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
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H4
-Q11
A1 A2
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1.13 1.14
X1 X2 X3 X4 24V 0V DC
IN OUT
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
0-1
0
Moeller Wiring Manual 02/08
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
Moeller Wiring Manual 02/08
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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Moeller Wiring Manual 02/08
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,
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demo programs and much more. You can also subscribe to the Moeller Newsletters.
Moeller Wiring Manual 02/08
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.
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0
Moeller Wiring Manual 02/08
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.
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Moeller Wiring Manual 02/08
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.
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Moeller Wiring Manual 02/08
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.
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Moeller Wiring Manual 02/08
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.
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Moeller Wiring Manual 02/08
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
Moeller Wiring Manual 02/08
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.
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Moeller Wiring Manual 02/08
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.
Moeller Wiring Manual 02/08
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.
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Moeller Wiring Manual 02/08
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.
Moeller Wiring Manual 02/08
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
Moeller Wiring Manual 02/08
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
Moeller Wiring Manual 02/08
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
Moeller Wiring Manual 02/08
The Moeller Wiring Manual Moeller power distribution equipment
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.
Moeller Wiring Manual 02/08
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.
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Moeller Wiring Manual 02/08
The Moeller Wiring Manual Moeller power distribution equipment
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.
Moeller Wiring Manual 02/08
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.
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Moeller Wiring Manual 02/08
The Moeller Wiring Manual Moeller power distribution equipment
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.
Moeller Wiring Manual 02/08
Notes
0
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Moeller Wiring Manual 02/08
Notes
0
0-24
Moeller Wiring Manual 02/08
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
Moeller Wiring Manual 02/08
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.
Moeller Wiring Manual 02/08
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
Moeller Wiring Manual 02/08
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.
Moeller Wiring Manual 02/08
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
Moeller Wiring Manual 02/08
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.
Moeller Wiring Manual 02/08
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
Moeller Wiring Manual 02/08
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
Moeller Wiring Manual 02/08
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
Moeller Wiring Manual 02/08
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.
Moeller Wiring Manual 02/08
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
Moeller Wiring Manual 02/08
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
Moeller Wiring Manual 02/08
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
Moeller Wiring Manual 02/08
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
Moeller Wiring Manual 02/08
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
Moeller Wiring Manual 02/08
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
Moeller Wiring Manual 02/08
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
Moeller Wiring Manual 02/08
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.
Moeller Wiring Manual 02/08
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
Moeller Wiring Manual 02/08
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
Moeller Wiring Manual 02/08
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
Moeller Wiring Manual 02/08
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.
Moeller Wiring Manual 02/08
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
Moeller Wiring Manual 02/08
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.
Moeller Wiring Manual 02/08
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
Moeller Wiring Manual 02/08
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
Moeller Wiring Manual 02/08
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
Moeller Wiring Manual 02/08
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
Moeller Wiring Manual 02/08
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
Moeller Wiring Manual 02/08
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
Moeller Wiring Manual 02/08
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
Moeller Wiring Manual 02/08
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
Moeller Wiring Manual 02/08
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
Moeller Wiring Manual 02/08
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
easy800 EC4P-200 ES4P
easy410 easy618 easy620
MFD-AC-CP8 MFD-CP8
easy200
easy800
easy202
easy410 easy618 easy620
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.
Moeller Wiring Manual 02/08
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
easy800 EC4P-200 ES4P
easy800 EC4P-200 ES4P
Geographic location, position1)
easyNet
easy410 easy618 easy620
easy200
F 0.3 m
easy410 easy618 easy620
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
Moeller Wiring Manual 02/08
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.
Moeller Wiring Manual 02/08
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
Moeller Wiring Manual 02/08
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
Moeller Wiring Manual 02/08
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
Moeller Wiring Manual 02/08
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 %.
Moeller Wiring Manual 02/08
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
easy800 ES4P MFD-CP8 EC4P-200
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
easy800 ES4P MFD-CP8 EC4P-200
b Recommendation F 0.3 m (EASY-NT-30)
easy800 ES4P MFD-CP8 EC4P-200
d F 0.3 m (EASY-NT-30)
Note Sreening is required for CANopen.
1-41
1
Moeller Wiring Manual 02/08
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.
Moeller Wiring Manual 02/08
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
Moeller Wiring Manual 02/08
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
Moeller Wiring Manual 02/08
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
Moeller Wiring Manual 02/08
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
Moeller Wiring Manual 02/08
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
Moeller Wiring Manual 02/08
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
Moeller Wiring Manual 02/08
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
Moeller Wiring Manual 02/08
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
Moeller Wiring Manual 02/08
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
Moeller Wiring Manual 02/08
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
Moeller Wiring Manual 02/08
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
Moeller Wiring Manual 02/08
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
Moeller Wiring Manual 02/08
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
Moeller Wiring Manual 02/08
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
Moeller Wiring Manual 02/08
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
Moeller Wiring Manual 02/08
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
Moeller Wiring Manual 02/08
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
Moeller Wiring Manual 02/08
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
Moeller Wiring Manual 02/08
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
Moeller Wiring Manual 02/08
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)
Moeller Wiring Manual 02/08
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
Moeller Wiring Manual 02/08
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
Moeller Wiring Manual 02/08
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
Moeller Wiring Manual 02/08
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
Moeller Wiring Manual 02/08
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
Moeller Wiring Manual 02/08
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
Moeller Wiring Manual 02/08
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
Moeller Wiring Manual 02/08
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
Moeller Wiring Manual 02/08
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
Moeller Wiring Manual 02/08
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.
Moeller Wiring Manual 02/08
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
Moeller Wiring Manual 02/08
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”
Moeller Wiring Manual 02/08
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
Moeller Wiring Manual 02/08
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
Moeller Wiring Manual 02/08
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
Moeller Wiring Manual 02/08
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
Moeller Wiring Manual 02/08
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
Moeller Wiring Manual 02/08
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
Moeller Wiring Manual 02/08
Notes
1
1-81
Moeller Wiring Manual 02/08
Notes
1
1-82
Moeller Wiring Manual 02/08
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
Moeller Wiring Manual 02/08
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.
Moeller Wiring Manual 02/08
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
Moeller Wiring Manual 02/08
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
Moeller Wiring Manual 02/08
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
Moeller Wiring Manual 02/08
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
Moeller Wiring Manual 02/08
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
Moeller Wiring Manual 02/08
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
Moeller Wiring Manual 02/08
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
Moeller Wiring Manual 02/08
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
Moeller Wiring Manual 02/08
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
Moeller Wiring Manual 02/08
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
Moeller Wiring Manual 02/08
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
Moeller Wiring Manual 02/08
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
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
Moeller Wiring Manual 02/08
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
Moeller Wiring Manual 02/08
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
Moeller Wiring Manual 02/08
Electronic motor starters and drives Basics of drives engineering
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.
Moeller Wiring Manual 02/08
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
Moeller Wiring Manual 02/08
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
Moeller Wiring Manual 02/08
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
Moeller Wiring Manual 02/08
Electronic motor starters and drives Basics of drives engineering
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
Moeller Wiring Manual 02/08
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
Moeller Wiring Manual 02/08
Electronic motor starters and drives Basics of drives engineering
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.
Moeller Wiring Manual 02/08
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
Moeller Wiring Manual 02/08
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
Moeller Wiring Manual 02/08
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
Moeller Wiring Manual 02/08
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
Moeller Wiring Manual 02/08
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
Moeller Wiring Manual 02/08
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
Moeller Wiring Manual 02/08
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
Moeller Wiring Manual 02/08
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
Moeller Wiring Manual 02/08
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
Moeller Wiring Manual 02/08
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
Moeller Wiring Manual 02/08
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~
Moeller Wiring Manual 02/08
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
Moeller Wiring Manual 02/08
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
Moeller Wiring Manual 02/08
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
Electronic motor starters and drives DS4 connection examples Moeller Wiring Manual 02/08
2
2-43
Moeller Wiring Manual 02/08
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
Electronic motor starters and drives DS4 connection examples Moeller Wiring Manual 02/08
2
2-45
Moeller Wiring Manual 02/08
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
Electronic motor starters and drives DS4 connection examples Moeller Wiring Manual 02/08
2
2-47
Moeller Wiring Manual 02/08
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.
Moeller Wiring Manual 02/08
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
Moeller Wiring Manual 02/08
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
Electronic motor starters and drives DS4 connection examples Moeller Wiring Manual 02/08
2
2-51
Moeller Wiring Manual 02/08
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
Electronic motor starters and drives DS4 connection examples Moeller Wiring Manual 02/08
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
Electronic motor starters and drives DS4 connection examples Moeller Wiring Manual 02/08
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
a section "Starting several motors sequentially with a soft starter (cascaded control)", page 2-52
Q14
Q11
i
Qm
K3
Qn
c
i
Qm
Kn2
Qm
Soft starter with motor cascade, control section part 2
Electronic motor starters and drives DS4 connection examples Moeller Wiring Manual 02/08
2
2-55
Moeller Wiring Manual 02/08
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
Moeller Wiring Manual 02/08
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
Moeller Wiring Manual 02/08
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
Moeller Wiring Manual 02/08
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
Moeller Wiring Manual 02/08
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
Moeller Wiring Manual 02/08
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
Moeller Wiring Manual 02/08
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
Moeller Wiring Manual 02/08
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
Moeller Wiring Manual 02/08
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
Moeller Wiring Manual 02/08
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
Moeller Wiring Manual 02/08
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
a section "Starting several motors sequentially with a soft starter (cascaded control)", page 2-66
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
Electronic motor starters and drives Connection examples, DM4 Moeller Wiring Manual 02/08
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
a section "Starting several motors sequentially with a soft starter (cascaded control)", page 2-66
Q14
K12
Q11
i
c
Qm
Kn2
Qm
Control section part 2
Electronic motor starters and drives Connection examples, DM4 Moeller Wiring Manual 02/08
2
2-69
Moeller Wiring Manual 02/08
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.
Moeller Wiring Manual 02/08
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
Moeller Wiring Manual 02/08
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
Moeller Wiring Manual 02/08
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
Moeller Wiring Manual 02/08
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
Moeller Wiring Manual 02/08
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
Moeller Wiring Manual 02/08
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
Moeller Wiring Manual 02/08
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
Moeller Wiring Manual 02/08
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
Moeller Wiring Manual 02/08
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
Electronic motor starters and drives DV6 connecting examples Moeller Wiring Manual 02/08
2
2-83
Moeller Wiring Manual 02/08
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
Electronic motor starters and drives DV6 connecting examples Moeller Wiring Manual 02/08
2-85
2
Moeller Wiring Manual 02/08
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
Moeller Wiring Manual 02/08
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
Moeller Wiring Manual 02/08
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
Moeller Wiring Manual 02/08
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
Moeller Wiring Manual 02/08
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.
Moeller Wiring Manual 02/08
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
Moeller Wiring Manual 02/08
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
Moeller Wiring Manual 02/08
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
Moeller Wiring Manual 02/08
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.
Moeller Wiring Manual 02/08
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
Moeller Wiring Manual 02/08
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
Moeller Wiring Manual 02/08
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
Moeller Wiring Manual 02/08
Electronic motor starters and drives Rapid Link system EMC correct assembly of speed control unit RA-SP
2
PE
PES e
2-98
Moeller Wiring Manual 02/08
Notes
2
2-99
Moeller Wiring Manual 02/08
Notes
2
2-100
Moeller Wiring Manual 02/08
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
Moeller Wiring Manual 02/08
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
Moeller Wiring Manual 02/08
Control circuit devices RMQ RMQ-Titan® system overview
3
ATEX
ATEX
3-3
Moeller Wiring Manual 02/08
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..
Moeller Wiring Manual 02/08
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
Moeller Wiring Manual 02/08
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.
Moeller Wiring Manual 02/08
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
M22-XLED60/ M22-XLED220
2 1
M22-XLED60/ M22-XLED220
2 1
1
M22-XLED-T
1
M22-XLED60/ M22-XLED220
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
Moeller Wiring Manual 02/08
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)
Moeller Wiring Manual 02/08
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
Moeller Wiring Manual 02/08
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
Moeller Wiring Manual 02/08
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
Moeller Wiring Manual 02/08
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
Moeller Wiring Manual 02/08
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
Moeller Wiring Manual 02/08
Control circuit devices LS-Titan® position switches Overview
3 LS, LSM
LSR…
3-14
LS4…ZB
LS…ZB
LS…ZBZ
Moeller Wiring Manual 02/08
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
Sicherheit geprüft tested safety
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
Moeller Wiring Manual 02/08
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
Moeller Wiring Manual 02/08
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
Moeller Wiring Manual 02/08
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
Safety contact Signalling contact Interlocked Released open
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
Moeller Wiring Manual 02/08
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
Safety contact Signalling contact Interlocked Released open
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
Moeller Wiring Manual 02/08
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
Safety contact Signalling contact Interlocked Released open
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.
Moeller Wiring Manual 02/08
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
Moeller Wiring Manual 02/08
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
Moeller Wiring Manual 02/08
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
Moeller Wiring Manual 02/08
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
Moeller Wiring Manual 02/08
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
Moeller Wiring Manual 02/08
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
Moeller Wiring Manual 02/08
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
Moeller Wiring Manual 02/08
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
–
Moeller Wiring Manual 02/08
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
Moeller Wiring Manual 02/08
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.
Moeller Wiring Manual 02/08
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
Moeller Wiring Manual 02/08
Notes
3
3-32
Moeller Wiring Manual 02/08
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
Moeller Wiring Manual 02/08
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
Moeller Wiring Manual 02/08
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
Moeller Wiring Manual 02/08
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.
Moeller Wiring Manual 02/08
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
Moeller Wiring Manual 02/08
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
Moeller Wiring Manual 02/08
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
Moeller Wiring Manual 02/08
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
Moeller Wiring Manual 02/08
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
Moeller Wiring Manual 02/08
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
Moeller Wiring Manual 02/08
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
Moeller Wiring Manual 02/08
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
Moeller Wiring Manual 02/08
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
Moeller Wiring Manual 02/08
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
Moeller Wiring Manual 02/08
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
Moeller Wiring Manual 02/08
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
Moeller Wiring Manual 02/08
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
Moeller Wiring Manual 02/08
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!
Moeller Wiring Manual 02/08
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
Moeller Wiring Manual 02/08
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.
Moeller Wiring Manual 02/08
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
Moeller Wiring Manual 02/08
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.
Moeller Wiring Manual 02/08
Notes
5
5-5
Moeller Wiring Manual 02/08
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
Moeller Wiring Manual 02/08
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
Moeller Wiring Manual 02/08
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.
Moeller Wiring Manual 02/08
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
Moeller Wiring Manual 02/08
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.
Moeller Wiring Manual 02/08
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
Moeller Wiring Manual 02/08
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
Contactors and relays SmartWire Moeller Wiring Manual 02/08
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
Contactors and relays SmartWire Moeller Wiring Manual 02/08
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
Contactors and relays SmartWire Moeller Wiring Manual 02/08
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
Contactors and relays SmartWire Moeller Wiring Manual 02/08
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 Moeller Wiring Manual 02/08
Moeller Wiring Manual 02/08
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
Contactors and relays SmartWire Moeller Wiring Manual 02/08
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
Contactors and relays SmartWire Moeller Wiring Manual 02/08
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
Contactors and relays SmartWire Moeller Wiring Manual 02/08
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
Contactors and relays SmartWire Moeller Wiring Manual 02/08
5
5-23
Moeller Wiring Manual 02/08
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
Moeller Wiring Manual 02/08
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
Moeller Wiring Manual 02/08
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,
Moeller Wiring Manual 02/08
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
Moeller Wiring Manual 02/08
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
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.
Auxiliary contact blocks For surface mounting
For side mounting
–
DILM1000-XHI…
V,
Moeller Wiring Manual 02/08
Contactors and relays Contactors DIL, overload relays Z
1000 V
Conventional free air thermal current Ith = Ie [A] AC-1 at 60 °C
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
Auxiliary contact blocks For surface mounting
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
Moeller Wiring Manual 02/08
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
Moeller Wiring Manual 02/08
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
Moeller Wiring Manual 02/08
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.
Moeller Wiring Manual 02/08
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
Moeller Wiring Manual 02/08
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).
Moeller Wiring Manual 02/08
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
Moeller Wiring Manual 02/08
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
Moeller Wiring Manual 02/08
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
Moeller Wiring Manual 02/08
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.
Moeller Wiring Manual 02/08
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
Moeller Wiring Manual 02/08
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 %.
Moeller Wiring Manual 02/08
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
Moeller Wiring Manual 02/08
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.
Moeller Wiring Manual 02/08
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
Moeller Wiring Manual 02/08
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
Moeller Wiring Manual 02/08
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
Moeller Wiring Manual 02/08
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.
Moeller Wiring Manual 02/08
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
Moeller Wiring Manual 02/08
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
Moeller Wiring Manual 02/08
Notes
5
5-51
Moeller Wiring Manual 02/08
Notes
5
5-52
Moeller Wiring Manual 02/08
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
Moeller Wiring Manual 02/08
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.
Moeller Wiring Manual 02/08
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
Moeller Wiring Manual 02/08
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.
Moeller Wiring Manual 02/08
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
Moeller Wiring Manual 02/08
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
Moeller Wiring Manual 02/08
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
Moeller Wiring Manual 02/08
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
Moeller Wiring Manual 02/08
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
Moeller Wiring Manual 02/08
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
Moeller Wiring Manual 02/08
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
Moeller Wiring Manual 02/08
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.
Moeller Wiring Manual 02/08
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
Moeller Wiring Manual 02/08
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)
Moeller Wiring Manual 02/08
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
Moeller Wiring Manual 02/08
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
Moeller Wiring Manual 02/08
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
Moeller Wiring Manual 02/08
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
Moeller Wiring Manual 02/08
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
Moeller Wiring Manual 02/08
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.
Moeller Wiring Manual 02/08
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).
Example 3: PKZ2/ZM-.../RS(...)
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
Moeller Wiring Manual 02/08
Motor-protective circuit-breakers PKZ2 – operating principle schematics Circuit-breaker with remote operator Actuation by control circuit devices.
Example 4: PKZ2/ZM-.../RS(...)
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
Moeller Wiring Manual 02/08
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
Moeller Wiring Manual 02/08
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
Moeller Wiring Manual 02/08
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
Moeller Wiring Manual 02/08
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
Moeller Wiring Manual 02/08
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
Moeller Wiring Manual 02/08
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
Moeller Wiring Manual 02/08
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
Moeller Wiring Manual 02/08
Notes
6
6-30
Moeller Wiring Manual 02/08
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
Moeller Wiring Manual 02/08
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
Moeller Wiring Manual 02/08
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
Moeller Wiring Manual 02/08
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.
Moeller Wiring Manual 02/08
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
Moeller Wiring Manual 02/08
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).
Moeller Wiring Manual 02/08
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
Moeller Wiring Manual 02/08
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
Moeller Wiring Manual 02/08
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
Moeller Wiring Manual 02/08
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
Moeller Wiring Manual 02/08
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.
Moeller Wiring Manual 02/08
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
Moeller Wiring Manual 02/08
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.
Moeller Wiring Manual 02/08
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
Moeller Wiring Manual 02/08
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
Moeller Wiring Manual 02/08
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
Moeller Wiring Manual 02/08
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
Moeller Wiring Manual 02/08
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
Moeller Wiring Manual 02/08
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
Moeller Wiring Manual 02/08
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
Moeller Wiring Manual 02/08
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
Moeller Wiring Manual 02/08
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
Moeller Wiring Manual 02/08
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
Moeller Wiring Manual 02/08
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+
Circuit-breakers IZM circuit-breakers Moeller Wiring Manual 02/08
7
7-27
7-28 Klemmen Terminals
Leitungsnummer Wire no.
Intern Internal
Leitungsnummer Wire no.
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
Circuit-breakers IZM circuit-breakers Moeller Wiring Manual 02/08
Klemmen Terminals
Leitungsnummer Wire no.
Intern Internal
Leitungsnummer Wire no.
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
Circuit-breakers IZM circuit-breakers Moeller Wiring Manual 02/08
7
7-29
7-30 Klemmen Terminals
Leitungsnummer Wire no.
Intern Internal
Leitungsnummer Wire no.
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
Circuit-breakers IZM circuit-breakers Moeller Wiring Manual 02/08
Farbe / color
Klemmen Terminals
Leitungsnummer Wire no.
Intern Internal
Leitungsnummer Wire no.
Klemmen Terminals
XEE 3
4
XEE Elektrisch "EIN" Electrical "ON"
XE
XE Einschaltmagnet Closing release
Closing release/electrical ON
Circuit-breakers IZM circuit-breakers Moeller Wiring Manual 02/08
7
7-31
7-32 Klemmen Terminals
Leitungsnummer Wire no.
Intern Internal
Leitungsnummer Wire no.
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
Circuit-breakers IZM circuit-breakers Moeller Wiring Manual 02/08
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
Circuit-breakers IZM circuit-breakers Moeller Wiring Manual 02/08
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
Trip magnet for overcurrent release
Auslösemagnet für Elektronischer Überstromauslösung Überstromauslöser
-
7-34 Interner Systembus Internal system bus
7 1)
+
Interner Systembus Internal system bus
Protective circuits for overcurrent release, metering module only
Circuit-breakers IZM circuit-breakers Moeller Wiring Manual 02/08
XZM...
G-Wandler G sensor
Overcurrent release
N-Wandler N sensor
Interner Systembus Internal system bus
+
BSS-Modul BSS module
Breaker Status Sensor
Breaker Status Sensor
1)Termination resistor on X8.1/X8.2, if no external system bus module (a figure, page 7-26).
Intern Internal
Klemmen Terminals
Trip magnet for overcurrent release
Auslösemagnet für Elektronischer Überstromauslösung Überstromauslöser
-
1)
+
Internal system bus
Interner Systembus
Protective circuits for overcurrent release, breaker status sensor only
Circuit-breakers IZM circuit-breakers Moeller Wiring Manual 02/08
7
7-35
Moeller Wiring Manual 02/08
Notes
7
7-36
Moeller Wiring Manual 02/08
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
Moeller Wiring Manual 02/08
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
Moeller Wiring Manual 02/08
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
Moeller Wiring Manual 02/08
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.
Moeller Wiring Manual 02/08
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
Moeller Wiring Manual 02/08
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
Moeller Wiring Manual 02/08
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
Moeller Wiring Manual 02/08
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.
Moeller Wiring Manual 02/08
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
Moeller Wiring Manual 02/08
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
Moeller Wiring Manual 02/08
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
Moeller Wiring Manual 02/08
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.
Moeller Wiring Manual 02/08
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
Moeller Wiring Manual 02/08
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.
Moeller Wiring Manual 02/08
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
Moeller Wiring Manual 02/08
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.
Moeller Wiring Manual 02/08
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
Moeller Wiring Manual 02/08
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.
Moeller Wiring Manual 02/08
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
Moeller Wiring Manual 02/08
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)
Moeller Wiring Manual 02/08
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
Moeller Wiring Manual 02/08
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
Moeller Wiring Manual 02/08
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
Moeller Wiring Manual 02/08
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
Moeller Wiring Manual 02/08
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
Moeller Wiring Manual 02/08
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.
Moeller Wiring Manual 02/08
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
Moeller Wiring Manual 02/08
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.
Moeller Wiring Manual 02/08
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
Moeller Wiring Manual 02/08
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
Moeller Wiring Manual 02/08
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
Moeller Wiring Manual 02/08
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.
Moeller Wiring Manual 02/08
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
Moeller Wiring Manual 02/08
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
Moeller Wiring Manual 02/08
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
Moeller Wiring Manual 02/08
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
Moeller Wiring Manual 02/08
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
Moeller Wiring Manual 02/08
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.
Moeller Wiring Manual 02/08
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
Moeller Wiring Manual 02/08
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
Moeller Wiring Manual 02/08
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
Moeller Wiring Manual 02/08
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
Moeller Wiring Manual 02/08
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
Moeller Wiring Manual 02/08
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.
Moeller Wiring Manual 02/08
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
Moeller Wiring Manual 02/08
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)
Moeller Wiring Manual 02/08
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
Moeller Wiring Manual 02/08
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
Moeller Wiring Manual 02/08
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
Moeller Wiring Manual 02/08
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
Moeller Wiring Manual 02/08
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
Moeller Wiring Manual 02/08
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
Moeller Wiring Manual 02/08
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
Moeller Wiring Manual 02/08
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)
Moeller Wiring Manual 02/08
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
Moeller Wiring Manual 02/08
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
Moeller Wiring Manual 02/08
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
Moeller Wiring Manual 02/08
Notes
8
8-58
Moeller Wiring Manual 02/08
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
Moeller Wiring Manual 02/08
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
Moeller Wiring Manual 02/08
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
Moeller Wiring Manual 02/08
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
Moeller Wiring Manual 02/08
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
Moeller Wiring Manual 02/08
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
Moeller Wiring Manual 02/08
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
Moeller Wiring Manual 02/08
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
Moeller Wiring Manual 02/08
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
Moeller Wiring Manual 02/08
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.
Moeller Wiring Manual 02/08
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
Moeller Wiring Manual 02/08
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
Control circuit devices
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
Moeller Wiring Manual 02/08
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
Moeller Wiring Manual 02/08
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
Moeller Wiring Manual 02/08
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
Moeller Wiring Manual 02/08
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
Moeller Wiring Manual 02/08
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
Moeller Wiring Manual 02/08
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.
Moeller Wiring Manual 02/08
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
Moeller Wiring Manual 02/08
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.
Moeller Wiring Manual 02/08
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
Moeller Wiring Manual 02/08
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
Moeller Wiring Manual 02/08
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
Moeller Wiring Manual 02/08
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)
Moeller Wiring Manual 02/08
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
Moeller Wiring Manual 02/08
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
Moeller Wiring Manual 02/08
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
Moeller Wiring Manual 02/08
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.
Moeller Wiring Manual 02/08
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
Moeller Wiring Manual 02/08
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.
Moeller Wiring Manual 02/08
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
Moeller Wiring Manual 02/08
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)
Moeller Wiring Manual 02/08
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
Moeller Wiring Manual 02/08
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
Moeller Wiring Manual 02/08
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
Moeller Wiring Manual 02/08
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
Moeller Wiring Manual 02/08
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
Moeller Wiring Manual 02/08
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
Moeller Wiring Manual 02/08
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
Moeller Wiring Manual 02/08
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
Moeller Wiring Manual 02/08
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
Moeller Wiring Manual 02/08
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
Moeller Wiring Manual 02/08
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
Moeller Wiring Manual 02/08
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
Moeller Wiring Manual 02/08
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
Moeller Wiring Manual 02/08
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
Moeller Wiring Manual 02/08
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
Moeller Wiring Manual 02/08
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
Moeller Wiring Manual 02/08
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
Moeller Wiring Manual 02/08
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
Moeller Wiring Manual 02/08
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>
Moeller Wiring Manual 02/08
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
Moeller Wiring Manual 02/08
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
Moeller Wiring Manual 02/08
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
Moeller Wiring Manual 02/08
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.
Moeller Wiring Manual 02/08
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
Moeller Wiring Manual 02/08
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
Moeller Wiring Manual 02/08
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
Moeller Wiring Manual 02/08
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
Moeller Wiring Manual 02/08
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
Moeller Wiring Manual 02/08
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
Moeller Wiring Manual 02/08
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
Moeller Wiring Manual 02/08
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
Moeller Wiring Manual 02/08
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
Moeller Wiring Manual 02/08
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
Moeller Wiring Manual 02/08
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
Moeller Wiring Manual 02/08
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
Moeller Wiring Manual 02/08
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
Moeller Wiring Manual 02/08
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
Moeller Wiring Manual 02/08
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
Moeller Wiring Manual 02/08
Export to the world market and to North America Marking of electrical equipment for North America Code letter
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
Moeller Wiring Manual 02/08
Export to the world market and to North America Marking of electrical equipment for North America Code letter
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
Moeller Wiring Manual 02/08
Export to the world market and to North America Marking of electrical equipment for North America Code letter
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
Moeller Wiring Manual 02/08
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
Moeller Wiring Manual 02/08
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
Moeller Wiring Manual 02/08
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
Moeller Wiring Manual 02/08
Export to the world market and to North America Circuit symbols, European – North America Description
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
Moeller Wiring Manual 02/08
Export to the world market and to North America Circuit symbols, European – North America Description
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
Moeller Wiring Manual 02/08
Export to the world market and to North America Circuit symbols, European – North America Description
IEC (DIN EN)
Electromechanical operating device with On-delay
NEMA ICS/ANSI/IEEE or
or
07-15-07
x device code letter a table, page 9-13
07-15-09
x device code letter a table, page 9-13
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
x device code letter a table, page 9-13
× ×
Moeller Wiring Manual 02/08
Export to the world market and to North America Circuit symbols, European – North America Description
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
Moeller Wiring Manual 02/08
Export to the world market and to North America Circuit symbols, European – North America Description
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
Moeller Wiring Manual 02/08
Export to the world market and to North America Circuit symbols, European – North America Description
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
Moeller Wiring Manual 02/08
Export to the world market and to North America Circuit symbols, European – North America Description
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
Moeller Wiring Manual 02/08
Export to the world market and to North America Circuit symbols, European – North America Description
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
Moeller Wiring Manual 02/08
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
Moeller Wiring Manual 02/08
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
Moeller Wiring Manual 02/08
Notes
9
9-35
Moeller Wiring Manual 02/08
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
Moeller Wiring Manual 02/08
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
Moeller Wiring Manual 02/08
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
Moeller Wiring Manual 02/08
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
Moeller Wiring Manual 02/08
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
Moeller Wiring Manual 02/08
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
Moeller Wiring Manual 02/08
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
Moeller Wiring Manual 02/08
Notes
9
9-43
Moeller Wiring Manual 02/08
Notes
9
9-44
Moeller Wiring Manual 02/08
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
Moeller Wiring Manual 02/08
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.
Moeller Wiring Manual 02/08
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
Moeller Wiring Manual 02/08
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
Control circuit devices
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
Moeller Wiring Manual 02/08
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
Moeller Wiring Manual 02/08
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
Moeller Wiring Manual 02/08
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
Moeller Wiring Manual 02/08
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-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)
Moeller Wiring Manual 02/08
Standards, formulae, tables Protective measures Protective devices and conditions for disconnection to IEC 364-4-1/VDE 0100 Part 410 Type of distribution system
TT system
Protection with
Circuit principle
Description so far
Overcurrent protective device
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
Moeller Wiring Manual 02/08
Standards, formulae, tables Protective measures Protective devices and conditions for disconnection to IEC 364-4-1/VDE 0100 Part 410 Type of distribution system
TT system
Protection with
Circuit principle
Insulation monitoring device
–
Overcurrent protective 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
Moeller Wiring Manual 02/08
Standards, formulae, tables Protective measures Protective devices and conditions for disconnection to IEC 364-4-1/VDE 0100 Part 410 Type of distribution system
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
Moeller Wiring Manual 02/08
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
Moeller Wiring Manual 02/08
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
Moeller Wiring Manual 02/08
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.
Moeller Wiring Manual 02/08
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
Moeller Wiring Manual 02/08
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
Moeller Wiring Manual 02/08
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
Moeller Wiring Manual 02/08
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
Moeller Wiring Manual 02/08
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
Moeller Wiring Manual 02/08
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.
Moeller Wiring Manual 02/08
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
Moeller Wiring Manual 02/08
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
Moeller Wiring Manual 02/08
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
Moeller Wiring Manual 02/08
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.
Moeller Wiring Manual 02/08
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
Moeller Wiring Manual 02/08
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
Moeller Wiring Manual 02/08
Standards, formulae, tables Degrees of protection for electrical equipment Protection against contact and foreign bodies First nume ral
Degree of protection Description
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
Moeller Wiring Manual 02/08
Standards, formulae, tables Degrees of protection for electrical equipment Protection against water
10
Second numeral
Degree of protection Description
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
Moeller Wiring Manual 02/08
Standards, formulae, tables Degrees of protection for electrical equipment Second numeral
Degree of protection Description
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
Moeller Wiring Manual 02/08
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
Moeller Wiring Manual 02/08
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
Moeller Wiring Manual 02/08
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
Moeller Wiring Manual 02/08
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
Moeller Wiring Manual 02/08
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
Moeller Wiring Manual 02/08
Standards, formulae, tables Utilisation categories for contactors and motor starters Verification of electrical endurance
Verification of switching capacity
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
Moeller Wiring Manual 02/08
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
Verification of switching capacity
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
Moeller Wiring Manual 02/08
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
Moeller Wiring Manual 02/08
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.
Moeller Wiring Manual 02/08
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
Moeller Wiring Manual 02/08
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
Moeller Wiring Manual 02/08
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
Moeller Wiring Manual 02/08
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
Moeller Wiring Manual 02/08
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
Moeller Wiring Manual 02/08
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
Moeller Wiring Manual 02/08
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
Moeller Wiring Manual 02/08
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
Short-circuit 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
Moeller Wiring Manual 02/08
Standards, formulae, tables Conductors
525 V
6%
rcuit
690/400 V
4% Rated current
6%
Short-circuit current
4% Rated current
Short-circuit 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
Moeller Wiring Manual 02/08
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
Moeller Wiring Manual 02/08
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
Moeller Wiring Manual 02/08
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
Moeller Wiring Manual 02/08
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
Moeller Wiring Manual 02/08
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
Moeller Wiring Manual 02/08
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
Moeller Wiring Manual 02/08
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
Moeller Wiring Manual 02/08
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
Moeller Wiring Manual 02/08
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
Moeller Wiring Manual 02/08
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
Moeller Wiring Manual 02/08
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
Moeller Wiring Manual 02/08
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
Moeller Wiring Manual 02/08
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
Moeller Wiring Manual 02/08
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
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Moeller Wiring Manual 02/08
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
Moeller Wiring Manual 02/08
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
Moeller Wiring Manual 02/08
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
Moeller Wiring Manual 02/08
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
Moeller Wiring Manual 02/08
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
Moeller Wiring Manual 02/08
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
Moeller Wiring Manual 02/08
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
Moeller Wiring Manual 02/08
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
Moeller Wiring Manual 02/08
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
Moeller Wiring Manual 02/08
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
Moeller Wiring Manual 02/08
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
Moeller Wiring Manual 02/08
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
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Moeller Wiring Manual 02/08
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
Moeller Wiring Manual 02/08
Notes
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Moeller Wiring Manual 02/08
Notes
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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
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[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
