

14 22 32 44

13 21 31 43

14 22 32 44

13 21 31 43

14 22 32 44

13 21 31 43

14 22 32 44

13 21 31 43

K4: Contact module On K5: Contact module On K6: Contact module Off

14 22 32 44


Motor-protective circuit-breakers PKZ2 – operating principle schematics Remotely actuated circuit-breaker with switch status indication Motor-protective circuit-breaker with remote operator + auxiliary contact (1 NO, 1 NC) + trip indicating auxiliary contact 72

A20

33

74

A40

Example: PKZ2/ZM.../RE + NHI11-PKZ2 + AGM2-11-PKZ2

B20

L1 L2 L3 1.13 1.21

34

-Q1 1.14 1.22 4.43 4.31

4.21

4.13

4.44 4.32

4.22

4.14

I> I> I>

T1 T2

6

T3

L1 1.13

-Q1 -S5

13 14

-S2

13 14

-S1

N

4.43

1.21

-Q1

1.22

-Q1

4.44

4.13

-Q1

4.14

13 14 21

-S2

1.14

72 74

-Q1

22

A20 A40 B20

13 21 22 43

A1

A1

A1

-K1

-K2

A2 14 31 32 44

13 21 22 43

-K3

A2 14 31 32 44

13 21 22 43

A1

-K4

A2 14 31 32 44

13 21 22 43

A2 14 31 32 44

S1: On S2: Off S5: Reset Q1: Auxiliary contact, indication: manual-auto K1: Circuit-breaker On K2: Circuit-breaker Off K3: Overload indication K4: Short-circuit indication

6-27


Motor-protective circuit-breakers PKZ2 – operating principle schematics Circuit-breaker with current limiter in separate mounting Example: PKZ2/ZM... + NHI11-PKZ2 with CL/EZ-PKZ2 L1 L2

L3 1.13

1.21

L1

-Q1 1.14 1.22 1.13

1.21

-Q1

-Q1 I> I> I>

1.14

1.22

T1 T2 T3

6

L1 L2 L3

-Q2

-K1

T1 T2 T3

-X1

1

2

3

PE

U1 V1 W1

M 3 -M1

Q2: Current limiter, separate mounting

6-28

A1

A1

I>> I>> I>>

-K2 A2

A2

N

13

14

13

21

22

21

31

32

31

32

43

44

43

44

K1: Circuit-breaker On K2: Circuit-breaker Off

14 22


Motor-protective circuit-breakers PKZ2 – operating principle schematics ZMR-...-PKZ2 special trip block with overload relay function For switching off a contactor in the control circuit in the event of an overload by means of a trip block ZMR-...PKZ2 with an overload relay function and with simultaneous indication. The L1 L2 L3 1.13

1.21

1.14

1.22

circuit-breaker thumb-grip remains in the “On” position. Circuit-breaker with trip block ZMR, high-capacity contact module S and NHI11-PKZ2. L1

-Q1 95

-Q1

95

97

97

-Q1 96

I> I> I>

98

98 96 T1 T2 T3

-Q11

21

A1

13

A2

14 22

6

1.13

-Q1 I>> I>> I>>

1.14

T1 T2 T3

-X1

-X1

1

2

3

X1

PE -E1

U1 V1 W1

-M1

X2

A1

-Q11

M 3

4

A2

N

-X1

5

Q11: Shutdown E1: Overload indication

Q11: High-capacity contact module

6-29


Notes

6

6-30


Circuit-breakers Page Overview

7-2

Shunt releases

7-4

Undervoltage releases

7-5

Contact diagrams of the auxiliary contacts

7-6

Internal circuit diagrams

7-8

Remote switch-off with voltage releases

7-11

Application of the undervoltage release

7-13

Shutdown of the undervoltage release -

7-14

Indication of the switch position

7-15

Short-time delayed circuit-breaker – internal circuit diagrams

7-16

Mesh network circuit-breakers

7-17

7

Remote operation with motor operator

7-18

as a transformer switch

7-19

with residual current device

7-20

IZM circuit-breakers

7-26

7-1


Circuit-breakers Overview NZM circuit-breakers These circuit-breakers protect electrical equipment against thermal overloading and short circuits. They cover the rated current range from 20 to 1600 A. Depending on the version, they have additional protective functions such as fault-current protection, earth-fault protection or the capability for energy management by recognition of load peaks, and deliberate load shedding. Circuit-breakers NZM are distinguished by their compact shape and their current-limiting characteristics.

7

Switch-disconnectors without overload or tripping units are available in the same sizes as the circuit-breakers and can be fitted with NZM1

NZM2

Note The NZM7, NZM10 and NZM14 circuit-breakers are no longer included in Moeller's product range. They have been replaced by the new device generation. This chapter provides information about these devices.

7-2

additional shunt or undervoltage releases to suit the respective versions. Circuit-breakers NZM and switch-disconnectors are built and tested according to standard IEC/EN 60947. They feature isolating characteristics. In conjunction with a locking device, they are suitable for use as main switches according to IEC/EN 60204/VDE 0113, part 1. The electronic releases of frame sizes NZM2, NZM3 and NZM4 feature communication capabilities. The current states of the circuit-breaker on site can be visualized via a Data Management Interface (DMI) or via digital output signals. Additionally, the circuit-breakers can be connected to a network, e.g. PROFIBUS-DP. NZM3

NZM4


Circuit-breakers Overview IZM circuit-breakers The IZM offers a circuit-breaker for use in the high rated current range from 630 A. IZM circuit-breakers and IN switch-disconnectors offer the main switch isolating characteristics in accordance with IEC/EN 60204-1 as they are lockable in the OFF position. They can therefore be used as supply disconnection devices. IZM circuit-breakers are built and tested in accordance with IEC/EN 60947. Depending on the type of equipment to be protected, main application areas can be implemented by different settings of the trip electronics: • • • •

System protection, Motor protection, Transformer protection, Generator protection.

IZM devices offer different tripping electronics, for applications ranging from simple system protection with overload and short-circuit release to digital releases with a graphical display and the possibility of creating selective networks. IZM1

IZM2

They can be adapted to a wide range of requirements by means of a comprehensive range of mounted accessories such as auxiliary contacts, trip-indicating auxiliary contacts, motor operators or voltage releases, fixed-mounted or withdrawable units. With their communication-capability, the IZM circuit-breakers open up new possibilities in power distribution. Important information can be passed on, collected and evaluated, also for preventative maintenance. They thus increase the transparency of the system. For example, by enabling rapid intervention in processes, system downtimes can be reduced or even prevented. The basic selection criteria of an IZM circuit-breaker are: • • • • • •

7

Max. short-circuit current Ikmax, Rated operational current In, Ambient temperature, 3 or 4-pole design, Protective function, Min. short-circuit current.

Detailed information about the IZM circuit-breaker is provided in AWB1230-1407. IZM3

7-3


Circuit-breakers Shunt releases Shunt releases A (Q1) L1 (L+) C1 C2

Q1

E1

-S11 0

-Q1

C1

-Q1 C2

N (L-, L2)

7

7-4

Shunt releases are solenoids that actuate a tripping mechanism when a voltage is applied to them. When de-energized, the system is in its rest position. A normally open contact actuates the system. If the shunt release is rated for intermittent duty (overexcited shunt release with 5% DF), the intermittent operation must be ensured by positioning appropriate auxiliary contacts (supplied) upstream of the circuit-breaker. This measure is not required when using a shunt release with 100 % DF. Shunt releases are used for remote tripping when an interruption in the voltage is not intended to lead to automatic disconnection. Tripping does not occur in the event of wire breakage, loose contacts or undervoltage.


Circuit-breakers Undervoltage releases Undervoltage release U (Q1) L1 (L+) D1 D2

Q1 U< E1

-Q1

-S11 0

D1

-Q1 U< D2

Undervoltage releases are solenoids that actuate a tripping mechanism upon interruption of the voltage. The system is in the rest position when energized. Actuation is produced by a normally closed contact. Undervoltage releases are always designed for uninterrupted operation. These are the ideal tripping elements for totally reliable interlocking tasks (e.g. Emergency-Stop). Undervoltage releases trip the circuit-breaker when the power fails in order, for example, to prevent motors from restarting automatically. They are also suitable for very reliable interlocking and remote switching off since disconnection always occurs in the event of a fault (e.g. wire breakage in the control circuit). The circuit-breakers cannot be closed when the undervoltage releases are de-energized.

N (L-, L2)

Off-delayed undervoltage release UV (Q1) The off-delayed undervoltage release is a combination of a separate delay unit (UVU) and the respective release. This release is used to prevent brief interruptions in power leading to disconnection of the circuit-breaker. The delay time is adjustable between 0.06 and 16 s.

L1 (L+) D1 D2

Q1 U<

E1

-S11 0

-Q1

D1

-Q1

U< D2

N (L-, L2)

7-5

7


Circuit-breakers Contact diagrams of the auxiliary contacts Auxiliary contact – standard HIN I

+ L1L2L3 HIN

I

+ L1L2L3 HIN

+

I

+

L1L2L3 HIN

Used to provide command or signal outputs from processes which are governed by the position of the contacts. They can be used for interlocking with other switches, and for the remote indication of the switching state. • Standard auxiliary contacts behave like main switch contacts • Switch position indication • Interlock • Disconnection of the shunt release

Auxiliary contact – trip-indicating HIA

7

+

I

L1L2L3 HIA

+

I

L1L2L3 HIA

+

+

L1L2L3 HIA

0rI Switch-on 0RI Switch-off +RI Trip Q contacts closed q contacts opened

7-6

I

Used to provide command and signal output relating to electrical tripping of the circuit-breaker (trip position +) as is required, for example, for mesh network switches. No pulse is produced when the switch is opened or closed manually, or by a motor operator. • Indication that the switch is in the tripped position • Switch position indication only if tripping is caused by, for example, overcurrent, short-circuit, test or voltage release. No fleeting contact when switched on or off manually or switched off with the motor (exception: manual switch off with motor operator NZM2, 3, 4).


Circuit-breakers Contact diagrams of the auxiliary contacts Auxiliary contact – early make HIV NZM1, NZM 1,2,2,3,37

I

+ L1L2L3 HIV

I

+ L1L2L3 HIV

+

I

+

L1L2L3 HIV

NZM 10

I

Used to provide command or signal outputs from processes which are initiated before the closure or opening of the main contact system. Because they close early, they can be used for interlocks with other switches. Furthermore, they allow a switch position indication. With the circuit-breaker in the Tripped position, the HIV is in the same position as it is at OFF. Because of its early-make characteristic, it can be used to apply voltage to the undervoltage release (a section "Undervoltage releases", page 7-5, a section "Remote switch-off with voltage releases", page 7-11, a section "Application of the undervoltage release", page 7-13).

+ L1L2L3 HIV

I

+ L1L2L3 HIV

+

I

+

L1L2L3 HIV

NZM 4

7

0rI Switch-on 0RI Switch-off +RI Trip Q contacts closed q contacts opened

I +

L1L2L3 HIV

+

I

L1L2L3 HIV

+

+

I

L1L2L3 HIV

7-7


Circuit-breakers Internal circuit diagrams

3.13

3.23

3.14

3.24

4.13 4.23 4.11 4.21

1.13 1.23 1.11 1.21

L1 L2 L3

NZM1

1

2

3

4

HIN: 1 NO, 1 NC, 2 NO, 2 NC or 1NO/1NC

1

2

3

3

HIA: 1 NO, 1 NC, 2 NO, 2 NC or 1NO/1NC

1

1

1

2

HIV: 2 S

1

1

1

1

-Q1

Contact elements M22-K10 (K01, K20, K02, K11) from the RMQ-Titan range from Moeller are used for the auxiliary contacts. Two early-make auxiliary contacts (2 NO) are also available.

I> I> I> HIV 4.14 4.24 4.12 4.22

HIA

T1 T2 T3

1.14 1.24 1.12 1.22

HIN

Maximum configuration: NZM

3.13

3.23

3.14

3.24

4.13 4.23 4.11 4.21

...

1.41

1.11

...

-Q1

1.43

1.13

L1 L2 L3

NZM2

I> I> I>

7-8

1.42

1.12

1.44

1.14

HIA

HIV 4.14 4.24 4.12 4.22

HIN T1 T2 T3

7

Details about the auxiliary contacts: a section "Maximum configuration:", page 7-8


Circuit-breakers Internal circuit diagrams

3.13

3.23

3.14

3.24

4.23 4.11 4.21

...

4.13

1.61

1.63

...

-Q1

1.11

1.13

L1 L2 L3

NZM3 Details about the auxiliary contacts: a section "Maximum configuration:", page 7-8

I> I> I> 4.14

1.62

1.64 1.63

1.12

1.14 1.13

T1 T2 T3

HIV 4.24 4.12 4.22

HIA

HIN

3.13

3.23

3.14

3.24

4.11

...

4.41

...

4.43

4.13

-Q1

...

1.61

...

1.11

L1 L2 L3

NZM4

I> I> I> HIN

4.42

4.12

4.44

HIV 4.14

1.62

1.12

1.64

T1 T2 T3

1.14

HIA

Details about the auxiliary contacts: a section "Maximum configuration:", page 7-8

3.33

3.13

4.11

1.11

L1 L2 L3

1.13

NZM7

-Q1

I> I> I> 3.34

3.14

4.12

1.12

RHI VHI 1.14

NHI

In the NZM7 two auxiliary contact modules can be fitted as NHI (NC or NO) as well as a trip-indicating auxiliary contact RHI (NC or NO). Contact elements EK01/EK10 are used from the Moeller RMQ range of control circuit devices. Early-make auxiliary contacts (2 NO) are also available.

7-9

7

I>

I>

7-10

4.11

RHI

I>

ZM(M)-

NZM14

-Q1

NRHI 003 3.22 3.14 3.34

4.14 4.22 4.44 4.32

1.14 1.22 1.44 1.32

NHI

1.21

1.11

7

1.12 1.14 1.22 1.24 4.12 4.14

L1 L2 L3

3.21 3.13 3.33

4.21 4.43 4.31

4.13

1.13 1.21 1.43 1.31

L1 L2 L3

Circuit-breakers Internal circuit diagrams Moeller Wiring Manual 02/08

NZM10

-Q1

VHI


Circuit-breakers Remote switch-off with voltage releases Remote switch-off with undervoltage releases L1 N (L+) (L-, L2)

L1 (L+)

-S. -S. D1 D2 -Q1 D1

-Q1 U< D2

N (L-, L2)

Remote switch-off with shunt releases L1 N (L+) (L-, L2)

-Q1 1.11

-S. -S. C1 C2 -Q1 1.13 1.14

7

L1 (L+)

-Q1 HIN

1.14

Terminal designation with NZM14 1.13 1.14 C1

-Q1 C2

N (L-, L2)

1.12

When the switch is in the Off position, the entire control circuit is live. In order to de-energize the entire control circuit when using a shunt release, the control voltage must be connected downstream of the switch terminals.

7-11


Circuit-breakers Remote switch-off with voltage releases Main switch application in processing machines with Emergency-Stop function conform to the standard IEC/EN 60204-1, VDE 0113 part 1

-S.

L1 L2 L3 D1

HIV -Q1 D2

-Q1 U<

E1

-Q1

NZM

7 -S.

L1 L2 L3 D1

HIV -Q1

3.13 3.14 D2

-Q1 U<

E1 NZM

7-12

-Q1

N

With the main switch in its OFF position all control elements and control cables which exit the control panel are voltage free. The only live components are the control-voltage tap-offs with the control lines to the early-make auxiliary contact.


Circuit-breakers Application of the undervoltage release Switch-off of the undervoltage release L1 N (L+) (L-, L2)

L1 (L+)

3.13

HIV -Q1

D1 D2

3.14

-Q1

The early-make auxiliary contact HIV (Q1) can – as shown above – disconnect the undervoltage release from the control voltage when the circuit-breaker is in the Off position. If the undervoltage release is to be disconnected in two poles, then a further normally open contact of Q2 must be connected between terminals D1 and N. The early-make auxiliary contact HIV (Q1) will always apply voltage to the undervoltage release in time to permit closure.

D1

-Q1 U<

3.13 3.14

D2

N (L-, L2)

7

Starting interlock of the undervoltage release L1 N (L+) (L-, L2)

L1 (L+)

D1 D2

-S5 -S6

1.13

-Q1 1.14

1.13 1.14

D1

-S6

-S5

-Q1 U<

Circuit-breakers with undervoltage release produce a positive Off position in conjunction with interlocking auxiliary contacts on the starter (S5), ancillary devices on the motor (e.g. brush lifting, S6) or on all switches in multi-motor drives. The circuit-breaker cannot be closed unless the starter or switch is in the zero or Off position.

D2

N (L-, L2)

7-13


Circuit-breakers Shutdown of the undervoltage release Interlocking of several circuit-breakers using an undervoltage release L1 (L+)

L1 N (L+) (L-, L2)

1.21

1.21

-Q1

-Q2 1.22

D1 D2 1.21 -Q1 1.22

D1 D2 1.21 -Q2 1.22

D1

-Q1 U< D2

1.22

D1

-Q2 U< D2

N (L-, L2)

7

-Q1/Q2 1.11

1.12 1.14

Terminal marking for NZM14

7-14

When interlocking three or more circuit-breakers, each circuit-breaker must be interlocked with the series-connected normally closed contacts of the auxiliary contacts on the other circuit-breakers using one contactor relay – for contact duplication – per auxiliary contact. If one of the circuit-breakers is closed, the others cannot be closed.


Circuit-breakers Indication of the switch position ON and OFF indication with auxiliary contact – standard HIN (Q1)

N (L-, L2)

L1 (L+) -F0

L1 -F0 (L+)

L1 -F0 (L+) 1.13

1.21

1.14

1.22

1.11

-Q1 1.21 1.22

X1

-Q1

-P2

X1

1.12

X2

-P1

1.13 1.14

1.14

X1

X1

X2

-P1

X1

X1

-P1

-P2 X2

-P2 X2

X2

N (L-, L+)

X2

N (L-, L+)

7

P1: On P2: Off

Tripped indication using trip-indicating auxiliary contact HIA (Q1) Trip-indicating auxiliary contacts for mesh network switches L1 N (L+) (L-, L2) -F0 X1

-P1 -Q1

4.13 4.14

X2

4.12

-Q1 4.11

4.14

Terminal designation with NZM14 L1 -F0 (L+) -Q1

4.13 4.14 X1

-P1

N (L-, L+)

X2

P1: Tripped

7-15


Circuit-breakers Short-time delayed circuit-breaker – internal circuit diagrams Time-discriminating network topology Short-time delayed circuit-breakers NZM2(3)(4)/VE, NZM10/ZMV and NZM14 enable a time-discriminating network design with variable stagger times.

L3

L2

L1

Where the prospective short-circuit currents are extremely high, additional installation protection is achieved by instantaneous releases, which respond without any delay.

NZM2(3)(4)...-VE... Trip block VE Adjustable short-time delay: 0, 20, 60, 100, 200, 300, 500, 750, 1000 ms NZM10../ZMV.. Trip-block ZMV only for circuit-breaker types NZM10N NZM10S Adjustable short-time delay:

-Q1

0, 10, 50, 100, 150, 200, 300, 500, 750, 1000 ms NZM14-... S(H) Standard circuit-breakers

7

NZM14-...S NZM14-...H Adjustable short-time delay: I> I>

7-16

100, 150, 200, 250, 300 ms


Circuit-breakers Mesh network circuit-breakers NZM1, NZM2, NZM3, NZM4, NZM7, NZM10, NZM14 Circuit with capacitor unit and shunt release 230 V, 50 Hz.

circuit-breaker can be configured independently of the circuit-breaker.

The capacitor unit which provides the energy for the shunt release of the mesh network

Connect NZM-XCM to the supply side!

18

24

19 20

23

22

21

7 19

24

USt 24 V H

18

L1

20

NZM-XCM

23

a

230 V 50/60 Hz N

21

a Mesh network relay

HIN-NZM... 51 (C1) 22

19

b

18

L1

20

24

NZM-XCM

23

51 (C1) 53 (C2)

230 V 50/60 Hz

53 (C2)

N

21

HIN-NZM...

22

b Mesh network relay with low power contacts

7-17


Circuit-breakers Remote operation with motor operator Two-wire control

Three-wire control

Three-wire control with automatic return to the Off position after tripping

NZM2, 3, 4 and NZM7, 10 L1 (L+)

L1 (L+)

L1 (L+)

0 I

HIA

P1

0

P1

P1

0

I 70

71

NZM-XR

72

70

I 71

72

NZM-XR

75

74

70

74

N (L-, L2)

71

72

NZM-XR

75

74

N (L-, L2)

N (L-, L2)

7 NZM14 L1 (L+)

L1 (L+)

L1 (L+)

RHI

0 I

0

0

I

I 70

71

70

72

74

7-18

70

72

74

N (L-, L2)

71

R-NZM14

R-NZM14

R-NZM14 N (L-, L2)

71

74

N (L-, L2)

72

75


Circuit-breakers as a transformer switch Faults upstream of the low-voltage circuit-breaker, e.g. in the transformer itself, are disconnected by suitable protective devices (e.g. a Buchholz relay) on the high-voltage side. The S7 auxiliary contact of the high-voltage circuit-breaker trips out the NZM transformer switch on the low-voltage side in order to prevent feedback to the high-voltage network. S7 thus isolates the transformer from the network on both sides. This interlocking with the Circuit-breakers with shunt releases Q1 L1 N (L+) (L-, L2) -S7

high-voltage circuit-breaker must always be provided when transformers are being operated in parallel. If only one normally open contact is available as the auxiliary contact, an undervoltage release must be used instead of the shunt release. At the same time, this provides protection against undervoltage.

Circuit-breakers with undervoltage releases Q1

L1 (L+)

L1 N (L+) (L-, L2)

L1 (L+)

-S7 -S7

C1 C2

7

-S7

D1 D2

Q1 C1

-Q1 C2

N (L-, L2)

Q1 D1

-Q1 U< D2

N (L-, L2)

7-19


Circuit-breakers with residual current device Residual current releases combined with circuit-breakers are used for protection against the effects of leakage currents. These device combinations fulfill the following tasks: • Overload protection, • Short-circuit protection, • Fault-current protection. Depending on type the residual current releases protect the following:

These kinds of residual current releases can be attached to the NZM1 and NZM2 circuit-breakers. No auxiliary voltage is required. In the event of a fault, the residual current release trips the circuit-breaker, i.e. the main contacts are opened. The circuit-breaker and the residual current release must be reset to restore the supply. The main functions and the associated values are shown in the following table.

• Persons against direct contact (basic protection), • Persons against indirect contact (fault protection), • Dangers of an earth fault (fire etc.)

7

Part no.

Rated current range

Ue

IDn

tv

A

V

A

ms

NZM1(-4)-XFI30(R)(U)

15 – 125

200 – 415

0.03

–

NZM1(-4)-XFI300(R)(U)

15 – 125

200 – 415

0.3

–

NZM1(-4)-XFI(R)(U)

15 – 125

200 – 415

0.03; 0.1; 0.3 0.5; 1; 3

10; 60; 150; 300; 450

NZM2-4-XFI301)

15 – 250

280 – 690

0.03

–

NZM2-4-XFI1)

15 – 250

280 – 690

0.1; 0.3; 1; 3

60; 150; 300; 450

NZM2-4-XFI30A1)

15 – 250

50 – 400

0.03

–

NZM2-4-XFIA1)

15 – 250

50 – 400

0.1; 0.3; 1

60; 150; 300; 450

1)

Devices are not dependent on the supply voltage.

7-20

Sensitivity

pulsating current

AC/DC


Circuit-breakers with residual current device They can be used in three-phase and single-phase systems. With 2-pole operation it must be ensured that voltage is applied to both terminals required for test functions.

Trip indication is implemented via auxiliary contacts. The NZM2-4-XFI… has fixed contacts. The NZM1(-4)-XFI… allows two M22-K… contact elements from the Moeller RMQ-Titan range to be clipped in. Contact representation for “not released” NZM1(-4)-XFI…

N L1 L2 L3 0+I Q1

M22-K10

b

I> I> I> I>

I n

M22-K02

NZM2-4-XFI… 6.13

6.21

6.14

6.22

7

tv

c a

d a a b c d

Test button (T) NZM1-(4)..., NZM2-4... +NZM2-4-XFI NZM1-(4)-XFI

7-21


Circuit-breakers with residual current device Residual-current relays PFR with ring-type transformers The area of application for the relay/transformer combination ranges – depending on the standards involved – from personnel protection to fire prevention to general protection of systems for 1- to 4-pole electrical power networks. There are three different relay types and seven different transformer types available. They cover operating currents ranging from 1 to 1800 A. The three relay types are:

The fault current relay indicates when a fault current has exceeded the predefined fault current by using a changeover contact. The contact signal can be processed further as a signal in programmable logic controllers or can initiate a trip via the undervoltage release of a circuit-breaker/switch-disconnector. The compact ring-type transformer is placed without any particular space requirement at a suitable position in the power chain.

• Rated fault current 30 mA, permanently set, • Rated fault current 300 mA, permanently set, • Rated fault current from 30 mA to 5 A and a delay time from 20 ms to 5 s which is variable in stages.

7

230 V AC g 20 % 50/60 Hz 3VA

L1 L2 L3 N 1S1

N L

1S2 5

6

7

8

> 3 m – 50 m

1

2

3

4

NO C NC

50/60 Hz

7-22

250 V AC

6A

LOAD


Circuit-breakers with residual current device Trip of circuit-breakers with shunt release and possible external reset of the relay by a pushbutton (NC contact) N L1 L2 L3 -S.

6A 5

6

7

8

NZM.-XA...

C2

7

C1 1

2

3

4

1S1 1S2

PFR-W

LOAD

7-23


Circuit-breakers with residual current device Trip of circuit-breakers with undervoltage release and possible external reset of the relay by a pushbutton (NC contact) N L1 L2 L3 -S.

6A 5

6

7

8

NZM.-XU...

7 1

2

3

D2 U< D1

4

1S1 1S2

PFR-W

LOAD

7-24


Notes

7

7-25

7-26

X7: Optional control circuit plug Not available with communication function IZMXCOM-DP. At the position of X7 a communications module is located.

a Electronic overload release

5 6

1

2

7

Open – + OUT XA, XU 8 9

3

XE

4

Close – +

XHIS signalling switch on second voltage release

Free – +

5

4

6

3

XHIS signalling switch on second voltage release

DPWrite Free IN Enable

8 7

2

9

External

1

10

11

13 12

14

X7

1

2

3

4

5

6

7

8

9

10

11

13 12

14

X8

Terminals

External Internal

Signal state Spring-operated stored energy XEE electrically “ON”

Tripped signalling switch XHIA

a

Internal

7

G transformer S1 IZM-XW(C) N current transformer IZM-XW(C) N current transformer external voltage transformer, star External voltage transformer L3 External voltage transformer L2 External voltage transformer L1 0 V DC 24 V DC Internal system bus + Internal system bus –

Control circuit plug IZM-XKL(-AV) for customer connection Control circuit plugs X8, X7, X6, X5 are identical X8: Optional control circuit plug (Standard for IZM...-U... XFR remote reset and IZM...-D...) G transformer S2

Us

1) current transformers in transformer´s star point or summation current transformers 1200 A/1 A

L/L+

IZM-XCOM-DP

Terminating resistor, 120 O no external system bus module

Us N/Le. g.1) Jumper with no N-converter L1 L2 L3 N 24 V LDC external Power supply

L/L+

Terminal assignment of the control circuit plug

Circuit-breakers IZM circuit-breakers Moeller Wiring Manual 02/08

XE/A first shunt release

Standard auxiliary contact XHI22: S4 “NC”, XHI31/XH40: S8 “NO” Motor operator a black-white, b brown Optional motor cut-off switch XMS

Standard auxiliary contact XHI22: S4 “NO”, XHI31/XHI40: S8 “NO”

Standard auxiliary contact XHI11/XHI22/XHI31: S3 “NC”, XHI40: S7

Standard auxiliary contact XHI11/XHI22/XHI31: S3 “NO”, XHI40: S7

XU, XUV or XA1 second voltage release

X5: Optional control circuit plug Only XUV “non-delayed trip”Only XUV

Standard auxiliary switch XHI: S2 “N/C”

Standard auxiliary switch XHI: S2 “N/O”

“Ready to close” auxiliary switch XHIB

Closing release XE/A

Standard auxiliary switch XHI: S1 "N/O"

Standard auxiliary switch XHI: S1 "N/C"

X6: Standard control circuit plugs

a M

b

1

2

3

4

5

6

7

8

9

10

11

12

13

14

X5

1

2

3

4

5

6

7

8

9

10

11

12

13

14

X6

US

Us

N/L-

L/L+

N/L-

L/L+

US

US

Emergency-Stop or short

L/L+

N/L-

N/L-

L/L+


7

7-27

7-28 Klemmen Terminals

Leitungsnummer Wire no.

Intern Internal


Klemmen Terminals

7 XHI: S1, XHI: S2 Standard-Hilfsstromschalter Standard auxiliary switches Optional auxiliary switches

XHI11(22)(31): S3, XHI22: S4 oder XHI40: S7, XHI40: S8 optionale Zusatz-Hilfsstromschalter

Auxiliary switches


Klemmen Terminals


Intern Internal


Klemmen Terminals

Farbe / color Farbe / color

X6.6 X6-6 XHIB

X7.10 X7-10 XHIF

“Spring charged” signal

XHIS

XA

XHIS1

XA1

XUV

XU

Bell switch alarm

Signal 2nd voltage release XA1, XU or XUV energized

Signal 1st voltage release energized

X7.6

“Ready to close” signal

de-energized

XHIA

X7.4

AusgelöstMeldeschalter

energized

XHIS1

X7.3

Meldeschalter zweiter Spannungsauslöser XA1, XU oder XUV

X7.1

XHIS

de-energized

Meldeschalter erster Spannungsauslöser XA

energized

XHIF

XHIA

X7.12

XHIB

Trip

EinschaltSpeicherbereitschafts- zustandsmeldung meldung

Reset

X7.14

Signalling switches


7

7-29



Intern Internal


Klemmen Terminals

7 XHIS

1 st shunt release

XA

XA erster Arbeitsstromauslöser

XHIS1

XU

XUV

Emergency-Stop or short terminals

XA1

Option: 2nd shunt release or undervoltage release or undervoltage release with delay

Optional: XA1 zweiter Arbeitsstromauslöser XU Unterspannungsauslöser oder XUV Unterspannungsauslöser, verzögert

Voltage release/electrical manual reset


Farbe / color

Klemmen Terminals


Intern Internal


Klemmen Terminals

XEE 3

4

XEE Elektrisch "EIN" Electrical "ON"

XE

XE Einschaltmagnet Closing release

Closing release/electrical ON


7

7-31



Intern Internal


Klemmen Terminals

Charging motor optional: motor cut-off switch XMS

Motor operator

XMS

XM Motorantrieb Optional: Motorabstellschalter XMS

XM Motorantrieb

7

Farbe / color Farbe / color

XFR

XFR remote reset coil S 13 cut-off switch for remote reset coll

XFR Fern-Rücksetzmagnet S13 Abstellschalter für Fern-Rücksetzung

Motor operator, remote reset magnet


XZM...

G-Wandler G sensor

N-Wandler N sensor

Interner Systembus Internal system bus

+

Messmodul

Messmodul Metering module

Spannungswandler Voltage transformer

Metering module

BSS-Modul BSS module

Breaker Status Sensor

1)Termination resistor on X8-1/X8-2, if no external system bus module. 2)When no metering module and also no BSS module is used: direct connection X8 to XZM...

Intern Internal

Klemmen Terminals

Trip magnet for overcurrent release

Overcurrent release

Auslösemagnet für Elektronischer Überstromauslösung Überstromauslöser

S42/S43

-

1)

+

S45

Internal system bus

Interner Systembus

Protective circuits for overcurrent release with breaker status sensor and metering module


7

7-33

XZM...

G-Wandler G sensor

Overcurrent release

N-Wandler N sensor

+

Messmodul Metering module

Spannungswandler Voltage transformer

Metering module

Messmodul

1)Termination resistor on X8-1/X8-2, if no external system bus module (a figure, page 7-26).

Intern Internal

Klemmen Terminals



-

7-34 Interner Systembus Internal system bus

7 1)

+


Protective circuits for overcurrent release, metering module only


XZM...

G-Wandler G sensor

Overcurrent release

N-Wandler N sensor


+

BSS-Modul BSS module



1)Termination resistor on X8.1/X8.2, if no external system bus module (a figure, page 7-26).

Intern Internal

Klemmen Terminals



-

1)

+

Internal system bus

Interner Systembus

Protective circuits for overcurrent release, breaker status sensor only


7

7-35


Notes

7

7-36


All about Motors Page Motor protection

8-3

Engineering notes

8-14

Circuit documents

8-18

Power supply

8-20

Control circuit supply

8-23

Contactor markings

8-24

Direct-on-line start of three-phase motors

8-25

Direct switch-on with PKZ2 motor-protective circuit-breaker

8-33

Control circuit devices for direct-on-line start

8-37

Star-delta switching of three-phase motors

8-38

Star-delta starting with motor-protective circuit-breakers PKZ2

8-48

Control circuit devices for star-delta starting

8-51

Pole-changing motors

8-53

Motor windings

8-56

Multi-speed contactors

8-59

Multi speed switches of three-phase motors

8-61

Control circuit devices for UPDIUL multi-speed contactors

8-69

Multi speed switches of three-phase motors

8-74

Multi speed switch with motor-protective circuit-breakers PKZ2

8-89

8-1

8


All about Motors Page Three-phase current-automatic stator starters Three-phase automatic rotor starters

8

8-2

8-91 8-96

Switching of capacitors

8-100

Duplex pump control

8-104

Fully automatic pump control

8-106

Off position interlock of the loads

8-110

Fully automatic main transfer switch with automatic reset

8-111


All about Motors Motor protection Selection aids

The Moeller selector slide enables you to determine quickly and reliably which motor starter is your most suitable for the application . All you need the operating voltage, the motor rating, the various short-circuit ratings and coordination types.

The selector slide can be used for dimensioning devices with short-circuit coordination types 1 and 2. Standard cable cross-sections and permissible cable lengths are stated for the tripping of protective devices in compliance with standards. They can vary according to the installation requirements. The selector slide has several variants of the movable section with numerical values for DOL and reversing starters or star-delta starters. The selector slide can be obtained free of charge. If you prefer to use the selector slide online, this is available on the Internet at: www.moeller.net/en/support/slider/index.jsp

8

8-3


All about Motors Motor protection Overload relay with manual reset These should always be used where continuous contact devices are required (e.g. pressure and position switches), to prevent automatic restarting. The reset button can be fitted as an external feature in order to make it accessible to all personnel. Moeller overload relays are always supplied with manual reset but can be converted to automatic reset by the user. Overload relays with automatic reset These can be used only with pulsed contact devices (three-wire control) such as pushbuttons etc., because on these, the cooling of the bimetal strips cannot lead to automatic reconnection.

8

Special circuitry Special circuitry such as is found in star-delta starters, individually compensated motors, current transformer-operated relays etc. may require that the relay setting deviates from the rated motor current. Frequently recurring operating cycles These make motor protection difficult. The relay should be set higher than the rated motor current in view of its shorter time constant. Motors which are rated for a high frequency of operation will withstand this setting to a certain degree. Although this will not ensure complete protection against overload, it will nevertheless provide adequate protection against non-starting.

8-4

Backup fuses and instantaneous releases These are needed to protect not only the motor, but also the relay, against the effects of short circuits. Their maximum rating is shown clearly on every relay and must be adhered to without fail. Higher ratings – chosen for instance according to the cable cross-section – would lead to the destruction of the motor and relay. The following important questions and answers give a further guide to the behaviour of an installation with motor protection. To what current must the overload relay be set? To the rated motor current - no higher, no lower. A relay set to too low will prevent the full utilization of the motor; set too high, it will not guarantee full overload protection. If a correctly set relay trips too frequently, then either the load on the motor should be reduced or the motor should be exchanged for a larger one. When is it right for the overload relay to trip? Only when the current consumption of the motor increases due to mechanical overloading of the motor, undervoltage or phase failure when the motor is at or nearly full load, or when the motor fails to start due to a stalled rotor.


All about Motors Motor protection When does the overload relay fail to trip in good time although the motor is at risk? With changes in the motor which do not cause an increase in current consumption: Effects of humidity, reduced cooling due to a reduction in speed or motor dirt, temporary additional external heating of the motor or bearing wear.

3-pole overload relays should be so connected in the case of single-phase and DC motors so that all three poles of the overload relay carry the current, whether in single-pole or 2-pole circuits. 1 pole

2 pole

What causes destruction of the overload relay? Destruction will take place only in the event of a short circuit on the load side of the relay when the back-up fuse is rated too high. In most cases, this will also endanger the contactor and motor. Therefore, always adhere to the maximum fuse rating specified on every relay.

An important characteristic feature of overload relays conforming to IEC/EN 947-4-1 are the tripping classes (CLASS 10 A, 10, 20, 30). They determine different tripping characteristics for the various starting conditions of motors (normal starting to heavy starting).

8

8-5


All about Motors Motor protection Pick-up times Response limits of time-delayed overload relays at all-pole load. Type of overload relay

8

Multiple of current setting

C Tripping class

Reference ambient temperature

A t>2h starting from cold state of relay

B tF2h

Non-ambient temperature compensated thermal relays and magnetic relays

1.0

1.2

1.5

7.2

+ 40 °C

Ambient temperature compensated relay

1.05

1.2

1.5

7.2

+ 20 °C

10 A 10 20 30

In the case of thermal overload relays with a current setting range, the response limits must apply equally to the highest and the lowest setting of the associated current.

8-6

Tripping time in minutes F2 F4 F8 F 12

D Tripping class

Tripping time in seconds

10 A 10 20 30

2 < T F 10 4 < T F 10 6 < T F 20 9 < T F 30


All about Motors Motor protection Response limits of 3-pole thermal overload relays at 2-pole load Type of thermal overload relay

Multiple of current setting

Reference ambient temperature

A t > 2 h, starting from cold state of relay

B tF2h

Ambient temperature compensated, without phase-failure sensitivity

3 poles

1.0

2 poles 1 pole

1.32 0

+ 20 °C

Non-ambient temperature compensated, without phase-failure sensitivity

3 poles

1.0

2 poles 1 pole

1.25 0

+ 40 °C

Ambient temperature compensated, with phase-failure sensitivity

2 poles 1 pole

1.0 0.9

2 poles 1 pole

1.15 0

+ 20 °C

In the case of thermal overload relays with a current setting range, the response limits must apply equally to the highest and the lowest setting of the associated current.

8

The point of destruction is the point of intersection between the projected tripping curves and the multiple of the current. Short-circuit rating of the main circuit

Overload capacity Overload relays and releases have heating coils which can be thermally destroyed by overheating. The making and breaking currents of the motor flow in thermal overload relays which are used for motor protection. These currents are between 6 and 12 x Ie (rated operational current), depending on the utilization category and the size of the motor. The point of destruction depends on the frame size and design and is usually approximately 12 to 20 x Ie.

With currents that exceed the breaking capacity of the motor starter in relation to the utilization category (EN 60947-1), it is permissible for the current flowing during the operating time of the protective device to damage the motor starter. The permissible behaviour of starters under short-circuit conditions is defined in the so-called types of co-ordination (1 and 2). It is common practice to state in the details of protective devices which type of co-ordination is ensured by them.

8-7


All about Motors Motor protection Type 1 coordination In the event of a short circuit the starter must not endanger persons and installations. It does not have to be fit for renewed operation without repair. Type 2 coordination In the event of a short circuit the starter must not endanger persons and installations. It must be fit for renewed operation. There is a risk of contact welding for which the manufacturer must give maintenance instructions.

The tripping characteristic of the overload relay must not differ from the given tripping curve after a short circuit. Short-circuit withstand strength of the auxiliary switch The manufacturer details the required overcurrent protective device. The combination is subjected to three test disconnection's at 1000 A prospective current with a power factor between 0.5 and 0.7 at rated operational voltage. Welding of the contacts may not occur (EN 60947-5-1, VDE 0660 Part 200).

Motor protection in special applications

8

Heavy starting duty An adequate tripping delay is essential in order to allow a motor to start up smoothly. In the majority of cases, overload relays ZB, motor-protective circuit-breakers PKZ(M) or circuit-breakers NZM can be used. The tripping delays can be taken from the tripping characteristics in the Moeller Main Catalogue, Industrial Switchgear. In the case of especially high-inertia motors, whose run-up time exceeds the tripping delay of the above devices, it would be completely wrong to adjust an overload relay which tripped out before the run-up time expired, to a current level higher than the rated motor current. This would, it is true, solve the starting problem, but the motor would no longer be adequately protected during normal operation. However, there are other solutions to the problem: Current transformer-operated overload relays ZW7 The ZW7 consists of three special saturable core current transformers, supplying an overload

8-8

relay Z.... It is used principally for medium and large motors. Up to two times rated current Ie, the transformation ratio I1/I2 of the saturable core current transformers is practically linear. Within this range it does not differ from the normal overload relay, i.e. it provides normal overload protection during normal operation. However, within the transformer characteristic range (I > 2 x Ie) , the secondary current no longer increases proportionally to the primary current. This non-linear increase in the secondary current produces an extended tripping delay if overcurrents greater than twice rated current occur, and hence permits longer starting times. Adjusting the current transformer-operated overload relay ZW7 for lower rated motor current The setting ranges quoted in the Moeller Main Catalogue, Industrial Switchgear apply when the incoming cable is looped once through the transformer relay.


All about Motors Motor protection If the current transformer-operated overload relay ZW7 is required to provide protection to a motor of below 42 A rating (minimum value in the setting range of 42 A to 63 A), the necessary range adjustment is achieved by looping the incomer several times through the aperture in the relay. The change in the rated motor current quoted on the rating plate is inversely proportional to the number of loops. Example: With the ZW7-63 relay, which has a setting range from 42 A to 63 A, a motor rating of 21 A to 31.5 A can be accommodated by looping the leads twice through the relay. Bridging of motor protection during starting For small motors the bridging of the motor protection during starting is more economical. Because of the additional parallel contactor, the overload relay does not carry the full current during starting. Only when the motor has reached full speed is the bridging contactor switched off and the full motor current is then

carried by the overload relay. Provided it has been set correctly to the rated motor current, this will ensure full motor protection during operation. Starting must be monitored. The motor is a limiting factor with regard to the tripping delay of the current transformer-operated relay and the bridging period. One must ensure that the motor is able to tolerate the high temperature generated by direct starting, for the prescribed starting time. Motor and starting procedure have to be selected carefully when dealing with machines having a very large rotating mass, which are practically the only ones subject to this problem when direct starting is used. Depending on the operating conditions adequate protection of the motor winding may no longer be given by an overload relay. In that case it must be weighed up whether an electronic motor-protective relay ZEV or a thermistor overload relay EMT 6 in conjunction with an overload relay Z meets the requirements.

Star-delta starter (y D) 1 operating direction Changeover time with overload relay in position A: < 15 s B: > 15 < 40 s Ie

C: > 40 s Ie

Ie B

-Q15

-Q11 A

-Q13

-Q11

-Q15

-Q13

-Q11

-Q15

-Q13 C

Setting of the overload relay 0.58 x Ie 1 x Ie 0.58 x Ie Full motor protection in Y (star) Only partial motor protection in Motor not protected in Y (star) position position y position

8-9

8


All about Motors Motor protection Multi-speed switches 2 speeds One tapped winding 2 separate windings

-Q17

-Q21

-Q23

-Q17

3 speeds 1 x tapped winding + 1 winding

-Q21

-Q23

-Q17

-Q11

-Q21

Attention must be paid to short-circuit protection of the overload relays. Separate supply leads should be provided if required. Heavy starting duty Current transformer-operated overload relays ZW7

Bridging of motor protection during starting

Bridging during starting using bridging relay

8 -Q11

For medium and large motors

8-10

-Q11

-Q12

-Q11

-Q12

For small motors; no protection Automatic cut out during starting


All about Motors Motor protection Individually compensated motor Ie Iw Ib Ic

= Rated motor operational current [A] Iw = I e xy [ A ] = Active current Proportion of motor 2 2 = Reactive current rated operational current [A] Ib = Ie – Iw [ A ] –6 = Rated capacitor current [A] Ic = U e× 3 × 2πf × C × 10 [ A ]

IEM cos v Ue Pc C

= Setting current of overload relay [A] = Motor power factor = Rated operational voltage [V] = Rated capacitor output [kvar] = Capacitance of capacitor [mF]

}

P c × 10 3 -----------------3 × Ue

Ic =

Capacitor connected to contactor terminals

to motor terminals

-Q11

-Q11

8 IEM

PC

IEM

PC

Setting IEM of overload relay I EM = 1 × I e

Capacitor does not relieve loading of cable between contactor and motor.

I EM =

I w2 + ( I b – I c )

2

Capacitor relieves loading of cable between contactor and motor; normal arrangement.

8-11


All about Motors Motor protection Thermistor overload relay for machine protection Thermistor overload relays are used in conjunction with temperature-dependent semiconductor resistors (thermistors) for monitoring the temperature of motors, transformers, heaters, gases, oils, bearings etc. Depending on the application, thermistors have positive (PTC thermistors) or negative (NTC thermistors) temperature coefficients. With PTC thermistors the resistance at low temperature is small. From a certain temperature it rises steeply. On the other hand, NTC thermistors have a falling resistance-temperature characteristic, which does not exhibit the pronounced change behaviour of the PTC thermistor characteristic.

8

Temperature monitoring of electric motors Thermistor overload relays EMT6 comply with the characteristics for the combination of protective devices and PTC sensors to VDE 0660 Part 303. They are therefore suitable for monitoring the temperature of series motors. When designing motor protection, it is necessary to differentiate between stator-critical and rotor-critical motors: • Stator-critical motors Motors whose stator winding reaches the permissible temperature limit quicker than the rotor. The PTC sensor fitted in the stator winding ensures that the stator winding and rotor are adequately protected even with a stalled rotor.

8-12

• Rotor-critical motors Squirrel-cage motors whose rotor in the event of stalling reaches the permissible temperature limit earlier than the stator winding. The delayed temperature rise in the stator can lead to a delayed tripping of the thermistor overload relay. It is therefore advisable to supplement the protection of rotor-critical motors by a conventional overload relay. Three-phase motors above 15 kW are usually rotor-critical. Overload protection for motors in accordance with IEC/EN 60204. These standards specify that motors above 2 kW used for frequent starting and stopping should be adequately protected for this type of duty. This can be achieved by fitting temperature sensors. If the temperature sensor is not able to ensure adequate protection with stalled rotors, an overcurrent relay must also be provided. Generally, where there is frequent starting and stopping of motors, intermittent operation and excessive frequency of operation, the use of overload relays in conjunction with thermistor overload relays is to be recommended. In order to avoid premature tripping out of the overload relay in these operating conditions, it is set higher than the predefined operational current. The overload relay then assumes stalling protection; the thermistor protection monitors the motor winding. Thermistor overload relays can be used in conjunction with up to six PTC sensors to DIN 44081 for direct monitoring of temperatures in EEx e motors compliant to the ATEX directive (94/9 EC). Copies of PTB certification are available on request.


All about Motors Motor protection Protection of current and temperature-dependent motor-protective devices Protection of the motor under the following conditions

Using bimetal

Using thermistor

Using bimetal and thermistor

Overload in continuous operation

+

+

+

Extended starting and stopping

(+)

+

+

Switching to stalled rotor (stator-critical motor)

+

+

+

Switching on stalled rotor (rotor-critical motor)

(+)

(+)

(+)

Single-phasing

+

+

+

Intermittent operation

–

+

+

Excessive frequency of operation

–

+

+

Voltage and frequency fluctuations

+

+

+

Increased coolant temperature

–

+

+

Impaired cooling

–

+

+

8

+ Full protection (+) Partial protection - No protection

8-13


All about Motors Engineering notes Three-phase automatic starters I Md

I

a I' Md

b M'd 20

40

60

I Md

80 100 % n

I

a

I'

Md

b M'd

8

20

40

60

80 100 % n

I Md

20

40

60

80 100 % n

I: Line current Md: Torque n: Speed a Reduction of the line current b Reduction of the torque

8-14

Automatic stator starters three-phase current with startup resistors Single or multi-step resistors are connected upstream of the three-phase squirrel-cage motors to reduce the starting current and torque. With single-step starters, the starting current is approximately three times the motor full-load current. With multi-step starters, the resistors can be so designed that the starting current is only 1.5 to 2 times the motor full-load current, with a very low level of starting torque. Three-phase autotransformer starters with starting transformers This type of starting is preferable where the same starting torque is to be obtained as with the primary resistance starters but the starting current taken from the mains is to be further reduced. A reduced voltage Ua (approximately 70 % of the rated operational voltage) is supplied to the motor when starting via the starting transformer. Thus, the current taken from the mains is reduced to approximately half the direct starting current. Three-phase automatic rotor starters with starting resistors Resistors are connected in the rotor circuit of the motor to reduce the starting current of motors with slip-ring rotors. The current taken from the mains is thus reduced. In contrast to stator resistance starters, the torque of the motor is practically proportional to the current taken from the mains. The number of steps of the automatic starter is determined by the maximum permissible starting current and by the type of the motor.


All about Motors Engineering notes Important data and features of three-phase automatic starters 1) Type of starter

Stator resistance starter (for squirrel-cage motors)

Rotor starter (for slipring rotors)

2) Type of starter

Star-delta switches

With starting resistors

With starting transformers

Rotor resistance starter

3) Number of starting stages

1 only

Normally 1

Normally 1

Selectable (no longer selectable when current or torque have been determined)

4) Voltage reduction at the motor

0.58 x rated operational voltage

Selectable: a x rated operational voltage (a < 1) e.g. 0.58 as with yd starter

Selectable: 0.6/0.7/0.75 x Ua (transformer tappings)

none

5) Starting current taken from mains

0.33 x inrush current at rated operational voltage

a x inrush current at rated operational voltage

Selectable (see 4) 0.36/0.49/0.56 x inrush current at rated operational voltage

Selectable: from 0.5 to about 2.5 x rated current

5a) Starting current at the motor

Selectable (see 4) 0.6/0.7/0.75 x Ie

6) Starting torque

0.33 x tightening torque at rated operational voltage

a2 x tightening torque at rated operational voltage

Selectable (see 4) 0.36/0.49/0.56 x tightening torque at rated operational voltage

Selectable (see 5) from 0.5 to pull-out torque

7) Current and torque reduction

Proportional

Current reduction less than torque reduction

Proportional

Current reduction much greater than torque reduction. From pull-out torque to rated speed almost proportional

8) Approximate price (for similar data). DOL starting = 100 (with overload relay, enclosed)

150 – 300

350 – 500

500 – 1500

500 – 1500

8-15

8


All about Motors Engineering notes Switching of capacitors DIL contactors for capacitors – individual switching Individual compensation L1...3

Group compensation L1...3

-F1

-Q11

-F1

-Q31

M 3

-C1

-M1

8

When capacitors are switched on, contactors are heavily stressed by transient current peaks. When a single capacitor is switched on, currents up to 30 times the rated current can occur; these can, however, be reliably switched by Moeller DIL contactors. When installing capacitors, the VDE specification 0560 part 4 (Germany) and the standards which apply to each country should be observed. According to these, capacitors not directly connected to an electrical device which forms a discharge circuit, should be equipped with a rigidly connected discharge device. Capacitors connected in parallel to the motor do not require a discharge device, since discharging is performed via the motor winding. No switch-disconnectors or fuses must be installed between the discharge circuit and the capacitor. A discharge circuit or discharge device must reduce the residual voltage of the capacitor to 8-16

-Q11

-C1

M 3

M 3

M 3

-M1

-M2

-M3

less than 50 V within a minute of the capacitor being switched off.


All about Motors Engineering notes Contactor for capacitor DILK… – Individual and group compensation Group compensation L1...3 -F1

-F2

-F3 -Q1

-Q11

I>

-Q13

-Q12

-Q32

-Q31

M 3

M 3

M 3

-M1

-M2

-M3

-C0

-C1

a -C2

a Additional inductance with standard contactor In the case of group compensation where capacitors are connected in parallel, it must be noted that the charging current is taken not only from the mains but also from the capacitors connected in parallel. This produces inrush current peaks which can exceed 150 times the rated current. A further reason for these peak currents is the use of low-loss capacitors as well as the compact construction, with short connecting elements between contactor and capacitor. Where standard contactors are used, there is danger of welding. Special contactors for capacitors such as those available from Moeller in the DILK… range, which can control inrush current peaks of up to 180 times the rated current, should be used here.

If no special contactors are available, the inrush currents can be damped by additional inductance's. This is achieved either by longer incoming leads to the capacitors or by inserting an air-cored coil with a minimum inductance of approximately 6 mH (5 windings, diameter of the coil approximately 14 cm) between contactor and capacitor. The use of series resistors is another way of reducing high inrush currents. Use of reactors Frequently the capacitors in group compensation are provided with reactors to avoid harmonics. The reactors also act to limit the inrush current and normal contactor can be used.

8-17

8


All about Motors Circuit documents General Circuit documents serve to explain the function of circuits or electrical connections. They provide information for the construction, installation and maintenance of electrical installations. The supplier and the operator must agree on the form in which the circuit documents are to be produced: paper, film, diskette, etc. They must also agree on the language or languages in which the documentation is to be produced. In the case of machines, user information must be written in the official language of the country of use to comply with EN 292-2. The circuit documents are divided into two groups:

Classification according to the type of representation Simplified or detailed • Single-line or multi-line representation • Connected, semi-connected or separate representation • Topographical representation In addition to this, there is the process-orientated representation with the function chart (see previous pages). Examples for drawing up circuit documents are given in IEC 1082-1, IEC/EN 61082-1. Circuit diagrams

Classification according to the purpose

8

Explanation of the mode of operation, the connections or the physical position of the components. This support covers: • • • • • • • • • • •

Explanatory circuit diagrams, Block diagrams, Equivalent circuit diagrams, Explanatory tables or diagrams, Flow diagrams, tables Time flow diagrams, tables Wiring diagrams, Device wiring diagrams, Interconnection diagrams, Terminal diagrams, Assignment diagrams.

8-18

Diagrams indicate the voltage-free or current-free status of the electrical installation. A distinction is drawn between: • Block diagram: Simplified representation of a circuit with its main parts, which shows how the electrical installation works and how it is subdivided. • Circuit diagram: Detailed representation of a circuit with its individual components, which shows how the electrical installation works. • Equivalent circuit diagram: Special version of an explanatory circuit diagram for the analysis and calculation of circuit characteristics.


All about Motors Circuit documents L1, L2, L3

L1 L2 L3 1 3 5

Q1

13

Q

14 I> I>I> 2 4 6

I>

1 3 5

Q11

Q12

Q11

1

Q12

2 4 6

3 5

2 4 6

PE U V W M 3~

M 3~

Circuit diagram: 1-pole and 3-pole representation

8 Wiring diagrams Wiring diagrams show the conductive connections between electrical components. They show the internal and/or external connections but, in general, do not give any information about the mode of operation. Instead of wiring diagrams, wiring tables can also be used. • Unit wiring diagram: Representation of all the connections within the device or combination of devices. • Interconnection diagram: Representation of the connections between the device or combination of devices within an installation.

• Terminal diagram: Representation of the connection points of an electrical installation and the internal and external conductive connections connected to them. • Assignment diagram (location diagram). Representation of the physical position of the electrical equipment, which does not have to be to scale. You will find notes on the marking of electrical equipment in the diagram as well as further diagram details in the section “Specifications, Formulae, Tables”.

8-19


All about Motors Power supply 4-conductor system, TN-C-S L11 a Protective earth conductor Protective earth terminal in enclosure (not L21 L31 totally insulated) N

햲 PE

L1 L2 L3 N PEN

Overcurrent protective device in the supply is required for compliance to IEC/EN 60204-1

8

5-conductor system, TN-S L11 L21 L31 N

햲

L1 L2 L3 N PE

Overcurrent protective device in the supply is required for compliance to IEC/EN 60204-1

8-20

a Protective earth conductor Protective earth terminal in enclosure (not totally insulated)


All about Motors Power supply 3-conductor system, IT L11 L21 L31

PE

L1 L2 L3

Overcurrent protective device is required in the supply for compliance to IEC/EN 60204-1 For all systems: use the N conductor only with the agreement of the user

8

Separate primary and secondary protection

L1 L3

1

Earthed control circuit. In non-earthed control circuit, remove link and provide insulation monitoring.

3 5

I⬎ I⬎ I⬎ 2 4 6

0

L01 L02

8-21


All about Motors Power supply Combined primary and secondary protection

L1 L3

1

Earthed control circuit. In non-earthed control circuit, remove link and provide insulation monitoring. Maximum ratio of U1/U2 = 1/1.73 Circuit not to be used with STI/STZ (safety and isolating transformers).

3 5

I> I> I> 2

4 6

0

L01 L02

8

8-22


All about Motors Control circuit supply Separate primary and secondary protection, with insulation monitoring on the secondary side

L1 L2 L3 L011

1 3 5

a Clear button b Test button

I. I. I. 2 4 6

ab 0

PE

L01 A1 15 S1 S2 E L 15 E R< A1 16 18

E A2 16 18 L A2

L02

DC power supply with three-phase bridge rectifier

L1 L2 L3

8 1 3 5

I⬎ I⬎ I⬎ 2 4 6

Yy0

–

+

8-23


All about Motors Contactor markings The contactors in contactor combinations have, in accordance with EN 61346-2 for equipment and function, the code letter Q, as well as numerical identification, which shows the function of the component (e.g. Q22 = mains Type of component

contactor with anticlockwise rotation for high speed). The following table shows the marking used in this Wiring Manual and in Moeller circuit documentation.

Mains contactors Standard motor

Step contactors 2 speed/4 speed

3 speed One speed Forward Up Hoist

8

DIL (/Z)

Q11

DIUL (/Z)

Q11

SDAINL (/Z)

Q11

SDAIUL (/Z)

Q11

Low speed Reverse Down Lower

Forward Up Hoist

High speed Reverse Down Lower

Forward Up Hoist

Reverse Down Lower

Star

Delta

Q13

Q15

Q13

Q15

Q12 Q17

UPIUL (/Z/Z)

Q17

UPSDAINL (/Z)

Q17

Q21

Q23

Q17

Q21

Q23

Q17

Q21

Q11

UPDIUL (/Z) ATAINL (/Z)

Q11

DAINL

Q11

DDAINL

Q11

DIL + discharge resistors

Q11

DIGL + discharge resistors

Q11

Q21 Q18

With contactor combinations which are made up of several basic types, the basic type is always maintained. Thus, the circuit diagram for a reversing star-delta starter, for example, is formed by combining the basic circuit of the reversing contactor and that of the standard star-delta starter.

8-24

Notes

Q16 to Qn

1-n starting stages

Q12

UPIL (/Z/Z)

U3PIL (/Z/Z/Z)

Starting stage

Q21

Q23 Q22

Q23

Q13

Q19

Q14


All about Motors Direct-on-line start of three-phase motors Typical circuits with DIL contactors Fuseless without overload relay Short-circuit protection1) and overload protection by means of PKZM motor-protective circuit-breaker or NZM circuit-breaker.

3

5

Short-circuit protection3) for contactor by means of fuses F1.

L1 L2 L3

L1 L2 L3 1

Fuses with overload relay Short-circuit protection2) for contactor and overload relay by means of fuses F1.

13

L1 L2 L3 -F1

-F1

14

-Q1 I> I> I> 2

4

-Q11

6

1

3 5

2 4 6

1

-Q11

2

3 4

5

1

3

5

2

4

6

-Q11

6

-F2

97

95

98

96

-F2 4

6

PE PE U V

M 3

95

98

96

PE 2

U

97

V

W

M 3

W

8

U V W

M 3 -M1

-M1 -M1 1)

Protective device in the supply line in accordance with Moeller Main Catalogue, Industrial Switchgear or AWA installation instructions. 2) Fuse size in accordance with data on the rating plate of the overload relay. 3) Fuse size in accordance with Moeller Main Catalogue, Industrial Switchgear (Technical data for contactors)

8-25


All about Motors Direct-on-line start of three-phase motors Typical circuit with bridging of overload relay during starting Without overload relay

with overload relay L1 (Q11/1)

L1 (Q11/1)

-F0

-F0

-Q1

95

13

-F2 14

21

21

0

0

22

-S11

-S11 13

22 13

I

I

14

14

-Q11

8

96

14

14

-Q11 13

13 A1

A1

-Q11

-Q11 A2

21

The short-circuit capacity of the contacts in the circuit has to be considered when selecting F0. Double actuator

22

21

22 14

13

A

Q11 I 13

Q11 14

0

13

F2 96

N

14

N

B

Control circuit device I: ON 0: OFF For connection of further control circuit devices a section "Pulse encoder", page 8-37 Method of operation: Actuation of pushbutton I energizes the coil of contactor Q11. The contactor switches on the motor and maintains itself after the button is enabled via its 8-26

A2

own auxiliary contact Q11/14-13 and pushbutton 0 (three-wire control contact). Contactor Q0 is de-energized, in the normal course of events, by actuation of pushbutton 11. In the event of an overload, it is de-energized via the normally closed contact 95-96 on overload relay F2.


All about Motors Direct-on-line start of three-phase motors Application on drive motors with heavy starting duty For connection when used with motor-protective circuit-breakers PKZM... and circuit-breakers NZM(H)... a section "Fuses with overload relays", page 8-29

L1 L2 L3 -F1

1

3

5

2

4

6

-Q11

1

3

5

2

4

6

-Q14

97

95 96

-F2 2

4

6

98

U

V

W

PE

8

M 3 -M1

8-27


All about Motors Direct-on-line start of three-phase motors Q14:Bridging contactor K1: Timing relays Q11:Mains contactor

L1 (Q11/1) -F0 95

13

-Q1

-F2 96

14

21

-Q11

-S11

13

21

Q14 14

0

13

43

22

-Q11

F2 96

14

A

I

21

13

14

44

Q11 22

22

-Q14

13

14

14

-Q14

21

I

22

22 13

14

0 -S11

B

16

-K1 15 A1

8

-Q14 N

A1

-K1 A2

A2

A1

-Q11

A2

Control circuit device I: ON 0: OFF For connection of further control circuit devices a section "Pulse encoder", page 8-37 Function Actuation of pushbutton I energizes bridging contactor Q14 which then maintains itself via Q14/13-14. At the same time, voltage is applied to the timing relay K1. The mains contactor Q11 is closed via Q14/44-43 and maintains itself via Q11/14-13. When the set time has elapsed, which corresponds to the starting time of the motor, bridging contactor Q14 is disconnected by K1/16-15. K1 is likewise disconnected and, exactly like Q14, cannot be energized again until after the motor has been switched off by pressing pushbutton 0. The normally closed 8-28

contact Q11/22-21 prevents Q14 and K1 closing whilst the motor is running. In the event of an overload, normally closed contact 95-96 on overload relay F2 effects de-energization.


All about Motors Direct-on-line start of three-phase motors Two directions of rotation, DIUL reversing contactor Fuseless without overload relay Short-circuit protection and overload protection by means of motor-protective circuit-breaker PKZM or circuit-breaker NZM. Fuse size in the supply line in accordance with Moeller Main Catalogue, Industrial Switchgear or AWA installation instructions.

13

-Q11

-F1

I>I>I> 2 4 6 1 3 5 2 4 6

-Q12

1 3 5

1 3 5

-Q11

2 4 6

2 4 6

-F2

U V W

1)

L1 L2 L3

-F1

14

-Q1

Short-circuit protection1) for contactor by means of fuses F1.

L1 L2 L3

L1 L2 L3 1 3 5

Fuses with overload relays Short-circuit protection1) for contactor and overload relay by means of fuses F1.

PE

1 3 5

-Q12

2 4 6

97

95

2 4 6

98

96

U V W

PE

-Q11

1 3 5 2 4 6

-Q12

1 3 5 2 4 6

-F2

8 U V W

M 3

M 3

M 3

-M1

-M1

-M1

PE

Fuse size in accordance with data on the rating plate of the overload relay F2

8-29


All about Motors Direct-on-line start of three-phase motors Changing direction of rotation after actuation of the 0 push-button

Changing direction of rotation without actuation of the 0 push-button

L1 (Q11/1)

L1 (Q11/1)

-F0

-F0 95

13

-F2

-Q1 96

14

96

14

21

21

0

0

22

22 22

21

II 22

21

14

13

-S11 II

I 13

14

14

-Q11

-Q12

13 22

21

22

II

I

8

95

13

-F2

-Q1

I 22

21

14

13

-S11 I

II

14

14

13

-Q12

-Q11

13

13

22

A1

A1

A1

-Q12

-Q11

-Q12

A2

A2

21

21

A1

-Q11

22

-Q11

-Q12

21

21

13

22

-Q11

-Q12

14

14

A2

N

A2

N

Q11: Mains contactor, clockwise Q12: Mains contactor, anticlockwise

A

Q12 Q12 13 14

B

C

22

21 13

22

II

14

13

21

0

14

F2 96

22

-S11

21

Q11 Q11 14 13 I

13

C

Control circuit device (three-way pushbutton) I = Clockwise 0 = Stop II = Anticlockwise

14

21

22

13

14

21

22

13

B

14

21

22

13

A

8-30

0

14

-S11

Q12 Q12 14 13 II

F2 96

Q11 13 I


All about Motors Direct-on-line start of three-phase motors Operating principle: Actuation of pushbutton I energizes the coil of contactor Q11. It switches on the motor running clockwise and maintains itself after pushbutton I is enabled via its own auxiliary contact Q11/14-13 and pushbutton 0 (three-wire control contact). The normally closed contact Q11/22-21 electrically inhibits the closing of contactor Q12. When pushbutton II is pressed, contactor Q12 closes (motor running

anticlockwise). Depending on the circuit, direction can be changed from clockwise to anticlockwise either after pressing pushbutton 0, or by directly pressing the pushbutton for the reverse direction. In the event of an overload, normally closed contact 95-96 of overload relay F2, normally open contact 13-14 of the motor-protective circuit-breaker or the circuit-breaker will switch.

Operating direction and two speeds (reversing contactor) Special circuit (tapped winding) for feed drives, etc.

FORWARD: feed or high speed RETRACT: high speed only STOP: tapped winding

L1 L2 L3

-F1

8

-Q17

1

3

5

2

4

6

-Q22

97

1

3

5

2

4

6

-Q21

1

3

5

2

4

6

95

-F21

97

95

98

96

-F2 2

4

6

98

2

96

4

6

PE 1U 1V 1W

-Q23

1

3

5

2

4

6

M 3

2U 2V 2W

-M1

8-31


All about Motors Direct-on-line start of three-phase motors 0: Stop I : Low speed – FORWARD (Q17) II: High speed – FORWARD (Q21 + Q23) III: High speed – BACK (Q22 + Q23)

L1 (Q17/1) -F0 95

-F2/F21

96 21

0 22 22

III

13

III 21

14

22

-S11 II I

21 21

14

I 13

II

22 13

-Q21

-Q17

8

-Q17

31

-Q22 -Q21 -Q23

32 21

-Q17 N

-Q22

A2

-Q17

22

21

-K1

-Q21 21

-K1

14 13

-Q21

-Q23

14 A1 A2

A1

-Q23

Q17: Feed forward Q21: High speed forward Q23: Star contactor K1: Contactor relay Q22: Retract high speed

31 13

-K1

A2

A2

43 44 44 43 A1

A1

Operating principle: Forward travel is initiated by pressing pushbutton I or II according to the speed required. Pushbutton I switches on the feed motion via Q17, which maintains itself via its normally open contact 13-14. If the feed movement is to occur at high speed, star contactor Q23 is energized via pushbutton II which energizes high speed contactor Q21 via its normally open contact Q23/13-14. Both contactors are maintained via Q21/13-14. A direct switch over from feed to high-speed during the forward travel is possible. 8-32

32 32

22

-K1 -Q23

13

31

22

22 22 21 A1

14

-Q22

21

13 14

14 13

14

-Q22

A2

High speed reverse is initiated by pushbutton III. Contactor relay K1 picks up and energizes star contactor Q23 via K1/14-13. High-speed contactor Q22 is energized via normally open contacts K1/43-44 and Q23/44-43, and is maintained via Q22/14-13. The reverse motion can only be stopped via pushbutton 0. Direct changeover/reversal is not possible.


All about Motors Direct switch-on with PKZ2 motor-protective circuit-breaker Reversing L1 L2 L3 -Q1

I> I> I>

T1

L1

-Q11

A1

13

A2

14

L2

T2

T3

L1

L3

21

-Q12

22

A1

13

A2

14

I>> I>> I>> T1

T2

L2

L3

21

8

11

I>> I>> I>>

T3

T1

U

V

T2

T3

W

M 3 -M1

Instead of the high-capacity contact modules S-PKZ2, contact module SE1A…-PKZ2 can also be used provided a switching capacity of the circuit-breaker of 30 kA/400 V is sufficient.

8-33


All about Motors Direct switch-on with PKZ2 motor-protective circuit-breaker

0

22 21

22

22

21

14

13

13

14

21

22

22

21

14

13

I 14

14

-Q11

8

13 14

-Q11

-Q12 13

13

13

22

22

22

-Q11

-Q12 21

-Q12

A2

21

A1

-Q11

A1

-Q12 A2

A2

A2

N

22

-Q11

A1

-Q12

14 13

21

21

A1

-Q11

14

-Q12

N

a

a

a Stop S11

RMQ-Titan, M22-…

Q1

PKZ2/ZM-…

Q12

S/EZ-PKZ2

Q11

S/EZ-PKZ2

F0

FAZ

14

14

-Q11

-Q12 13

13

a 22

-Q12

22

-Q11 21

21

a remove links with position switches 8-34

22

21

22

-S11 II

I

14

C

1.14 21

0

13

21

22

B

1.13

1.14 21

-S11 II

13

A

14

13

-F0 -Q1

-Q1

21

-S11 L1 (Q11/1)

Q12 13 II

0 22

21

C

B

1.13

Q12 14

Q11 14 I

22

13

22

21

A

Q11 13

Q12 13 II

14

13

-F0

14

13

22

21

L1 -S11 (Q11/1)

Q12 14 0

14

Q1 1.14 I

14

Q11 13


All about Motors Direct switch-on with PKZ2 motor-protective circuit-breaker Two speeds L1 L2 L3

L1 L2 L3 1.13 1.21

L1 L2 L3 1.13 1.21

-Q1

-Q2 1.14

1.22

1.14

I> I> I>

I> I> I>

T1 T2 T3

-Q17

A1

13

A2

14 22

21

-Q21

A1

13

A2

14 22

I>> I>> I>> T1 T2 T3

21 I>> I>> I>> T1 T2 T3

1.22

Instead of the high-capacity contact modules S-PKZ2, contact module SE1A…-PKZ2 can also be used provided a switching capacity of the circuit-breaker of 30 kA/400 V is sufficient.

8 2U

1U 1V 1W

M 3

2V 2W

-M1

1U

1W

n<

2U

1V

2W

2V

n>

8-35


All about Motors Direct switch-on with PKZ2 motor-protective circuit-breaker Version 2

22

21

22

22

21

14

13

-S11 II

22

21

-S11 II n>

I

22

21

14

13

I 13

n<

14 14

-Q17

13

-Q21

22

8

-Q21

21 A1

13 22

-Q17

13

-Q21

22

-Q21

21 A1

21 A1

22

-Q17

21 A1 A2

A2

N

13

-Q21

-Q17 A2

A2

14

14

-Q17

-Q21

-Q17

14

13

n<

14

N Stop

n<

Stop

n>

S11

RMQ-Titan, M22-…

–

Q1, Q2

PKZ2/ZM-…/S

–

Q21

S-PKZ2

n>

Q17

S-PKZ2

n<

S11

RMQ-Titan, M22-…

–

n<

21

22

13

C

B

0

22

Q21 13

n>

14

21

22

13

A

1.14 21

0

8-36

1.14 1.13

-Q2

1.14 21

n>

1.13

14

-Q1

C

14

-F0

1.13

-Q2

21

22

21

B

Q21 Q17 Q2 14 1.14 14 II 0

I

13

A

1.14

13

13

14

-Q1

13

1.13

14

22

21

-S11 -F0

II

0 21

I

Q17 13 L1 (Q17/1) -S11

Q21 13

Q21 14

22

L1 (Q17/1)

Q2 1.14

14

Q17 13

22

Version 1


All about Motors Control circuit devices for direct-on-line start Typical example of circuits with contactors DILM… Pulse encoder

22

21 13

14

22

21

A

B

I

B

X2

Illuminated pushbutton actuators

B

Two two-way pushbuttons Q11 Q11 F2 14 13 96

Q11 Q11 F2 14 13 96

1 0

21

Q11 13

0 I 1 Start

Start 0

0 1 Start 1 2 3 4

13

22

21

14

13

A

I

22

Q11 Q11 A2 14

0

14

F2 96

13

21

22

13

14

A X1

0 -S11

14

21

22

21

13

14

22

22

21

13

13

0 -S11

14

Q11 Q11 13 14 I

F2 96

Q11 Q11 Q11 14 I 13 A2

14

F2 96 0

C

Double actuator pushbutton with indicator light

S11

T0-1-15511 spring-return switch with automatic return to position 1

1 2 3 4

I

1 S11

T0-1-15366 spring-return switch with automatic return to rest position

Maintained contact sensors Q11 Q11 F2 14 13 96

Q11 A1

I ON 0 OFF 0 1 2 3 4

F2 96

1

2 S11

P>

I4 1

-S12

Changeover switch T0-1-15521 MCS pressure switches with fleeting contact in the intermediate position

8-37

8


All about Motors Star-delta switching of three-phase motors Star-delta starters with overload relay

3 5

1

-Q11

2 4 6

-F2

2 4

6

97

95

98

96

U1 V1 W1

-F1

8

97

95

98

96

-F2 2 4

-Q11

6

1 3 5 2

4 6

U1 V1 W1

8-38

Arrangement in the motor line In a standard circuit configuration, the star-delta starter with overload relay, including a thermally delayed overcurrent relay are situated in the cables leading to the motor terminals U1, V1, W1 or V2, W2, U2. The overload relay can also be operated in a star circuit as it is usually connected in series with the motor winding and the relay current flowing through it = rated motor current x 0.58. For the complete circuit diagram a section "Automatic star-delta starters SDAINL", page 8-40. Arrangement in the mains supply line Instead of the arrangement in the motor line, the overload relay can be placed in the mains supply line. The section shown here indicates how the circuit differs from that on a section "Automatic star-delta starters SDAINL", page 8-40. For drives where the F2 relay trips out when the motor is starting in the star circuit, the F2 relay rated for the rated motor current can be switched in the mains line. The tripping delay is thus increased by approximately four to six times. In the star circuit the current also flows through the relay but here the relay does not offer full protection since its limit current is increased to 1.73 times the phase current. It does, however, offer protection against non-starting.


All about Motors Star-delta switching of three-phase motors

-Q15 -F2

5

1

3

2

4 6

2

4

6

V2 W2 U2

-Q13 97

95

98

96

1 3 5 2 4 6

Configuration in the delta circuit Instead of the arrangement in the motor line or mains supply line, the overload relay can be placed in the delta circuit. The section shown here indicates the modified circuit diagram from a section "Automatic star-delta starters SDAINL", page 8-40. When heavy, long-starting procedures are involved (e.g. for centrifuges) the F2 relay, rated for relay current = rated motor current x 0.58, can also be connected in the connecting lines between delta contactor Q15 and star contactor Q13. In the star circuit no current then flows through relay F2. This circuit is used wherever exceptionally heavy and long starting procedures are involved and when saturable core current transformer-operated relays react too quickly.

8

8-39


All about Motors Star-delta switching of three-phase motors Automatic star-delta starters SDAINL L1 L2 L3 3

1

5

21

13

-Q1 22

14

B

-F1 I> I> I> 2

1

3

5

2

4

6

-Q11

A

8

6

4

1

3

5

2

4

6

97

95

98

96

1

3

5

2

4

6

-Q13

-Q15

-F2 2

4

6

PE

U1 V1 W1

V2

M 3

W2 U2

-M1

Arrangement and rating of protective devices Position A

Position B

F2 = 0,58 x Ie with F1 in position B ta F 15 s

Q1 = Ie ta > 15 – 40 s

Motor protection in y and d configuration

Only partial motor protection in y configuration

Rating of switchgear Q11, Q15 = 0.58 x Ie Q13 = 0.33 x Ie 8-40


All about Motors Star-delta switching of three-phase motors Further notes on the configuration of the overload relay a section "Automatic star-delta starters SDAINL", page 8-40. SDAINLM12 to SDAINLM55 Pushbutton actuators

0 S11

21

K1: Timing relay approx. 10 s Q11: Mains contactor Q13: Star contactor Q15: Delta contactor Double actuator

22

Q11 I

13

13

14

14

Q11

54

54

54

53

53

53

Q13

17

K1

18

Q15

A1

(–)N

21

A2

Q13

A1

A1

K1

A2

Q13

N

A2

17 28 22

22

Q15 Q11

K1

21 A1

Q15

A2

Y

SDAINLM70 to SDAINLM260

0 S11

Q11 and Q13 maintain themselves via the normally open contacts Q11/14–13 and Q11/44–43. Q11 applies voltage to motor M1 in star connection.

21 22

Q11 I

13

13

14

14

Q11

44

14

14

43

13

13

Q13

K1

Q15 Q15

Q11 (–)N

A2

N

17 18

K1

A2

Q13

A1

A1

K1

21

Q13

A2

17 28 22

22

A1

Function Pushbutton I energizes timing relay K1. The normally open contact K1/17-18 (instantaneous contact) which applies voltage to star contactor Q13, which closes and applies voltage to mains contactor Q11 via normally open contact Q13/14-13.

21 A1

Q15

A2

Y 8-41

8


All about Motors Star-delta switching of three-phase motors For connection of further control circuit devices a section "Control circuit devices for star-delta starting", page 8-51

SDAINLM12 to SDAINLM260 Two-wire control L1 (Q11/1) -F0 HAND

95

-F2

2

96

4

-S14 P > MCS

2

-S14 Q SW

1

14

-Q11

-Q11

13

44

8

13

Q11 Q11 14 13 I

21

22

21

22

13

13

14

0

14

-S11

-Q15 13

F2 96

A

Double actuator Control circuit device I = ON 0 = OFF

14

14

-Q13

43

8-42

1

B


All about Motors Star-delta switching of three-phase motors thus interlocking against renewed switching on while the motor is running. The motor cannot start up again unless it has previously been disconnected by pushbutton 0, or in the event of an overload by the normally closed contact 95-96 of overload relay F2, or via normally open contact 13-14 of the circuit-breaker.

When the set changeover time has elapsed, K1/17-18 opens the circuit of Q13 and after 50 ms closes the circuit of Q15 via K1/17-28. Star contactor Q13 drops out. Delta contactor Q15 closes and switches motor M1 to full mains voltage. At the same time, normally closed contact Q15/22-21 interrupts the circuit of Q13 Automatic star-delta starters SDAINL EM Pushbutton actuators

Maintained contact sensors

L1 (Q11/1)

L1 (Q11/1) -F0

-F0 HAND

13

95

-F2

-Q1

95

-F2

14

96

96

2

-S14 P > MCS

21 1

22

-Q11

2

43

-Q13

13

15

14

44

-Q11

14

-Q11

13

14

-K1 13

16 18 22

-Q15

14

44

-Q11

-Q13

43

-Q13 21

21

Q11 Q11 14 44

F2 96

I

K1: Timing relay approx. 10 s Q11: Mains contactor Q13: Star contactor Q15: Delta contactor

A1

-Q15 A2

A2

-S11

A

21 13

21

N

-Q13 A2

14

A1

A1

-Q11

13

A1 A2

22

0

-K1

13

22

22

I

-S14 Q SW

14

13

1

14

0 -S11

4

B

Double actuator Control circuit device I = ON 0 = OFF 8-43

8


All about Motors Star-delta switching of three-phase motors For connection of further control circuit devices a section "Control circuit devices for star-delta starting", page 8-51 Function Pushbutton I energizes star contactor Q13, normally open contact Q13/14-13 applies voltage to mains contactor Q11, which closes and applies mains voltage to motor M1 in star connection. Q11 and Q13 maintain themselves via normally open contact Q11/14-13 and Q11 additionally via Q11/44-43 and pushbutton 0. Timing relay Q11 is energized at the same time as mains contactor K1. When the set changeover time has elapsed, K1 opens the circuit of Q13 via changeover contact 15-16 and closes the circuit of Q15 via 15-18. Star contactor Q13 drops out.

8

8-44

Delta contactor Q15 closes and switches motor M1 to full mains voltage. At the same time, normally closed contact Q15/22–21 interrupts the circuit of Q13, thus interlocking against renewed switching on while the motor is running. The motor cannot be started up again unless it has previously been disconnected by pushbutton 0, or in the event of an overload, by normally closed contact 95–96 of overload relay F2, or via the normally open contact 13–14 of the circuit-breaker.


All about Motors Star-delta switching of three-phase motors Automatic reversing star-delta starter SDAIUL Reversing L1 L2 L3

1

3

5

13

21

14

22

-Q1 -F1 I> I> I> 2

1

3

5

2

4

6

4

1

3

5

2

4

6

1

3

5

2

4

6

97

95

98

96

1

3

5

2

4

6

-Q13

-Q15

-Q12

-Q11

6

-F2 2

4

6

8 PE

V2

W1 V1 U1

M 3

W2 U2

-M1

Rating of switchgear Q11, Q12: Ie

Standard version: Relay current = motor rated current x 0.58

F2, Q15 :

0,58 x Ie

Q13 :

0,33 x Ie

For other arrangements of overload relay a section "Star-delta starters with overload relay", page 8-38

The maximum motor output is limited by the upstream reversing contactor, and is lower than with automatic star-delta starters for only one direction of operation

8-45


All about Motors Star-delta switching of three-phase motors Changing direction of rotation after actuation of the 0 pushbutton Three-way pushbutton Control circuit devices I = Clockwise 0 = Stop II = Anticlockwise

I

22 14

I

II 14

13

-Q11

-Q11

13

44

-Q12

43

-K1 22

-Q12

8

N

8-46

-Q15

21 A1

-Q11

A2

17 18 22 21 A1

A1

-K1

A2

-Q13

A2

-K1 -Q13 -Q15

44 43 17

-Q12

28 22 21 A1 A2

14 13

22

-Q11 -Q12

21 A1 A2

21 13

A

14

Q12 13 II

B

21

21

0

13

II -S11

-S11

13

22

21

21

22

22

0

Q12 14

F2 96 I

13

21

C

22

Q11 13

14

14

13

-Q1

96

14

-F2

22

-F0 95

14

L1 (Q11/1)


All about Motors Star-delta switching of three-phase motors Changing direction of rotation without actuation of the 0 pushbutton Three-way pushbutton L1 (Q11/1) Control circuit devices I = Clockwise -F0 0 = Stop 95 II = Anticlockwise 13 -F2

-Q1

96

Q11 Q11 F2 13 14 96 I 0

14

21

0

Q12 14

Q12 13

II

II

14

I

13

14

-Q11

13

-Q11

44

-Q12

43

-K1 22

-Q12 -Q11

-Q15

21 A1 A2

A1

-K1

A2

-Q13

17 18 22 21 A1 A2

-K1 -Q13 -Q15

14

44 43 17

-Q12

28 22 21 A1 A2

13

A

21

22 14

13

21

22

B

14

21

-S11

13

-S11

21

13

22

I

22

14

II

22

22 21

C

14

13

22

-Q11 -Q12

21 A1 A2

8

N

For connection of further control circuit devices a section "Control circuit devices for star-delta starting", page 8-51 Function Pushbutton I energizes contactor Q11 (e.g. clockwise). Pushbutton II energizes contactor Q12 (e.g. anticlockwise). The contactor first energized applies voltage to the motor winding and maintains itself via its own auxiliary contact 14-13 and pushbutton 0. Normally open contact 44-43 fitted to each mains contactor energizes star contactor Q13, which energizes and switches on motor M1 in the star connection. At the same time, timing relay K1 is triggered. When the set changeover time has elapsed, K1/17-18 opens the circuit of Q13, which drops out. K1/17-28 closes the circuit of Q15.

Delta contactor Q15 energizes and switches motor M1 to the delta configuration, i.e. full mains voltage. At the same time, normally closed contact Q15/22–21 interrupts the circuit of Q13, thus interlocking against renewed switching on while the motor is running. Motor direction can be changed, either after pressing pushbutton 0, or by direct actuation of the reverse button, depending upon the circuit. In the event of an overload, disconnection is effected by normally closed contact 95–96 of overload relay F2.

8-47


All about Motors Star-delta starting with motor-protective circuit-breakers PKZ2 L1 L2 L3

L1

L2

L3

1.13

1.21

1.14

1.22

-Q1

U F 690 V I> I> I> L1 L2 L3 T1

T2

Q13

T3

A1

13

21

A2

14

22

I>> I>> I>> T1

T2

T3

U F 500 V L1

8

A1

13

A2

14

-Q11

L2

L3

L1

21

A1

13

21

A2

14

22

-Q15

22

I>> I>> I>> T1

T2

L3

T1

1V 1W

2V

M 3

2W 2U

-M1

With Icc > Icn short-circuit proof installation required.

1

3

5

2

4

6

-Q13 I>> I>> I>>

T3

1U

8-48

L2

T2

T3


All about Motors Star-delta starting with motor-protective circuit-breakers PKZ2 L1 (Q11/1) -F0 1.13

-Q1

1.14 21

0

22

13

-S11 I

14

14

-Q11

13

44

14

-Q13

-Q11 43

-K1

13

15

A2 16 18 22

22

-Q13

-Q15 21 A1

A1

-Q11

-K1 10 s

N

A1

-Q15

A2

A2

N

8

21

A1

-Q13 A2

A2

Y

2 x RMQ-Titan, M22-… with indicator light M22-L… T0-1-8 rotary switch Q1 1.14

Q11 Q11 43 A214

0

I

Q11 44

0

S11 21 13

A

22

21

14

13

Q11 Q11 Q1 44 14 1.14

22 14

1 2 3 4

1 S11

B

8-49


All about Motors Star-delta starting with motor-protective circuit-breakers PKZ2

S11

RMQ-Titan, M22-…

Q1

PKZ2/ZM-…

dQ15

S/EZ-PKZ2

yQ13

DIL0M Ue F 500 V AC

yQ13

S/EZ-PKZ2 Ue F 660 V AC

K1

ETR4-11-A

t

t y (s)

15 – 40

Q11

S/EZ-PKZ2

N

Motor protection

(y) + d

F0

FAZ

Setting

l

8

8-50


All about Motors Control circuit devices for star-delta starting Automatic star-delta starters SDAINL Pulse encoder

X1

21

22 14

13

22

21

A

I

14

13

22

21

0 -S11

B

A

X2

Q11 44

I

13

21

22 14

-S11

Q11 14

0

14

F2 96

13

22

21

14

14

22

21

13

-S11

Q11 Q11 Q11 Q11 13 14 44 A2 I

0

13

F2 96

B

Illuminated pushbutton actuators Two two-way pushbuttons

B

Q11 Q11 F2 14 13 96

1 0

0 I 1 Start

Start 0

0 1 Start 1 2 3 4

14

13

A

Q11 Q11 F2 14 13 96

22

21

21

22

13

-S11

Q11 Q11 Q11 Q11 13 A2 14 44 1

14

F2 96

C

S11

1 2 3 4

I

1 S11

Double actuator pushbutton with Spring-return switch T0-1-15511 Spring-return switch indicator light with automatic return to position T0-1-15366 with automatic return to rest position. 1.

8

Two-wire control Q11 Q11 F2 14 13 96

Q11 Q11 14 44

I ON 0 OFF 0 1 2 3 4

F2 96

1

S14 S11

Changeover switch T0-1-15521 e.g. selector switch Rotary switch T with fleeting contact in the LS position switches intermediate position MCS pressure switches

8-51


All about Motors Control circuit devices for star-delta starting Three-phase reversing contactor DIULRR Reversing star-delta starter SDAIUL

A

Two-way pushbutton1) without self-maintaining circuit (inching) for use only with reversing contactors Q12 F2 Q11 13 96 13 0

21 22

D

E

0

2

0 1

2

FS 4011

FS 684

Changeover switch1) Spring-return switch1) T0-1-8214, without Switch T0-1-8210 remains self-maintaining circuit in position 1 or 2 (inching) automatic return to 0 only for reversing contactors

8

Q12 F2 Q12 Q11 14 96 13 13

1

START

1 0 2

START

1 2 3 4 5 6 7 8

Position switches Connected by removing the links between contactor terminals Q11/13 and Q12/22 and between Q12/13 and Q11/22 and interposing the position switches.

START

0

2 START

FS 140660

Spring-return switch T0-2-8177 with automatic return to position 1 or 2 Q11/13 Q12/22

Overload relays always with manual reset

8-52

C

2

1 2 3 4

1)

B

Three-way pushbutton with indicator light. Reversing after actuation of pushbutton 0

1 1

Q11 Q12 Q12 21 14 II 13

13 14

21 22 13 14

B

13 14

21 22 13 14

A

21 22

-S11

-S11

Q12 F2 A2 21 96 0 21 22

Q11 13 I

Q12 Q11 II 13 13

13 14

F2 96 I

Q12/13 Q11/22


All about Motors Pole-changing motors The speed is determined by the number of poles on induction motors. Several speeds can be

obtained by altering the number of poles. The usual types are:

2 speeds 1:2

1 reversible tapped winding

2 speeds

2 separate windings

3 speeds

1 reversible tapped winding 1:2, 1 separate winding

4 speeds

2 reversible tapped windings 1:2

2 speeds

Tapped winding The y/y y is preferred for better matching of the motor to machines in which the torque increases by a quadratic factor (pumps, fans, rotary compressors). Moeller multi-speed starters can be used for both types of connection.

The various tapped winding configurations give differential output ratios for the two speeds Type of connection d/y y y/y y Output ratio 1/1,5–1,8 0,3/1 The d/y y configuration comes nearest to satisfying the most common requirement for constant torque. It has the additional advantage that, because nine terminals are available, y/d starting can be used to provide smooth starting or to reduce the starting current for the low speed condition (a section "Motor windings", page 8-56).

2 speeds – separate windings In theory, motors with separate windings allow any combination of speed and any output ratio. Both windings are arranged in y connection and are completely independent of one another. Preferred speed combinations are:

Motors with tapped winding

1500/3000

–

750/1500

500/1000

Motors with separate windings

–

1000/1500

–

–

Number of poles

4/2

6/4

8/4

12/6

Code no. low/high

1/2

1/2

1/2

1/2

The code numbers are prefixed to the main notations to denote increasing speed. Example: 1U, 1V, 1W, 2U, 2V, 2W. Comparable to EN 60034-8.

8-53

8


All about Motors Pole-changing motors Motor circuit Circuit A

Circuit B

Circuit C

Selection of low and high speed only from zero. No return to low speed, only to zero.

Selection of either speed from zero. Switching from low to high speed possible. Return only to zero.

Selection of either speed from zero. Switching back and forward between low and high speed (high braking torque). Return also to zero.

High speed Low speed Off (zero) Switch-on and further switching Switch-off

8

3 speeds The 1:2 speeds - tapped windings - are supplemented by the speed of the separate winding. This speed can be below, between or

above the two tapped winding speeds. The circuit must consider it (a figure, page 8-84). Preferred speed combinations are:

Speeds

1000/1500/3000

750/1000/1500

750/1500/3000

Number of poles

6/4/2

8/6/4

8/4/2

Connectio n

X

Y

Z

8-54

= separate winding (in the circuit diagrams)


All about Motors Pole-changing motors Motor circuit Circuit A

Circuit B

Circuit C

Selection of any speed only from zero. Return only to zero.

Selection of any speed from zero and from low speed. Return only to zero.

Selection of any speed from zero and from low speed. Return to low speed (high braking torque) or to zero.

3rd speed 2nd speed 1st speed Off (zero)

4 speeds The 1:2 speeds - tapped windings - can follow in sequence or overlap, as the following examples show:

8

1st winding

500/1000

2nd winding

1500/3000 = 500/1000/1500/3000

or 1st winding

500/1000

2nd winding

750/1500 = 500/750/1000/1500

For motors with 3 or 4 speeds the non-connected winding has to be opened at certain pole ratios to avoid inductive circulating currents. This is achieved with additional motor terminals. A range of rotary switches is equipped with this connection (a section "Multi-Speed Switches", page 4-7).

8-55


All about Motors Motor windings Tapped winding 2 speeds

Low speed d

Low speed y

Motor circuit 2 speeds 2 separate windings

Tapped winding with yd starting at low speed

Tapped winding 3 speeds Motor circuit X Motor circuit Y 2 windings, medium and high 2 windings, low and speed – tapped winding speed – tapped win

Low speed

Low speed y

2

1U

1U

2W1

2W 2W

2W2 2U2 2U1 2V2 2V11V 1W

2V 2U

2V 1V

1W 1W

1V

2U

High speed yy

High speed yy

2U

2W

1U

1W

2V

2W2

a figure, page 8-61

2V

3W 3V

3U

2W1 2U2

2V2

2V1

1V

a figure, page 8-65

3V

3U

3W

2V

1W

3V

3U

1

Medium speed Separate winding 1

1U

2U

2W2 1V

1U 2V2 2W1

1U

Low speed Separate winding 1

2U1 1W 2U2

1W

or 2

3W

2W

3V

3U 2V

1U

High speed yy

1W 2V1

a figure, page 8-74

8-56

3W

2U

2U1

2V 2W

1U

or 2

1W

2W 1U

a figure, page 8-61

Low speed d

2U

1V

1W

2U

2W

1V

High speed

2U

1V

1W

8

2

1U

1U

1V

a figure, page 8-83

2W

a figure, page 8-8

V


All about Motors Motor windings

Motor circuit 2 speeds 2 separate windings

Tapped winding with yd starting at low speed

Tapped winding 3 speeds Motor circuit X Motor circuit Y 2 windings, medium and 2 windings, low and high high speed – tapped winding speed – tapped winding

Motor circuit Z 2 windings, low and medium speed – tapped winding

Low speed

Low speed y

2

2

2

1U

1U

2W1 2W2 2U2 2U1 2V2 2V11V 1W 1W

Low speed d

2U

2W2

3W

3W

2W

3V

3U

1U 2W1 2U2

2V2

2V1

1V

a figure, page 8-65

1W

1U 3V

3U

2W

1V

1W

2V

2U

8

1V

High speed Separate winding 1

Medium speed Separate winding 1

3U

2U

2W2 1V

1U 2V2 2W1

2V

1U

2U1

or 2

3W

Low speed Separate winding 1

High speed yy

1W 2U2

3U

1V

1W

1U 3V

2V

2U 1V

1W

or 2

3W

2W

3V

3U 2V

2U

2U1

2V

1U

or 2

1W 2W

1U

2W

1V

High speed

2U

1W 2V1

a figure, page 8-74

1V

a figure, page 8-83

2W

2V

a figure, page 8-85

3W

3V

a figure, page 8-87

8-57


Notes

8

8-58


All about Motors Multi-speed contactors indexing facilities of rotary switches allow for these possibilities. Multi-speed contactor starters can achieve these circuits by interlocking with suitable control circuit devices.

Certain operating sequences for multi-speed motors may be necessary, or undesirable, depending on the nature of the drive. If, for example, the starting temperature rise is to be reduced or high inertia loads are to be accelerated, it is advisable to switch to low speed first and then to high speed.

Fuse protection of the overload relays When a common fuse is used in the supply line, it must not be larger than the back-up fuses specified on the rating plate of either overload relay, otherwise each relay must be protected by its own back-up fuse, as shown in the diagram.

It may be necessary to prevent switching from high to low speed in order to avoid oversynchronous braking. In other cases, it should be possible to switch each speed on and off directly. The operating sequence and L1 L2 L3

8 -F11

-F1

1

3

5

2

4

6

-Q17

1

3

5

2

4

6

-Q21 97

95

-F21

97

95

98

96

-F2 2

4

6

98

96

2

4

6

8-59


All about Motors Multi-speed contactors Fuseless surface mounting which provide all the advantages of a fuseless circuit. Normally, the fuse in the supply line protects the switches from welding.

Multi-speed motors can be protected against short circuits and overloads by motor-protective circuit-breakers PKZ or circuit-breakers NZM, L1 L2 L3

1

3

5

1

13

3

5

-Q1

8

I> I> I> 2

4

6

1

3

5

2

4

6

-Q17

8-60

13 14

14

-Q2

I> I> I> 2

4

6

1

3

5

2

4

6

-Q21


All about Motors Multi speed switches of three-phase motors Tapped winding, non-reversing, 2 speeds Multi-speed contactors UPIL Fuseless, without overload relay, with motor-protective circuit-breaker or circuit-breaker. L1 L2 L3

1

3

13

5

1

3

5

14

-Q1

14

-Q2

I> I> I> 2

4

6

1

3

5

2

4

6

-Q21

13

I> I> I>

1

3

5

2

4

6

-Q23

-Q17

1

3

5

2

4

6

8

PE 1U

2U 2V 2W

M 3

1V 1W

-M1

a section "Motor windings", page 8-56 Synchronous speeds One multi-speed winding

8-61


All about Motors Multi speed switches of three-phase motors Motor terminals

1U, 1V, 1W

2U, 2V, 2W

Number of poles

12

6

500

1000

8

4

750

1500

4

2

rpm

1500

3000

Contactors

Q17

Q21, Q23

rpm Number of poles rpm Number of poles

Rating of switchgear Q2, Q17: I1 (low speed) Q1, Q21: I2 (high speed) Q23: 0.5 x I2

8

8-62


All about Motors Multi speed switches of three-phase motors Circuit A (a figure, page 8-55) One three-way pushbutton

B

21

Q21 13 22

21

22

13

14

A

14

II

13

21

13

-Q1

22

-S11

Q21 14

0

13

-F0

F21 96

14

Q17 13 I

14

L1 (Q11/1)

C

13

-Q2 14 21

0 -S11

22 22

21

II

I 21

22

I

14

II

13

Three-way pushbutton I: Low speed (Q17) 0: Stop II: high speed (Q21 + Q23) Q17: Mains contactor, low speed Q23: Star contactor Q21: Mains contactor, high speed

14

13

-Q17

14

14

13 21

21

-Q21

-Q17

22 22

22

-Q23

-Q23 21 A1

-Q17

A1

-Q23 A2

8

-Q21

13

14 13 A1

-Q21 A2

A2

N

For connection of further control circuit devices a figure, page 8-69, a figure, page 8-70, a figure, page 8-71 Function Pushbutton I energizes mains contactor Q17 (low speed), wich maintains itself via its normally open contact 13-14. Pushbutton II energizes star contactor Q23 and via its normally open contact 13-14 mains contactor Q21. Q21 and Q23 maintain themselves via normally open contact 13-14 of Q21.

Speed can be changed either after pressing pushbutton 0 (circuit A) or directly by pressing the appropriate pushbutton (circuit C), depending upon the circuit. The motor can be switched off either by pressing pushbutton 0, or in the event of an overload, by normally open contact 13–14 of the circuit-breaker.

8-63


All about Motors Multi speed switches of three-phase motors Circuit C (a figure, page 8-55) One three-way pushbutton Three-way pushbutton I: Low speed (Q17) 0: Stop II: High speed (Q21 + Q23)

A

21

0 -S11 II I

22 21

22

I

22 14

II

13

8

13 14

-Q17

14

-Q21

13 22

-Q21 -Q23

13 21 22 14

-Q23

22 A1

A1

-Q23 A2

14

-Q17

21 21

-Q17

13 A1

-Q21 A2

A2

N

Q17: Mains contactor, low speed Q23: Star contactor Q21: Mains contactor, high speed For connection of further control circuit devices a figure, page 8-72

8-64

21

B

21

Q21 13

22

II

13

13 14

14

0

C

14

21

-S11

F21 96

21

14 13

-Q2

Q17 13 I

22

Q17 14

13

13

-Q1

14

-F0

22

L1 (Q11/1)

Q21 14


All about Motors Multi speed switches of three-phase motors Two separate windings, non-reversing, two speeds Multi-speed contactor UPDIUL, fuseless without overload relay L1 L2 L3

1

3

5

13

1

3

5

14

-Q1

14

-Q2

I> I> I> 2

4

6

1

3

5

2

4

6

-Q17

13

I> I> I> 2

4

6

1

3

5

2

4

6

-Q21

8

PE 2U

1U 1V 1W

M 3

2V 2W

-M1

Rating of switchgear Q1, Q17 = I1 (low speed) Q2, Q21 = I2 (high speed)

Motor windings a section "Motor windings", page 8-56.

8-65


All about Motors Multi speed switches of three-phase motors Two separate windings, non-reversing, two speeds Multi-speed contactor UPDIUL, with fuses and overload relay L1 L2 L3

F1

F1 1

3

5

2

4

6

Q17 95

3

5

2

4

6

97

95

2

4

6

98

96

F2

F21 2

4

6

98

96

8

2U

1U 1V 1W

M 3

2V 2W

M1

Fuse size in accordance with data on the rating plate of overload relays F2 and F21. If overload relays F2 and F21 cannot be protected by a common fuse, then use circuit a figure, page 8-59. Motor windings a section "Motor windings", page 8-56.

8-66

1

Q21 97


All about Motors Multi speed switches of three-phase motors Circuit A (a figure, page 8-55) One three-way pushbutton

Circuit C (a figure, page 8-55) One three-way pushbutton L1 (Q17/1)

L1 FO

-F0 95

13

Q1 Q2

F2

14 13

F21

14

-Q1

96

-Q2

21

0 S11

95

-F2

14 13

96 95

-F21

14

96

21

22 21

22

II

I 22 14

I

FL1

13

96 95

II

13

0 -S11

21 13

II

14

I

14

14

Q17

Q21

13

22 21

22

I

22 14

II

13

-Q17

22

Q21

Q17

Q21 A2

21

A1

-Q17

A2

8

-Q17 21

A1

N

13 22

22

-Q21

21

A1

14

-Q21

13

Q17 21

13 14

14 13

22

21

A1

-Q21 A2

A2

N

Q17: Mains contactor, low speed Q21: Mains contactor, high speed

Three-way pushbutton I: Low speed (Q17) 0: Stop II: High speed (Q21 + Q23)

Q17 F21 13 96

A

Q21 Q21 13 14 II 21

22

13

14

21

22

13

B

14

0 22

21

I -S11

13

C

Q17 14

14

21 22 13

14

21 22 13

B

14

21 22

A

14

-S11

13

Q17 F21 Q21 Q21 96 13 14 13 0 I II

C

For connection of further control circuit devices a figure, page 8-73.

8-67


All about Motors Multi speed switches of three-phase motors Operating principle Actuation of pushbutton I energizes the coil of contactor Q17,which switches on the low speed of the motor and, after pushbutton I is released, maintains itself via its auxiliary contact 13-14 and pushbutton 0.

8

8-68

Speed can be changed either after pressing pushbutton 0, or directly by pressing the appropriate pushbutton, depending upon the circuit. The motor is switched off either by pressing pushbutton 0, or in the event of an overload, by normally closed contact 95–96 of overload relays F2 and F21.


All about Motors Control circuit devices for UPDIUL multi-speed contactors Two separate windings, non-reversing, two speeds Circuit A (a figure, page 8-55) One three-way pushbutton with indicator lights

L1 -F0 95

-F2/F21

96 21

0

22 22

21

I

II 22 14

I

II 14

14

13

-Q17

-Q21

13

-Q21 -Q17 A2

N

A1

D

-Q21 A2

A

C

D

21

22

13

14

21

22

13

B

14

22

13

21

Q21 F21 Q17 Q21 Q21 A2 96 21 14 13 21 0 I II

14

-S11

8

B 21

A1

Q17 13

13

-Q17 21

B

14

22

22

A

21 13

Control circuit devices I : Low speed (Q17) 0: Stop II : High speed (Q21)

E

8-69


All about Motors Control circuit devices for UPDIUL multi-speed contactors Circuit A (a figure, page 8-55) Two three-way pushbuttons L1 -F0 95

-F2/F21 96 21

0a 22 21

0b

22 22

21

IIb

14

Ia

13

IIa

13

14

22

21

Ia

IIa 21

22

14

14

-Q17

-Q21 13

13

22

22

-Q21

21

A

8-70


A

B

C

14

22

21

IIb

13

21

0b 22

Ib -S11

14

Q21 14

13

21

22

C

14

13

22

21

B

14

13

14

13

22

21

Q21 F21 Q17 13 96 13 Ia 0a IIa -S11

B

-Q17 21

21

A

IIb

22

8

21 13 14

14

14

Ib

Ib

13

13

22

I: Low speed (Q17) 0: Stop II: High speed (Q21) Remove existing links and rewire


All about Motors Control circuit devices for UPDIUL multi-speed contactors Circuit A (a figure, page 8-55)

T0-1-8210 changeover switch Always set overload relay to manual reset Q21 F2 Q17 13 96 13

L1 -F0

1 0 2 1 2 3 4

95

-F2/F21

S12

96 1

2

2

4

-S12

-S12

1

3 14

14

-Q17

-Q21 13

13

22

22

-Q21

A

-Q17

B 21

21

Circuit B (a figure, page 8-55) One three-way pushbutton L1 -F0

8

95

-F2/F21 96 21

0

22 21

II

II 22 14

I

14

-Q17

13

14

-Q21 13

13 22

22

A

-Q21

-Q17

B

21

21

A1

A1

-Q17 N

13 14

-Q21 A2

A2

8-71


All about Motors Control circuit devices for UPDIUL multi-speed contactors Circuit B(a figure, page 8-55) Two three-way pushbuttons L1 -F0 95

-F2(1) 0a 0b IIb IIa Ib

96 21 22 21 22 21 22 21 22 14 13

Ia

14

14 13

A

-Q17 -Q21

14

IIa

13 -Q21 13 22 22 21

-Q17

21

13

13

14

14

IIb

B

Control circuit device for circuit B

8

21

22

21

13

14

13

A

IIa

0a

Ia

8-72

Q21 Q21 13 14

F21 96

Q17 Q17 14 13

22 21

14

B

14

13

C

0b

Ib 22

S11

IIb

21

22

21

22

21

22

13

14

13

14

13

14

A

B

C

S11


All about Motors Control circuit devices for UPDIUL multi-speed contactors Circuit C (a figure, page 8-55) Two three-way pushbuttons L1 -F0 95

-F2(1) 0a 0b IIb IIa Ib

96 21 22 21 22 21

Ib

22 21

Ia

22 14

14

Ia

13

13

-Q17 -Q21

A

14 13 22

-Q21 -Q17

21

14

IIa

13 22 21

22 21 22 21 13 14

13

IIb

14

B

Control circuit device for circuit C

21

22

IIb

13 14

21

22

0b

13 14

21

-S11

22

Ib

13 14

21

22

21

22

8

Q21 13

13 14

A

IIa

13 14

21

13 14

-S11

22

Q17 Q21 F21 14 13 14 96 0a Ia

B

C

A

B

C

8-73


All about Motors Multi speed switches of three-phase motors Tapped winding, non-reversing, 2 speeds Multi-speed contactors UPSDAINL Star-delta starting at low speed Fuseless Without overload relay L1 L2 L3

1

3

5

1

13

3

5

14

2

4

6

1

3

5

1

3

5

2

4

6

1

3

5

2

4

6

-Q19

4

6

1U 1V 1W PE 2U2 2V2 2W2

2U1

3 Y -M1

Rating of switchgear Q1, Q17 = I1 (low speed) Q2, Q21 = I2 (high speed) Q19, Q23 = 0,5 x I2

8-74

2

4

6

1

3

5

2

4

6

-Q21 2

-Q23

I> I> I>

I> I> I>

-Q17

8

14

-Q2

-Q1

2V1 2W1

13


All about Motors Multi speed switches of three-phase motors With fuses and overload relays L1 L2 L3

-F1

1

3

5

2

4

6

-Q17

-Q21 97

3

5

2

4

6

1

3

5

2

4

6

5

4

6

2

4

6

97

95

98

96

-F21 2

1

3

2

95

-F2

-Q23

1

4

6

98

96

-Q19

1U 1V 1W 2U2 2V2 2W2

PE

8

2U1

3 Y

2V1 2W1

-M1

Rating of switchgear F2, Q17 = I1 (low speed) F21, Q21 = I2 (high speed) Q19, Q23 = 0,5 x I2 F1 = I2

Overload relays F2 and F21 are not used on multi-speed contactors without motor protection. If F2 and F21 cannot be protected by a common fuse, then use circuit on a figure, page 8-59. Motor windings a section "Motor windings", page 8-56.

8-75


All about Motors Multi speed switches of three-phase motors Circuit

L1 (Q17/1)

Low speed selected only from zero, high speed only via low speed without actuation of the Stop button. Three-way pushbutton I: Low speed (Q17, Q19) 0: Stop II: High speed (Q21, Q19, Q23)

-F0 -Q1 -Q2 -S11 0 I

13

95

14 13

96 95

14 21

96

-F21

22 13 14

-Q17

13 14

-Q17

43 44

-Q23

22

15

-K3

-Q19

-Q23

-Q21

21

A1

-Q17

A1

-K3 A2

-Q21

A2

43 44 22

-Q17

13

A1

-Q23 A2

14

-Q21

-Q19 21

II 22 14

22

13 14 13

21

31

22

8

-Q19

16

32

21

II

13 14

A1

-Q19

A2

-Q21

21 A1 A2

N

8-76

A

21 13

22

Q21 Q19 22 44 14 II

14

22

21 13

B

14

-S11

21

Q17 F21 Q17 13 96 14 I 0

13

Function Actuation of pushbutton I energizes the coil of star contactor Q23. Its normally open contact 13-14 energizes the coil of contactor Q17. The motor runs in star at low speed. The contactors are maintained via auxiliary contact Q17/13-14. At the same time, timing relay K3 is triggered. When the set time has elapsed, K3/15-16 opens the circuit of Q23, which drops out, the coil of delta contactor Q19 is energized and maintains itself via Q19/13-14. The timing relay is de-energized via normally closed contact Q19/32-31.

Q17 43

22

Q19: Delta contactor Q21:Mains contactor, high speed

14

Q17: Mains contactor, low speed K3: Timimg relays Q23: Star contactor

C

The motor runs in delta at low speed. Actuation of pushbutton II de-energizes the coil of Q17 and via Q17/22–21 energizes the coil of Q21. This state is maintained by Q21/43–44: The coil of star contactor Q23 is re-energized by normally open contact Q21/14–13. The motor runs at high speed. Pushbutton 0 (= Stop) effects disconnection.


All about Motors Multi speed switches of three-phase motors Tapped winding, reversing, 2 speeds (direction preselected) Multi-speed contactors UPIUL Overload relays F2 and F21 are not used on multi-speed contactors without motor protection.

L1 L2 L3

-F1

1

3

5

2

4

6

1

3

5

2

4

6

2

4

6

-Q11

-Q17 Rating of switchgear Q11, Q12 = I2 (low and high -F2 speed) F2, Q17 = I1 (low speed) F1, Q21 = I2 Q23 = 0.5 x I2 (high speed)

1

3

5

2

4

6

1

3

5

2

4

6

2

4

6

-Q12

-Q21 97

95

98

96

97

95

98

96

-F21

-Q23

1

3

5

2

4

6

8

PE

1U 1V 1W

M 3

2U 2V 2W

-M1

8-77


All about Motors Multi speed switches of three-phase motors Five-way pushbutton

L1 (Q11/1) -F0 95

-F2 -F21

96 95 96 21

0 -S11 II

22

I 44

14

14 13

I

22

21 22

-Q11

13

-Q11

-Q12

43 21

IV

14

III -Q17

14

14

B

C

-Q23

A1 A2

-Q21

21

22

13

14

22

21

D

14

13

21

21

21

22

13

14

14

13

A

22

0

-Q23

21

A2

E

Function Contactor Q11 is energized by pressing pushbutton I. Contactor Q11 selects the direction, and maintains itself after release of pushbutton I via its auxiliary contact 14–13 and pushbutton 0. Speed-selection buttons III and IV are made operative by Q11/44–43. Pushbutton III energizes Q17, which maintains itself via its contact 14–13. Pushbutton IV 8-78

-Q21

14

14 13

22 14

22

Q12 Q12 Q17 Q11 Q17 Q17 43 14 21 13 14 13 I III II IV 22

Q11 13

13

N

-S11

-Q17

A2

-Q17

22

A1

A1

-Q11

F21 96

-Q23

21

14

-Q12

14 II

13

21

21

22

-Q12

21 13

IV

13

13

-Q21

8

21

13

44 43 22

22

III

Connection Change of direction FORWARD–REVERSE after actuation of Stop button, optionally followed by SLOW–FAST with no return to low speed.

13 A1 A2

22

-Q11

21 A1

-Q12

A2

Control circuit device 0: Stop I: Forward (Q11) II: Back (Q12) III: Slow (Q17) IV: Fast (Q21 + Q23) energizes high-speed contactors Q23 and Q21. Auxiliary contact Q17/14–13 makes low-speed pushbutton III inoperative. Pushbutton 0 must be pressed before any change in speed or direction.


All about Motors Multi speed switches of three-phase motors Tapped winding, reversing, 2 speeds (Direction and speed selected simultaneously) Multi-speed contactor UPIUL

Fuseless without overload relay

L1 L2 L3

1

3

5

13

1

3

5

I>

I>

I>

13 14

14

-Q1

-Q2 I>

I>

I>

2

4

6

1

3

5

2

4

6

-Q17

1

3

5

2

4

6

2

4

6

1

3

5

2

4

6

1

3

5

2

4

6

-Q22

-Q21

-Q18

8 PE 2U

1U 1V 1W

-Q23

1

3

5

2

4

6

M 3

2V 2W

-M1

Rating of switchgear Q1, Q17, Q18 = I1 (low speed) Q2, Q21, Q22 = I2 Q23 = 0.5 x I2 (high speed)

8-79


All about Motors Multi speed switches of three-phase motors Multi-speed contactor UPIUL With fuses and overload relays L1 L2 L3 -F1

1

3

5

2

4

6

2

4

6

-Q17

97

1

3

5

2

4

6

-Q21

-Q18

1

3

5

2

4

6

2

4

6

95

-F2

1

3

5

2

4

6

-Q22

97

95

98

96

-F21 98

96

8

PE 1U 1V 1W 1

3

5

2

4

6

-Q23

Rating of switchgear F2, Q17, Q18 = I1 (low speed) F21, Q21, Q22 = I2 Q23 = 0.5 x I2 (high speed)

8-80

2U

M 3

2V 2W

-M1

Overload relays F2 and F21 are not used on multi-speed contactors without motor protection


All about Motors Multi speed switches of three-phase motors Circuit Simultaneous selection of direction and speed via one pushbutton. Always operate Stop button before changeover. L1 (Q17/1) -F0 -Q1

95

13

-F2 14 13

-Q2

14

-F21

96 95 96

21

0 22

22 21 31

-Q22 -Q21

14

-Q18 13

22 14

IV 21 13

II

III 14

22

-K1

32

22 22

III

22

21 13

14

IV

13

43

14

-K1

21

-Q17

22

8

31 31

21

22

I

21

-Q17

13

21

21

-Q22

22

-Q18

13

32 22 21

13

32

14

-Q22

-Q21 13

-Q18

21

II -S11 I

14

14

-Q17

-Q23

32

14

-Q23

-K1

13

14

-Q21

31

44 44

-Q23

43

13 A1

-Q18

-Q17 N

A2

A1

A1

-K1

-Q23

-Q21 A2

A2

A2

A1

A1

A1

-Q22 A2

A2

Q17:Slow forward Q18:Slow back Q21:Fast forward Q23:Star contactor K1: Contactor relay Q22:Fast back 8-81


All about Motors Multi speed switches of three-phase motors

22

21 13

14

21

D

22

13 14

21

22

13

C

14

22

21 13

B

14

21 13

A

14

-S11

22

F21 Q23 Q18 Q21 Q17 Q23 Q18 Q22 22 22 32 96 21 21 14 32 I III IV II 0

E

Function Desired speed and direction can be selected by actuation of the appropriate pushbutton. Contactors Q17, Q18, Q21 and Q23 maintain themselves by their contact 14–13 and can be de-energized only by actuation of pushbutton 0. Contactors Q21 and Q22 can maintain themselves only when Q23 has picked up and contact Q23/13/13–14 or 44–43 is closed.

8

8-82

Five-way pushbutton Control circuit device 0: Stop I: Slow forward (Q17) II: Slow back (Q18) III: Fast forward (Q21 + Q23) IV: Fast back (Q22 + Q23)


All about Motors Multi speed switches of three-phase motors Tapped winding, medium and high speed, Non reversing, 3 speeds, 2 windings Multi-speed contactor U3PIL

Multi-speed contactor U3PIL with overload relay a figure, page 8-85

L1 L2 L3

1

3

5

13

1

3

5

1

13

-Q1 I>

I> 4

6

1

3

5

2

-Q17

4

1

3

5

2

4

6

4

I>

I>

I>

6

2

4

6

1

3

5

2

4

6

-Q21

-Q11 2

13 14

I>

I>

I>

2

5

-Q3

-Q2 I>

3

14

14

6

8 1U 1V 1W PE 3U

2U 2V 2W

-Q23

1

3

5

2

4

6

M 3

3V 3W

-M1

Synchronous speed Winding

1

2

2

Motor terminals

1U, 1V, 1W

2U, 2V, 2W

3U, 3V, 3W

Number of poles

12

8

4

rpm

500

750

1500

Number of poles

8

4

2

rpm

750

1500

3000

Number of poles

6

4

2

rpm

1000

1500

3000

Contactors

Q11

Q17

Q21, Q23

Rating of switchgear Q2, Q11 :

I1 (low speed)

Q1, Q17 :

I2 (medium speed)

Q3, Q21 :

I3 (high speed)

Q23 :

0.5 x I3 8-83


All about Motors Multi speed switches of three-phase motors Circuit of motor winding: X Circuit A

Circuit A Selection of any speed only from zero. No return to low speed, only to zero.

L1 (Q17/1)

F22 96

-F0

N

A2

A2

-Q23

A1 A2

-Q21

13 A1 A2

Q11: Low speed winding 1 Q17: Medium speed winding 2 Q23: High speed winding 2 Q21: High speed winding 2 Function Pushbutton I energizes mains contactor Q11 (low speed), pushbutton II mains contactor Q17 (medium speed), pushbutton III star contactor Q23 and via its normally open contact Q23/14–13 mains contactor Q21 (high speed). All contactors maintain themselves by their auxiliary contact 13–14. Speed sequence from low to high is optional. Switching in steps from high to medium or low speed is not possible. The motor is always switched off by pressing pushbutton 0. In the event of an overload, normally open contact 13–14 of the 8-84

21

22

13

14

21

22 14

13

21

22 14

13

21

22

-S11

Q11 14 0

A

Q21 13

Q11 Q17 Q17 Q23 13 14 13 14 III II I

B

C

4-way pushbutton 0: Stop I: Low speed (Q11) II: Medium speed (Q17) III: High speed (Q21 + Q23) motor-protective circuit-breaker or circuit-breaker can also switch off.

D

22

32 14

F22 96

14

-Q23

31 31

21

21 A1

-Q17

14 32

13

-Q17

-Q11

21 21 22 22

22

-Q23

22

14

-Q21

-Q21

14

21

31 A1

-Q11

13

21 31 32 32

-Q17

Circuit B Selection of any speed from zero or from low speed. Return only to zero.

14

-Q11

22

13

22

-Q23

14

13

21

-Q21

13

13 13

D

C

22

-Q11

-Q17

14

II

B

14

13

21 22

13

8

III

14

I

13

A

22

21 14

14

14 21

22

III -S11 II

Q21 13

13

21

0

Q21 14 III

Q17 14 II

I

13

-Q1 -Q2 -Q3

Q11 14

0


All about Motors Multi speed switches of three-phase motors Tapped winding, low and high speed, Non-reversing, 3 speeds, 2 windings Multi-speed contactor U3PIL Multi-speed contactor U3PIL without overload relay a figure, page 8-83 L1 L2 L3 F1

1

3

5

2

4

6

1

3

5

97

95

2

4

6

98

96

Q17

1

3

5

2

4

6

1

3

5

97

95

2

4

6

98

96

Q11

F2

1

3

5

2

4

6

Q21

1

3

5

97

95

2

4

6

98

96

F4

F3

8

3U 3V 3W 2U

1U

M 3

1V 1W

1

3

5

2

4

6

2V 2W

M1

Q23

Synchronous speed

rpm

750

1000

1500

Contactors

Q17

Q11

Q21, Q23

Winding

2

1

2

Motor terminals

1U, 1V, 1W

2U, 2V, 2W

3U, 3V, 3W

Number of poles

12

8

6

F2, Q17:

I1 (low speed)

rpm

500

750

1000

F3, Q11:

I2 (medium speed)

Number of poles

8

6

4

F4, Q21:

I3 (high speed)

Q23:

0.5 x I3

Rating of switchgear

8-85


All about Motors Multi speed switches of three-phase motors Circuit of motor winding: Y Circuit A

Circuit A Selection of any speed only from zero. No return to low speed, only to zero.

21

22

13

14

Q21 13

D

Q17: Low speed winding 1 Q11: Medium speed winding 1 Q23: High speed winding 2 Q21: High speed winding 2 Function Pushbutton I energizes mains contactor Q17 (low speed), pushbutton II mains contactor Q11 (medium speed), pushbutton III star contactor Q23 and via its normally open contact Q23/14–13 mains contactor Q21 (high speed). All contactors maintain themselves by their auxiliary contact 13–14.

A

B

C

21

-S11

Q21 13 22

A2

13

A2

N

F22 Q17 Q17 Q11 Q11 Q21 14 I 13 14 13 14 96 III 0 II

14

A2

13 A1

Q21

21

A1

Q23

32 14

22

A2

Q23

21 A1

Q11

Q17

Q17

22 22

31 31

13

31 A1

Q21 Q23

32

Q11

21 21

14

32 32

Q17

14

21

Q23

22

22

Q21

Q21

22 21 31

13

13 14

13

Q11

Q11

14

14

13

13 13

13

Q17

Circuit B Selection of any speed from zero or from low speed. Return only to zero. 4-way pushbutton 0: Stop I: Low speed (Q17) II: Medium speed (Q11) III: High speed (Q21 + Q22)

21

13

22

II

14

8

C

B

14

III 14

22

S1 I

III

14

21 21

S2 II

Q21 14

21

21

22

13

14

A

II

22

21

21

S3 III

8-86

22

96

22 22

Q11 14

I

13

-S11

Q17 14

14

95

F2 F3 F4 S0 0

0

13

F22 96

F0

14

L1

D

Speed sequence from low to high is optional. Switching in steps from high to medium or low speed is not possible. The motor is always switched off by pressing pushbutton 0. In the event of an overload, normally closed contact 95–96 of overload relays F2, F21 and F22 can also switch off.


All about Motors Multi speed switches of three-phase motors Tapped winding, low and medium speed, Non-reversing, 3 speeds, 2 windings Multi-speed contactor U3PIL

Multi-speed contactor U3PIL without overload relay a figure, page 8-59

L1 L2 L3 F1

1

3

5

2

4

6

1

3

5

97

95

2

4

6

98

96

Q17

1

3

5

2

4

6

1

3

5

97

95

2

4

6

98

96

Q11

F2

1

3

5

2

4

6

Q21

1

3

5

97

95

2

4

6

98

96

F4

F3

8 3U 3V 3W 2U

1U

M 3

1V 1W

1

3

5

2

4

6

2V 2W

M1

Q23

Synchronous speed Winding

2

2

1

Motor terminals

1U, 1V, 1W

2U, 2V, 2W

3U, 3V, 3W

Number of poles

12

6

4

rpm

500

1000

1500

Number of poles

12

6

2

rpm

500

1000

3000

Number of poles

8

4

2

rpm

750

1500

3000

Contactors

Q17

Q21, Q23

Q11

Rating of switchgear F2, Q17:

I1 (low speed)

F4, Q21:

I2 (medium speed)

F3, Q11:

I3 (high speed)

Q23:

0.5 x I3 8-87


All about Motors Multi speed switches of three-phase motors Circuit of motor winding: Z Circuit A

Circuit A Selection of any speed from zero. No return to low speed, only to zero.

0

21

22

22

21

Q21 Q21 14 III 13

96 21

B

13

14

13

14

13

A

14

14

13

95

D

C

22

-Q23 -Q17

21 A1 A2

-Q23 -Q23

A1 A2

-Q21

32 14 13 A1 A2

-Q11

Q17: Low speed winding 1 Q23: Medium speed winding 2 Q21: Medium speed winding 2 Q11: High speed winding 1 Function Pushbutton I energizes mains contactor Q17 (low speed), pushbutton II mains contactor Q23 (low speed) and via its normally open contact Q23/14-13 mains contactor Q21 (high speed), pushbutton III mains contactor Q11. All contactors maintain themselves by their auxiliary contacts 13-14.

32 32

A

B

C

22 14

21 13

21

Q11 Q17 Q17 Q23 Q23 13 13 14 13 14 II III 22

21 31

I

14

-Q21 -Q23

-S11

Q11 14 0 21

-Q17

F22 96

13

-Q17

22 22

31 31

13 14 22

22

-Q11

21 21

-Q11

14

-Q21

13 14 32

13

-Q21

14 22

-Q11

N

13

21

-Q17

13

8

14

II 13

22

I

13

13

21 14

Circuit B Selection of any speed from zero or from low speed. Return only to zero.

14

III

21 22

14

22

III -S11 II

8-88

21

-S11

22

-F0 -F2 -F21 -F22

Q17 14 II

Q11 14 I

0

21

F22 96

22

L1 (Q17/1)

D

31 A1 A2

4-way pushbutton 0: Stop I: Low speed (Q17) II: Medium speed (Q21 + Q23) III: High speed (Q11) Speed sequence from low to high is optional. Switching in steps from high to medium or low speed is not possible. The motor is always switched off by pressing pushbutton 0. In the event of an overload, normally closed contact 95–96 of overload relays F2, F21 and F22 can also switch off.


All about Motors Multi speed switch with motor-protective circuit-breakers PKZ2 U F 690 V

L1 L2 L3

L1 L2 L3

-Q23

A1

13

A2

14 22

21

I>> I>> I>> T1 T2 T3 L1 L2 L3 1.13 1.21

L1 L2 L3 1.13 1.21

-Q1

-Q2 1.14 1.22

1.14 1.22

I> I> I>

I> I> I>

U F500 V -Q21

A1

13

A2

14 22

21

-Q17

21

A1

13

A2

14 22

I>> I>> I>>

1

3

5

2

4

6

-Q23 I>> I>> I>>

T1 T2 T3

T1 T2 T3

8 1U

2U 2V 2W

M 3h

1V 1W

-M1

Number of poles rpm Number of poles rpm Number of poles rpm

12

6

500

1000

8

4

750

1500

4

2

1500

3000

8-89


All about Motors Multi speed switch with motor-protective circuit-breakers PKZ2

1.14 21

21

22

22

21

14

13

13

14 14

-Q17

13

22

22

-Q17

21 22

-Q23

-S11 II n>

-Q23 A1

-Q23

21

22

13

14

I n<

A2

13 14

13

-Q17

14

14

-Q21

13 22

-Q21

21

13 A1

A1

A2

13 A1

-Q21

-Q23

A2

21 14

-Q23

21 A1

-Q17

13 22

-Q17 21 22

-Q23

-Q21

A2

22 21

22

14

21 A1

-Q17

21

14

-Q21

13

-Q21

A2

A2

N

N Stop

n<

n>

Circuit Aa figure, page 8-55

Stop

n<

n>

Circuit Ca figure, page 8-55

S11

RMQ-Titan, M22-…

–

–

–

Q1, Q21

PKZ2/ZM-…/S

n>

–

–

Q2, Q17

PKZ2/ZM-…/S

n<

–

–

Q23

DIL0M

yn > Ue F 500 V

–

–

Q23

S/EZ-PKZ

yn > Ue F 660 V

F0

FAZ

8-90

14

21

22

13

21

22

22

22

8

C

B

1.14 21

0

I n<

A

-Q2

0

-S11 II n>

1.13 1.14 1.13

II

14

-Q1

C

0

14

-F0

13

21

B

I

Q21 13

Q21 14

Q17 Q2 14 1.14

Q17 13

L1 (Q17/1)

-S11

22

13

22

21

Q21 13 II

14

13

A

1.14 1.13

-Q2

22

21 13

1.13

Q21 14 0

14

-S11 -F0 -Q1

Q2 1.14 I

14

Q17 13

L1 (Q17/1)


All about Motors Three-phase current-automatic stator starters Three-phase automatic stator resistance starter DDAINL with mains contactor and resistors, 2-stage, 3-phase version L1 L2 L3 1

2

13

3

14

-Q1

-Q11

-F1

I> I> I> 2

4

1

3

5

2

4

6

6

-Q17 X

-R2

1

3

5

2

4

6

-R1

U1 V1

Y

2

3

5

2

4

6

U2 V2

W1

Z

1

-Q16

4

W2

6

97

95

98

96

-F2

U

V

W

8

PE

M 3 -M1

When using F1 instead of Q1, use F2. Rating of switchgear: Starting voltage: 0.6 x Ue Inrush current: 0.6 x direct switching system Tightening torque: 0.36 x direct switching system Q1, Q11: Ie Q16, Q17: 0.6 x Ie

8-91


All about Motors Three-phase current-automatic stator starters DDAINL three-phase automatic stator resistance starter with mains contactor and resistors, 2-stage, 3-phase version L1 (-Q11) -F0

13

-Q1 0 -S11

I

-F2

95 96

14 21 22 13 14 22

-Q11

32

-Q11

21

-Q16

31 14

14

-Q11

13

13 14

-K1

8

-Q16 N

A1

-K1

A2

A1

-Q17

A2

Q16: Step contactor K1: Timing relay Q17: Step contactor

-Q17

15 18 A1

A1

-K2

A2

A2

15

13

-K2 -Q11

A1 A2

K2: Timing relay Q11: Mains contactor

Two-wire control

L1 (Q11/1)

Always set overload relay to manual reset

-F0 13

-Q1

14

-S12 32

22

-Q11

8-92

21

-Q11

31

18


All about Motors Three-phase current-automatic stator starters F2 96

A

21

22

13

Two-wire control

F2 96

Q11 Q11 22 32

-S12

14

21

22

13

-S11

Q11 21

Q11 32 I

0

14

Three-wire control Double actuator I = ON 0 = OFF

B

Function Pushbutton I energizes step contactor Q16 and timing relay K1. Q16/14-13 – self-maintaining through Q11, Q11/32-31 and pushbutton 0. The motor is connected to the supply with rotor resistors R1 + R2. When the set starting time has elapsed, normally open contact K1/15-18 energizes Q17. Step contactor Q17 bypasses the starting stage R1. At the same time, normally open contact Q17/14-13 energizes K2. When the set starting time has elapsed, K2/15-18 energizes mains contactor Q11. This bypasses the second starting stage R2, and the motor runs at the rated speed. Q11 maintains itself via

Q11/14-13. Q16, Q17, K1 and K2 are de-energized by normally closed contacts Q11/22-21 and Q11/32-31. The motor is switched off with pushbutton 0. In the event of an overload, normally closed contact 95-96 of the overload relay F2 or normally open contact 13-14 of the motor-protective circuit-breaker switch off the motor. Step contactor Q17, resistor R2 and timing relay K1 are omitted in single-stage starting circuits. Timing relay K2 is connected directly to Q16/13 and resistor R2 is connected by means of its terminals U1, V1 and W1 to Q11/2, 4, 6.

8-93

8


All about Motors Three-phase current-automatic stator starters Three-phase automatic stator resistance starter ATAINL with mains contactor and starting transformer, 1-stage, 3-phase L1 L2 L3 1

3

5

13

Q1 14

F1

I>I> I> 6

1

3

5

2

4

6

K1

1

3

5

2

4

6

1U1

Q11

1W1

4

1V1

2

2W1 2V1

4

6

97

95

98

96

Q13 U

V

W2

2

U2

a

V2

2U1

8

1

3

5

2

4

6

W

M 3 M1

When using F1 instead of Q1, use F2.

Rating of switchgear

Starting voltage

= 0.7 x Ue (typical value)

Tightening torque

= 0.49 x direct switching system

Inrush current

= 0.49 x direct switching system

Q1, Q11

= Ie

IA/Ie

=6

Q16

= 0.6 x Ie

tA

= 10 s

Q13

= 0.25 x Ie

Ops/h

= 30

8-94


All about Motors Three-phase current-automatic stator starters Two-wire control

L1

Always set overload relay to manual reset (automatic reset)

F0 13

Q1 0 S11

14 21

L1 (Q11/1)

95

F2 96

-F0

22

95 13

13

I

K1

96 14

14

55

67

K1 14

56

22

22 21 A1

Q13

Q11

K1 13

I

A

21

21

0

13

-S11

K1 14

22

F2 96

13

Three-wire control I: ON 0: OFF

A2

A2

A2

55

67

-K1

68

-K1

96

Q16: Step contactor K1: Timing relay Q11: Mains contactor Q13: Star contactor Two-wire control

F2 96

8

K1 55

-S12

14

K1 A2

Q11 21 A1

A1

22

Q16 N

68

Q13

13 A1

-S12

K1

14

Q13

-F2

B

Function Pressing pushbutton I simultaneously energizes star contactor Q13, timing relay K1 and, via normally open contact Q13/13–14, step contactor Q16, and are maintained via K1/13-14. When K1 has elapsed, normally closed contact K1/55–56 de-energizes star contactor Q13, and – via normally open contact Q13/13–14 – Q16 de-energizes: The starting transformer is disconnected, and the motor runs at the rated speed.

The motor cannot start up again unless previously switched off by actuation of pushbutton 0, or in the event of an overload, by normally closed contact 95–96 of the overload relay F2. With two-wire control, overload relay F2 must always be set to manual reset. If the motor has been switched off by F2, the motor cannot start up again unless the manual reset is released.

8-95


All about Motors Three-phase automatic rotor starters DAINL three-phase automatic rotor starters Three stage, rotor three phase L1 L2 L3 1

3 5

13

-F1

14

-Q1

-Q11

-F2

8

2

4 6

97

95

98

96

I> I> I> 2 4 6

1

3 5

2

4 6

-Q12

1

3 5

2

4 6

U V W PE

M 3

When using F1 instead of Q1, use F2.

8-96

-Q14

1

3

5

2

4

6

-R1 U1

V2

V3

6

-R2 U2

U3 W3

-M1

3 5

2 4

-R3

K L M

1

-Q13

V1 W2

W2


All about Motors Three-phase automatic rotor starters 2-stage, rotor 2-phase L1 L2 L3

1

3

5

13

-F1

14

-Q1

-Q11

97

95

98

96

I> I>

I>

2

4

1

3

5

2

4

6

6

-Q12

1

3 5

2

4

6

-Q14

1

3 5

2

4

6

-F2 2

4

6

8 U

V

W

PE

M 3

L M

-R1

-R2

K

U1

U2 XY V2

V1

-M1

When using F1 instead of Q1, use F2. Rating of switchgear Inrush current

= 0.5 – 2.5 x Ie

Tightening torque

= 0.5 to pull-out torque

Q1, Q11

= Ie

Step contactors

= 0.35 x Irotor

Final step contactors

= 0.58 x Irotor

8-97


All about Motors Three-phase automatic rotor starters With mains contactor, style 3-stage, rotor 3-phase L1 F0

Q1

13

F2

14

95 96

21

0 S11

22 13

I

14

14

Q11

Q11

44 43

13

14

32

Q13

Q13 31

15

K1 A1

Q11

Q14

14

K2

13

A2

A1

A1

U3

Q13

Q12 A2

14

Q12 18

15 18 A1

13 A1

K2 A2

A2

A2

A2

N

Q12: Step contactor Q13: Final step contactor K3: Timing relay

Q11: Mains contactor K1: Timing relay Q14: Step contactor K2: Timing relay

A

8-98

21 13

B

Q11 13

22

I

14

13

-S11

Q11 14

0

21

F2 96

22

Double actuator I: ON 0: OFF

14

8

A1

K1 A2

Q14

18 A1

15

U3 13

For connection of further control circuit devices: a section "Control circuit devices for star-delta starting", page 8-51


All about Motors Three-phase automatic rotor starters Function Pushbutton I energizes mains contactor Q11: normally open contact Q11/14–13 transfers the voltage, Q11/44–43 energizes timing relay K1. The motor is connected to the supply with rotor resistors R1 + R2 + R3 in series. When the set starting time has elapsed, normally open contact K1/15–18 energizes step contactor Q14, which short-circuits starting stage R1 and via Q14/14–13 energizes timing relay K2. When the set starting time has elapsed, K2/15–18 energizes step contactor Q12, which short-circuits starting stage R2 and via Q12/14–13 energizes timing relay K3. When the set starting time has elapsed, K3/15–18 energizes final step contactor Q13, which is maintained via Q13/14–13. Step contactors Q14 and Q12 as well as timing relays K1, K2 and K3 are de-energized via Q13. Final step contactor

Q13 short-circuits the rotor slip rings: the motor operates at the rated speed. The motor is switched off either by pushbutton 0, or in the event of an overload, by normally closed contact 95–96 of the overload relay F2 or normally open contact 13–14 of the motor-protective circuit-breaker or circuit-breaker. Step contactor Q13 and Q12 with their resistors R3, R2 and timing relays K3, K2 are omitted in single-stage or two-stage starting circuits. The rotor is then connected to the resistance terminals U, V, W2 or U, V, W1. The references for step contactors and timing relays in the wiring diagrams are then changed from Q13, Q12 to Q12, Q11 or to Q13, Q11 as appropriate. When there are more than three stages, the additional step contactors, timing relays and resistors have appropriate increasing designations.

8

8-99


All about Motors Switching of capacitors Contactors for capacitors DIL Individual circuit without quick-discharge resistors

Individual circuit with quick-discharge resistors

L1 L2 L3

L1 L2 L3

-F1

-F1

1

3

5

2

4

6

-Q11

1

3

5

2

4

6

-Q11

31

21

-Q11

-Q11 22

8

-R1

-R1 -C1

-C1

-R1

-R1

R1 discharge resistors fitted in capacitorR1 discharge resistors fitted to contactor

8-100

32

-R1


All about Motors Switching of capacitors

A

22

-S11

22

13

14

21 13

21

0

14

-F0

22

0

21

Q11 Q11 14 I 13

L1

L1 (Q11/1)

B

Double actuator For connection of further control circuit devices: a section "Control circuit devices for star-delta starting", page 8-51

13

I 14

14

-Q11 13

A1

-Q11 A2

N

Maintained contact sensors In the case of actuation by means of power factor correction relay, check that this has sufficient power to actuate the contactor coil. Interpose a contactor relay if necessary.

L1

8

Q11 A1

-S12

Function Pushbutton I actuates contactor Q11, which picks up and maintains itself via its own auxiliary contact 14-13 and pushbutton 0. Capacitor C1 is thus energized. Discharge resistors R1 are not active when contactor Q11 is energized. Actuation of pushbutton 0 effects de-energization. Normally closed contacts Q11/21–22 then switch discharge resistors R1 to capacitor C1.

8-101


All about Motors Switching of capacitors Capacitor contactor combination Capacitor contactor with pilot contactor and series resistors. Individual and parallel circuit

with and without discharge resistors and with series resistors. L1 L2 L3

-F1

A1

21

13

1

3

5

31

43

A1

21

13

1

3

5

31

43

14

2

4

6

32

44

-Q11

-Q14 A2

22

14

2

4

6

32

44

A2

22

8 -R2

-R1

-R1

-C1

On the version without discharge resistors, resistors R1 and the connections to the auxiliary contacts 21–22 and 31–32 are omitted.

8-102


All about Motors Switching of capacitors L1 (Q11/1)

L1 (Q11/1) -F0

-F0

T0 (3)-1-15431

21

1 0 2

0

1 2 3 4

22

-S11

21

13

I

0

14 14

-Q11

22

-S12

13

-S12 13

I 14

-Q14

14 14

-Q11

13

A1

14

A1

-Q14

-Q14

-Q11 A2

13

13 A1

A2

N

-Q11

A1

-Q14 A2

A2

8

N

Q11: Mains contactor Q14: Pilot contactor Actuation by two-way pushbutton S11

Function Actuation by two-way pushbutton S11. Pushbutton I energizes pilot contactor Q14, which switches capacitor C1 in with bridged series resistors R2. Normally open contact Q14/14-13 energizes mains contactor Q11. Capacitor C1 is then switched in with bridged series resistors R2. Q14 is maintained via Q11/14-13 when Q11 has closed.

Actuation by selector switch S13, two-wire control S12 (power factor correction relay) and two-way pushbutton S11 Discharge resistors R1 are not operative when Q11 and Q14 are energized. Pushbutton 0 effects de-energization. Normally closed contacts Q11/21–22 and 31–32 then switch discharge resistors R1 to capacitor C1.

8-103


All about Motors Duplex pump control Fully automatic control with two pumps P1 Auto

Starting sequence of pumps 1 and 2 can be selected by control switch S12 Control circuit wiring with two float switches for basic and peak loads (operation is also possible with two pressure switches)

= Pump 1 constant load, Pump 2 peak load = Pump 2 constant load, Pump 1 peak load = Direct operation independent of float switches (or pressure switches)

P2 Auto P1 + P2

L1 L2 L3

a a b

-Q1

0

I>I> I>

c F7: 0 F7 F8

-F21

-F11

d

F8: I

8

F8 Q

0

F7: I F8: 0

F7 Q

-Q12

-Q11

I

-F22

-F12 I

e

U

g

f

h

f

-M1

V

W

M 3

U

-M2

i j a Cable with float, counterweight, pulleys and clamps b Storage tank c Inlet d Pressure pipe e Outlet 8-104

f g h i j

Centrifugal or reciprocating pump Pump 1 Pump 2 Suction pipe with filter Well

V

M 3

W

95

-F7 Q

2 1

-S11 13

14

-F8 Q

2 1

-S21 13

14

-Q12 13

14

-Q11 13

14 9

13

12

11

10

T0(3)-4-15833 Q12: Pump 2 mains contactor

A2

A1

96

95

In position P1 + P2, both pumps are in operation, independent of the float switches (Caution! Tank may possibly overflow). On the version of duplex pump control with automatic load sharing (T0(3)-4-15915), S12 has a further position: the sequence of operations is automatically reversed after each cycle.

-Q12

-F22

Q11: Pump 1 mains contactor

A2

A1

96

8

7

6

5

4

3

2

1

L

the range of F7 (discharge is greater than intake), F8 starts pump 2 (peak load). When the water level rises again, F8 is deactivated. Pump 2 continues running until F7 stops both pumps. The operating sequence of pumps 1 and 2 can be determined using operating mode selector switch S12: Position P1 auto or P2 auto.

-Q11

-F12

-S12

Function The duplex pump control is designed for operation of two pump motors M1 and M2. Control is via float switches F7 and F8. Operating mode selector switch S12 in position P1 auto: The system operates as follows: When the water level in the storage tank falls or rises, F7 switches pump 1 on or off (basic load). If the water level drops below

EO

F0 0 P 1 Auto P 2 Auto P 1, P 2

Float switch F7 closes before F8

N

F11

All about Motors Duplex pump control Moeller Wiring Manual 02/08

8

8-105


All about Motors Fully automatic pump control With pressure switch for air tank and domestic water supply without water failure (run dry) safety device

F1: Fuses (if required) Q1: Motor-protective switch, manual (z. B. PKZ) F7: Pressure switch MCSN, 3-pole M1:Pump motor a Air or pressure tank b Non-return valve c Pressure pipe d Centrifugal (or reciprocating) pump e Suction pipe with filter f Well

L1 L2 L3 -F1

-Q1

I> I> I>

a

P -F7

d

U V W

b c

M

e f

8

8-106

With 3-pole pressure switch MCSN (main circuit)

3 -M1


All about Motors Fully automatic pump control With single-pole pressure switch MCS (control circuit) L1 L2 L3 N -Q11 -F1

1 3 5 2 4 6

a

P -F7

-F2

96

c

b d

95

e f

U V W

M 3

F1: Fuses Q11:Contactor or automatic star-delta starter F2: Overload relay with reclosing lockout F7: Pressure switch MCS, 1-pole M1:Pump motor a Air or pressure tank b Non-return valve c Centrifugal (or reciprocating) pump d Pressure pipe e Suction pipe with filter f Well

-M1

8

8-107


All about Motors Fully automatic pump control With 3-pole float switch SW (main circuit)

a HW

L1 L2 L3

b

c

NW

-F1

-Q1

I> I> I>

-F7

e

d f

g

8

8-108

U V W

M 3 -M1

F1: Fuses (if required) Q1: Motor-protective circuit-breakers, manual (z. B. PKZ) F7: Float switch 3-pole (circuit: pump full) M1:Pump motor 0 HW:Highest level NW:Lowest value a Cable with float, counterweight, pulleys and clamps Q b Storage tank c Pressure pipe d Centrifugal (or reciprocating) pump I e Outlet f Suction pipe with filter g Well


All about Motors Fully automatic pump control With 1-pole float switch SW (control circuit)

a

L1 L2 L3 N

b

0

HW

-F8

-F1 -Q11

NW

2 4 6

S1

95

c -F2

e

d f

0 H

96

U V W

M 3

-M1

I

g-F9 h

Q

1 3 5

0

Q

A

I

F1: Fuses Q11:Contactor or automatic star-delta starter F2: Overload relay with reclosing lockout F8: Float switch 1-pole (circuit: pump full) S1: Changeover switch MANUAL-OFF-AUTO F9: Float switch 1-pole (circuit: pump full) M1:Pump motor a Cable with float, counterweight, pulleys and clamps b Storage tank c Pressure pipe d Centrifugal (or reciprocating) pump e Outlet f Suction pipe with filter g Water-failure monitoring by means of a float switch h Well

8-109

8


All about Motors Off position interlock of the loads Solution using NZM circuit-breakers Off position interlock for control switches (Hamburg circuit) with auxiliary contact VHI (S3)

and undervoltage release. Cannot be used with motor operator.

-Q1 -S3 -R1

I> I> I>

-R2 51 52

U<

8

-Q2

8-110

I> I> I>

-Q3

I> I> I>

-Q4

I> I> I>


All about Motors Fully automatic main transfer switch with automatic reset Off position interlock for control or master switches by means of auxiliary contacts VHI (S3),

a Emergency-Stop b Off position interlock contacts on the control or master switches

-Q1

-S1

V

-S3 95 96

a

NHI (S1) and undervoltage release. Cannot be used with motor operator.

10 11

b

10 11

b

10 11

b

I> I> I>

51

U< 52

8

8-111


All about Motors Fully automatic main transfer switch with automatic reset Changeover device to DIN VDE 0108 – Power systems and safety power supply in buildings for public gatherings: Automatic resetting, the phase-monitor is set to:

Pick-up voltage Drop-out voltage

a

L1 L2 L3 N

Uan = 0,95 x Un Ub = 0,85 x Uan

b L1.1 L2.1 L3.1 N

c -Q1

-Q1.1

-Q11

-F01

-Q12

-F02 21

13

8

-K2

11

14 22

-Q12

I> I> I>

6 4 2

5 3 1

4 2

6

3 1

5

I>I> I>

R

S

-K2

T

11 R

-K1 21

-Q11

S

22 22 21

12 14 T 12 14 A1

-Q12 A1

-Q11

A2

A1

-K2 A2

A2

a Main supply b Auxiliary supply

c To load

Function Main switch Q1 is closed first, followed by main switch Q1.1 (auxiliary supply).

supply) and normally open contact K2/13-14 closes the circuit of contactor Q11, which energizes and switches the mains supply on the load. Contactor Q12 is also interlocked against mains supply contactor Q11 via normally closed contact Q11/22-21.

Phase monitor K1 is energized via the main supply and immediately energizes contactor relay K2. Normally closed contact K2/21–22 blocks the circuit. Contactor Q12 (auxiliary

8-112


Export to the world market and to North America Page Approvals and certificates

9-2

Fuses for circuits in North America

9-4

Approval authorities

9-6

Test authorities and approval stamps

9-10

Marking of electrical equipment for North America

9-12

Circuit symbols, European – North America

9-21

Circuit diagram examples to North American specifications

9-33

North American classification for control switches

9-36

Rated motor currents for North American motors

9-38

Protection types for electrical equipment for North America

9-39

North American cable cross-sections

9-41

9-1

9


Export to the world market and to North America Approvals and certificates Approved products on their own are not always enough for successful exporting. A good knowledge of the relevant standards and the special characteristics of the market for the application must be taken into account in addition to the approved products themselves.

Approvals for switching and protective devices or for power distribution systems are national, regional or application-specific approvals for the use of these products.

9

• Additional tests by independent and nationally approved test bodies are often required and some approvals require the regular production monitoring by the approval authority. • Approvals often require mandatory marking on the approved products. • Some approvals require the modification of the permissible technical data of the approved products. • At present, application restrictions apply to the approved products. • The flexibility of the manufacturer is restricted by the fact that each product modification has to be approved. Further information is provided in the Main Catalogue for Industrial Switchgear, in the chapter “Approvals for the World Market”. www.moeller.net/en/support/pdf_katalog.jsp

9-2

A check list may help to clarify important questions and take them into account at the quotation stage. After a system is completed, any special requirements that were not taken into account in the engineering stage may require a high level of cost and time for their implementation. Special characteristics for the export to North America (USA, Canada) What has become well-established worldwide is not necessarily also acceptable in North America. The following should be taken into account for exports to North America: • North American approvals, • North American product and installation standards, • Special market practices, • Approval by local inspectors (AHJ = Authority Having Jurisdiction). North American practices unknown in the IEC world: • Device types and main applications, • Product-specific differences in the scope of the approval, • Different main circuits (feeder circuits, branch circuits), • Restrictions according to network types, • Application-related differences in device selection.


Export to the world market and to North America Approvals and certificates Device types in North America In North America a distinction is made between devices for energy distribution, such as in compliance with UL 489 and industrial switchgear in compliance with UL 508. UL 489 and CSA-C22.2 No. 5-02 stipulate larger clearance and creepage distances than the IEC standards and the relevant harmonised European standards. This affects, for example, the European motorprotective circuit breaker, which now has additional terminals on the incoming side to provide the required clearance and creepage distances. Distribution Equipment • Circuit breakers UL 489, CSA-C22.2 No. 5-02 • Disconnectors UL 489, CSA-C22.2 No. 5-02 • Switch-disconnectors UL 98, CSA-C22.2 No. 4 • Fuse switch-disconnectors UL 98, CSA-C22.2 No. 4 • Fuses UL 248, CSA-C22.2 No. 248

Examples of special device selection for North America • The type of load that a circuit has is important for selecting the correct switching and protective devices. Motor starters must only switch and protect motors. • Motor starters on busbar adapters in the feeder circuit only with large clearance and creepage distances1). • Small clearance and creepage distances are sufficient for motor starters on busbar adapters in the branch circuit1). • Additional handles required for door coupling rotary handles used in North America. 1)

Example circuit a figure, page 9-34

Comprehensive information and tips on the export of low-voltage switchgear and systems to North America can be downloaded free of charge from the Internet. www.moeller.net/publications

Industrial control equipment UL 508 and CSA-C22.2 No. 14 • • • • • • •

Contactors Contactor relays Overload relays Rotary switches Control circuit devices, position switches Electronic devices/systems User-programmable controllers

9-3

9


Export to the world market and to North America Fuses for circuits in North America Selection and application of fuses suitable for circuits (feeder and branch circuits) in North America. Type or design in:

Fuse characte ristics

SCCR

Typical values in A

Fields of application

Notes

10 kA, 250 VAC

0…600

Primarily domestic

Types H, K therefore they may

USA

Canada

Class H, "Code"

Class H, No. 59 "Code"

UL 248-6/7, C22.2 248-6/7

fast

Class CC

Class CC

UL 248-4, C22.2 248-4

fast slow

200 kA, 600 VAC

0.5…30

fast:

slow:

Extremely Current-l

Class G

Class G

UL 248-5, C22.2 248-5

fast slow

100 kA, 480 VAC

21…60

100 kA, 600 VAC

0.5…20

Protection from resistive and inductive loads.

Compact Current-l All other f

Class J HRCI-J

UL 248-8, C22.2 248-8

fast slow

200 kA, 600 VAC

1…600

Protection from inductive and highly inductive loads.

Class K K1, K5

Class K K1, K5

UL 248-9, C22.2 248-9

fast slow

50 kA/100 kA/ 200 kA, 600VAC

0…600

Circuits for motors, transformers, lighting etc.

Class L

Class L

UL 248-10, C22.2 248-10

fast slow

200 kA, 600 VAC

601…6000

Circuits for heating, lighting, feeders and branches for mixed loads.

Class R RK1, RK5

Class R HRCI-R RK1, RK5

UL 248-12, C22.2 248-12

fast slow

50 kA/100 kA/ 200 kA, 600VAC

0…600

Class T

Class T

UL 248-15, C22.2 248-15

fast

200 kA, 300 VAC 200 kA, 600 VAC

0…1200

Class J

9

Standards UL, CSA

The characteristics data and the assigned applications are a rough overview only. The practice, it is always advisable to find out both this information and the required fusel type from the North American end customer.

9-4

10 kA, 600 VAC

Compact Current-l All other f

Not curre In the USA replaced b

Current-l All other f

Current-l Types RK1 fuse types RK1 fuses _

Extremely Current-l All other f


Export to the world market and to North America Fuses for circuits in North America

Tripping characte ristic

SCCR

Typical values in A

Fields of application

Notes

fast

10 kA, 250 VAC

0…600

Primarily domestic

Types H, K and No. 59 “Code” fit the same bases and are therefore interchangeable. There is therefore a risk that they may be incorrectly used! See also note on K.

10 kA, 600 VAC

fast slow

200 kA, 600 VAC

0.5…30

fast:

slow:

Extremely compact design! Current-limiting to UL/CSA!

fast slow

100 kA, 480 VAC

21…60

100 kA, 600 VAC

0.5…20

Protection from resistive and inductive loads.

Compact design. Current-limiting to UL/CSA! All other fuse types do not fit into bases.

fast slow

200 kA, 600 VAC

1…600

Protection from inductive and highly inductive loads.

fast slow

50 kA/100 kA/ 200 kA, 600VAC

0…600

Circuits for motors, transformers, lighting etc.

fast slow

200 kA, 600 VAC

601…6000

Circuits for heating, lighting, feeders and branches for mixed loads.

fast slow

50 kA/100 kA/ 200 kA, 600VAC

0…600

fast

200 kA, 300 VAC 200 kA, 600 VAC

0…1200

Compact design. Current-limiting to UL/CSA! All other fuse types do not fit into bases. Not current-limiting to UL/CSA! In the USA, the K types are therefore being increasingly replaced by the RK types. Current-limiting to UL/CSA! All other fuse types do not fit into bases. Current-limiting to UL/CSA! Types RK1, RK5 and HRCI-R fit the same bases. All other fuse types do not fit into these bases. RK1 fuses have lower let-through values than RK5.

_

Extremely compact design! Current-limiting to UL/CSA! All other fuse types do not fit into bases.

The NA fuse types are largely tested and suitable for DC circuits in accordance with UL and CSA.

9-5

9


Export to the world market and to North America Approval authorities

9

Code

Full title

Country

ABS

American Bureau of Shipping Ship classification association

USA

AEI

Assoziazione Elettrotechnica ed Elettronica Italiana Italian electrotechnical industry organisation

Italy

AENOR

Asociacion Española de Normalización y Certificación, Spanish organisation for standards and certification

Spain

ALPHA

Gesellschaft zur Prüfung und Zertifizierungvon NiederspannungsgerätenGerman test laboratories association

Germany

ANSI

American National Standards Institute

USA

AS

Australian Standard

Australia

ASA

American Standards Association American association for standards

USA

ASTA

Association of Short-Circuit Testing Authorities Association of the testing authorities

Great Britain

BS

British Standard

Great Britain

BV

Bureau Veritas, Ship´s classification association

France

CEBEC

Comité Electrotechnique Belge, Belgian electro-technical product quality mark

Belgium

CEC

Canadian Electrical Code

Canada

CEI

Comitato Elettrotecnico Italiano Italian standards organisation

Italy

CEI

Commission Electrotechnique Internationale International electrotechnical commission

Switzerland

CEMA

Canadian Electrical Manufacturers’ Association Verband der Kanadischen Elektroindustrie

Canada

CEN

Comité Européen de Normalisation European standards committee

Europe

CENELEC

Comité Européen de coordination de Normalisation Électrotechnique, European committee for electro-technical standards

Europe

9-6


Export to the world market and to North America Approval authorities Code

Full title

Country

CSA

Canadian Standards Association Canadian standards association, Canadian standard

Canada

DEMKO

Danmarks Elektriske Materielkontrol Danish material control for electrotechnical products

Denmark

DIN

Deutsches Institut für Normung German institute for standardisation

Germany

DNA

Deutscher Normenausschuss German standards committee

Germany

DNV

Det Norsk Veritas Ship classification association

Norway

EN

European standard

Europe

ECQAC

Electronic Components Quality Assurance Committee Committee for components with a verified quality

Europe

ELOT

Hellenic Organization for Standardization Greek organization for standardization

Greece

EOTC

European Organization for Testing and Certification Europäische Organisation für Konformitätsbewertung

Europe

ETCI

Electrotechnical Council of Ireland Irish organization for standardization

Ireland

GL

Germanischer Lloyd Ship classification association

Germany

HD

Harmonization document

Europe

IEC

International Electrotechnical Commission International Electrotechnical Commission

–

IEEE

Institute of Electrical and Electronics Engineers Verein der Elektro- und Elektronik-Ingenieure

USA

IPQ

Instituto Portoguês da Qualidade Portuguese quality institute

Portugal

ISO

International Organization for Standardization Internationale Organisation für Normung

–

9

9-7


Export to the world market and to North America Approval authorities

9

Code

Full title

Country

JEM

Japanese Electrical Manufacturers Association Electrical industry association

Japan

JIC

Joint Industry Conference Gesamtverband der Industrie

USA

JIS

Japanese Industrial Standard

Japan

KEMA

Keuring van Elektrotechnische Materialen Testing institute for electrotechnical products

Netherlands

LOVAG

Low Voltage Agreement Group

–

LRS

Lloyd's Register of Shipping Ship classification association

Great Britain

MITI

Ministry of International Trade and Industry

Japan

NBN

Norme Belge, Belgian standard

Belgium

NEC

National Electrical Code

USA

NEMA

National Electrical Manufacturers Association Electrical industry association

USA

NEMKO

Norges Elektrische Materiellkontroll Norwegian testing institute for electrotechnical products

Norway

NEN

Nederlands Norm, Dutch standard

Netherlands

NFPA

National Fire Protection Association US-amerikanische Gesellschaft für Brandverhütung

USA

NKK

Nippon Kaiji Kyakai Japanese classification association

Japan

OSHA

Occupational Safety and Health Administration

USA

ÖVE

Österreichischer Verband für Elektrotechnik Austrian electrotechnical association

Austria

PEHLA

Prüfstelle elektrischer Hochleistungsapparate der Gesellschaft für elektrische Hochleistungsprüfungen Electrical high-performance apparatus test laboratory of the association for electrical high-performance testing

Germany

9-8


Export to the world market and to North America Approval authorities Code

Full title

Country

PRS

Polski Rejestr Statków Ship classification association

Poland

PTB

Physikalisch-Technische Bundesanstalt German physical/technical federal agency

Germany

RINA

Registro Italiano Navale Italian ship classification association

Italy

SAA

Standards Association of Australia

Australia

SABS

South African Bureau of Standards

South Africa

SEE

Service de l'Energie de l'Etat Luxemburg authority for standardisation, testing and certification

Luxemburg

SEMKO

Svenska Elektriska Materielkontrollanstalten Swedish test institute for electrotechnical products

Sweden

SEV

Schweizerischer Elektrotechnischer Verein Swiss electrotechnical association

Switzerland

SFS

Suomen Standardisoimisliitlo r.y. Finnish standardisation association, Finnish standard

Finland

STRI

The Icelandic Council for Standardization Isländische Normungsorganisation

Iceland

SUVA

Schweizerische Unfallversicherungs-Anstalt Swiss accident insurance federal agency

Switzerland

TÜV

Technischer Überwachungsverein Technical inspection association

Germany

UL

Underwriters' Laboratories Inc. Vereinigte Versicherungslaboratorien

USA

UTE

Union Technique de l'Electricité Electrotechnical federation

France

VDE

Verband der Elektrotechnik, Elektronik, Informationstechnik (Verband Deutscher Elektrotechniker)Association of electrical, electronics and information technology

Germany

ZVEI

Zentralverband Elektrotechnik- und Elektronikindustrie Central association of the electrical and electronic industry

Germany

9

9-9


Export to the world market and to North America Test authorities and approval stamps Test authorities and approval stamps in Europe and North America The standard versions of most Moeller devices are approved for use throughout the world, including the USA and Canada. Some devices, such as circuit-breakers, are in their basic design usable worldwide with the exception of USA and Canada. For export to North America devices are available with a special UL and CSA approval. In some cases special country specific installation and operating specifications, installation materials and types must be taken into account as well as special circumstances such as difficult climatic conditions. Since January 1997 all devices that conform to the European low-voltage guidelines and are for

9

sale in the European Union must be marked with the CE mark. The CE mark shows that the marked device corresponds with all relevant requirements and standards. This marking duty allows unlimited use of this device within the European economic area. As devices provided with the CE mark comply with the harmonised standards, approval in the countries of the European Union is unnecessary. This does not apply to installation material. Additional marking with a national test mark is often required for device groups of miniature and residual current circuit-breakers. The following table shows a selection of test marks.

Country

Test authority

Belgium

Comité Electrotechnique Belge Belgisch Elektrotechnisch Comité (CEBEC)

Denmark

Danmarks Elektriske Materielkontrol (DEMKO)

Germany

Verband Deutscher Elektrotechniker (VDE)

Finland

FIMKO

France

Union Technique de l’Electricité (UTE)

9-10

Characters

v


Export to the world market and to North America Test authorities and approval stamps Country

Test authority

Netherlands

Naamloze Vennootschap tot Keuring van Electrotechnische Materialien (KEMA)

Norway

Norges Elektriske Materiellkontrol (NEMKO)

Austria

Österreichischer Verband für Elektrotechnik (ÖVE)

Russia

Goststandart(GOST-)R

Sweden

Svenska Elektriska Materielkontrollanstalten (SEMKO)

Switzerland

Schweizerischer Elektrotechnischer Verein (SEV)

USA

Underwriters Laboratories

Characters

Listing

9

Recognition Canada

Canadian Standards Association (CSA)

9-11


Export to the world market and to North America Marking of electrical equipment for North America Component marking in the USA and Canada to NEMA ICS 19, ANSI Y32.2/IEEE 315/315 A In order to differentiate between devices with similar functions, 3 figures and/or letters can be added to the marking. When using two or more of these markings, the function marking is usually put first.

Example: The relay which introduces the first jog function is marked with “1 JCR”. That means here: 1 = numerical specification J = jog function of the equipment CR = control relay (contactor relay) – type of equipment

9

9-12


Export to the world market and to North America Marking of electrical equipment for North America Device or Function Code Letters to NEMA ICS 19-2002 Code letter

Device or Function

A

Accelerating

AM

Ammeter

B

Braking

C or CAP

Capacitor, capacitance

CB

Circuit-breaker

CR

Control relay

CT

Current transformer

DM

Demand meter

D

Diode

DS or DISC

Disconnect switch

DB

Dynamic braking

FA

Field accelerating

FC

Field contactor

FD

Field decelerating

FL

Field-loss

F or FWD

Forward

FM

Frequency meter

FU

Fuse

GP

Ground protective

H

Hoist

J

Jog

LS

Limit switch

L

Lower

M

Main contactor

MCR

Master control relay

MS

Master switch

9

9-13


Export to the world market and to North America Marking of electrical equipment for North America

9

Code letter

Device or Function

OC

Overcurrent

OL

Overload

P

Plugging, potentiometer

PFM

Power factor meter

PB

Pushbutton

PS

Pressure switch

REC

Rectifier

R or RES

Resistor, resistance

REV

Reverse

RH

Rheostat

SS

Selector switch

SCR

Silicon controlled rectifier

SV

Solenoid valve

SC

Squirrel cage

S

Starting contactor

SU

Suppressor

TACH

Tachometer generator

TB

Terminal block, board

TR

Time-delay relay

Q

Transistor

UV

Undervoltage

VM

Voltmeter

WHM

Watthour meter

WM

Wattmeter

X

Reactor, reactance

9-14


Export to the world market and to North America Marking of electrical equipment for North America As an alternative to device designation with code letter to NEMA ICS 19-2002 the designation to class designation is permissible. Class designation marking should simplify

harmonization with international standards. The code letters used here are, in part, similar to those of IEC 61346-1 (1996-03).

Class designation code letter to ANSI Y32.2/IEEE 315, 315 A Code letter

Device or Function

A

Separate Assembly

B

Induction Machine, Squirrel Cage Induction Motor Synchro, General • Control transformer • Control transmitter • Control Receiver • Differential Receiver • Differential Transmitter • Receiver • Torque Receiver • Torque Transmitter Synchronous Motor Wound-Rotor Induction Motor or Induction Frequency Convertor

BT

Battery

C

Capacitor • Capacitor, General • Polarized Capacitor Shielded Capacitor

CB

Circuit-Breaker (all)

9

9-15


Export to the world market and to North America Marking of electrical equipment for North America

9

Code letter

Device or Function

D, CR

Diode • Bidirectional Breakdown Diode • Full Wave Bridge Rectifier • Metallic Rectifier • Semiconductor Photosensitive • Cell • Semiconductor Rectifier • Tunnel Diode • Unidirectional Breakdown Diode

D, VR

Zener Diode

DS

Annunciator Light Emitting Diode Lamp • Fluorescent Lamp • Incandescent Lamp • Indicating Lamp

E

Armature (Commutor and Brushes) Lightning Arrester Contact • Electrical Contact • Fixed Contact • Momentary Contact Core • Magnetic Core Horn Gap Permanent Magnet Terminal Not Connected Conductor

9-16


Export to the world market and to North America Marking of electrical equipment for North America Code letter

Device or Function

F

Fuse

G

Rotary Amplifier (all) A.C. Generator Induction Machine, Squirrel Cage Induction Generator

HR

Thermal Element Actuating Device

J

Female Disconnecting Device Female Receptacle

K

Contactor, Relay

L

Coil • Blowout Coil • Brake Coil • Operating Coil Field • Commutating Field • Compensating Field • Generator or Motor Field • Separately Excited Field • Series Field • Shunt Field Inductor Saturable Core Reactor Winding, General

LS

Audible Signal Device • Bell • Buzzer • Horn

M

Meter, Instrument

9

9-17



Device or Function

P

• Male Disconnecting Device • Male Receptable

Q

Thyristor • NPN-Transistor • PNP-Transistor

R

Resistor • Adjustable Resistor • Heating Resistor • Tapped Resistor • Rheostat Shunt • Instrumental Shunt • Relay Shunt

S

Contact • Time Closing Contact • Time Opening Contact • Time Sequence Contact • Transfer Contact • Basic Contact Assembly • Flasher

9

9-18



Device or Function

S

Switch • Combination Locking and Nonlokking Switch • Disconnect Switch • Double Throw Switch • Drum Switch • Flow-Actuated Switch • Foot Operated Switch • Key-Type Switch • Knife Switch • Limit Switch • Liquid-Level Actuated Switch • Locking Switch • Master Switch • Mushroom Head • Operated Switch • Pressure or Vacuum • Operated Switch • Pushbutton Switch • Pushbutton Illuminated Switch, Rotary Switch • Selector Switch • Single-Throw Switch • Speed Switch Stepping Switch • Temperature-Actuated Switch • Time Delay Switch • Toggle Switch • Transfer Switch • Wobble Stick Switch Thermostat

9

9-19



Device or Function

T

Transformer • Current Transformer • Transformer, General • Polyphase Transformer • Potential Transformer

TB

Terminal Board

TC

Thermocouple

U

Inseparable Assembly

V

Pentode, Equipotential Cathode Phototube, Single Unit, Vacuum Type Triode Tube, Mercury Pool

W

Conductor • Associated • Multiconductor • Shielded Conductor, General

X

Tube Socket

9

9-20


Export to the world market and to North America Circuit symbols, European – North America Circuit symbols to DIN EN, NEMA ICS/ANSI/IEEE/CSA The following comparison of circuit symbols is based upon the following international/national specifications: • IEC 60617 graphic symbol database (DIN EN 60617-2 to DIN EN 60617-12) • NEMA ICS 19-2002, ANSI Y32.2/ IEEE 315/315 A, CSA Z99 Description

IEC (DIN EN)

NEMA ICS/ANSI/IEEE

Conductors, connectors Junction of conductors 03-02-04

or

03-02-05

or

Connection of conductors (node) 03-02-01

Terminal 03-02-02

Terminal strip/block

9 1 2 3 4

1 2 3 4

03-02-03

Conductors

03-01-01

9-21


Export to the world market and to North America Circuit symbols, European – North America Description Conductor (for later expansion)

IEC (DIN EN) 103-01-01

Line of application, general symbol

02-12-01

Line of application, optional, denoting small interval

02-12-04

Separation between two fields

NEMA ICS/ANSI/IEEE

02-01-06

Line of separation between functional units 02-01-06

Shielding 02-01-07

Earth, general symbol Ground, general symbol

9

GRD 02-15-01

Protective earth Protective ground 02-15-03

Connector with plug and socket 03-03-05

Isolating point, lug, closed 03-03-18

9-22

or

03-03-06


Export to the world market and to North America Circuit symbols, European – North America Description

IEC (DIN EN)

NEMA ICS/ANSI/IEEE

Passive components Resistor, general symbol

or 04-01-02

or

RES

04-01-02

Resistor with fixed tappings

or

RES

04-01-09

Variable resistor, general RES

04-01-03

Adjustable resistor

RES

Resistor with sliding contact, potentiometer

RES 04-01-07

Winding, inductance, general

or 04-03-02

04-03-01

Winding with fixed tapping

9 04-03-06

Capacitor, general symbol

or 04-02-01

or 04-02-02

Variable capacitor 104-02-01

9-23



IEC (DIN EN)

NEMA ICS/ANSI/IEEE

Control circuit devices Visual indicator, general symbol

*with colour stated or

Indicator light, general symbol

or

08-10-01

*with colour stated or

Buzzers

ABU 08-10-11

08-10-10

Horn, claxon HN 08-10-05

9

Drives Manual operation, general use 02-13-01

Operated by pushing 02-13-05

Operated by pulling 02-13-03

Operated by turning 02-13-04

Operated by key 02-13-13

Operated by rollers, sensors 02-13-15

9-24



IEC (DIN EN)

NEMA ICS/ANSI/IEEE

Stored energy mechanism, general symbol 02-13-20

Switch mechanism with mechanical release 102-05-04

Operated by motor

M

MOT

02-13-26

Emergency switch 02-13-08

Operated by electromagnetic overcurrent protection 02-13-24

Operated by thermal overcurrent protection

OL 02-13-25

Electromagnetic operation

9 02-13-23

Control by fluid level 02-14-01

Electromechanical, electromagnetic operating devices Electromechanical operating device, general symbol, relay coil, general symbol Operating device with special features, general symbol

or 07-15-01

or

×

x device code letter a table, page 9-13 or

or

×

x device code letter a table, page 9-13

9-25



IEC (DIN EN)

Electromechanical operating device with On-delay

NEMA ICS/ANSI/IEEE or

or

07-15-07


07-15-09


or

Electromechanical device with Off-delay

or

Electromechanical device with On- and Off-delay

Electromechanical device of a thermal relay

or

or

or 07-15-21

Contacts N/O contact

9

or 07-02-01

N/C contact

or 07-02-02

or 07-02-03

Changeover contact with interruption

or 07-02-04

Early-make N/O contact of a contact assembly

TC or TDC 07-04-01

T0 or TD0

Late-break N/C contact of a contact assembly 07-04-03

9-26

×

07-15-08


× ×



IEC (DIN EN)

N/O contact, delayed when closing

NEMA ICS/ANSI/IEEE

or 07-05-01

07-05-02

N/C contact, delayed when reclosing

T.C.

or T.C. 07-05-03

07-05-04

Control devices Push-button (not stay-put)

PB 07-07-02

Spring-return switches with N/C contact, manually operated by pushing, e.g. push-button

PB

Spring-return switches with N/O and N/C contacts, manually operated by pushing

PB

Spring-return switches with latching position and one N/O contact, manually operated by pushing

9

PB

Spring-return switches with latching position and one N/C contact, manually operated by striking (e.g. mushroom button) Position switches (N/O contacts) Limit switches (N/O contacts)

LS 07-08-01

Position switches (N/C contacts) Limit switches (N/C contacts)

LS 07-08-02

Spring-return switches with N/O contacts, mechanically operated, N/O contacts closed

LS

9-27



IEC (DIN EN)

NEMA ICS/ANSI/IEEE

Spring-return switches with N/C contacts, mechanically operated, N/C contacts open

LS

Proximity switches (N/C contacts), actuated by the proximity of iron

Fe

Proximity switches, inductive, N/O contacts

Fe

07-20-04

Proximity switches, block diagram 07-19-02

Under-pressure relays, N/O contacts

P<

P

or

07-17-03

Pressure switches, N/C contact P>

9

Float switches, N/O contact

Float switches, N/C contact

9-28

P

or



IEC (DIN EN)

NEMA ICS/ANSI/IEEE

Switchgear Contactors (N/O contacts) x code letter

07-13-02

Three-pole contactor with bimetal relay (3 thermal elements)

OL

x code letter Three-pole switch-disconnector

DISC 07-13-06

Three-pole circuit-breaker

CB 07-13-05

Three-pole breaker with switch mechanism with three thermoelectric overcurrent releases, three electromagnetic overcurrent releases, motorprotective circuit-breaker

x

x

9

x

l> l> l> 107-05-01

Fuse, general symbol

FU 07-21-01

Transformers, current transformers Transformers with two windings

or 06-09-02

H1 06-09-01

X1

H2 X2

9-29



IEC (DIN EN)

Autotransformer

NEMA ICS/ANSI/IEEE

or

or

06-09-07 06-09-06

Current transformer

or

or

(H1) (X1)

06-09-11

CT

06-09-10

Machines Generator G

G

or

GEN

06-04-01

Motor, general symbol

DC motor, general symbol

9

M

M

06-04-01

06-04-01

M

M

or

MOT

06-04-01

AC motor, general symbol

M

~

06-04-01

Three-phase asynchronous motor with squirrel-cage rotor

or M 3~ 06-08-01

Three-phase asynchronous motor with slip-ring rotor

M 3~ 06-08-03

9-30

M



IEC (DIN EN)

NEMA ICS/ANSI/IEEE

Semiconductor components Static input Static output

Static input with negation 12-07-01

Static output with negation 12-07-02

Dynamic input, change of status from 0 to 1 (L/H) 12-07-07

Dynamic input with negation, change of status from 1 to 0 (H/L) 12-07-08

AND gate, general symbol

&

9 A

12-27-02

OR gate, general symbol

ⱖ1

OR

12-27-01

NOT gate, inverter

1

OR

12-27-11

AND with negated output, NAND

1 2 13

&

A

12-28-01

OR with negated output, NOR

3 4 5

ⱖ1

OR

12-28-02

9-31


Export to the world market and to North America Circuit symbols, European – North America Description Exclusive OR gate, general

IEC (DIN EN)

NEMA ICS/ANSI/IEEE

=1

OE

12-27-09

RS flip-flop

S R

S FF 1 T C 0

12-42-01

Monostable gate, cannot be triggered during the output pulse, general symbol

SS

1 12-44-02

Delay, variable with indication of delay values

TP Adj. m/ms 02-08-05

Semiconductor diode, general symbol

(K)

(A) 05-03-01

Limiting diode Zener diode

9

05-03-06

Light-emitting diode (LED), general symbol

05-03-02

Bi-directional diode, diac

(T)

(T)

(A)

(K)

05-03-09

Thyristor, general symbol 05-04-04

PNP transistor

(A)

(K) or (E)

NPN transistor, in which the collector is connected to the enclosure

9-32

(C) (B)

05-05-01

(K)

(A) or (E)

(C) (B)

05-05-02


Export to the world market and to North America Circuit diagram examples to North American specifications Direct motor starters, fuseless with circuit-breakers Control circuit with fuse CB

L1 L2

L1 L2

M

L3

L3

T1 T2

M

T3

H1

H4

1FU

2FU H2

1 H3

4

X2

X1

2 PB

1 PB

START

STOP 12

11

X1 A1

13 13

M

14 14

W M

X2 A2

Control circuit, fuseless CB

L1 L2

L1 L2

L3

L3

9 T1 T2

M

T3

H4

H1

H1

M

1 H3

X1

H2

4

H4

X2

9-33

9-34

a Feeder Circuit b Branch Circuit 1 c Branch Circuit 2

2 FU-2

d

2 FU-1 3T

5 FU-1

4 FU-1

e

2T

2 M-120 L

g Class 2 Circuit

2 M-1

2 PB-2 2 PB-2 2 M-1 1 LS

1 SOL

2 PB-1

1 M-2

1 M-2

1 CR-1

1 CR-1

1 FS

1 M-1

1 M-1

1 M-1

1 PB-2

1T

1 M-110 L

5 FU-2

1 PB-1

4 FU-2

d Power Transformer e Control Circuit Transformer f Class 2 Transformer

3 FU-2

1 FU-1 1 FU-2 1 FU-3

9

a

1 DISC L1 L1 T1 L2 L2 T2 L3 L3 T3

g

f

MTR2

MTR1

c

b

Motor starters to UL

Export to the world market and to North America Circuit diagram examples to North American specifications Moeller Wiring Manual 02/08


Notes

9

9-35


Export to the world market and to North America North American classification for control switches Classification

Designation At maximum rated voltage of

Thermal uninterrupted current

Switching capacity

AC voltage

600 V

300 V

150 V

A

Rated voltage V

Make A

Break A

Heavy Duty

A600 A600 A600 A600

A300 A300 – –

A150 – – –

10 10 10 10

120 240 480 600

60 30 15 12

6 3 1.5 1.2

Standard Duty

B600 B600 B600 B600

B300 B300 – –

B150 – – –

5 5 5 5

120 240 480 600

30 15 7.5 6

3 1.5 0.75 0.6

C600 C600 C600 C600

C300 C300 – –

C150 – – –

2.5 2.5 2.5 2.5

120 240 480 600

15 7.5 3.75 3

1.5 0.75 0.375 0.3

– –

D300 D300

D150 –

1 1

120 240

3.6 1.8

0.6 0.3

Heavy Duty

N600 N600 N600

N300 N300 –

N150 – –

10 10 10

125 250 301 – 600

2.2 1.1 0.4

2.2 1.1 0.4

Standard Duty

P600 P600 P600

P300 P300 –

P150 – –

5 5 5

125 250 301 – 600

1.1 0.55 0.2

1.1 0.55 0.2

Q600 Q600 Q600

Q300 Q300 –

Q150 – –

2.5 2.5 2.5

125 250 301 – 600

0.55 0.27 0.10

0.55 0.27 0.10

– – –

R300 R300 –

R150 – –

1.0 1.0 –

125 250 301 – 600

0.22 0.11 –

0.22 0.11 –

9 DC voltage

to UL 508, CSA C 22.2-14 and NEMA ICS 5

9-36


Export to the world market and to North America North American classification for control switches

ed voltage of

Thermal uninterrupted current

Switching capacity

300 V

150 V

A

Rated voltage V

Make A

Break A

Make VA

Break VA

A300 A300 – –

A150 – – –

10 10 10 10

120 240 480 600

60 30 15 12

6 3 1.5 1.2

7200 7200 7200 7200

720 720 720 720

B300 B300 – –

B150 – – –

5 5 5 5

120 240 480 600

30 15 7.5 6

3 1.5 0.75 0.6

3600 3600 3600 3600

360 360 360 360

C300 C300 – –

C150 – – –

2.5 2.5 2.5 2.5

120 240 480 600

15 7.5 3.75 3

1.5 0.75 0.375 0.3

1800 1800 1800 1800

180 180 180 180

D300 D300

D150 –

1 1

120 240

3.6 1.8

0.6 0.3

432 432

72 72

N300 N300 –

N150 – –

10 10 10

125 250 301 – 600

2.2 1.1 0.4

2.2 1.1 0.4

275 275 275

275 275 275

P300 P300 –

P150 – –

5 5 5

125 250 301 – 600

1.1 0.55 0.2

1.1 0.55 0.2

138 138 138

138 138 138

Q300 Q300 –

Q150 – –

2.5 2.5 2.5

125 250 301 – 600

0.55 0.27 0.10

0.55 0.27 0.10

69 69 69

69 69 69

R300 R300 –

R150 – –

1.0 1.0 –

125 250 301 – 600

0.22 0.11 –

0.22 0.11 –

28 28 –

28 28 –

9

9-37


Export to the world market and to North America Rated motor currents for North American motors Motor rated currents for North American three-phase motors1) Motor rating

Motor rated operational current in amperes2)

HP

115 V 120 V

230 V3) 240 V

460 V 480 V

575 V 600 V

1/2

4.4 6.4 8.4

2.2 3.2 4.2

1.1 1.6 2.1

0.9 1.3 1.7

12 13.6

6.0 6.8 9.6

3.0 3.4 4.8

2.4 2.7 3.9

5 71/2 10

15.2 22 28

7.6 11 14

6.1 9 11

15 20 25

42 54 68

21 27 34

17 22 27

30 40 50

80 104 130

40 52 65

32 41 52

60 75 100

154 192 248

77 96 124

62 77 99

125 150 200

312 360 480

156 180 240

125 144 192

250 300 350

302 361 414

242 289 336

400 450 500

477 515 590

382 412 472

3/4

1 11/2 2 3

9

1) Source: 2)

3)

1/2 – 200 HP 250 – 500 HP

= NEC Code, Table 430-250 = UL 508, Table 45.2

The motor full-load current values given are approximate values. For exact values consult the data stated by the manufacturer or the motor rating plates. For motor full-load currents of 208 V motors/200 V motors, use the appropriate values for 230 V motors, increased by 10 – 15 %.

9-38


Export to the world market and to North America Protection types for electrical equipment for North America Protection types for electrical equipment for USA and Canada to IEC/EN 60529 (VDE 0470 part 1) The IP ratings quoted in the table represent a rough comparison only. A precise comparison is

not possible since the degree of protection tests and the evaluation criteria differ.

Designation of the enclosure and the protection type to: – NFPA 70 (National Electrical Code) – CEC (Canadian Electrical Code) – UL 50 – CSA-C22.2 No. 94-M91 (2006) – NEMA 250 -20031) Comparable IP protection types to IEC/EN 60529 DIN 40050

Comparable IP protection types to IEC/EN 60529 DIN 40050

UL/CSA type 1 General purpose

IP20

UL/CSA type 4 X dust-tight, watertight,corrosion-resistant, rain-tight

IP66

UL/CSA type 2 Drip-tight

IP22

UL/CSA type 5 drip-tight, dust-tight

IP53

UL/CSA type 3 Dust-tight, rain-tight, resistant to sleet and ice

IP55

UL/CSA type 6 rain-tight, water-tight, immersible, resistant to hail and ice

IP67

UL/CSA type 3 R Rain-proof, resistant to sleet and ice

IP24

UL/CSA type 12 For use in industry, driptight, dust-tight

IP54

UL/CSA type 3 S Dust-tight, rain-tight, resistant to sleet and ice

IP55

UL/CSA type 13 dust-tight, oil-tight, driptight

IP54

UL/CSA type 4 dust-tight, water-tight, rain-tight

IP66

1)

9

NEMA = National Electrical Manufacturers Association

9-39


Export to the world market and to North America Protection types for electrical equipment for North America Terms German/English: General purpose:

general purpose

tropfdicht:

drip-tight

staubdicht:

dust-tight

regendicht:

rain-tight

regensicher:

rain-proof

wettersicher:

weather-proof

wasserdicht:

water-tight

eintauchbar:

submersible

eisbeständig:

ice resistant

hagelbeständig:

sleet resistant

korrosionsbeständig:

corrosion resistant

öldicht:

oil-tight

9

9-40


Export to the world market and to North America North American cable cross-sections Conversion of North American cable cross sections into mm2 USA/Canada

Europe

AWG

mm2

mm2

(exact)

(nearest standard size)

22

0.324

0.4

20

0.519

0.5

18

0.823

0.75

16

1.31

1.5

14

2.08

12

3.31

4

10

5.261

6

8

8.367

10

6

13.30

16

4

21.15

25

3

26.67

2

33.62

1

42.41

35

1/0 (0)

53.49

50

2/0 (00)

67.43

70

3/0 (000)

85.01

4/0 (0000)

107.2

9

95

9-41


Export to the world market and to North America North American cable cross-sections

9

USA/Canada

Europe

kcmil

mm2

mm2

(exact)

(nearest standard size)

250

127

120

300

152

150

350

177

185

400

203

450

228

500

253

550

279

600

304

650

329

700

355

750

380

800

405

900

456

1,000

507

240 300

500

In addition to “circular mills”, cable sizes are often given in “MCM”: 250 000 circular mills = 250 MCM

9-42


Notes

9

9-43


Notes

9

9-44


Standards, formulae, tables Page Marking of electrical equipment

10-2

Protective measures

10-5

Overcurrent protection of cables and conductors

10-13

Electrically critical equipment of machines

10-21

Measures for risk reduction

10-26

Degrees of protection for electrical equipment

10-28

Utilisation categories for contactors and motor starters

10-34

Utilisation categories for switch-disconnectors

10-38

Rated motor currents

10-40

Conductors

10-43

Formulea

10-50

Standard international units

10-54

10-1

10


Standards, formulae, tables Marking of electrical equipment Marking according to DIN EN 61346-2:2000-12 (IEC 61346-2:2000) Moeller has decided to apply the above standard over a transitional period. In contrast to the previously used designation, it is now the function of the electrical apparatus within the circuit that determines its identifying letter. This provides a great deal of freedom in the choice of a device’s identifying letter. Example for a resistor • Normal current limiter: R • Heater resistor: E • Measuring resistor: B In addition, Moeller has introduced companyspecific stipulations for implementing the standard, which deviate from the standard to some extent.

10

• The marking of connection terminals are not readable from the right. • A second code letter for the marking of the use of the equipment is not given, e. g.: timer relay K1T becomes K1. • Circuit-breakers with the main function of protection are still marked with Q. They are numbered from 1 to 10 from the top left. • Contactors are newly marked with Q and numbered from 11 to nn. e. g.: K91M becomes Q21. • Relays remain K and are numbered from 1 to n.

10-2

The marking appears in a suitable position as close as possible to the circuit symbol. The marking forms the link between the equipment in the installations and the various circuit documents (wiring diagrams, parts lists, circuit diagrams, instructions). To simplify maintenance, the marking can also be applied in full or in part on or near to the equipment. Selected equipment with a comparison of the Moeller used code letters old – new a table, page 10-3.


Standards, formulae, tables Marking of electrical equipment Code letter old

Example for electrical equipment

Code letter new

B

Measuring transducer

T

C

Capacitors

C

D

Memory device

C

E

Electro filter

V

F

Bimetal release

F

F

Pressure switches

B

F

Fuses (fine, HH, signal fuse )

F

G

Frequency inverters

T

G

Generators

G

G

Soft starters

Q

G

UPS

G

H

Lamps

E

H

Optical and acoustic indicators

P

H

Signal lamps

P

K

Auxiliary relays

K

K

Relay

K

K

Semiconductor contactors

Q

K

Contactor

Q

K

Timing relays

K

L

Reactor coil

R

M

Motor

M

N

Buffer amplifier, inverting amplifier

T

P

Meters

P

10

10-3


Standards, formulae, tables Marking of electrical equipment

10

Code letter old

Example for electrical equipment

Code letter new

Q

Switch-disconnector

Q

Q

Circuit-breaker for protection

Q

Q

Motor-protective circuit-breakers

Q

Q

Star-delta switches

Q

Q

Disconnectors

Q

R

Variable resistor

R

R

Measurement resistor

B

R

Heating resistor

E

S


S

S

Pushbutton actuators

S

S

Position switches

B

S

Switches

S

T

Voltage transformers

T

T

Current transformer

T

T

Transformers

T

U

Frequency converter

T

V

Diodes

R

V

Rectifier

T

V

Transistors

K

Z

EMC filter

K

Z

Suppressors and arc quenching devices

F

10-4


Standards, formulae, tables Protective measures Protection against electrical shock to IEC 364-4-41/VDE 0100 Part 410 A distinction is drawn here between protection against direct contact, protection against indirect contact and protection against both direct and indirect contact. • Protection against direct contact These are all the measures for the protection of personnel and working animals from

dangers which may arise from contact with live parts of electrical equipment. • Protection against indirect contact This is the protection of personnel and working animals from dangers which may arise from accidental contact with components or extraneous conductive parts.

Protective measures

Protection against direct as well as indirect contact

Protection against direct contact

Protection against indirect contact

Protection by extra-low voltage: – SELV – PELV

Protection by insulation of active parts

Protection by automatic disconnection of the power supply

Protection by covering or encapsulating

10

Protective insulation (Total insulation) k

Protection by partitioning

Protection by non-conductive spaces

Protection by distancing

Protection by non-earthed local equipotential bonding

Protective separation Protection must be ensured by either a) the equipment itself or b) the use of protective

measures when erecting the installation or c) a combination of a) and b). 10-5


Standards, formulae, tables Protective measures Protection against indirect contact by means of disconnection or indication The conditions for disconnection are determined by the type of system in use and the protective device selected. Systems to IEC 364-3/VDE 0100 Part 310 Earth continuity type systems

Meaning of designation

TN system L1 L2 L3 N PE

T: Direct earthing of a point (system earth) N:Chassis directly connected to the system earth

b a

TT system L1 L2 L3 N

T: Direct earthing of a point (system earth) T: Chassis directly earthed, independent of the earthing of the power supply (system earth)

L1 L2 L3

I: All live parts isolated from earth or one point connected to earth via an impedance T: Chassis directly earthed, independent of the earthing of the power supply (system earth)

b

10

a

PE

IT network

c

b PE

a System earth b Chassis c Impedance

10-6


Standards, formulae, tables Protective measures Protective devices and conditions for disconnection to IEC 364-4-1/VDE 0100 Part 410 Type of distribution system

TN system

Protection with

Circuit principle

Overcurrent protective device

TN-S system separated neutral and earth conductors throughout the system

Description so far

L1 L2 L3 N PE

Fuses Miniature circuit-breakers Circuit-breakers

TN-C system Neutral conductor and protection functions are combined throughout the system in a single PEN conductor.

Protective multiple earthing

Condition for disconnection Zs X Ia F U0 Zs = Impedance of the fault circuit Ia = current, which causes disconnection in: • F5s • F 0.2 s in circuits up to 35 A with sockets and hand-held components which can be moved U0 = rated voltage against earthed conductor

L1 L2 L3 PEN

10-7

10



TN system

Protection with

Circuit principle


TN-C-S system Neutral conductor and protection functions are in a part of the system combined in a single PEN conductor

Description so far

Condition for disconnection

L1 L2 L3 N PE(N)

Residual-current protective device

10 Residual voltage protection device (in special case) Insulation monitoring device * a table, page 10-12

10-8

L1 L2 L3 N PE(N)

Residualcurrent protective circuit

Zs X IDn F U0 IDn = Rated fault current U0 = Maximum permissible touch voltage*: (F 50 V AC, F 120 V DC)



TT system

Protection with

Circuit principle

Description so far


L1 L2 L3 N PE

Fuses Miniature circuit-breakers Circuit-breakers

Residual-current protective device

Protective earth PE

PE

L1 L2 L3 N F1

F1

F1

Residual-current protective circuit

Conditions for indication/disconnection RA X Ia F UL RA = Earthing resistance of conductive parts of the chassis Ia = Current which causes automatic disconnection in F 5 s UL = Maximum permissible touch voltage*: (F 50 V AC, F 120 V DC) RA X IΔn F UL IΔn = Rated fault current

L1 L2 L3 N

PE

Residual-voltage protective device (for special cases)

PE

10

PE

L1 L2 L3 N

FU

Residualvoltage protective circuit

RA: max. 200 O

PE

* a table, page 10-12

10-9



TT system

Protection with

Circuit principle

Insulation monitoring device

–


10

* a table, page 10-12

10-10

L1 L2 L3 PE

Description so far

Conditions for indication/disconnection

Feed back to protective multiple earthing

RA X Id F UL (1) ZS X Ia F Uo (2) RA = Earthing resistance of all conductive parts connected to an earth Id = Fault current in the event of the first fault with a negligible impedance between a phase conductor and the protective conductor or element connected to it UL = Maximum permissible touch voltage*: F 50 V AC, F 120 V DC



IT network

Protection with

Circuit principle

Residual current protective device

L1 L2 L3 F1

F1

L1 L2 L3 FU

Conditions for indication/disconnection

Residualcurrent protective circuit

RA X IΔn F UL IΔn = Rated fault current

Residualvoltage protective circuit

RA: max. 200 O

Protectiveconductor system

R X Ia F UL R = Resistance between components and extraneous conductive parts which can be touched simultaneously

PE

PE

Residual voltage protective device (for special cases)

Description so far

FU PE

PE

Insulation monitoring device

L1 L2 L3 PE Z< 햲

a additional potential equalisation * a table, page 10-12

10-11

10


Standards, formulae, tables Protective measures The protective device must automatically disconnect the faulty part of the installation. At no part of the installation must there be a touch voltage or an effective duration greater than

that specified in the table below. The internationally agreed limit voltage at a maximum disconnect time of 5 s is 50 V AC or 120 V DC.

Maximum permissible effective duration dependent on touch voltage to IEC 364-4-41 Anticipated touch voltage t [s] 5.0

AC eff [V]

DC eff [V]

1.0

< 50

< 120

0.5

50

120

·

75

140

1.0

90

160

0.5

110

175

0.2

150

200

0.1

220

250

0.05

280

310

0.03

2.0

0.2 0.1 0.05

10 0.02

10-12

Max. permissible disconnection time

50 100

200

300

400 U [V]

[s]

5.0


Standards, formulae, tables Overcurrent protection of cables and conductors Overcurrent protective devices must be used to protect cable and conductors against excessive

warming, which may result both from operational overloading and from short-circuit.

Overload protection Overload protection means providing protective devices which will interrupt overload currents in the conductors of a circuit before they can cause temperature rises which may damage the conductor insulation, the terminals and connections or the area around the conductors.

IB Anticipated operating current of the circuit IZ Current carrying capacity of conductor or cable In Rated current of protective device

For the protection of conductors against overload the following conditions must be fulfilled (source: DIN VDE 0100-430)

For adjustable protective devices, In corresponds to the value set.

Note:

I2 The current which causes tripping of the protective device under the conditions specified in the equipment regulations (high test current).

IB F In F IZ I2 F 1,45 IZ

Re

yI z cit pa ca ing rry -ca s nt lue rre va I B Cu r ce en cto fer ndu co of

Operational current

1.

Charactistics of protective device

nt

re

g tin

r cu

d-

te

Ra

o

⫻

I

z

I

In nt

rre

t

e rs

45

ing ipp

10

A

I2

cu

Tr

Arrangement of protection devices for overload protection Protection devices for overload protection must be fitted at the start of every circuit and at every point where the current-carrying capacity is reduced unless an upstream protection device can ensure protection.

10-13


Standards, formulae, tables Overcurrent protection of cables and conductors Note: Reasons for the current-carrying capacity being reduced: Reduction of the conductor cross-section, a different installation method, different conductor insulation, a different number of conductors. Protective devices for overload protection must not be fitted if interruption of the circuit could

prove hazardous. The circuits must be laid out in such a way that no possibility of overload currents occurring need be considered. Examples: • • • •

Energizing circuits for rotating machines Feeder circuits of solenoids Secondary circuits of current transformers Circuits for safety purposes

Short-circuit protection Short-circuit protection means providing protective devices which will interrupt shortcircuit currents in the conductors of a circuit before they can cause a temperature rise which may damage the conductor insulation, the terminals and connections, or the area around the cables and conductors. In general, the permissible disconnection time t for short circuits of up to 5 s duration can be specified approximately using the following equation:

10

S 2 t = ⎛ kx --⎞ or ⎝ T⎠

I2 x t = k2 x S2

The meaning of the symbols is as follows: t: Permissible disconnection time in the event of short-circuit in s S: Conductor cross-section in mm2 I: Current in the cast of short-circuit in A k: Constants with the values – 115 for PVC-insulated copper conductors – 74 for PVC-insulated aluminium conductors – 135 for rubber-insulated copper conductors – 87 for rubber-insulated aluminium conductors – 115 for soft-solder connections in copper conductors 10-14

With very short permissible disconnection times (< 0,1 s) the product from the equation k2 x S2 must be greater than the I2 x t value of the current-limiting device stated by manufacturer. Note: This condition is met provided that there is a cable protective fuse up to 63 A rated current present and the smallest cable cross-section to be protected is at least 1.5 mm2 Cu. Arrangement of protective devices for protection in the event of a short-circuit. Protective devices for protection in the event of a short-circuit must be fitted at the start of every circuit and at every point at which the shortcircuit current-carrying capacity is reduced unless a protective device fitted upstream can ensure the necessary protection in the event of a short circuit.


Standards, formulae, tables Overcurrent protection of cables and conductors Note: Causes for the reduction in the short-circuit current-carrying capacity can be: Reduction of the conductor cross-section, other conductor insulation.

Short-circuit protection must not be provided where an interruption of the circuit could prove hazardous.

Protection of the phase conductors and the neutral conductor Protection of the phase conductors Overcurrent protection devices must be provided in every phase conductor: they must disconnect the conductor in which the overcurrent occurs, but not necessarily also disconnect the other live conductors. Note: Where the disconnection of an individual phase conductor could prove hazardous, as for example, with three-phase motors, suitable precautions must be taken. Motor-protective circuit-breakers and circuit-breakers disconnect in three poles as standard. Protection of the neutral conductor: 1. In installations with directly earthed neutral point (TN or TT systems) Where the cross-section of the neutral conductor is less than that of the phase conductors, an overcurrent monitoring device appropriate to its cross-section is to be provided in the neutral conductor; this overcurrent monitoring device must result in the disconnection of the phase conductors but not necessarily that of the neutral conductor. An overcurrent monitoring device is not necessary where: • the neutral conductor is protected in the event of a short circuit by the protective device for the phase conductors • the largest current which can flow through the neutral conductor is, in normal operation, considerably less than the current-carrying capacity of this conductor.

Note: This second condition is met provided that the power transferred is divided as evenly as possible among the phase conductors, for example where the total power consumption of the load connected between phase and neutral conductors, lamps and sockets is much less than the total power transferred via the circuit. The cross-section of the neutral conductor must not be less than the values in the table on the next page. 2.In installations without a directly earthed neutral point (IT system) Where it is necessary for the neutral conductor to be included, an overcurrent monitoring device must be provided in the neutral conductor of each circuit, to cause disconnection of all live conductors in the relevant circuit (including the neutral conductor). The overcurrent monitoring device may however be omitted where the neutral conductor in question is protected against short circuit by an upstream protective device, such as in the incoming section of the installation. Disconnection of the neutral conductor Where disconnection of the neutral conductor is specified, the protective device used must be designed in such a way that the neutral conductor cannot under any circumstances be disconnected before the phase conductors and reconnected again after them. 4-pole NZM circuit-breakers always meet these conditions.

10-15

10

10

10-16

Number of cores

Single-core cable

In heat-insulating walls, in conduit under the surface

Single wires in conduit on the wall surface

2 3 2 3 Current-carrying capacity Iz in A for 25 C ambient temperature and 70 C operating temperature. For the allocation of overcurrent protective devices apply the following conditions Ib F In F Iz and I2 F 1.45 Iz t. For overcurrent protection devices with a tripping current of I2 F In only apply the condition:

Multi-core cable under the surface

B1

A1

Type of installation

Multi-core cable Spur wiring in the wall or under plaster

Direct installation

exposed

E

⭌ 0.3 d

d

⭌ 0.3 d

d

NYY, NYCWY, NYKY, NYM, NYMZ, NYMT, NYBUY, NHYRUZY

In F ---------- ⋅ I n ; =

1,45 x

Iz In

2 3 2 3 2 3 Ib F In F Iz (Ib: Operating current of the circuit). Circuit-breakers and switchdisconnectors fulfil this condition. For overcurrent protective devices with other tripping currents, only the following condition applies:

Multi-core cable in conduit on the wall surface or on the floor

Multi-core cable

B2 C On or under the wall surface, under plaster In electrical conduit or cable channel

NYM, NYBUY, NHYRUZY, NYIF, H07V-U, H07V-R, H07V-K, NYIFY

Type of cable or conductor

Current-carrying capacity and protection of cables and conductors with PVC insulation to DIN VDE 0298-4, at 25 °C ambient temperature

Standards, formulae, tables Overcurrent protection of cables and conductors Moeller Wiring Manual 02/08

28 36 49 65 85 105 126 160 193 223

2.5

4

6

10

16

25

35

50

70

95

120

200

160

160

125

100

80

63

40

35

25

20

16

In

199

174

144

114

94

77

59

45

33

25

19

14

Iz

3

160

160

125

100

80

63

50

40

32

25

16

13

In

285

246

204

160

133

107

81

60

43

34

25

18.5

Iz

2

B1

250

200

200

160

125

100

80

50

40

32

25

16

In

253

219

181

142

118

94

72

53

38

30

22

16.5

Iz

3

25 35 50 63 80

30 39 53 72 95 117 – – – –

80 100 125 160 200 250

63

50

35

25

–

–

–

–

100

16 20

16.5

15

–

–

–

–

101

82

65

50

35

28

20

13

–

–

–

–

100

80

63

50

35

25

20

–

–

–

–

146

119

90

67

49

37

28

21

Iz

Iz

In

Iz

In

2

3

2

22

20

16

In

C

B2

–

–

–

–

125

100

80

63

40

35

25

20

In

–

–

–

–

126

102

81

63

43

35

25

18.5

Iz

3

–

–

–

–

125

100

80

63

40

35

25

16

In

–

–

–

–

154

125

94

70

51

39

29

21

Iz

2

E

–

–

–

–

125

125

80

63

50

35

25

20

In

For overcurrent protective devices whose rated current In does not conform to the values given in the table, select the next lower available rated current value.

16.5 21

1.5

Iz

2

Number of cores

Copper conductor crosssection in mm2

A1

Type of installatio n

Continue

–

–

–

–

134

107

85

64

46

36

27

19.5

Iz

3

–

–

–

–

125

100

80

63

40

35

25

16

In

Standards, formulae, tables Overcurrent protection of cables and conductors Moeller Wiring Manual 02/08

10

10-17


Standards, formulae, tables Overcurrent protection of cables and conductors Minimum cross section for protective conductors to DIN VDE 0100-510 (1987-06, t), DIN VDE 0100-540 (1991-11) Protective conductor or PEN

Protective conductor3) laid

Phase conductors

Insulated power cables

0,6/1-kV cable with 4 conductors

Protected

Unprotected2)

mm2

mm2

mm2

mm2 Cu

Al

mm2 Cu

up to

10

1)

0.5

0.5

–

2.5

4

4

0.75

0.75

–

2.5

4

4

1

1

–

2.5

4

4

1.5

1.5

1.5

2.5

4

4

2.5

2.5

2.5

2.5

4

4

4

4

4

4

4

4

6

6

6

6

6

6

10

10

10

10

10

10

16

16

16

16

16

16

25

16

16

16

16

16

35

16

16

16

16

16

50

25

25

25

25

25

70

35

35

35

35

35

95

50

50

50

50

50

120

70

70

70

70

70

150

70

70

70

70

70

185

95

95

95

95

95

240

–

120

120

120

120

300

–

150

150

150

150

400

–

185

185

185

185

PEN conductor f 10 mm2 Cu or 18 mm2 Al. 2) It is not permissible to lay aluminium conductors without protection. 3) With phase conductors of f 95 mm2 or more, it is advisable to use non-insulted conductors

10-18


Standards, formulae, tables Overcurrent protection of cables and conductors Conversion factors When the ambient temperature is not 30 °C; to be used for the current-carrying capacity of wiring or cables in air to VDE 0298 Part 4. Insulation material1)

NR/SR

PVC

EPR

Permissible operational temperature

60 °C

70 °C

80 °C

Ambient temperature °C

Conversion factors

10

1.29

1.22

1.18

15

1.22

1.17

1.14

20

1.15

1.12

1.10

25

1.08

1.06

1.05

30

1.00

1.00

1.00

35

0.91

0.94

0.95

40

0.82

0.87

0.89

45

0.71

0.79

0.84

50

0.58

0.71

0.77

55

0.41

0.61

0.71

60

–

0.50

0.63

65

–

–

0.55

70

–

–

0.45

10

1) Higher ambient temperatures in accordance with information given by the manufacturer

10-19


Standards, formulae, tables Overcurrent protection of cables and conductors Converstion factors to VDE 0298 part 4 Grouping of several circuits Arrangement

Number of circuits 1

2

3

4

6

9

12

15 16

20

1 Embedded or enclosed

1.00

0.80

0.70

0.70 0.65

0.55 0.57

0.50

0.45

0.40 0.41

0.40 0.38

2 Fixed to walls or floors

1.00

0.85

0.80 0.79

0.75

0.70 0.72

0.70

–

–

–

3 Fixed to ceilings

0.95

0.80 0.81

0.70 0.72

0.70 0.68

0.65 0.64

0.60 0.61

–

–

–

0.97 0.90

0.87 0.80

0.77 0.75

0.73 0.75

0.72 0.70

–

–

–

0.84 0.85

0.83 0.80

0.81 0.80

0.79 0.80

0.78 0.80

–

–

–

4 Fixed to cable trays arranged horizontally or vertically 5 Fixed to cable trays or consoles

10

10-20

1.00

1.00


Standards, formulae, tables Electrically critical equipment of machines Extract from IEC/EN 60204-1 (VDE 0113 Teil 1) This world wide binding standard is used for the electrical equipment of machines, provided that for the type of machine to be equipped there is no product standard (Type C).

must be sufficient to simultaneously disconnect the stalled current of the largest motor in the machine and the total current drawn by all the other loads in normal operation.

Safety requirements regarding the protection of personnel, machines and material according to the European Machinery Directive are stressed under the heading “Safety of machines”. The degree of possible danger is to estimated by risk assessment (EN 1050). The Standard also includes requirements for equipment, engineering and construction, as well as tests to ensure faultless function and the effectiveness of protective measures.

Its Off position must be lockable and must not be indicated until the specified clearances and creepage distances between all contacts have been achieved. It must have only one On and one Off position with associated stops. Stardelta, reversing and multi-speed switches are not permissible for use as mains isolating devices.

The following paragraphs are an extract from the Standard. Mains isolating device (main switches) Every machine must be equipped with a manually-operated main switch, henceforth referred to as a mains isolating device. It must be possible to isolate the entire electrical equipment of the machine from the mains using the mains isolating device. The breaking capacity

The tripped position of circuit-breakers is not regarded as a switch position, therefore there is no restriction on their use as mains isolating devices. Where there are several incomers, each one must have a mains isolating device. Mutual interlocking must be provided where a hazard may result from only one mains isolating device being switched off. Only circuit-breakers may be used as remotely-operated switches. They must be provided with an additional handle and be lockable in the Off position.

Protection against electric shock The following measures must be taken to protect personnel against electric shock: Protection against direct contact This is understood as meaning protection by means of an enclosure which can only be opened by qualified personnel using a key or special tool. Such personnel is not obliged to disable the mains isolating device before opening the enclosure. Live parts must be protected against direct contact in accordance with IEC 50274 or VDE 0660 part 514.

Where the mains isolating device is interlocked with the door, the restrictions mentioned in the previous paragraph cease to apply because the door can only be opened when the mains isolating device is switched off. It is permissible for an interlock to be removable by an electrician using a tool, e.g. in order to search for a fault. Where an interlock has been removed, it must still be possible to switch off the mains isolating device.

10-21

10


Standards, formulae, tables Electrically critical equipment of machines Where it is possible for an enclosure to be opened without using a key and without disconnection of the mains isolating device, all live parts must at the very least comply with IP 2X or IP XXB degree of protection in accordance with IEC/EN 60529.

Protection against indirect contact This involves prevention of a dangerous touch voltage resulting from faulty insulation. To meet this requirement, protective measures in accordance with IEC 60364 or VDE 0100 must be used. An additional measure is the use of protective insulation (protection class II) to IEC/EN 60439-1 or VDE 0660 Part 500.

Protection of equipment Protection in the event of power failure When the power returns following a failure in the supply, machines or parts of machines must not start automatically where this would result in a dangerous situation or damage to property. With contactor controls this requirement can easily be met via self-maintaining circuits.

10

For circuits with two-wire control, an additional contactor relay with three-wire control in the supply to the control circuit can carry out this function. Mains isolating devices and motorprotective circuit-breakers with undervoltage releases also reliably prevent automatic restarting on return of voltage. Overcurrent protection No overcurrent protective device is normally required for the mains supply cable. Overcurrent protection is provided by the protective device at the head of the incoming supply. All other circuits must be protected by means of fuses or circuit-breakers. The stipulation for fuses is that replacement must be freely obtainable in the country in which the fuses are used. This difficulty can be avoided by using circuit-breakers, with the added benefits of disconnection in all poles, rapid operational readiness and prevention of singlephasing.

10-22

Overload protection of motors Continously operating motors above 0.5 kW must be protected against overload. Overload protection is recommended for all other motors. Motors which are frequently starting and braking are difficult to protect and often require a special protective device. Built-in thermal sensors are particularly suitable for motors with restricted cooling. In addition, the fitting of overload relays is always recommended, particularly as protection by stalled rotor.


Standards, formulae, tables Electrically critical equipment of machines Control functions in the event of a fault A fault in the electrical equipment must not result in a dangerous situation or in damage. Suitable measures must be taken to prevent danger from arising. The expense of using appropriate measures can be extremely high if applied generally. To permit a better assessment of the magnitude of the risk in conjunction with the respective application, the standard EN ISO 13849-1 has been published: “Safety-related parts of control systems Part 1: General rules for design”. The use of risk assessment to EN 13849-1 is dealt with in the Moeller manual “Safety Specifications for Machines and Plant” (Order No. TB 0-009). Emergency-Stop device Every machine which could potentially cause danger must be equipped with an EmergencyStop device which, in a main circuit may be an Emergency-Stop switch, and in a control circuit an Emergency-Stop control circuit device. Actuation of the Emergency-Stop device must result in all current loads which could directly result in danger, being disconnected by deenergization via another device or circuit, i.e. electromechanical devices such as contactors, contactor relays or the undervoltage release of the mains isolating device. For direct manual operation, Emergency-Stop control circuit devices must have a mushroomhead push-button and positively opening contacts. Once the Emergency-Stop control circuit device has been actuated, it must only be possible to restart the machine after local resetting. Resetting alone must not allow restarting.

Furthermore, the following apply for both Emergency-Stop switch and Emergency control circuit device: • The handle must be red with a yellow background • Emergency-Stop devices must be quickly and easily accessible in the event of danger • The Emergency-Stop function must take precedence over all other functions and operations • It must be possible to determine functional capability by means of tests, especially in severe environmental conditions. • Where there is separation into several Emergency-Stop areas, it must be clearly discernible to which area an Emergency-Stop device applies Emergency operations The term Emergency-Stop is short and concise, and should continue to be used for general usage. It is not clear however from the term EmergencyStop which functions are carried out with this. In order to be able to give a more precise definition here, IEC/EN 60204-1 describes under the generic term “Emergency operations” two specific functions: 1. Emergency-Stop This involves the possibility of stopping dangerous motions as quickly as possible. 2. Emergency-Off Where there is a risk of an electric shock by direct contact, e.g. with live parts in electrical operating areas, then an Emergency-Off device shall be provided.

10-23

10


Standards, formulae, tables Electrically critical equipment of machines Colours of push-buttons and their meanings To IEC/EN 60073, VDE 0199, IEC/EN 60204-1 (VDE 0113 Part 1) Colour

Meaning

Typical application

RED

Emergency

• Emergency-Stop • Fire fighting

YELLOW

Abnormal condition

Intervention, to suppress abnormal conditions or to avoid unwanted changes

GREEN

Normal

Start from safe conditon

BLUE

Enforced action

Resetting function

WHITE

No specific meaning assigned

• Start/ON (preferred) • Stop/OFF

GREY

• Start/ON • Stop/OFF

BLACK

• Start/ON • Stop/Off (preferred)

10

10-24


Standards, formulae, tables Electrically critical equipment of machines Colours of indicator lights and their meanings To IEC/EN 60073, VDE 0199, IEC/EN 60204-1 (VDE 0113 Part 1) Colour

Meaning

Explanation

Typical application

RED

Emergency

Warning of potential danger or a situation which requires immediate action

• Failure of pressure in the lubricating system • Temperature outside specified (safe) limits • Essential equipment stopped by action of a protective device

YELLOW

Abnormal condition

Impending critical condition

• Temperature (or pressure) different from normal level • Overload, which is permissible for a limited time • Reset

GREEN

Normal

Indication of safe operating conditions or authorization to proceed, clear way

• Cooling liquid circulating • Automatic tank control switched on • Machine ready to be started

BLUE

Enforced action

Operator action essential

• Remove obstacle • Switch over to Advance

WHITE

No specific meaning assigned (neutral)

Every meaning: may be used whenever doubt exists about the applicability of the colours RED, YELLOW or GREEN; or as confirmation

• Motor running • Indication of operating modes

10

Colours of illuminated push-buttons and their meanings Both tables are valid for illuminated pushbuttons, Table 1 relating to the function of the actuators.

10-25


Standards, formulae, tables Measures for risk reduction Risk avoidance in a malfunction The IEC/EN 60204 1 specifies a range of measures which can be taken to reduce danger in the event of a fault.

A fault in the electrical equipment must not result in a dangerous situation or in damage. Suitable measures must be taken to prevent danger from arising. The use of proven circuits and components L01

L1 L2

⎧ ⎧ ⎪ ⎪ ⎪ 햳⎨ ⎪ ⎪ ⎪ ⎩ 햲⎨ ⎪ ⎪ ⎪ ⎪ ⎩

햴

0

햵

I

K1

햶

K1 L02

10

햷 a All switching functions on the non-earthed side b Use of break devices with positively opening contacts (not to be confused with interlocked opposing contacts) c Shut-down by de-excitation (fail-safe in the event of wire breakage) d Circuit engineering measures which make undesirable operational states in the event of a fault unlikely (in this instance, simultaneous interruption via contactor and position switch) e Switching of all live conductors to the device to be controlled 10-26

f Chassis earth connection of the control circuit for operational purposes (not used as a protective measure) Redundancy This means the existence of an additional device or system which takes over the function in the event of a fault.


Standards, formulae, tables Measures for risk reduction Diversity The construction of control circuits according to a range of function principles or using various types of device.

c 21

e 13

a

22

K1

d

14

K2

b K1

K2

10 a Functional diversity by combination of N/O and N/C contacts b Diversity of devices due to use of various types of device (here, various types of contactor relay) c Safety barrier open d Feedback circuit e Safety barrier closed

Performance tests The correct functioning of the equipment can be tested either manually or automatically.

10-27


Standards, formulae, tables Degrees of protection for electrical equipment Degrees of protection for electrical equipment by enclosures, covers and similar to IEC/EN 60529 (VDE 0470 part 1) The designation to indicate degrees of enclosure protection consists of the characteristic letters IP (Ingress Protection) followed by two characteristic numerals. The first numeral indicates the degree of protection of persons

against contact with live parts and of equipment against ingress of solid foreign bodies and dust, the second numeral the degree of protection against the ingress of water.

Protection against contact and foreign bodies

10

First numeral

Degree of protection Description

Explanation

0

Not protected

No special protection of persons against accidental contact with live or moving parts. No protection of the equipment against ingress of solid foreign bodies.

1

Protection against solid objects f 50 mm

Protection against contact with live parts with back of hand. The access probe, sphere 50 mm diameter, must have enough distance from dangerous parts. The probe, sphere 12,5 mm diameter, must not fully penetrate.

2

Protection against solid objects f 12.5 mm

Protection against contact with live parts with a finger. The articulated test finger, 12 mm diameter and 80 mm length, must have suffient distance from dangerous parts. The probe, sphere 12.5 mm diameter, must not fully penetrate.

10-28


Standards, formulae, tables Degrees of protection for electrical equipment Protection against contact and foreign bodies First nume ral


Explanation

3

Protection against solid objects f 2.5 mm

Protection against contact with live parts with a tool. The entry probe, 1.0 mm diameter, must not penetrate. The probe, 2.5 mm diameter, must not penetrate.

4

Protection against solid objects f 1 mm

Protection against contact with live parts with a wire. The entry probe, 1.0 mm diameter, must not penetrate. The probe, 1.0 mm diameter, must not penetrate.

5

Protection against accumulation of dust

Protection against contact with live parts with a wire. The entry probe, 1.0 mm diameter, must not penetrate. The ingress of dust is not totally prevented, but dust does not enter in sufficient quantity to interfere with satisfactory operation of the equipment or with safety.

6

Protection against the ingress of dust

Protection against contact with live parts with a wire. The entry probe, 1.0 mm diameter, must not penetrate.

Dust-tight

No entry of dust.

10 Example for stating degree of protection:

IP

4

4

Characteristic letter First numeral Second numeral

10-29


Standards, formulae, tables Degrees of protection for electrical equipment Protection against water

10

Second numeral


Explanation

0

Not protected

No special protection

1

Protected against vertically dripping water

Dripping water (vertically falling drops) shall have no harmful effect.

2

Protected against dripping water when enclosure tilted up to 15?

Dripping water shall have no harmful effect when the enclosure is tilted at any angle up to 15? from the vertical.

3

Protected against sprayed water

Water falling as a spray at any angle up to 60° from the vertical shall have no harmful effect.

4

Protected against splashing water

Water splashed against the enclosure from any direction shall have no harmful effect.

5

Protected against water jets

Water projected by a nozzle against the equipment from any direction shall have no harmful effect.

6

Protected against powerful water jets

Water projected in powerful jets against the enclosure from any direction shall have no harmful effect.

7

Protected against the effects of occasional submersion

Ingress of water in harmful quantities shall not be possible when the enclosure is immersed in water under defined conditions of pressure and time.

10-30


Standards, formulae, tables Degrees of protection for electrical equipment Second numeral


Explanation

8

Protected against the effects of submersion

Ingress of water in harmful quantities must not be possible when the equipment is continuously submerged in water under conditions which are subject to agreement between manufacturer and user. These conditions must be more stringent than those for characteristic numeral 7.

9K*

Protected during cleaning using high-pressure/steam jets

Water which is directed against the enclosure under extremely high pressure from any direction must not have any harmful effects. Water pressure of 100 bar Water temperature of 80 °C

* This characteristic numeral originates from DIN 40050 9.

10

10-31


Standards, formulae, tables Degrees of protection for electrical equipment Type of current

Utilisation catorgory

Typical applications:

I = Switch-on current, Ic = Switch-off current, Ie = Rated operational current, U = Voltage, Ue = Rated operational voltage Ur = Recovery voltage, t0,95 = Time in ms, until 95 % of the steady-state current has been reached. P = Ue x Ie = Rated power in Watts Alternating current

10

Direct current

Switch on

Abnorm

Switch off

I

U

Ie

Ue

Switch

c

I

U

Ie

Ue

c

I Ie

AC-12

Control of resistive and solid state loads as in optocoupler input circuits

1

1

0.9

1

1

0.9

–

AC-13

Control of solid state loads with transformer isolation

2

1

0.65

1

1

0.65

10

AC-14

Control of small electromagnetic loads (max. 72 VA)

6

1

0.3

1

1

0.3

6

AC-15

Control of electromagnetic loads (above 72 VA)

10

1

0.3

1

1

0.3

10

DC-12

I

U

Ie

Ue

t0,95

I

U

Ie

Ue

T0,95

I Ie

Control of resistive and solid state loads as in optocoupler input circuits

1

1

1 ms

1

1

1 ms

–

DC-13

Control of electromagnets

1

1

6 x P1)

1

1

6 x P1)

1.1

DC-14

Control of electromagnetic loads with economy resistors in the circuit

10

1

15 ms

1

1

15 ms

10

to IEC 60947-5-1, EN 60947-5-1 (VDE 0600 part 200)

10-32

Normal conditions of use

1)

The value “6 x P” results from an empirical re loads to an upper limit of P = 50 W, i.e. 6 [ms]/[W greater than 50 W are assumed to consist of sma an upper limit, irrespective of the power consum

s:

ent, Ic = Switch-off current, onal current, U = Voltage, onal voltage age, until 95 % of the steady-state eached. ed power in Watts


Standards, formulae, tables Degrees of protection for electrical equipment Normal conditions of use

Switch on

Abnormal conditions of use

Switch off

I

U

Ie

Ue

Switch on

c

I

U

Ie

Ue

c

Switch off

I

U

Ie

Ue

c

I

U

Ie

Ue

c

and solid state loads as in circuits

1

1

0.9

1

1

0.9

–

–

–

–

–

–

te loads with transformer iso-

2

1

0.65

1

1

0.65

10

1.1

0.65

1.1

1.1

0.65

ectromagnetic loads (max. 72

6

1

0.3

1

1

0.3

6

1.1

0.7

6

1.1

0.7

magnetic loads (above 72 VA)

10

1

0.3

1

1

0.3

10

1.1

0.3

10

1.1

0.3

I

U

T0,95

I

U

T0,95

Ie

Ue

Ie

Ue

I

U

Ie

Ue

t0,95

I

U

Ie

Ue

T0,95

10

1

1

1 ms

1

1

1 ms

–

–

–

–

–

–

magnets

1

1

6 x P1)

1

1

6 x P1)

1.1

1.1

6 x P1)

1.1

1.1

6 x P1)

magnetic loads with economy uit

10

1

15 ms

1

1

15 ms

10

1.1

15 ms

10

1.1

15 ms

and solid state loads as in circuits

t 200)

1) The value “6 x P” results from an empirical relationship that represents most DC magnetic loads to an upper limit of P = 50 W, i.e. 6 [ms]/[W] = 300 [ms]. Loads having a power consumption greater than 50 W are assumed to consist of smaller loads in parallel. Therefore, 300 ms is to be an upper limit, irrespective of the power consumption.

10-33


Standards, formulae, tables Utilisation categories for contactors and motor starters Type of current

Alternating current

10

10-34

Utilisation catorgory

Typical applications: I = Switch-on current, Ic = Switch-off current, Ie = Rated operational current, U = voltage, Ue = Rated operational voltage Ur = Recovery voltage

Verification of electrical lifespan

AC-1

Non-inductive or slightly inductive loads, resistance furnaces

All values

1

1

0.95

1

1

0.95

All values

1

AC-2

Slip-ring motors: starting, switch-off

All values

2.5

1

0.65

2.5

1

0.65

All values

4

AC-3

Squirrel-cage motors: stating, switch-off, switch-off during running4)

Ie F 17 6 Ie > 17 6

1 1

0.65 0.35

1 1

0.17 0.17

0.65 0.35

Ie F 100 Ie > 100

8 8

AC-4

Sqirrel-cage motors: starting, plugging, reversing, inching

Ie F 17 6 Ie > 17 6

1 1

0.65 0.35

6 6

1 1

0.65 0.35

Ie F 100 Ie > 100

1 1

AC-5A

Switching of electric discharge lamp controls

3

AC-5B

Switching of incandescent lamps

1.

AC-6A3)

Switching of transformers

AC-6B3)

Switching of capacitor banks

AC-7A

Slightly inductive loads in household appliances and similar applications

Verification of

Switch on

Switch off

Ie

I

U

A

Ie

Ue

Data as supplied by the manufacturer

c

Ic

Ur

Ie

Ue

Switch on c

Ie

I

A

I

1

AC-7B

Motor load for household appliances

8

AC-8A

Switching of hermetically enclosed refrigerant compressor motors with manual reset of overload releases5)

6

AC-8B

Switching of hermetically enclosed refrigerant compressor motors with automatic reset of overload releases5)

6

AC-53a

Switching of squirrel-cage motor with semi-conductor contactors

8


Standards, formulae, tables Utilisation categories for contactors and motor starters

s: nt, ent, nal current,

onal voltage age

Verification of electrical lifespan

Verification of switching capacity

Switch on

Switch off

Ie

I

U

A

Ie

Ue

c

Ic

Ur

Ie

Ue

Switch on c

Switch off

Ie

I

U

A

Ie

Ue

c

Ic

Ur

Ie

Ue

c

ghtly inductive loads,

All values

1

1

0.95

1

1

0.95

All values

1.5

1.05

0.8

1.5

1.05

0.8

arting, switch-off

All values

2.5

1

0.65

2.5

1

0.65

All values

4

1.05

0.65

4

1.05

0.8

rs: stating, switch-off, unning4)

Ie F 17 6 Ie > 17 6

1 1

0.65 0.35

1 1

0.17 0.17

0.65 0.35

Ie F 100 Ie > 100

8 8

1.05 1.05

0.45 0.35

8 8

1.05 1.05

0.45 0.35

: starting, plugging,

Ie F 17 6 Ie > 17 6

1 1

0.65 0.35

6 6

1 1

0.65 0.35

Ie F 100 Ie > 100

10 10

1.05 1.05

0.45 0.35

10 10

1.05 1.05

0.45 0.35

c discharge lamp con-

3.0

1.05

0.45

3.0

1.05

0.45

descent lamps

1.52)

1.05

2)

1.52)

1.05

2)

1.5

1.05

0.8

1.5

1.05

0.8

8.0

1.05

1)

8.0

1.05

1)

6.0

1.05

1)

ormers tor banks

ads in household applipplications

sehold appliances

Data as supplied by the manufacturer

tically enclosed refrigertors with manual reset s5)

6.0

1.05

1)

tically enclosed refrigertors with automatic leases5)

6.0

1.05

1)

6.0

1.05

1)

el-cage motor with ntactors

8.0

1.05

0.35

8.0

1.05

0.35

10-35

10


Standards, formulae, tables Utilisation categories for contactors and motor starters Type of current

Direct current

Utilization category

Typical applications: I = Switch-on current, Ic = Switch-off current, Ie = Rated operational current, U = voltage, Ue = Rated operational voltage, Ur = Recovery voltage

Verification of electrical endurance

Verification of sw

DC-1

Non-inductive or slightly inductive loads, resistance furnaces

All values

1

1

1

1

1

1

All values

1

DC-3

Shunt motors: starting, plugging, reversing, inching, dynamic braking

All values

2.5

1

2

2.5

1

2

All values

4

DC-5

Series motors: starting, plugging, reversing, inching, dynamic braking

All values

2.5

1

7.5

2.5

1

7.5

All values

4

DC-6

Switching of incandescent lamps

Switch on

Switch off

Ie

I

U

A

Ie

Ue

L/R ms

Ic

Ur

Ie

Ue

Switch on L/R ms

Ie A

I

1

To IEC/EN 947 4-1-60947, VDE 0660 Part 102 1) 2) 3)

c = 0,45 for Ie F 100 A; c = 0,35 for Ie > 100 A. Tests must be carried out with an incandescent lamp load connected. Here, the test data are to be derived from the AC-3 or AC-4 test values in accordance with TableVIIb, IEC/EN 60 947-4-1.

10

10-36

4)

Devices for utilization category AC-3 may be u limited period such as for setting up a machin operations must not exceed a total of five per 5) Hermetically enclosed refrigerant compressor a motor both of which are housed in the same the motor running in the refrigerant.

: nt, ent, nal current,

onal voltage, ge


Standards, formulae, tables Utilisation categories for contactors and motor starters Verification of electrical endurance


Switch on

Switch off

Ie

I

U

A

Ie

Ue

L/R ms

Ic

Ur

Ie

Ue

Switch on L/R ms

Switch off

Ie

I

U

A

Ie

Ue

L/R ms

Ic

Ur

Ie

Ue

L/R ms

ghtly inductive loads,

All values

1

1

1

1

1

1

All values

1.5

1.05

1

1.5

1.05

1

ng, plugging, reversic braking

All values

2.5

1

2

2.5

1

2

All values

4

1.05

2.5

4

1.05

2.5

ng, plugging, reversic braking

All values

2.5

1

7.5

2.5

1

7.5

All values

4

1.05

15

4

1.05

15

1.52)

1.05

2)

1.52)

1.05

2)

escent lamps

Ie > 100 A. t lamp load connected. AC-3 or AC-4 test values in accordance with

4)

5)

Devices for utilization category AC-3 may be used for occasional inching or plugging during a limited period such as for setting up a machine; during this limited time period, the number of operations must not exceed a total of five per minute or more than ten in a ten minute period. Hermetically enclosed refrigerant compressor motor means a combination of a compressor and a motor both of which are housed in the same enclosure with no external shaft or shaft seals, the motor running in the refrigerant.

10-37

10


Standards, formulae, tables Utilisation categories for switch-disconnectors Type of current

Alternating current

Direct current

10 1)

Utilization category

Typical applications: I = switch-on current, Ic = Switch-off current, Ie = Rated operational current, U = voltage, Ue = Rated operational voltage, Ur = Recovery voltage


AC-20 A(B)1)

Making and breaking without load

All values

1)

1)

1)

AC-21 A(B)1)

Switching resistive loads including low overloads

All values

1.5

1.05

0.95

1.5

1

AC-22 A(B)1)

Switching mixed resistive and inductive loads including low overloads

All values

3

1.05

0.65

3

1

AC-23 A(B)1)

Switching motors and other highly inductive loads

Ie F100 Ie > 100

10 10

1.05 1.05

0.45 0.35

8 8

1 1

L/R ms

Switch o

Ie

I

U

A

Ie

Ue

Ie

I

U

A

Ie

Ue

c

Ic

U

Ie

U

Ic

U

Ie

U

DC-20 A(B)1)

Making and breaking without load

All values

1)

1)

1)

1)

1)

DC-21 A(B)1)

Switching resistive loads including low overloads

All values

1.5

1.05

1

1.5

1

DC-22 A(B)1)

Switching mixed resistive and inductive loads, including low overloads (e.g. shunt motors)

All values

4

1.05

2.5

4

1

DC-23 A(B)1)

Switching highly inductive loads (e.g. series motors)

All values

4

1.05

15

4

1

A: Frequent operation, B: Occassional operation.

For load-break switches, switch-disconnectors and switch-fuse units to IEC/EN 60947-3 (VDE 0660 part 107). Switch-disconnectors that are suitable for switching motors are also tested according to the criteria stated in a section "Utilisation categories for contactors and motor starters", page 10-34.

10-38

Switch on


Standards, formulae, tables Utilisation categories for switch-disconnectors

ons: rrent, urrent, tional current,

ational voltage, oltage

Verification of switching capacity Switch on

Switch off

Ie

I

U

A

Ie

Ue

c

Ic

Ur

Ie

Ue

c

aking without load

All values

1)

1)

1)

ve loads including low overloads

All values

1.5

1.05

0.95

1.5

1.05

0.95

resistive and inductive loads including low over-

All values

3

1.05

0.65

3

1.05

0.65

s and other highly inductive loads

Ie F100 Ie > 100

10 10

1.05 1.05

0.45 0.35

8 8

1.05 1.05

0.45 0.35

L/R ms

Ic

Ur

Ie

Ue

L/R ms

Ie

I

U

A

Ie

Ue

1)

aking without load

All values

1)

1)

1)

1)

1)

1)

ve loads including low overloads

All values

1.5

1.05

1

1.5

1.05

1

resistive and inductive loads, including low overmotors)

All values

4

1.05

2.5

4

1.05

2.5

inductive loads (e.g. series motors)

All values

4

1.05

15

4

1.05

15

10

tion.

tors and switch-fuse units to

ing motors are also tested according to the ies for contactors and motor starters",

10-39


Standards, formulae, tables Rated motor currents Rated motor currents of three-phase motors (guideline values for cage motors) Smallest possible short-circuit protection for three-phase motor The maximum value is determined by the switchgear or overload relay. The rated motor currents are for standard 1500 r.p.m. motors with normal inner and outer surface cooling. D.O.L. starting:

Maximum starting current: 6 x rated current Maximum starting time: 5 sec.

y/d starting:

Maximum starting current: 2 x rated current Maximum starting time: 15 sec. Motor overload relay in phase current: set to 0.58 x rated current.

10

10-40

Rated fuse currents for y/d starting also apply to three-phase motors with slip-ring rotors. For higher rated currents, starting currents and/or longer starting times, larger fuses will be required. Table applies for time-lag and gL fuses (VDE 0636). In the case of low-voltage h.b.c. fuses (NH type) with aM characteristics, fuses are to be selected according to their current rating.


Standards, formulae, tables Rated motor currents Motor rating

230 V

400 V

Rated motor current

Fuse

y/d

Rated motor current

Fuse

Direct starting

Direct starting

y/d

kW

cos v

h [%]

A

A

A

A

A

A

0.06 0.09 0.12 0.18

0.7 0.7 0.7 0.7

58 60 60 62

0.37 0.54 0.72 1.04

2 2 4 4

– – 2 2

0.21 0.31 0.41 0.6

2 2 2 2

– – – –

0.25 0.37 0.55 0.75

0.7 0.72 0.75 0.79

62 66 69 74

1.4 2 2.7 3.2

4 6 10 10

2 4 4 4

0.8 1.1 1.5 1.9

4 4 4 6

2 2 2 4

1.1 1.5 2.2 3

0.81 0.81 0.81 0.82

74 74 78 80

4.6 6.3 8.7 11.5

10 16 20 25

6 10 10 16

2.6 3.6 5 6.6

6 6 10 16

4 4 6 10

4 5.5 7.5 11

0.82 0.82 0.82 0.84

83 86 87 87

14.8 19.6 26.4 38

32 32 50 80

16 25 32 40

8.5 11.3 15.2 21.7

20 25 32 40

10 16 16 25

15 18.5 22 30

0.84 0.84 0.84 0.85

88 88 92 92

51 63 71 96

100 125 125 200

63 80 80 100

29.3 36 41 55

63 63 80 100

32 40 50 63

37 45 55 75

0.86 0.86 0.86 0.86

92 93 93 94

117 141 173 233

200 250 250 315

125 160 200 250

68 81 99 134

125 160 200 200

80 100 125 160

90 110 132 160

0.86 0.86 0.87 0.87

94 94 95 95

279 342 401 486

400 500 630 630

315 400 500 630

161 196 231 279

250 315 400 400

200 200 250 315

200 250 315 400

0.87 0.87 0.87 0.88

95 95 96 96

607 – – –

800 – – –

630 – – –

349 437 544 683

500 630 800 1000

400 500 630 800

450 500 560 630

0.88 0.88 0.88 0.88

96 97 97 97

– – – –

– – – –

– – – –

769 – – –

1000 – – –

800 – – –

10

10-41


Standards, formulae, tables Rated motor currents Motor rating

10

500 V

690 V

Rated motor current

Fuse

y/d

Rated motor current

Fuse

Direct starting

Direct starting

y/d

kW

cos v

h [%]

A

A

A

A

A

A

0.06 0.09 0.12 0.18

0.7 0.7 0.7 0.7

58 60 60 62

0.17 0.25 0.33 0.48

2 2 2 2

– – – –

0.12 0.18 0.24 0.35

2 2 2 2

– – – –

0.25 0.37 0.55 0.75

0.7 0.72 0.75 0.79

62 66 69 74

0.7 0.9 1.2 1.5

2 2 4 4

– 2 2 2

0.5 0.7 0.9 1.1

2 2 4 4

– – 2 2

1.1 1.5 2.2 3

0.81 0.81 0.81 0.82

74 74 78 80

2.1 2.9 4 5.3

6 6 10 16

4 4 4 6

1.5 2.1 2.9 3.8

4 6 10 10

2 4 4 4

4 5.5 7.5 11

0.82 0.82 0.82 0.84

83 86 87 87

6.8 9 12.1 17.4

16 20 25 32

10 16 16 20

4.9 6.5 8.8 12.6

16 16 20 25

6 10 10 16

15 18.5 22 30

0.84 0.84 0.84 0.85

88 88 92 92

23.4 28.9 33 44

50 50 63 80

25 32 32 50

17 20.9 23.8 32

32 32 50 63

20 25 25 32

37 45 55 75

0.86 0.86 0.86 0.86

92 93 93 94

54 65 79 107

100 125 160 200

63 80 80 125

39 47 58 78

80 80 100 160

50 63 63 100

90 110 132 160

0.86 0.86 0.87 0.87

94 94 95 95

129 157 184 224

200 250 250 315

160 160 200 250

93 114 134 162

160 200 250 250

100 125 160 200

200 250 315 400

0.87 0.87 0.87 0.88

95 95 96 96

279 349 436 547

400 500 630 800

315 400 500 630

202 253 316 396

315 400 500 630

250 315 400 400

450 500 560 630

0.88 0.88 0.88 0.88

96 97 97 97

615 – – –

800 – – –

630 – – –

446 491 550 618

630 630 800 800

630 630 630 630

10-42


Standards, formulae, tables Conductors Wiring and cable entries with grommets Cable entry into closed devices is considerably simplified and improved by using cable grommets. Membrane grommets metric

• IP66, with integrated pushthrough diaphragm • PE and thermoplasti c elastomer, halogen free

Cable entry

Cable grommets For direct and quick cable entry into an enclosure and as a plug.

Hole diamter

Cable external diameter

For use with NYM/NYY cables, 4-core

Cable grommet

mm

mm

mm2

M16

16.5

1–9

H03VV-F3 x 0.75 NYM 1 x 16/3 x 1.5

KT-M16

M20

20.5

1 – 13

H03VV-F3 x 0.75 NYM 5 x 1.5/5 x 2.5

KT-M20

M25

25.5

1 – 18

H03VV-F3 x 0.75 NYM 4x 10

KT-M25

M32

32.5

1 – 25

H03VV-F3 x 0.75 NYM 4 x 16/5 x 10

KT-M32

Detailed information on material properties a table, page 10-45.

10

10-43


Standards, formulae, tables Conductors Wiring and cable entries with cable glands Metric cable glands to EN 50262 with 9, 10, 12, 14 or 15 mm long thread. Cable glands

• With lock nut and built-in strain relief • IP68 up to 5 bar, polyamide, halogen-free

10

Cable entry

Hole diamter

Cable external diameter

For use with NYM/NYY cables, 4-core

mm

mm

mm2

M12

12.5

3 –7

H03VV-F3 x 0.75 NYM 1 x 2.5

V-M12

M16

16.5

4.5 – 10

H05VV-F3 x 1.5 NYM 1 x 16/3 x 1.5

V-M16

M20

20.5

6 – 13

H05VV-F4 x 2.5/3 x 4 NYM 5 x 1.5/5 x 2.5

V-M20

M25

25.5

9 – 17

H05VV-F5 x 2.5/5 x 4 NYM 5 x 2.5/5 x 6

V-M25

M32

32.5

13 – 21

NYM 5 x 10

V-M32

M32

32.5

18 – 25

NYM 5 x 16

V-M32G1)

M40

40.5

16 – 28

NYM 5 x 16

V-M40

M50

50.5

21 – 35

NYM 4 x 35/5 x 25

V-M50

M63

63.5

34 – 48

NYM 4 x 35

V-M63

1) Does not correspond to EN 50262.

Detailed information on material properties a table, page 10-45.

10-44

Cableglands Type


Standards, formulae, tables Conductors Material characteristics KT-M…

V-M…

Material

Polyethylene and thermoplastic elastomer

Polyamide, halogen free

Colour

Grey, RAL 7035

Grey, RAL 7035

Protection type

up to IP66

IP68 up to 5 bar (30 min)

Chemical resistant

Resistant to: • Alcohol, • Animal and plant-based oils, • Weak alkalis, • Weak acids, • water

Resistant to: • Acetone, • Petrol, • paraffin, • Diesel oil, • Greases, • Oils, • Solvents for paints and lacquers

Danger of stress fracture

Relative high

low

Heat resistance

–40 °C…80 °C, short-time up to approx. 100 °C

–20 °C…100 °C, short-time up to approx. 120 °C

Flame retardant

–

Glow wire test 750 °C according to EN 60695-2-11

Flammability to UL94

–

V2

10

10-45


Standards, formulae, tables Conductors External diameter of conductors and cables Number of conductors

10

Cross-section mm2 2 x 1.5 2 x 2.5 3 x 1.5 3 x 2.5 3 x 4 3 x 6 3 x 10 3 x 16 4 x 1.5 4 x 2.5 4 x 4 4 x 6 4 x 10 4 x 16 4 x 25 4 x 35 4 x 50 4 x 70 4 x 95 4 x 120 4 x 150 4 x 185 4 x 240 5 x 1.5 5 x 2.5 5 x 4 5 x 6 5 x 10 5 x 16 8 x 1.5 10 x 1.5 16 x 1.5 24 x 1.5

Approximate external diameter (average of various makes) NYM NYY H05 H07 RR-F RN-F mm mm mm mm max. max. max. 10 11 9 10 11 13 13 11 10 12 10 10 11 13 11 12 13 17 – 14 15 18 – 16 18 20 – 23 20 22 – 25 11 13 9 11 12 14 11 13 14 16 – 15 16 17 – 17 18 19 – 23 22 23 – 27 27 27 – 32 30 28 – 36 – 30 – 42 – 34 – 47 – 39 – 53 – 42 – – – 47 – – – 55 – – – 62 – – 11 14 12 14 13 15 14 17 15 17 – 19 17 19 – 21 20 21 – 26 25 23 – 30 – 15 – – – 18 – – – 20 – – – 25 – –

NYM: sheathed conductor NYY: plastic-sheathed cable H05RR-F: light rubber-sheathed flexible cable (NLH + NSH)

10-46

NYCY NYCWY mm 12 14 13 14 15 16 18 22 13 15 16 18 21 24 30 31 34 38 43 46 52 60 70 15 17 18 20 – – – – – –

NYCY: cable with concentric conductor and plastic sheath NYCWY: cable with concentric wave-form conductor and plastic sheath


Standards, formulae, tables Conductors Cables and wiring, type abbreviation Identification of specification Harmonized specification Recognized national type

H A

Rated operational voltage UO/U 300/300V 300/500V 450/750V

03 05 07

Insulating material PVC Natural and/or synthetic rubber Silicon rubber

V R S

Sheathing material PVC Natural and/or synthetic rubber Polychloroprene rubber Fibre-glass braid Textile braid

V R N J T

Special construction feature Flat, separable conductor Flat, non-separable conductor

H H2

Type of conductor Solid Stranded Flexible with cables for fixed installation Flexible with flexible cables Highly flexible with flexible cables Tinsel cord Number of cores Protective conductor Without protective conductors With protective conductors Rated conductor cross-section Examples for complete cable designation PVC-sheathed wire, 0.75 mm2 flexible, H05V-K 0.75 black

10 -U -R -K -F -H -Y ... X G ... Heavy rubber-sheathed cable, 3-core, 2.5 mm2 without green/yellow protective conductor A07RN-F3 x 2.5 10-47


Standards, formulae, tables Conductors Rated operational currents and short-circuit currents for standard transformers Rated voltage 400/230 V

525 V

690/40

Un Short-circuit voltage UK Rating

10

4%

6%

4%

6%

Rated current

Short-circuit current

Rated current


Rated cu

In

IK’’

In

IK’’

In

kVA

A

A

A

A

A

A

A

50

72

1967

–

55

1498

–

42

63

91

2478

1652

69

1888

1259

53

100

144

3933

2622

110

2997

1998

84

125

180

4916

3278

137

3746

2497

105

160

231

6293

4195

176

4795

3197

134

200

289

7866

5244

220

5993

3996

167

250

361

9833

6555

275

7492

4995

209

315

455

12390

8260

346

9440

6293

264

400

577

15733

10489

440

11987

7991

335

500

722

19666

13111

550

14984

9989

418

630

909

24779

16519

693

18879

12586

527

800

1155

–

20977

880

–

15983

669

1000

1443

–

26221

1100

–

19978

837

1250

1804

–

32777

1375

–

24973

1046

1600

2309

–

41954

1760

–

31965

1339

2000

2887

–

52443

2199

–

39956

1673

2500

3608

–

65553

2749

–

49945

2092

10-48


Standards, formulae, tables Conductors

525 V

6%

rcuit

690/400 V

4% Rated current

6%


4% Rated current


6%

In

IK’’

In

IK’’

A

A

A

A

A

A

A

–

55

1498

–

42

1140

–

1652

69

1888

1259

53

1436

958

2622

110

2997

1998

84

2280

1520

3278

137

3746

2497

105

2850

1900

4195

176

4795

3197

134

3648

2432

5244

220

5993

3996

167

4560

3040

6555

275

7492

4995

209

5700

3800

8260

346

9440

6293

264

7182

4788

10489

440

11987

7991

335

9120

6080

13111

550

14984

9989

418

11401

7600

16519

693

18879

12586

527

14365

9576

20977

880

–

15983

669

–

12161

26221

1100

–

19978

837

–

15201

32777

1375

–

24973

1046

–

19001

41954

1760

–

31965

1339

–

24321

52443

2199

–

39956

1673

–

30402

65553

2749

–

49945

2092

–

38002

10

10-49


Standards, formulae, tables Formulea Ohm's Law U = I × R [V]

U I = --- [ A ] R

U R = --- [ Ω ] I

Resistance of a piece of wire l R = ------------ [ Ω ]

Copper:

m χ = 57 --------------2Ωmm

l = Length of conductor [m]

Aluminium:

m χ = 33 --------------2Ωmm

z = Conductivity [m/Omm2]

Iron:

m χ = 8,3 --------------2Ωmm

A = Conductor cross section [mm2]

Zinc:

m χ = 15,5 --------------2Ωmm

χ×A

Resistors Transformer

XL = 2 × π × f × L [ Ω ]

Capacitors

1 X C = ----------------------------- [ Ω ] 2×π×f×C

Impedance

10

L = Inductance [H] C = Capacitance [F] XL = Inductive impedance [O] XC = Capacitive impedance [O] Parallel connection of resistances

Z =

2

R + ( XL – XC )

2

R Z = ----------- [ Ω ] cosv

f = Frequency [Hz] v = Phase angle

With 2 parallel resistances:

With 3 parallel resistances:

R1 × R2 R g = ---------------- [ Ω ] R1 + R2

R1 × R2 × R3 R g = --------------------------------------------------------------- [ Ω ] R1 × R2 + R2 × R3 + R1 × R3

General calculation of resistances: 1- ---1 1 --1- = ---+ - + ----- + ... [ 1 ⁄ Ω ] R R1 R2 R3 1- ---1 1 --1- = ---+ - + ----- + ... [ 1 ⁄ Ω ] X1 X2 X3 X

10-50

1 ---1 1 --1 = ---+ + ---- + ... [ 1 ⁄ Ω ] Z Z1 Z2 Z3


Standards, formulae, tables Formulea Electric power Power

Current consumption

Direct current

P = U × I [W]

P I = --- [ A ] U

Single-phase AC

P = U × I × cosϕ [ W ]

P I = --------------------- [ A ] U × cosϕ

Alternating current

P =

3 × U × I × cosϕ [ W ]

P I = ---------------------------------- [ A ] 3 × U × cosϕ

Mechanical force between 2 parallel conductors 2 conductors with currents I1 and I2 0,2 × I 1 × I 2 × s - [N] F 2 = ---------------------------------a

s = Support spacing clearance [cm]

I1 I2

a

s

a = Support spacing clearance [cm] Mechanical force between 3 parallel conductors

10

3 conductors with current I F 3 = 0,808 × F 2 [ N ] F 3 = 0,865 × F 2 [ N ] F 3 = 0,865 × F 2 [ N ]

10-51


Standards, formulae, tables Formulea Voltage drop Known power

Known current

Direct current

2×l×P ΔU = ---------------------- [ V ] z×A×U

2×l×l ΔU = ------------------ [ V ] z×A

Single-phase AC

2×l×P ΔU = ---------------------- [ V ] z×A×U

2×l×l ΔU = ------------------ × cos ϕ [ V ] z×A

Alternating current

l×P ΔU = ---------------------- [ V ] z×A×U

ΔU =

l×l 3 × ------------ × cos ϕ [ V ] z×A

Calculation of cross-section from voltage drop Direct current

Single-phase AC

Alternating current

2×l×P 2 A = -------------------------- [ mm ]

l×P 2 A = -------------------------- [ mm ]

Known power 2×l×P 2 A = -------------------------- [ mm ] z × Δu × U

z × Δu × U

z × Δu × U

Known current 2×l×l 2 A = ------------------ [ mm ] z × Δu

10

2×l×l 2 A = ------------------ × cosϕ [ mm ] z × Δu

A =

l×l 2 3 × ---------------- × cos ϕ [ mm ] z × Δu

Power loss Direct current 2×l×P×P P Verl = -------------------------------- [ W ] z×A×U×U

Single-phase AC 2×l×P×P P Verl = ------------------------------------------------------------------- [ W ] z × A × U × U × cosv × cosv

Alternating current l×P×P P Verl = ------------------------------------------------------------------- [ W ] z × A × U × U × cosv × cosv

l = Single length of conductor [m]; A = Conductor cross section [mm2]; m z = Conductivity (copper: z = 57; aluminium: z = 33; iron: z = 8.3 --------------2- ) Omm Du = Voltage drop

10-52


Standards, formulae, tables Formulea Power of electric motors Output

Current consumption

Direct current

P1 = U × l × h [ W ]

P1 - [A] l = -----------U×h

Singlephase AC

P 1 = U × l × cosv × h [ W ]

P1 - [A] l = -----------------------------U × cosv × h

Alternating current

P 1 = (1,73) × U × l × cosv × h [ W ]

P1 - [A] l = ------------------------------------------------(1,73) × U × cosv × h

P1 = Rated mechanical power at the motor shaft P2 = Electrical power consumption Efficiency

P1 h = ----- × (100 %) P2

P P 2 = ----1- [ W ] h

Number of poles

Synchronous speed

Full-load speed

2

3000

2800 – 2950

4

1500

1400 – 1470

6

1000

900 – 985

8

750

690 – 735

10

600

550 – 585

10

Synchronous speed = approx. no-load speed

10-53


Standards, formulae, tables Standard international units International Unit System (SI) Basic parameters Physical parameters

Symbol

SI basic unit

Further related SI units

Length

l

m (Metre)

km, dm, cm, mm, mm, nm, pm

Mass

m

kg (Kilogram)

Mg, g, mg, mg

Time

t

s (Second)

ks, ms, ms, ns

Electrical current

I

A (Ampere)

kA, mA, mA, nA, pA

Thermo-dynamic temperature

T

K (Kelvin)

–

Amount of substance

n

mole (Mol)

Gmol, Mmol, kmol, mmol, mmol

Light intensity

Iv

cd (Candela)

Mcd, kcd, mcd

Factors for conversion of old units into SI units Conversion factors

10

Size

Old unit

SI unit exact

Approximate

Force

1 kp 1 dyn

9.80665 N 1·10-5 N

10 N 1·10-5 N

Momentum of force

1 mkp

9.80665 Nm

10 Nm

Pressure

1 at 1 Atm = 760 Torr 1 Torr 1 mWS 1 mmWS 1 mmWS

0.980665 bar 1.01325 bar 1.3332 mbar 0.0980665 bar 0.0980665 mbar 9.80665 Pa

1 bar 1.01 bar 1.33 bar 0.1 bar 0.1 mbar 10 Pa

Tension

kp 1 ---------2mm

N 9,80665 ---------2mm

N 10 ---------2mm

Energy

1 mkp 1 kcal 1 erg

9.80665 J 4.1868 kJ 1·10-7 J

10 J 4.2 kJ 1·10-7 J

10-54


Standards, formulae, tables Standard international units Conversion factors Size

Old unit

SI unit exact

Approximate

Power

kcal 1 -------h

kJ 4,1868 ---h

kJ 4,2 ---h

kcal 1 -------h

1.163 W

1.16 W

1 PS

0.73549 kW

0.74 kW

kcal 1 -------------2 m h°C

kJ 4,1868 -----------2 m hK

kJ 4,2 ----------2 m hK

kcal 1 -------------2 m h°C

W 1,163 --------2 m K

W 1,16 --------2 m K

Heat transfer coefficient

dynamic viscosity

1 ⋅ 10

–6

kps------2 m

0, 980665 ⋅ 10

1 Poise

Ns 0,1 ------2 m

1 Poise 0.1

Pa ⋅ s

–5

Ns----2 m

– 5 Ns 1 ⋅ 10 ------2 m

Ns 0,1 ------2 m

Kinetic viscosity

1 Stokes

Angle (flat)

1

1------pla 360

2, 78 ⋅ 10 pla

1 gon

1------pla 400

2, 5 ⋅ 10 pla

1

π -------- rad 180

17, 5 ⋅ 10 rad

1 gon

π------rad 200

15, 7 ⋅ 10 pla

1 ⋅ 10

–4

2

m -----s

1 ⋅ 10

–4

2

m -----s

10

–3

–3

–3

–3

57,296

1 rad

63,662 gon

1 rad

10-55


Standards, formulae, tables Standard international units Conversion of SI units, coherences Conversion of SI units and coherences Size

Symbol

Basic unit

Force

SI units name Newton

N

kg ⋅ m 1 ⋅ ------------2 s

Force momentum

Newtonmetre

Nm

kg ⋅ m 1 ⋅ --------------2 s

Pressure

Bar

bar

5 kg 10 -------------2 m⋅s

5 5 N 1 bar = 10 Pa = 10 ------2 m

Pascal

Pa

kg 1 ⋅ ------------2m⋅s

1 Pa = 10 bar

Energy, heat

Joule

J

kg ⋅ m1 ⋅ --------------2 s

2

1 J = 1 Ws = 1 Nm

Power

Watt

W

kg ⋅ m1 ⋅ --------------3 s

2

J N⋅m W = 1 - = 1 -----------s s

N ----------2 mm

6 kg 10 -------------2 m⋅s

N 2 N 1 ---------2- = 10 -------2cm mm

Tension

10

Angle (flat)

Conversion of SI units

2

–5

Degree Gon Radian

1 gon rad

Voltage

Full circle Volt

pla V

Resistor

Ohm

O

kg ⋅ m1 ⋅ --------------3 2 s ⋅A

Conductivity

Siemens

S

s ⋅A 1 ⋅ ---------------2kg ⋅ m

Electric charge

Coulomb

C

1· A · s

10-56

360° = 1 pla = 2p rad 400 gon = 360° m 1 ---m

1 pla = 2p rad = 360° 2

W 1 V = 1 ⋅ ---A

2

V W 1 Ω = 1 ⋅ --- = 1 ⋅ ----2A A

2

A A 1 S = 1 ⋅ --- = 1 ⋅ ----W V

kg ⋅ m 1 ⋅ --------------3 s ⋅A

3

2


Standards, formulae, tables Standard international units Conversion of SI units and coherences Size Capacity

SI units name Farad

Field strength

Symbol

Basic unit

Conversion of SI units

F

s ⋅A 1 ⋅ ---------------2kg ⋅ m

C s⋅A 1 F = 1 ⋅ --- = 1 ⋅ -----------V W

V--m

kg ⋅ m1 ⋅ ------------3 s ⋅A

V W 1 ---- = 1 ⋅ -----------m A⋅m

4

2

Flux

Weber

Wb

kg ⋅ m 1 ⋅ --------------2 s ⋅A

W⋅s 1 W b = 1 ⋅ V ⋅ s = 1 ⋅ ----------A

Flux density

Tesla

T

kg 1 ⋅ ----------2 s ⋅A

W V⋅s W⋅s 1 T = ------2b = 1 ⋅ --------= 1 ⋅ ---------2 2 m m A m

Inductance

Henry

H

kg ⋅ m1 ⋅ --------------2 2 s ⋅A

2

2

W V⋅s W ⋅ s1 H = ------b = 1 ⋅ --------- = 1 ⋅ ---------2 A A A

Decimal powers (parts and multiples of units) Power

Symbol

Power

Prefix

Symbol

Atto

a

10–1

Deci

d

Femto

f

10

Deca

da

10–12

Pico

p

102

Hecto

h

10–9

Nano

n

103

Kilo

k

10–6

Micro

m

106

Mega

M

10–3

Milli

m

109

Giga

G

c

1012

Tera

T

10–18 10–15

10–2

Prefix

Centi

10

10-57


Standards, formulae, tables Standard international units Physical units Obsolete units Mechanical force SI unit:

N (Newton) J/m (Joule/m)

Previous unit:

kp (kilopond) dyn (Dyn)

1N

= 1 J/m

1 J/m 1 kg

m/s2

= 1 kg m/s2

= 0.102 kp

= 105 dyn

m/s2

= 0.102 kp

= 105 dyn

= 0.102 kp

= 105 dyn

=1N

= 1 kg

=1N

= 1 J/m

m/s2

= 0.981 106 dyn

1 kp

= 9.81 N

= 9.81 J/m

= 9.81 kg

1 dyn

= 10–5 N

= 10–5 J/m

= 10–5 kg m/s2

= 1,02 10–5 kp

Pressure

10

SI unit:

Pa (Pascal) bar (Bar)

Previous unit:

at = kp/cm2 = 10 m Ws Torr = mm Hg atm

1 Pa

= 1 N/m2

= 10–5 bar

1 Pa

= 10–5 bar

= 10,2 · 10–6 at

= 9,87 · 10–6 at

= 7,5 · 10–3 Torr

105

1 bar

=

= 1.02 at

= 0.987 at

= 750 Torr

1 at

= 98.1 · 103 Pa

= 0.981 bar

= 0.968 at

= 736 Torr

1 atm

= 101.3 · 103 Pa

= 1.013 bar

= 1.033 at

= 760 Torr

1 Torr

= 133.3 Pa

= 1.333 · 10–3 bar

= 1.359 · 10–3 at

= 1.316 · 10–3 atm

10-58

Pa


Standards, formulae, tables Standard international units Work SI unit:

J (Joule) Nm (Newtonmeter)

SI unit: (as before)

Ws (Wattsecond) kWh (Kilowatthour) kcal (Kilocalorie) = cal · 10–3

Previous unit:

107 erg

1 Ws

=1J

= 1 Nm

1 Ws

= 278 · 10–9 kWh

= 1 Nm

=1J

= 0.102 kpm

= 0.239 cal

1 kWh

= 3.6 · 106 Ws

= 3.6 · 106 Nm

= 3.6 · 106 J

= 367 · 106 kpm

= 860 kcal

1 Nm

= 1 Ws

= 278 · 10–9 kWh

=1J

= 0.102 kpm

= 0.239 cal

1J

= 1 Ws

= 278 · 10–9 kWh

= 1 Nm

= 0.102 kpm

= 0.239 cal

1 kpm

= 9.81 Ws

= 272 · 10–6 kWh

= 9.81 Nm

= 9.81 J

= 2.34 cal

1 kcal

= 4.19 · 103 Ws

= 1.16 · 10–3 kWh

= 4.19 · 103 Nm

= 4.19 · 103 J

= 427 kpm

Power SI unit:

Nm/s (Newtonmetre/s) J/s (Joule/s)

SI unit: (as before)

W (Watt) kW (Kilowatt)

Previous unit:

kcal/s (Kilocalorie/sec.) = cal/s · 103

10

kcal/h (Kilocalorie/hour.) = cal/h · 106 kpm/s (Kilopondmetre/Sec.) PS (metric horsepower) 1W

= 1 J/s

= 1 Nm/s

1W

= 10–3 kW

= 0.102 kpm/s

= 1.36 ·10–3 PS

= 860 cal/h

= 0.239 cal/s

1 kW

= 103 W

= 102 kpm/s

= 1.36 PS

= 860 ·103 cal/h

= 239 cal/s

1 kpm/s

= 9.81 W

= 9.81 · 10–3 kW

= 13.3 ·10–3 PS

= 8.43 ·103 cal/h

= 2.34 cal/s

1 PS

= 736 W

= 0.736 kW

= 75 kpm/s

= 632 · 103 cal/h

= 176 cal/s

1 kcal/h

= 1.16 W

= 1.16 · 10–3 kW

= 119 · 10–3 kpm/s

= 1.58 ·10–3 PS

= 277.8 · 10–3 cal/s

1 cal/s

= 4.19 W

= 4.19 ·

10–3

kW

= 0.427 kpm/s

= 5.69 ·

10–3 PS

= 3.6 kcal/h

10-59


Standards, formulae, tables Standard international units Magnetic field strength SI unit:

A--m

Previous unit:

Oe = (Oerstedt)

Ampere---------------Meter

A 1 ---m

kA = 0, 001 ----m

= 0.01256 Oe

kA 1 ----m

A = 1000 ---m

= 12.56 Oe

1 Oe

A = 79, 6 ---m

kA = 0, 0796 ----m

Magnetic field strength SI unit

Wb (Weber) mWb (Microweber)

Previous unit:

10

M = Maxwell

1 Wb

= 1 Tm2

1 Wb

= 106 mWb 10–6

1 mWb

=

1M

= 10–8 Wb

Wb

= 108 M = 100 M = 0.01 mWb

Magnetic flux density SI unit:

T (Tesla) mT (Millitesla)

Previous unit:

G = Gauss Wb/m2

1T

=1

1T

= 103 mT 10–3

T

1 mT

=

1G

= 0,1–3 T

10-60

= 104 G = 10 G = 0,1 mT


Standards, formulae, tables Standard international units Conversion of Imperial/American units into SI units Length

1 in

1 ft

1 yd

1 mile Land mile

1 mile Sea mile

m

25.4 · 10 –3

0.3048

0.9144

1.609 ·103

1.852 · 103

Weight

1 lb

1 ton (UK) long ton

1 cwt (UK) long cwt

1 ton (US) short ton

1 ounce

1 grain

kg

0.4536

1016

50.80

907.2

28.35 ·10–3

64.80 ·10–6

Area

1 sq.in

1 sq.ft

1 sq.yd

1 acre

1 sq.mile

m2

0.6452 · 10–3

92.90 · 10–3

0.8361

4.047 · 103

2.590 · 103

Volume

1 cu.in

1 cu.ft

1 cu.yd

1 gal (US)

1 gal (UK)

m3

16.39 · 10–6

28.32 · 10–3

0.7646

3.785 · 10–3

4.546 · 10–3

Force

1 lb

1 ton (UK) long ton

1 ton (US) short ton

1 pdl (poundal)

N

4.448

9.964 ·103

8.897 ·103

0.1383

Speed

mile 1 --------h

1 knot

ft 1 --s

ft 1 -------min

m--s

0.447

0.5144

0.3048

5.080 ·10–3

1 in Hg

1 ft H2O

1 in H2O 2.491 · 10-3

Pressure

lb sq.in

1 ---------- 1 psi

bar

65.95 · 10-3

33.86 · 10-3

29.89 · 10-3

Energy, Work

1 HPh

1 BTU

1 PCU

J

2.684 ·106

1.055 · 103

1.90 · 103

10

10-61


Standards, formulae, tables Standard international units Conversion of Imperial/American units into SI units Length

Weight

Area

Volume

Force

Speed

10

Pressure

Energy, Work

10-62

1 cm

1m

1m

1 km

1 km

0.3937 in

3.2808 ft

1.0936 yd

0.6214 mile (land mile)

0.5399 mile (sea mile)

1g

1 kg

1 kg

1t

1t

15.43 grain

35.27 ounce

2.2046 lb.

0.9842 long ton

1.1023 short ton

1cm2

1 m2

1 m2

1 m2

1 km2

0.155 sq.in

10.7639 sq.ft

1.196 sq.yd

0.2471 · 10–3 acre

0.3861 sq.mile

1cm3

1l

1 m3

1 m3

1 m3

0.06102 cu.in

0.03531 cu.ft

1.308 cu.yd

264.2 gal (US)

219.97 gal (UK)

1N

1N

1N

1N

0.2248 lb

0.1003 · 10–3 long ton (UK)

0.1123 · 10–3 short ton (US)

7.2306 pdl (poundal)

1 m/s

1 m/s

1 m/s

1 m/s

3.2808 ft/s

196.08 ft/min

1.944 knots

2.237 mph

1 bar

1 bar

1 bar

1 bar

14.50 psi

29.53 in Hg

33.45 ft H2O

401.44 in H2O

1J 0.3725 ·

1J 10–6

HPh

0.9478 ·

1J 10–3

BTU

0.5263 · 10–3 PCU


Index A AC/DC sensitive ................................................................... 7-20 Accessories contactors ......................................................... 5-30 Air circuit-breakers ................................................................ 7-3 Analog inputs, easy ..................................................1-23…1-26 Analog output, easy ............................................................ 1-31 Approval authorities worldwide ............................................. 9-6 AS-Interface® data bus ....................................................... 2-89 Asynchronous motor .............................................................. 2-2 ATEX approval ..................................................................... 3-10 EMT6 .............................................................................. 8-12 Motor protection system ZEV ......................................... 5-39 Overload relays .............................................................. 5-35 PKZM0, PKZM4 ................................................................ 6-4 RMQ-Titan ...................................................................... 3-10 Rotary switches, switch-disconnectors ........................... 4-17 Thermistor relay for machine protection EMT6 ............... 5-45 Automatic stator starters Engineering starting resistor ........................................... 8-14 Engineering starting transformer .................................... 8-14 Example resistors ........................................................... 8-91 Example starting transformer ......................................... 8-94 Auxiliary contact module ....................................................... 5-2 Auxiliary switch PKZ2 .............................................................................. 6-17 Auxiliary switches Early make ....................................................................... 7-7 PKZM01, PKZM0, PKZM4 ................................................ 6-7 Standard, trip-indicating ................................................... 7-6 Trip-indicating .................................................................. 7-6 B Basic circuits Delta, star ......................................................................... 2-4 easy .....................................................................1-54…1-59 Bimetal Motor protection ............................................................ 8-13 Motor-protective circuit-breakers ..................................... 6-4 Overload relay ................................................................ 5-35 Braking oversynchronous ..................................................... 8-59 Braking resistance ............................................................... 2-84 Break-Down Service ............................................................... 0-9

11-1

11


Index Bridging during starting Heavy starting duty .........................................................8-10 Motor contactor ................................................................8-9 Overload relays ...............................................................8-26 Busbar system ......................................................................0-22

11

C Cables ................................................................................10-43 Cage Clamp .........................................................................5-31 CANopen ................................................................. 1-39…1-41 Capacitor Central compensation, use of reactors ............................8-17 Single, group compensation ...........................................8-16 Capacitor group compensation ............................................8-17 Cascade control ...................................................................2-52 Changeover circuit ...............................................................1-56 Changeover contact Wattmeter ......................................................................4-13 Changeover switch Ammeter .........................................................................4-12 Voltmeter ........................................................................4-12 Changeover switches .............................................................4-5 Circuit diagram auxiliary protection .......................................5-6 Circuit diagram Internal circuit diagrams Circuit-breaker .......7-8 Circuit documents general ....................................................8-18 Circuit documents wiring diagram .......................................8-19 Circuit examples Bridging during starting ..................................................8-26 Contactors DIL ................................................................8-25 Circuit for overload relay 1-pole, 2-pole .................................8-5 Circuit-breaker Internal circuit diagrams ...................................................7-8 Meshed network circuit-breakers ....................................7-17 Remote operation with motor operator ..........................7-18 Residual current device ...................................................7-20 Switch position ...............................................................7-15 Transformer switches ......................................................7-19 Circuit-breaker remote switching .........................................7-11 Classification types of soft starters .......................................2-17 Coil functions .......................................................................1-52 Coils .....................................................................................1-50 COM-LINK connection ..........................................................1-47 Compact circuit-breakers .......................................................7-2 11-2


Index Compact PLC, PS4 ............................................................... 1-68 Compensated motor ............................................................ 8-11 Connecting examples DF51, DV51 .........................................................2-74…2-79 DF6 .....................................................................2-80…2-81 DM4 ....................................................................2-56…2-69 DS4 ................................................................................ 2-55 DS6 .....................................................................2-37…2-39 DV6 .....................................................................2-82…2-87 Connection RA-MO to AS-Interface® .................................. 2-92 Connection RA-SP to AS-Interface® .................................... 2-95 Contact module PKZ2 .......................................................... 6-13 Contact protection relay ...................................................... 5-46 Contactor for capacitor ...................................................... 8-102 Contactor relays circuit diagrams ........................................... 5-6 Contactor relays reference letters .......................................... 5-3 Contactor, marking .............................................................. 8-24 Contactors DC operated ................................................................... 5-32 DILM .............................................................................. 5-31 Overview .............................................................5-24…5-25 SmartWire ...................................................................... 5-10 Contacts .............................................................................. 1-50 Control circuit devices For direct-on-line start .................................................... 8-37 For multi-speed contactors ..................................8-69…8-73 For star-delta .................................................................. 8-51 RMQ ................................................................................. 3-2 Control circuit supply motor ................................................. 8-23 Control relays Basic circuits ................................................................... 1-54 Overview ........................................................................ 1-12 Control relays a easyRelays .............................................. 1-12 Co-ordination type motor protection ..................................... 8-8 Core-balance transformer .................................................... 5-38 Current Limiter a Current limiter PKZ2 ................................................ 6-28 a Current limiters PKZM0, PKZM4 ................................ 6-5 Current limiter PKZ2 ............................................................ 6-28 Current limiter PKZM0, PKZM4 .............................................. 6-5 Current monitoring relays ...................................................... 1-6 Current transformer-operated overload relays ZW7 ............... 8-8

11-3

11


Index D Darwin ..................................................................... 0-11…0-13 DC motors ..............................................................................8-5 Degrees of protection for electrical equipment ...................10-28 Delta circuit, motor ..............................................................2-78 Delta connection ....................................................................2-4 Digital inputs, easy AC devices ......................................................................1-21 DC devices ......................................................................1-22 Direct-on-line starter Motor-protective circuit-breakers ......................................6-3 Disconnect Control Unit .......................................................2-91 DOL starters Features ..........................................................................2-10 SmartWire .......................................................................5-12 Three-phase asynchronous motors ...................................2-5 With bypass ....................................................................2-30 Double-frame terminal .........................................................5-31 Drives engineering basics .......................................................2-7

11

E Early-make auxiliary switches .................................................7-7 Earth-leakage circuit-breaker ...............................................7-22 easy ......................................................................................1-12 easy expansion ......................................................... 1-32…1-43 easy expansion units for networking ....................................1-42 easy inputs ............................................................... 1-21…1-27 easy inputs, MFD Analog ............................................................................1-23 easy local expansion ............................................................1-32 easy modem operation .........................................................1-49 easy outputs ............................................................. 1-28…1-31 easy power supply ................................................................1-20 easy printer connection ........................................................1-48 easy remote expansion .........................................................1-32 easy system overview ............................................... 1-12…1-19 easyControl ..........................................................................1-16 easyHMI ...............................................................................1-14 easyNet .................................................................... 1-34…1-38 easyRelay .............................................................................1-12 EEx e motors Overload relays ...............................................................5-35 PKZM0, PKZM4 ................................................................6-4 11-4


Index Electrical connector ................................................................ 6-4 Electrical isolation .................................................................. 5-2 Electronic Catalogue .............................................................. 0-8 Electronic safety relays ......................................................... 1-10 Electronic timing relays .......................................................... 1-2 EMC compliant connection .................................................. 2-21 EMC measures frequency inverters ...................................... 2-22 Emergency-Stop function ..................................................... 7-12 EMR4 measuring and monitoring relays ................................ 1-6 Encoder ............................................................................... 2-84 Engineering easy .....................................................................1-20…1-49 EM4, LE4 ........................................................................ 1-78 Motor ..................................................................8-14…8-17 PS4 ................................................................................. 1-75 Switching of capacitors .................................................. 8-16 Three-phase automatic starters ...................................... 8-14 XC100, XC200 ............................................................... 1-79 Ethernet module .................................................................. 1-46 Explosive atmospheres ........................................................ 4-17 F Fault current ........................................................................ 5-38 Fault indication, differential ................................................. 6-10 Flat band conductor ............................................................. 2-89 Floor-standing enclosure ..................................................... 0-21 Free-wheel diode suppressor ................................................. 5-4 Frequency generators .......................................................... 1-27 Frequency inverters, features ............................................... 2-70 FU a Frequency inverter ..................................................... 2-7 Function blocks .................................................................... 1-50 Functions easy ..................................................................... 1-18 Fuseless, Reversing contactor DIUL ...................................... 8-29 G German Trade Association ................................................... 3-22 Graphic operator panel ........................................................ 1-72 Group compensation ........................................................... 8-16 Group protection Motor-protective circuit-breakers ............... 6-6 H Hamburg circuit, off position interlock ............................... 8-110 Hazard reduction ................................................................. 1-10 11-5

11


Index Heater switches ....................................................................4-14 Heavy starting duty Bridging during starting ..................................................8-10 Example ..........................................................................8-27 Motor protection ...............................................................8-8 High-capacity compact starters ............................................6-18 High-speed counter ..............................................................1-27 HMI systems .........................................................................1-72 Housing ...................................................................... 0-18, 0-21 I Impulse relays ......................................................................1-57 Incremental encoders ...........................................................1-27 In-delta circuit ......................................................................2-35 Indication of tripping circuit-breaker ....................................7-15 Individual compensation ......................................................8-16 In-line circuit ........................................................................2-35 Insulation monitoring relays ...................................................1-8 Interface assignment, XC100/XC200 RS ..............................1-80 Interlock circuits, rotary switches .........................................4-11 IZM terminal assignment .....................................................7-26

11

L Labeleditor .............................................................................3-9 Let-through energy ...............................................................2-91 Level monitoring relay ............................................................1-7 Load-shedding contact ...........................................................4-4 Low-voltage switchgear systems ..........................................0-14 M Main switches ......................................................................7-12 Main transfer switch ..........................................................8-111 Maintenance switches, rotary switches ..................................4-4 Markings, contactor .............................................................8-24 Master switch, off position interlock ..................................8-111 Mechanical interlock ............................................................5-32 Mesh network circuit-breaker ..............................................7-17 MFD-Titan ............................................................................1-12 Mirror contact ......................................................................5-34 Modular PLC ........................................................................1-70

11-6


Index Moeller .................................................................................. 0-4 Electronic Catalogue ........................................................ 0-8 Field Service ..................................................................... 0-9 Low-voltage switchgear systems .................................... 0-14 Support Portal .................................................................. 0-4 Monitoring relays ................................................................... 1-6 Motor Circuit documents .......................................................... 8-18 Control circuit devices for direct-on-line start ................. 8-37 Control circuit supply ...................................................... 8-23 Engineering .........................................................8-14…8-17 Mains changeover ........................................................ 8-111 Motor windings .............................................................. 8-56 Multi speed switch PKZ2 ................................................ 8-89 Multi-speed contactors ................................................... 8-59 Pole-changing .....................................................8-53…8-55 Power supply .................................................................. 8-20 Separate windings .......................................................... 8-53 Star-delta of three-phase motors .........................8-38…8-47 Star-delta with PKZ2 ...........................................8-48…8-50 Starting with PKZ2 ..............................................8-33…8-36 Switching of capacitors .................................. 8-100…8-103 Switching on three-phase motors ........................8-25…8-32 Tapped winding ............................................................. 8-53 Motor connection ................................................................ 2-95 Motor Control Unit .............................................................. 2-92 Motor feeder ......................................................................... 2-2 Motor full-load current ...................................................... 10-40 Motor operator circuit-breaker ............................................ 7-18 Motor overload relay, motor protection ............................... 5-35 Motor power supply ............................................................ 8-20 Motor protection ........................................................8-3…8-13 Motor protection system ZEV ....................................5-38…5-44 Motor rating ........................................................................ 5-31 Motor windings ................................................................... 8-56 Motor-protective circuit-breaker Operating principle schematics PKZM01, PKZM0, PKZM4 6-9 Motor-protective circuit-breakers For starter combinations .................................................. 6-5 Operating principle schematics PKZ2 ..................6-18…6-29 Operating principle schematics PKZM01, PKZM0, PKZM4 ..... 6-9….............................................................................. 6-11 Motor-protective circuit-breakers, overview .......................... 6-1 11-7

11


Index Motor-starter combination MSC .............................................6-4 SmartWire .......................................................................5-10 Multi-function display Overview .........................................................................1-12 Multi-function display a easyHMI .....................................1-14 Multi-speed contactors .........................................................8-59 Control circuit devices ......................................... 8-69…8-73 Star-delta ........................................................................8-74 Multi-speed switch Bridging during starting .........................8-10 Multi-speed switch for three-phase motors Star-delta ............................................................ 8-74…8-88 Multi-speed switch of three-phase motors ............... 8-61…8-68 Multi-speed switch with PKZ2 ..............................................8-89 Multi-speed switches Rotary switches .................................................................4-7 Multi-speed switching, marking ...........................................8-24 N Negation ..............................................................................1-54 Networking display and operating devices ...........................1-74 Networking easy ...................................................... 1-32…1-43 Networking PS40 and XC series ...........................................1-73

11

O Off-delayed undervoltage release ...........................................7-5 Off-position interlock Loads ............................................................................8-110 Off-postion interlock Hamburg circuit ............................................................8-110 Master switch ...............................................................8-111 Ohm's Law .........................................................................10-50 Operands .............................................................................1-50 Operating frequency ...............................................................8-4 Operating principle schematic PKZ2 ......................... 6-18…6-29 Operating principle schematics PKZM01, PKZM0, PKZM4 6-9… 6-11 Overload motor ....................................................................5-38 Overload motor-protective circuit-breaker ..............................6-2 Overload protection contactor ..............................................8-25 Overload protection, Rapid Link ...........................................2-90 Overload relay Tripping ............................................................................8-4 Overload relay a Motor protection overload relay ............5-35 11-8


Index Overload relay function ....................................................... 6-12 Overload relay function PKZ2 .............................................. 6-29 Overload relay time-delayed .................................................. 8-6 Overload relays .................................................................... 2-57 In delta circuit ................................................................ 8-39 In motor circuit, in mains line ......................................... 8-38 Oversynchronous braking .................................................... 8-59 Overvoltage ......................................................................... 2-57 P Parallel circuit ...................................................................... 1-55 Permanent contact .............................................................. 1-57 Personnel protection Enhanced ....................................................................... 3-17 LS ................................................................................... 3-16 LSR ................................................................................. 3-21 Phase failure ........................................................................ 5-38 Phase imbalance relay ........................................................... 1-7 Phase monitoring relays ........................................................ 1-6 Phase sequence relays ........................................................... 1-7 Phase-failure sensitivity ....................................................... 5-35 Point-to-point connection .................................................... 1-47 Pole-changing motors ...............................................8-53…8-55 Power bus ............................................................................ 2-89 Power electronics .................................................................. 2-7 Process protection ............................................................... 3-19 Programmable contacts ....................................................... 5-39 Programming easy ....................................................1-50…1-66 Protective measures ............................................................. 10-5 Proximity switches ....................................................3-27…3-31 Pt100/Ni1000 inputs, easy .................................................. 1-26 PTC Thermistor, Thermistor machine protection relay .......... 5-45 PTC-Thermistor, motor protection ....................................... 8-12 Pump control ....................................................................... 2-50 Float switches .............................................................. 8-108 Pressure switches ......................................................... 8-106 Two pumps .................................................................. 8-104 Pushbutton control circuit devices ....................................... 8-69 Push-through sensor ZEV ..................................................... 5-39 Q Quick-discharge resistor .................................................... 8-100

11-9

11


Index

11

R Rapid Link ............................................................................2-88 RC suppressor ........................................................................5-4 Reclosing lockout ...................................................................8-4 Reference letter contactor relays ............................................5-3 Reflected-light barrier, reflected-light beam .........................3-29 Relay outputs, easy ..............................................................1-28 Remote display .....................................................................1-44 Remote operator circuit-breaker ...........................................7-18 Remote operator PKZ2 .........................................................6-14 Remote switch off PKZ2 .......................................................6-25 Remote switch off PKZM01, PKZM0, PKZM4 .......................6-11 Residual-current protection ..................................................7-20 Residual-current protection relays ........................................7-22 Residual-current release circuit-breaker ...............................7-20 Reversing combination a Reversing contactor ..................8-29 Reversing contactor ..............................................................8-29 Reversing soft starter ...........................................................2-45 Reversing star-delta 2 directions of rotation ...................................................8-45 Direction change .............................................................8-46 Rotary switches .................................................................4-6 Reversing starter Motor-protective circuit-breakers ......................................6-3 SmartWire .......................................................................5-12 Soft starters ....................................................................2-30 Reversing switches .................................................................4-5 Risk reduction .......................................................... 1-10, 10-26 Rogowski principle ...............................................................5-38 Rogowski sensor ..................................................................5-44 Root -3 circuit ......................................................................2-65 Rotary switches ATEX approval ................................................................4-18 Changeover switches, reversing switches .........................4-5 Heater switches ..............................................................4-14 Interlock circuits ..............................................................4-11 Main switch, maintenance switch .....................................4-3 Meter selector switches ..................................................4-12 Multi speed switches ........................................................4-7 Speed switching ..............................................................8-59 Star-delta, reversing star-delta ..........................................4-6 Step switches ..................................................................4-15 Use, mounting forms ........................................................4-2 11-10


Index Rotor automatic starter Engineering starting resistor ........................................... 8-14 Properties of slipring rotor .............................................. 8-15 Slipring rotor .................................................................. 8-96 Rotor-critical motors ............................................................ 8-12 S Safety category .................................................................... 5-19 Safety of machines .............................................................. 1-10 Safety position switches ...................................................... 3-15 Safety relays ........................................................................ 1-10 Safety technology ................................................................ 1-10 SASY60 ................................................................................ 0-22 Screening measures ..................................................2-23…2-25 Sealing power ...................................................................... 5-31 Selectivity a time selectivity .............................................. 7-16 Self-latching ......................................................................... 1-56 Semiconductor contactors ..................................................... 2-7 Sensor belt ZEV .................................................................... 5-39 Separate windings Multi speed switch ..............................................8-65…8-68 Speeds ............................................................................ 8-53 Separation galvanic ............................................................... 5-2 Series circuit ........................................................................ 1-55 Shift register ........................................................................ 1-63 Short-circuit current, maximum ........................................... 2-91 Short-circuit monitoring ....................................................... 5-43 Short-circuit protection ........................................................ 8-25 Short-circuit protection, RA-MO .......................................... 2-90 Short-circuit rating ................................................................. 8-7 Short-circuit releases .............................................................. 6-4 Shunt releases Circuit-breaker remote tripping ........................................ 7-4 Circuit-breakers .............................................................. 7-19 Operating principle schematics PKZ2 ............................. 6-25 PKZM01, PKZM0, PKZM4 ................................................ 6-8 Remote switch off PKZ2 ................................................. 6-16 Remote switch-off .......................................................... 7-11 Single phase motors .............................................................. 8-5 Single-phasing sensitive ........................................................ 6-4 SL signal towers ................................................................... 3-11 Slipring rotor a Rotor automatic starter ............................ 8-96

11-11

11


Index

11

SmartWire Gateway easyNet/CANopen ...........................................1-43 Gateway PROFIBUS-DP .....................................................5-9 Modules ..........................................................................5-10 System .................................................................. 5-8…5-23 Soft starters ............................................................................2-7 Classification types .........................................................2-17 DM4 ...............................................................................2-33 DS4, DS6 .........................................................................2-29 Examples ........................................................................2-13 Features ..........................................................................2-12 Soft starting a Soft starters .................................................2-7 Special purpose relays ............................................................1-2 Speed Control Unit ...............................................................2-95 Speeds, separate windings ...................................................8-53 Spring-loaded terminal .........................................................5-31 Stairwell lighting ..................................................................1-60 Standard auxiliary contact, ON-OFF indication .....................7-15 Standard auxiliary switch .......................................................7-6 PKZ2 ...............................................................................6-17 Star connection ......................................................................2-4 Star connection, motor .........................................................2-79 Star-delta Bridging during starting ....................................................8-9 easy ................................................................................1-58 Marking ..........................................................................8-24 Motor start .....................................................................2-11 Multi-speed contactors ...................................................8-74 Rotary switches .................................................................4-6 SDAINL ............................................................... 8-40…8-44 Three-phase asynchronous motors ...................................2-5 Three-phase motors ............................................ 8-38…8-47 With PKZ2 ........................................................... 8-48…8-50 Star-delta starters, with overload relays ...............................8-38 Starting with PKZ2 ................................................... 8-33…8-36 Stator automatic starters Properties of squirrel cage rotor ......................................8-15 Support Portal ........................................................................0-5 Suppressor circuit ...................................................................5-4 Suppressor circuit integrated, pluggable ..............................5-31 Switch position indication ......................................................4-4 Switch position indication circuit-breaker .............................7-15 Switch-disconnectors Use, mounting forms ............................4-2 Switch-disconnectors with ATEX approval ...........................4-18 11-12


Index Switching of capacitors ........................................ 8-100…8-103 Switching on three-phase motors .............................8-25…8-32 System Range xEnergy ......................................................... 0-14 System-protective circuit-breakers ......................................... 6-2 T Tapped winding ................................................................... 8-10 Feed drive ....................................................................... 8-31 Four speeds .................................................................... 8-55 Marking .......................................................................... 8-24 Multi speed switch ..............................................8-61…8-64 Multi speed switch star-delta ..............................8-74…8-88 Pole-changing motors .................................................... 8-53 Rotary switches .....................................................4-7…4-10 Three speeds .................................................................. 8-54 Temperature compensated .................................................... 6-4 Temperature monitoring ...................................................... 8-12 Test authorities and approval stamps .................................. 9-10 Text display, easy ................................................................. 1-65 Text operator panel ............................................................. 1-72 Thermal overload relays ....................................................... 5-35 Thermistor ........................................................................... 8-12 Thermistor motor protection ................................................ 5-42 Thermistor overload relay for machine protection EMT6 ...... 5-45 Thermistor protection .......................................................... 5-42 Three-phase asynchronous motor .......................................... 2-2 Three-phase automatic rotor starters ........................8-96…8-99 Three-phase automatic starters ........................................... 8-14 Three-phase automatic stator starters ......................8-91…8-95 Three-phase current-automatic stator starters ..................... 8-91 Three-phase motors Multi speed switch ...................8-61…8-68 Three-phase motors star-delta Multi speed switch ...8-74…8-88 Time selectivity circuit-breaker ............................................. 7-16 Timing relay, on-delayed ..................................................... 1-57 Timing relays, functions ......................................................... 1-2 Transformer switch circuit-breaker ....................................... 7-19 Transformer-protective circuit-breaker ................................... 6-5 Trip-indicating auxiliary contact circuit-breaker ..................... 7-6 Trip-indicating auxiliary contact PKZ2 .................................. 6-17 Trip-indicating auxiliary contacts PKZM01, PKZM0, PKZM4 .. 6-7 Tripping characteristics motor protection system ................. 5-40 Tripping characteristics Overload relays ............................... 5-36 Tripping CLASS .................................................................... 5-38 11-13

11


Index U U/f inverters a Frequency inverters .....................................2-7 Unbalanced current consumtion ..........................................5-38 Undervoltage release Circuit-breakers ..............................................................7-19 Interlocking of multiple switches ....................................7-14 Off-delayed .......................................................................7-5 PKZ2 ...............................................................................6-16 PKZM01, PKZM0, PKZM4 .................................................6-8 Remote switch-off ...........................................................7-11 Starting interlock ............................................................7-13 Switch-off .......................................................................7-13 Use or reactor capacitor .......................................................8-17 Utilisation categories contactors, motor starters ................10-34 Utilisation categories for switch-disconnectors ...................10-38

11

V Varistor suppressor ................................................................5-4 Vector control ......................................................................2-70 Visualisation, easyHMI .........................................................1-66 Voltage releases Interlock with undervoltage releases ..............................7-14 Off-delayed undervoltage release .....................................7-5 PKZ2 ...............................................................................6-16 PKZM01, PKZM0, PKZM4 .................................................6-8 Remote switch-off ...........................................................7-11 Shunt releases ..................................................................7-4 Starting interlock Undervoltage releases .........................7-13 Undervoltage releases ......................................................7-5 W Wall-mounting distribution system .......................................0-21 Wall-mounting enclosure .....................................................0-18 Wiring examples for PS4 .......................................... 1-75…1-77 X xEnergy ................................................................................0-14 XSoft ....................................................................................1-71 Z ZEV motor protection system ................................... 5-38…5-44

11-14


Notes

11

11-15


Notes

11

11-16

E-mail: [email protected] Internet: www.moeller.net www.eaton.com Issued by Moeller GmbH Hein-Moeller-Str. 7-11 D-53115 Bonn © 2008 by Moeller GmbH, Germany Subject to alterations FB0200-004EN_(02/08) ip/Ins/CPI Printed in Germany (11/08) Article No.: 119816

Eaton’s electrical business is a global leader in electrical control, power distribution, uninterruptible power supply and industrial automation products and services. Eaton’s global electrical brands, including Cutler-Hammer®, MGE Office Protection Systems™, Powerware®, Holec®, MEM®, Santak and Moeller, provide customer-driven PowerChain Management® solutions to serve the power system needs of the industrial, institutional, government, utility, commercial, residential, IT, mission critical and OEM markets worldwide. www.eaton.com

For service issues please contact your Moeller representative or the Moeller Field Service. Hotline +49(0)180 5 228322 (de, en) Tel. +49(0)228 602-3640 Fax +49(0)228 602-61400 E-Mail: [email protected] Internet: www.moeller.net/fieldservice

Wiring Manual | 2008

Moeller addresses worldwide: www.moeller.net/address

Wiring Manual | 2008 Automation and Power Distribution

L1

CB

L1 L2

L2

L3

L3

M

T1 T2

M

T3

6

-Q1

H1

1 H3

X1

SmartWire

SmartWire

H4

H1

H2

4

X2

H4

-Q11

A1 A2

6

1.13 1.14

X1 X2 X3 X4 24V 0V DC

IN OUT

Wiring Man En

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