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66SmartWire SmartWire

Wiring Manual | 2008Automation and Power Distribution

Wir

ing

Man

ual

| 20

08

Eaton’s electrical business is a globalleader in electrical control, powerdistribution, uninterruptible power supply and industrial automationproducts and services.

Eaton’s global electrical brands,including Cutler-Hammer®, MGE OfficeProtection Systems™, Powerware®,Holec®, MEM®, Santak and Moeller,provide customer-driven PowerChainManagement® solutions to serve thepower 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)228 602-3640Fax +49(0)228 602-61400

E-Mail: [email protected]: www.moeller.net/fieldservice

Moeller addresses worldwide:www.moeller.net/address

E-mail: [email protected]: www.moeller.net www.eaton.com

Issued by Moeller GmbHHein-Moeller-Str. 7-11D-53115 Bonn

© 2008 by Moeller GmbH, GermanySubject to alterationsFB0200-004EN_(02/08) ip/Ins/CPIPrinted in Germany (11/08)Article No.: 119816

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 RiegeTranslator: 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, photo-copy, microfilm or any other process) or processed, duplicated or distrib-uted 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

0chapter

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


0-2

The Moeller Wiring Manual

0
Page
What's new in this edition? 0-3

Moeller – Competence and Experience from a Single Source 0-4

The Moeller Support Portal 0-5

Online Training Center 0-6

Electronic Catalogue 0-8

Moeller Field Service 0-9

Moeller Darwin technology 0-11

Moeller power distribution equipment 0-14


The Moeller Wiring ManualWhat's new in this edition?

0Export to the world market and to North America

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.

The way to a safe machine

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

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.

0-3


0

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

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,

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

0-4

http://www.moeller.net/en

http://www.moeller.net/en/support


The Moeller Wiring ManualThe Moeller Support Portal

0Uncomplicated and quick way of finding the information you need:

• 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

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

• Selection aids– Motor starters a section "Selection aids",

page 8-3– Frequency inverters a section "Selection

aids", page 2-28

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

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

0-5


0

The Moeller Wiring ManualOnline Training Center

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.

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

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

The Products area provides:

• An overview of the device series and accessories,

• mounting instructions, operating manuals and product information for download as PDF files.

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

0-6

http://www.easy-forum.net

http://trainingscenter.moeller.net/software/easysoft.html

http://trainingscenter.moeller.net/software/easysoftcodesys.html

The Moeller Wiring ManualOnline Training Center


0The Programming section of the Basics area also explains how to use the programming system by means of example projects.

The "Networking" section provides examples on networking the devices.

The Functions area provides 54 preprogrammed functions with:

• a complete function description,• example program that you can load directly

onto your easy or test beforehand with easySoft, and if necessary adapt it to your required application,

• small Flash animations that illustrate how to create the function in easySoft,

• sorted according to device class easy500/700/800 and easyHMI.

The Applications area shows typical applications with easy such as temperature controls in greenhouses or stairway lighting controls as well as examples of graphic display applications with easyHMI. These applications are:

• “ready to use”: simply load the completed programs onto your easy and put them into operation,

• tested and fully documented.

The References area shows you that Moeller products are used in a wide range of areas and are in use worldwide. To obtain a short overview of their versatility look at some of the applications for the easy family on the page presented in PDF format.

The Software area provides information and downloads for:

• the easySoft operating and programming software,

• the OPC server, supplied free-of-charge with easySoft

• the Labeleditor for the customised labelling of the easyHMI,

• Fieldbus interfaces with the necessary device master data,

• CAD files for electrical engineering design.

0-7


0

The Moeller Wiring ManualElectronic Catalogue

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.

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.

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.

0-8

http://int.catalog.moeller.net/en


The Moeller Wiring ManualMoeller Field Service

0Our services for your success.

• Helpline• Onsite Service• Repairs• Online Service

Moeller Helpline

Break-Down ServiceYou 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 ServiceDuring 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 onsiteQualified technicians and specialists can visit you in order to rectify faults quickly and reliably.

Inspection and maintenanceDIN 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.

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 supportContact us if you require fast and competent support in installing and commissioning tasks.

Conversions and expansionsWhether with controllers, circuit-breakers or other components, we can bring your machines and plants up to the latest state-of-the-art.

ThermographyThermography gives us an efficient way of analysing your electrical systems and controls during operation.

Network analysisNetwork analysis provides clear information about the specific state of your networks without the need for lengthy and expensive troubleshooting.

0-9

The Moeller Wiring ManualMoeller Field Service


0
Bus monitoringIf required we can inspect the communication networks of your systems with the latest technical equipment.
Moeller Repairs

Direct exchangeIn the event of a fault, the direct exchange service for selective Moeller products considerably reduces the downtime of your production plant.

RepairsThe repair of Moeller products in our Service Center is an inexpensive alternative for fault rectification.

Moeller Online Service

Online troubleshootingWe 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 QuestionsThere 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.

DownloadsYou'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.

Contact

• Faults hotlineFor field service contact your Moeller agentwww.moeller.net/address or the Moeller Field Service directlyTel.: +49 (0) 180 522 3822 (de, en)(round the clock)

• Consulting serviceTel.: +49 (0) 228 602 3640(Mo. - Fr. 08:00 - 16:00 CET)

• [email protected]

• Internetwww.moeller.net/fieldservice

0-10

http://www.moeller.net/address

mailto: [email protected]

http://www.moeller.net/en/support/fieldservice/index.jsp


The Moeller Wiring ManualMoeller Darwin technology

0Darwin. The technological quantum spring.

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.

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

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

Switching

Controlling

Protecting

Drives

HMI

0-11



0
Evolution of the control panel
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.

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

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

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.

Before Today

0-12



0

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.

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

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

All devices connected with SmartWire Darwin operate as local or remote inputs/outputs of easyControl. The system is fully self-configuring.

Further informationa section "Connect, don't wire", page 5-8 and a section "SmartWire Gateway", page 1-43.

Today with SmartWire Tomorrow with SmartWired

0-13


0

The Moeller Wiring ManualMoeller power distribution equipment

Low-voltage switchgear systems for infrastructure

System range xEnergyxEnergy 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.

It consists of:

• Switching and protective devices,• the modular enclosure system,• the control panel complete with planning and

calculation tools.

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

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

0-14



0Type-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
XFixed Panels
• 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



0XGeneral Panels

• Mounting systems for rail-mounted service installation devices

• Customized fixed mounted units on mounting plates up to 630 A, e.g. soft starters, frequency inverters, power factor correction

• Automation engineering• Control technology adapter systems xStart• Incoming busbar 3, 4 pole and TP + N

0-17



0
Sheet steel wall-mounting enclosure CS
With mounting plate

45 enclosure sizes are available for selection from 250 × 200 × 150 to 1200 × 1200 × 250 mm.

The stable CS enclosure series made from solid sheet steel is used in applications wherever effective protection against the direct contact of live parts is required.

The high IP55 degree of protection allows installed equipment to be protected from most harmful ambient conditions.

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.

0-18



0Their powder coated surface provides an abrasion and corrosion resistant protection.

The enclosure door can be removed easily for other mechanical measures. Inside hinges that are covered can thus be undone simply and the door stop exchanged from right to left or vice versa.

Moeller can also provide customised solutions on request. This includes for example:

• other RAL colour tones,• other dimensions,• cutouts in doors and side panels, e.g. for

mounting command and signalling devices, touch panels, meters and cable glands.

0-19



0
Terminal K
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).

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.

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

0-20



0CI 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,

• "Total insulation" provides maximum personnel protection and operational safety.

• Transparent neutral cover allows unrestricted view,

• Floor-standing distribution boards with base covers for routing, fastening or covering large cable cross sections.

Enclosed distribution boards are type-tested assemblies (TTA) in accordance with VDE 0660 part 500 or Type Tested Assemblies (TTA) to IEC 60 439.

0-21



0
SASY60i busbar system for the world market
The SASY60i modular busbar system from Moeller is designed for effective energy distribution in the control panel.

Thanks to the innovative mounting technology feeder and outgoing circuit-breakers can be mounted quickly and compactly. SASY60i is safe and reliable.

In conjunction with the latest generation of Moeller motor protective circuit-breakers and other circuit-breakers, the SASY 60i provides a universal, UL certified solution for switching, controlling, protecting and distributing energy. Together with the appropriate switching and protective devices, the busbar system is designed for worldwide use.

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.

0-22

NotesMoeller Wiring Manual 02/08

0

0-23


0

0-24


Switching, control, visualisation

1

Page

Timing relays 1-2

EMR4 measuring and monitoring relays 1-6

The way to the safe machine 1-10

System overview E 1-12

Engineering E 1-20

Programming E 1-50

Overview of automation products 1-67

Compact PLC, PS4 1-68

Modular PLC, XC100/XC200 1-70

HMI systems 1-72

Networking 1-73

Engineering PS4 1-75

Engineering EM4 and LE4 1-78

Engineering XC100, XC200 1-79

1-1


1

Switching, control, visualisationTiming relays

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 VAC 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 VAC 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 (on-delayed)

• ETR2-12 Function 12 (off-delayed)

• ETR2-21Function 21 (fleeting contact on energisation)

• ETR2-42 Function 42 (flashing, pulse initiating)

• 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 de-energisation)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 de-energisation)Function 42 (flashing, pulse initiating)Function 43 (flashing, pause initiating)Function 82 (pulse shaping)

• Star-delta timing relays ETR4-51Function 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 25-28 (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.

1-2



1

Function 11

On-delayed

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 (25-28).

Function 12

Off-delayed

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.

Function 16

On- and Off-delayed

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

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.

t

A1-A215-18

A1-A2

B115-18(25-28)

Y1-Y2

t

A1-A2

B115-18(25-28)

Y1-Y2

t t

A1-A2

15-18(25-28)t

1-3



1

Function 82

Pulse forming

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

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 (25-28) and returns to its original position 0.5-15

(16-25) after 26 s. This function is therefore a fleeting pulse with a time delay.

Function 22

Fleeting contact on de-energization

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 15-18 (25-28) closes for the duration of the set time.

Function 42

Flashing, pulse initiating

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.

A1-A2

B115-18(25-28)

Y1-Y2

t

A1-A2

15-18(25-28)0.5 st

B1

A1-A2

15-18(25-28)

Y1-Y2

t

t t t t

A1-A2

15-18(25-28)

1-4



1

Function 43

Flashing, pause initiated

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).

Function 44

Flashing, two speeds

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.

Function 51 Star-delta

On-delayed

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

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…: AWA2527-2372Main catalogue for industrial switchgear, Section 4 “Timing relays”

LED

ttt t

A1-A2

15-18

t

A1-B1

A1-A2

Rel LED

A1-B1

Rel LED

ttt t15-18

t t1 2 1 2 1 2

15-18ttt t t t1 2 1 2 1 2

tu

A1-A2

17-1817-28

t

A1-A2

15-18(25-28)LED

OFF OFFON

1-5


1

Switching, control, visualisationEMR4 measuring and monitoring relays

General

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

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.

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 peaksBy using the selected time delay of between 0.05 and 30 s short current peaks can be bridged.

EMR4-W phase monitoring relay

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.

1-6



1

The delay time can be set between 0.1 and 10 s.

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

Phase sequence relay EMR4-F

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.

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.

Phase imbalance relay EMR4-A

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

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

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



1

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.

An earth-fault is signalled via a changeover contact so that a fault can be cleared without expensive down time.

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.

AC or DC control voltageDevices 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) three-phase 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



1

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.

Further information sources

Installation instructions

• Phase imbalance monitoring relay EMR4-A400-1 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…, EMR4-AWN…, EMR4-W…AWA2431-2271

Main catalogue Industrial Switchgear, Section 4 “monitoring relays”.

1-9


1

Switching, control, visualisationThe way to the safe machine

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 “safety-related 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 TB0200-009.

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 13849-1 and EN IEC 62061.

Further technical information on the individual safety products is provided at www.moeller.net/Safety.

1-10

http://www.moeller.net/en/themenauftritte/safety/products/index.jsp

Switching, control, visualisationThe way to the safe machine


1

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.

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

Reliable disconnection with DILM contactors and CMD contactor monitoring relay.

Fast and secure detection

Safe monitoring and processing

Reliable shutdown

Input

Logic

Output

1-11


1

Switching, control, visualisationSystem overview E

eRelay

ESC

DEL

OK

ALT

ESC

POW

BUS

POWER

COM-ERR

ADR

ERRMS

NS

221 3

5 6

6

4

4 5

8

7

9 10

9

8

11 12 13 14

1-12



1

1) Detachable display MFD-80… and MFD(-AC)-CP4-500

2) Ethernet-Gateway EASY209-SE3) Detachable display MFD-80… and MFD(-

AC)-CP4-8004) Basic device easy5005) Basic device easy700, expandable6) Basic unit easy800, expandable,

networkable via easyNet7) EASY202-RE output expansion8) easy410 I/O expansion9) easy6… I/O expansion10) Coupling unit EASY200-EASY for remote

expansion of easy700, easy80011) Expansion unit for networking PROFIBUS-

DP EASY204-DP12) Expansion unit for networking AS-Interface

EASY205-ASI13) Expansion unit for networking CANopen

EASY221-CO14) Expansion unit for networking DeviceNet

EASY222-DN

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1

eHMI

POW

BUSPOWER

COM-ERR

ADR

ERR

MS

NS

1

3

4

2

9

6

10 1112

8

7

7

6

5

1-14



1

1) Ethernet gateway EASY209-SE2) I/O module with or without temperature

measuring for MFD-Titan3) Power supply unit/CPU MFD(-AC)-CP8…4) Display/operating unit MFD-80…5) EASY202-RE output expansion6) easy410 I/O expansion7) easy6… I/O expansion8) Coupling unit EASY200-EASY for remote

expansion of MFD(-AC)-CP8…9) Expansion unit for networking PROFIBUS-




EASY222-DN

1-15



1

eControl

POW

BUS

ESC

DEL

OK

ESC

ALTALT

OK

POWER

COM-ERR

ADR

ERR

MS

NS

1

1

3

2

2

53

4

4

6 78

12

11

11

9

10

10

1-16



1

1) CANopen connection for MFD-80… and MFD-CP4-CO

2) Detachable display MFD-80… and MFD(-AC)-CP4-800

3) Basic device EC4P-2004) CANopen I/O expansion EC4E…5) Expansion unit for networking PROFIBUS-




EASY222-DN9) EASY202-RE output expansion10) easy410 I/O expansion11) easy6… I/O expansion12) Coupling unit EASY200-EASY for remote

expansion of EC4P-200

1-17



1

Functions e

e500 and e700

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.

MFD(-AC)-CP8… and e800

MFD…CP8… and easy800 have the same functions. With its degree of protection MFD-80...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.

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1

eControl: EC4P-200

easyControl is the obvious successor to the easyRelay. The easyControl EC4P-200 can be used for implementing both small and medium-sized 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 easySoft-CoDeSys (ECP-SOFT) based on IEC 61131-3.

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

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 MFD-CP4.. 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.

easy500

easy700

easy800

EC4P-200

ES4P-200

1-19


1

Switching, control, visualisationEngineering E

Power supply connection

for AC devices for DC devices

Basic devices

EASY512-AB-…EASY719-AB-…

24 V AC24 V AC

Basic devices

EASY512-DA-…EASY719-DA-…

12 V DC12 V DC

EASY512-AC-… EASY719-AC-…EASY819-AC-…

115/230 V AC115/230 V AC115/230 V AC

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

24 V DC24 V DC24 V DC24 V DC

ES4P-… 24 V DC

EC4P-200 24 V DC

MFD-AC-CP8-… 115/230 V AC MFD-CP8-… 24 V DC

Expansion devices

EASY618-AC… 115/230 V AC

Expansion devices

EASY410-DC…EASY618-DC…EASY620-DC…

24 V DC24 V DC24 V DC

L

L.1

N

L N N

> 1A

+

+.1

–

+...V 0 0

> 1A

1-20



1

Digital input connection of the AC devices

a Input signal via relay contact e.g. DILERb Input signal via pushbutton RMQ Titanc Input signal via position switch e.g. LS-Titand 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)

e Increased input currentf Limiting the input current g Increasing the input current with EASY256-

HCIh EASY256-HCI ballast device

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 kO

N

L.1

1 N

1N4007100 nF

/275 V h

100 nF

/275 V h

a b c d e g hf

1-21



1

Digital input connection of the DC devices

a Input signal via relay contact e.g. DILERb Input signal via pushbutton RMQ Titanc Input signal via position switch e.g. LS-Titand Proximity switch, three-wire e Proximity switch, four-wire

Note

• Consider the voltage drop across the used conductor length.

• Because of the high residual currents, two-wire proximity switches should not be used.

–

+.1

a b c d e

p p

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1

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:

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.

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

• 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.

I7 = IA01

I8 = IA02

I11 = IA03

EASY512-AB/DA/DC…

EASY719-AB/DA/DC…EASY721-DC…EASY819/820/821/822-DC…MFD-R16, MFD-R17,MFD-T16, MFD-TA17EC4P-200

I12 = IA04

1-23



1

Connecting power supply and analog inputs for e…AB device

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 DC-supplied analog sensors must be electrically connected.

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

I7L N I1N

L

N

~

0 V+12 V

L01h

N01 h

I8

F1

EASY200-POW

1-24



1

Connecting analog inputs of e…DA/DC-… or MFD-R…/T… or EC4P-200

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

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

• 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.

+.1

+

–

a b c

a

d

+...V 0 V

+12 V 0 V

4...20 mA

(0...20 mA)

0 V

h+..V-0 V

Out0...10 V -35...55 ˚C 500 O

1-25



1

Connecting Pt100/Ni1000 with MFD-T(A)P…

Note

Cable length, shielded < 10 m.

a b

a Three wire connection b Two wire connection

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

-40 °C ... +90 °C

0 °C ... +250 °C

0 °C ... +400 °C

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

0 °C ... +250 °C

-40 °C ... +90 °C

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

0 °C ... +850 °C

-200 °C ... +200 °C

1-26



1

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

a High-speed counters, square wave signal via proximity switch, mark to space ratio should be 1:1easy500/700 max. 1 kHzeasy800 max. 5 kHzMFD-R/T… max. 3 kHzEC4P-200 max. 50 kHz

b Square wave signal via frequency generator, mark to space ratio 1:1easy500/700 max. 1 kHzeasy800 max. 5 kHzMFD-R/T… max. 3 kHzEC4P-200 max. 50 kHz

c Square wave signals via 24 V DC incremental encodereasy800-DC… and MFD-R/T… max. 3 kHzEC4P-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

+

–

a b

p

+.1

+

–

A B

c

1-27



1

Connecting relay outputs on EASY…R, MFD…R and EC4P-…MR, ES4P…

Fuse protection switch potential L..

F 8 A/B16

Possible AC voltage range:24 to 250 V, 50/60 Hze.g. L1, L2, L3 phase to zero conductor

Possible DC voltage range:12 to 300 V DC

a Lamp, max. 1000 W at 230/240 V ACb 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

1

M

2

L… L… L… L… L…

a b c d e

1 2 1 2 1 2 1 2

1-28



1

Connecting transistor outputs on EASY…T, MFD-T… and EC4P…MT, ES4P…

NotePlease 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.

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.

a b c d

f 2.5 AF 10.0 A

24 V DC

+ 24 V 0 V

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

1-29



1

Parallel connection

a Resistor

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.

a

0 V

if 4 outputs in parallel, max. 2 A at 24 V DC

if 4 outputs in parallel,max. 2 A at 24 V DCInductance without suppression max. 16 mH

12 or 20 W at 24 V DCOutput dependant upon device types and outputs

1-30



1

Connecting analog output on EASY820-DC-RC…, EASY822-DC-TC…, MFD-RA…, MFD-TA…, EC4P…MTA, EC4P…MRA…

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

+

–

a b

+...V 0 V 0 V 0 V Q A1 0 V Q A1

0 V I A

1-31



1

Input/output expansion e

Central expansion, up to 40 I/Oeasy700, 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/Oeasy700, 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/OUp 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

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

1-32



1

Central and remote expansion e

Central expansion

Remote expansion

Central expansion

Remote expansion

I 1 - I...1 2

Q 1 - Q...

easy700easy800EC4P-200ES4P

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

R 1 - R...

S 1 - S...

easy700easy800EC4P-200ES4P

easy200

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

1 2I 1 - I...

Q 1 - Q...

R 1 - R...E+ E-

E+ E-S 1 - S...

F 3

0 m

MFD-AC-CP8...MFD-CP8...

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

R 1 - R...

S 1 - S...

MFD

easy200easy410...easy618...easy620...

R 1 - R...E+ E-

E+ E-S 1 - S...

F 3

0 m

MFD-AC-CP8...MFD-CP8...

MFD

EASY-LINK-DS

1-33



1

eNet, “loop through the device” network connection

Geographic location, position1)

StationExample 1 Example 2

1) 1)The geographic location/place 1 always has the device address 1.

• 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.

• 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.

easy410easy618easy620

easy800EC4P-200ES4P

easy202easy800

easy800EC4P-200ES4P

easyNetEASY-NT-R(124 OPIN1+2)

easy200easy410easy618easy620

MFD-AC-CP8MFD-CP8

1 1 1

2 2 3

3 3 8

8 8 2

EASY-LINK-DS

1-34



1

eNet, network connection “T piece with spur cable”

Geographic location, position1)

StationExample 1 Example2

1) The geographic location/place 1 always has the station address 1.

• 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 MFD-

Titan is 0,30 m.

• 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.

easy410easy618easy620

easy800EC4P-200ES4P

easy202easy800

easy800EC4P-200ES4P

easyNetEASY-NT-R(124 OPIN1+2)

easy200easy410easy618easy620

MFD-AC-CP8MFD-CP8

F 0.3 m

F 0.3 m

1 1 1

2 2 3

3 3 8

8 8 2

EASY-LINK-DS

1-35



1

Network connection eNet

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

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

a Cable entry side 8-pole RJ45, EASY-NT-RJ45

Pin assignment for eNet PIN 1; ECAN_H; Data conductor; conductor

pair APIN 2; ECAN_L; Data conductor; conductor

pair APIN 3; GND; ground conductor; conductor pair BPIN 4; SEL_IN; Select conductor; conductor

pair B

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

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.

NoteCable 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.

Bus terminating resistorA 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.

12345678

12345678

a A 1 ECAN_H

A 2 ECAN_L

B 3 GND (Ground)

B 4 SEL_IN

1-36



1

Prefabricated cables, RJ45 plug at both ends

User prepared cables

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

RJ45 plug: EASY-NT-RJ45

Crimping tool for RJ45 plug: EASY-RJ45-TOOL.

Calculating cross-section with known cable lengthsThe minimum cross-section is determined for the known maximum expansion of the network.

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

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

Cable length [cm] Type designation

30 EASY-NT-30

80 EASY-NT-80

150 EASY-NT-150

l = Length of conductor in mSmin = minimum cross-section in mm2

rcu = specific resistance of copper, unless otherwise stated 0.018 Omm2/m

Smin =l x rcu

12.4

lmax = Length of conductor in mS = Conductor cross-section in mm2

rcu = specific resistance of copper, when nothing else state 0.018 Omm2/m

lmax =S x 12.4

rcu

1-37



1

Permissible network lengths with eNet

Total cable length of eNet

Transmission speed

Conductor cross-section, standardised

Bus conductor, minimum conductor cross-section

EN AWG

m Kbaud mm2 mm2

F 6 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



1

Network connection, CANopen

Loop through the device T piece with spur line

EC4P-200

XC100/200

MFD

DF51/DV51 DF51/DV51DE51-NET-CAN

124 O

124 O

EC4P-200

XC100/200

MFD

DE51-NET-CAN

124 O

124 O

12345678

654321

123

45

6789

1 2 3 4 5

GNDCAN-LCAN-H

GND

CAN-HCAN-L

GNDCAN-LCAN-H

CAN-HGNDCAN-L

GNDCAN-H

CAN-L

F 0.3 m

F 0.3 m

F 0.3 m

1-39



1

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

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

Properties of the CANopen cableUse only a cable that is approved for CANopen with the following characteristics:

• Surge impedance 120 O• Capacitance per unit length < 60 pF/mThe 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).

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 %.

6

5

4

3

2

1

6

5

4

3

2

1

6

5

4

3

2

1

CAN_LCAN_H

120 O 120 O

Cable cross-section [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

1-40



1

Network connection with cable cross-sections > 0.14 mm2, AWG26

Network connect “through the device”.

Example A, with terminals

a Recommendation F 0.3 m

Example B, with interface element

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

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

c F 0.3 m (3-core)

Example B, with interface element

d F 0.3 m (EASY-NT-30)

Note Sreening is required for CANopen.

easy800 ES4PMFD-CP8 EC4P-200

RJ45

1

2

3

4

1

2

3

4RJ45

a

IN

OUT


IN

OUT

RJ45

RJ45

RJ45

RJ45

b 13

57

24

68

13

57

24

68


1

2

3

4

RJ45

c

IN

OUT


IN

OUT

RJ45

RJ45

d

13

57

24

68

1-41



1

Expansion units for networking

A network module can be connected with easy700, easy800, MFD(-AC)-CP8… and EC4P-200. 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).

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.

EASY204-DP EASY221-C0 EASY222-DN EASY205-ASI

easy700, easy800 EC4P-200

MFD…CP8… ES4P

1-42



1

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 eNetIn 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 Head-end controller (easy800, MFD-CP8-NT, EC4P-200, ES4P, XC201)

b SmartWire Gatewayc easyNetd easyNet station, e.g. easy800, ES4Pe easyNet station, e.g. MFD-CP8-NTf SmartWire module, e.g.: for xStartg SmartWire connection cable

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 CANopen PLC e.g. EC4P-200, XC100/XC200

b SmartWire Gatewayc CANopen PLC, e.g. EC4P-200 d CANopen station, e.g. MI4/MFD4 e SmartWire module, e.g.: for xStartf SmartWire connection cable

EC4P

easyNet

e

ca

MFD Titaneasy 800

SmartWire

d

g1 2 3 4 5 16

f

b

CANopena

easy 800

SmartWire

c df

1 2 3 4 5 16

e

b

1-43



1

Detachable display with protection type IP65

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.

L L.1N

L N115/230 V50/60 Hz

> 1 A

+ L.1–

+ 24 V 0 V

> 1 A

MFD-CP4-500-CAB5F 5 m

MFD-CP4-800-CAB5

easy800

easy700

ESCOK

DELALT

easy500

ESCOK

DEL ALT

F 5 m

EC4P-200

F 5 m

MFD...CP4...

MFD-80...

ES4P

F 5

m

1-44



1

Communication connections e

1) only EC4P-222… and XC200

easy800 MFD...CP8...

easy700

ESCOK

DELALT

easy500

ESCOK

DEL ALT

a EASY-SOFT-BASIC

b EASY-SOFT-PRO

c ESP-SOFT

d ECP-SOFT(CoDeSys)

e OPC

EASY-PC-CAB

EASY209-SE

EASY-USB-CAB

EASY800-MO-CAB

EASY800-PC-CAB

EASY800-USB-CAB

XT-CAT5-X...

XT-CAT5-X...1)

MFD-CP4-500-CAB5

MFD-CP4-800-CAB5

EC4P-200

EU4A-RJ45-CAB1

EU4A-RJ45-USB-CAB

b e de

a b e

ES4Pc

1-45



1

EASY209-SE standard connection

a Ethernet connection (RJ45 socket)b Status LED (POW/RUN)c COM terminal, cage clamp terminal 5-poled RESET buttone Device power supply 24 V DC V f Device labelg Strain relief

24 V connection

Ethernet connection

COM connection

press – insert – remove1 = grey, 2 = brown, 3 = yellow, 4 = white,

5 = green

g

fe

c

d

a

b

+24 V

> 1 A

0 V

+24 V 0 V

2

1

12345

TX+TX–RX+

RX–678

23

112345

1 2 3

1-46



1

COM-LINK connection

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.

POW-Side

MFD-80… easy800 MFD…CP8…MFD..T../R..

MFD…CP8…MFD..T../R..

1-47



1

Connecting and operating the e800 on the serial log printer

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.

Pin assignment of EASY800-MO-CAB:

Serially controlled printer

EASY800-MO-CAB

easy800

2 white T x D3 brown R x D5 green GND

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

1

6 7 8 9

2 3 4 5 1

6 7 8 9

2 3 4 5

1-48



1

Connection and modem operation with e or MFD

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

easy800

MFD...CP8...

easy700

ESCOK

DELALT

OPC

easy500

ESCOK

DEL ALT

EASY-PC-CAB EASY800-MO-CAB

EASY800-PC-CAB

SMS

Modem 1 Modem 2

PC Fax e-mail Pager

1-49


1

Switching, control, visualisationProgramming E

Programming instead of wiring

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.

Contacts, coils, function modules, operands

S1 K1

K1 K2 K3

S4

K3 K3

S5

S6

Operand Description easy500,easy700

easy800 MFD(-AC)-CP8…

I Bit input, basic unit x x x

nI Bit input, basic unit via easyNET – x x

IA Analogue input x x x

R Bit input, expansion device1) x x x

nR Bit input, expansion device via easyNET – x x

Q Bit output, basic unit x x x

nQ Bit output, basic unit via easyNET – x x

QA Analogue output – X x

S Bit output, expansion device x x x

nS Bit output, expansion device via easyNET – x x

ID Diagnostic alarm – x x

1ID COM-Link diagnostic alarm – – x

LE Bit output display backlight + Front LEDs – – x

M Marker x x x

1M Marker COM-Link – – x

MB Marker Byte – x x

MD Marker double word – x x

MW Marker word – x x

1MB/1MW

/1MD

Marker operand COM-Link – – x

N Marker x – –

P x x x

1-50



1: Jump x x x

nRN Bit input via easyNET – x x

nSN Bit output via easyNET easyNET – x x

A Analog value comparator x x x

AR Arithmetic – x X

BC Block comparison – X x

BT Block transfer – x x

BV Boolean sequence – X x

C Counter relays X X x

CF Frequency counters X2) X x

CH High-speed counters X2) X x

CI Incremental counters – X x

CP Comparators – X x

D (reverse order) x x –

DB Data function block – x x

DC PID controllers – X x

FT PT1 signal smoothing filter – X x

GT Get value from easyNet – X x

Ö H/HW (clock)/Week time clock X X x

Y/HY Year time switch X X x

JC Conditional jump – x x

LB Jump label – x x

LS Value scaling – x x

Z/MR Master reset x x x

MX Data multiplexer – x –

NC Numerical converters – X x

O/OT Operating hours counters X X x

PO Pulse output – x –

PW Pulse width modulation – X x

SC Sychronise clock via network – X x

ST Set cycle time – X x

SP Serial protocol – x –

SR Shift register – x x

T Timing relays X X x

TB Table function – x x

VC Value limitation – X x

1) With easy700, easy800 and MFD…CP8…2) With easy500 and easy700 programmable as operation type.

n = NET station 1…8

Operand Description easy500,easy700

easy800 MFD(-AC)-CP8…

1-51



1

Coil functions

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.

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

Circuit diagram symbol e Display Coil function Example

Ä Contactor function ÄQ1, ÄD2,ÄS4, Ä:1,ÄM7

Å 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

1-52



1

Parameter sets for times

Example based on EASY512Depending up on the programme the following parameters can be set:

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

T1 Relay no.

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

+ Parameter display

30.000 constant as value, e. g. 30 s

I7 Variable, e. g. Analoge value I7

T:00 clock time

Possible coil functions:

• Trigger = TT..• Reset = RT..• Halt = HT..

T1 ü S +

I1 30.000

I2 I7# T:00

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



1

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 closed1 = N/O contact closed, N/C contact open

For relay coils Qx”

0 = Coil not energized1 = Coil energized

NoteThe examples shown are based on easy500 and easy700. easy800 and MFD…CP8… provide four contacts and one coil per rung.

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

Parameters Time range and setpoint time Resolution

S 00.000 Seconds: 0.000 to 99.999 s easy500, easy700 10 mseasy800, MFD…CP8… 5 ms

M:S 00:00 Minutes: Seconds 00:00 to 99:59 1 s

H:M 00:00 Hours: Minutes, 00:00 to 99:59 1 min.

Parameters Displaying the parameter set via menu item “Parameter”

+ Call enabled

- Access disabled

I1 Q1

1 0

0 1

I1-------ÄQ1

1-54



1

Series connection

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

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

Parallel switching

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

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

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

I1-I2-I3-ÄQ1I1-I2-I3-ÄQ2

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

I1u------ÄQ1I2sI3k

I1u------ÄQ2I2sI3k

1-55



1

Changeover circuit

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

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

Logic table

Self-latching

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

Latching is established by 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.

Logic table

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.

I1 I2 Q1

0 0 0

1 0 1

0 1 1

1 1 0

I1-I2u---ÄQ1I1-I2k

I1uI2----ÄQ1Q1k

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

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-------SQ1

I2-------RQ1

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

1-56



1

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.

Logic table

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.

Permanent contact

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

Logic table

I1 Status of Q1 Q1

0 0 0

1 0 1

0 1 1

1 1 0

S1 normally open contact on I1

I1-------äQ1

--- Q1

1 1

S1 normally open contact on I1

I1-------TT1

T1-------ÄM1

---------ÄQ1

1-57



1

Wiring of contacts and relays

Hardwiredt

Wiring with easyt

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.

.

P1

S1

S2

K1

K1

P1

S1 S2

K1

NQ11

Q11

Q11

K1

K1

Q12

Q12

Q13

Q13

L

S1

S2

Q12

1-58



1

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.

I1: Mains contactor switched onQ1: Star contactor ONQ2: Delta contactor ONT1: Changeover time star/delta (10 to 30 s)T2: Wait time between star off, delta on (30, 40,

50, 60 ms)

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.

1 12 2

Q1

I1L N

Q2

Q12 Q13Q11N

Q11

LN

S1

S2

K1

I1u------TT1dT1----ÄQ1dT1----TT2hT2----ÄQ2

1-59



1

Stairway lighting

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

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

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

NL

S1

S2

S3

K3K1 K2

Q11

Q11

Q12

Q12

K3 K1

K2

Q12

5 s 6 min

E1

E2

E3

K3

1-60



1

NL

S1

S2

S3

E1

E2

E3

1 2

Q1

I1L N

K1

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



1

The easy circuit configuration for the function below looks like this:

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

Meaning of the contacts and relays used:I1: ON/OFF pushbuttonQ1: Output relay for light ON/OFFM1: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, ( , 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. ( , on-delayed, value 5 s)

T3: Switch off after the light has been on for von 6 min. ( , on-delayed, value 6:00 min.)

T4: Switch off after 4 hours continuously on. ( , on-delayed, value 4:00 h)

I1-------TT2

T2-------SM1

I1u------äQ1T3kQ1-M1----TT3Q1-------RM1

I1------uTT1hTT2

T2-------SM1

T1u------äQ1T3sT4kQ1uM1----TT3h------TT4

Q1-------RM1

ü

X

XX

1-62



1

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.

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:

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

Block diagram of the 4-way shift register

a Pulseb Valuec Resetd Storage position

Function:

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 locationM2: 2nd storage locationM3: 3rd storage locationM4: 4th storage locationM7: Marker relay for cycle pulseM8: Cyclical pulse for shift pulse

1 2 3 4

a b cd

Pulse Value Storage position

1 2 3 4

1 1 1 0 0 0

2 0 0 1 0 0

3 0 0 0 1 0

4 1 1 0 0 1

5 0 0 1 0 0

Reset = 1 0 0 0 0

1-63



1
Generate shift pulse
4th memory position, set

4th memory position, delete

3rd memory position, set

3rd memory position, delete

2nd memory position, set

2nd memory position, delete

1st memory position, set

1st memory position, delete

Delete all memory positions

I1uM7----ÄM8h------ÄM7

M8uM3----SM4dM3----RM4dM2----SM3dM2----RM3dM1----SM2dM1----RM2dI2----SM1hI2----RM1

I3------uRM1dRM2dRM3hRM4

1-64



1

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. Example of a text display:

The text display can display the following:

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.

SWITCHING;

CONTROL;

DISPLAY;

ALL EASY!

Line 1, 12 characters

Line 2, 12 characters, a setpoint or actual value

Line 3, 12 characters, a setpoint or actual value

Line 4, 12 characters

RUNTIME M:S

T1 :012:46

C1 :0355 ST

PRODUCED

1-65



1

Visualisation with eHMI

The visualisation with easyHMI is by “screens”, on which the display is shown.

Example of a “screen”:

The following screen elements can be combined.

• Graphic elements– Bit display– Bitmap– Bargraph– Message bitmap

• 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

M3 h

S1 S2

S3

1-66


Switching, control, visualisationOverview of automation products

1

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

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.

Modular PLC, XC100/XC200

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

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-XRC-30", page 1-72) and touch operator panels.

1-67


1

Switching, control, visualisationCompact PLC, PS4

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.

PS4CCompact PLC

EM4Expansion module

LE4Local expansion module

1-68

Switching, control, visualisationCompact PLC, PS4


1

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.

• 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


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


Suconet, PROFIBUS-DP, Ethernet

1-69


1

Switching, control, visualisationModular PLC, XC100/XC200

XC100

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.

XC200

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.

DC INPUT EH-XD16

04812

15913

26

1014

37

1115

DC INPUT EH-XD16

04812

15913

26

1014

37

1115

DC INPUT EH-XD16

04812

15913

26

1014

37

1115

DC INPUT EH-XD16

04812

15913

26

1014

37

1115

XC-CPU101

0404

1515

26214

37315

XC-CPU201

0404

1515

26214

37315

1

2

3

1-70

Switching, control, visualisationModular PLC, XC100/XC200


1

System components

• Modular PLCs– XC100 a

8 DI, 6 DO, CANopen, RS 232, 4 interrupt inputsSlot 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

http://www.moeller.net/en/support


1

Switching, control, visualisationHMI systems

Text operator panel MI4

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.

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.

1-72


Switching, control, visualisationNetworking

1

PS40 Series

XC series

Suco

net

CAN

open

PRO

FIBU

S

Ethe

rnet

Mod

bus

PS4-141-MM1PS4-151-MM1

PS4-201-MM1PS4-271-MM1PS4-341-MM1

LE4-501-BS1LE4-504-BS1LE4-504-BT1COBOX

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

EM4-201-DX2EM4-204-DX1

Suconet K + RS 232Suconet K + RS 232

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

Suconet K,PROFIBUS-DP,PROFIBUS-DP,Ethernet

Suconet K/K1Suconet K/K1

Suconet KPROFIBUS-DP

6 LE4

Net

wor

king

PS4

0 se

ries

Part no. Interfaces

max.

masterslave

master or slave

Suco

net

CAN

open

PRO

FIBU

S

Ethe

rnet

Mod

bus

XC-CPU101-xxXIOC-SER

XIOC-NET-SK-MXIOC-NET-DP-MXIOC-NET-DP-S

XC-CPU201-xxXIOC-SER

XIOC-NET-SK-MXIOC-NET-DP-MXIOC-NET-DP-S

Net

wor

king

XC

seri

es

InterfacesPart no.

RS232, CANopen1 serial interface with RS232C, 485, 422 Suconet K slaveModbus master, slave

Suconet K masterPROFIBUS DP masterPROFIBUS DP slave

Ethernet, RS232, CANopen, USB1 serial interface with RS232C, 485, 422 Suconet K slaveModbus master, slave

Suconet K masterPROFIBUS DP masterPROFIBUS DP slave

1-73

Switching, control, visualisationNetworking


1

Display and operator panels CA

Nop

en

Suco

net

PRO

FIBU

SM

PI

MI4-110-KC1MI4-110-KD1MI4-110-KG1/2

120 X 32120 X 32120 X 32

MI4-130-TA1 320 X 240

MFD4-5-XRC-30 320 X 240

CAN

open

Ethe

rnet

easy

Net

MI4-117-KC1MI4-117-KD1

3,8”

120 X 32120 X 32

MI4-137-KD1 320 X 2403,8”

5,7”

Part no. Resolution

Dis

pla

y an

d o

per

ato

r u

nit

s

Touch operator panel MI4

Text operator panel MI4

STN mono

STN color

STN mono

seria

l

1-74


Switching, control, visualisationEngineering PS4

1

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

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

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

L2

N

**

Q1

1

*

2

1

F1

T1MM

0 V+24 V

T2

2

1

L1 N PE

F2

*

+24 V

B1

0 V

A

+24 V

B2

0 V

A

X1

1

PRG Suconet K

NL1 0 V.0 .1 .2 .3 .4 .5 .6 .7

0 V

II

2

A1

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

I

RR

24 V

.0 .1 .2 .3 .4 .5 .6 .7U10

U1U0

IA/QA

A1

A2Q12

M1

A1

A2

F7

A1

A2

A1

A2Q13

A1

A2Q14

A1

A2

P2A1

A2Q11

X1

X2

P1

F6F5F3 F4

2.5 mm 2

L3

PE

L1

31

2

Q21 5

2 4 6I >I > I >

1-75



1

PS4-201-MM1 compact PLC

• Shared power supply for PLC and inputs/outputs

• Non-earthed operation with insulation monitoring

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

3

S2L1

L2

NL3

PE

L1

1

2

13 23 33

14

Q11 Q1124 34

0 V+24 V

T1

PEL2 L3

3L144

0 V+24 V

T2

N PE

43

2

1

F1C1 C1

A1

A2Q11

A1

A2

2

1

F2

11

22

14P1

21

S1

14

13

2

1

F3

P1

A1

A2

1

PRG Suconet K

0 V

24 V 0 V

+24 V

22

1

F41

F5

13

14

S313

14

B4

0 V

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

.0 .1 .2 .3 .4 .5

A

0 V

U10

II

Q

2

A1

A1

A2Q12 Q13 M1

A1

A2

0 V+24 V24

V

U0 U1

Q11 5

2 4 6I >I > I >

A1

A2

12

*

1-76



1

PS4-341-MM1 compact PLC

• Shared power supply for PLC and inputs/outputs

• Non-earthed operation with insulation monitoring

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

3

S2L1

L2

NL3

PE

L1

1

2

13 23 33

14

Q1124 34

0 V+24 V

T1

PEL2 L3

3L144

Q11

0 V+24 V

T2

N PE

43

2

1

F1C1 C1

A1

A2Q11

A1

A2

2

1

F2

11

22

14P1

21

S1

14

13

2

1

F3

P1

A1

A2

F4 F5 F6

0 V+24 V

Q11 5

2 4 6I >I > I >

12

1 2

0 V I

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

Digital Input

Digital Output

Digital Input

Digital OutputDigital InputPRG Suconet K

24 V 0 V

0 V A

.0 .1 .2 .3 .4 .5

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

0 V Q

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

U 0 U 1 U 10

*

1-77


1

Switching, control, visualisationEngineering EM4 and LE4

EM4-201-DX2 expansion module and LE4-116-XD1 local expansion module

• Inputs and outputs have a separate power supply

• Earthed operation

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

PE

0 V+24 V

T1

L1 N PE

L2

N

Q1

1

L3

L1

2

1

F1

2

1

F2

A1

1

Suconet K1/K

0 V

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

II

I

2

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

Q

24 V

.8 .9 .10

.11

.12

.13

.14

.15

.8 .9 .10

.11

.12

.13

.14

.15

24 V

0 V

Q

Q12K112

11

14

13

12

11

Q15 Q16 Q17

15

K118

13

Q1814

13

Q1914

Q14 P1A1

A2

X1

X2

A2

A1

A2

A1

1

*

31

2

Q21 5

2 4 6I >I > I >

0 V+24 V

T2

L1 N PE

11

*

31

2

Q31 5

2 4 6I >I > I >

1-78


Switching, control, visualisationEngineering XC100, XC200

1

Device arrangement

Install the rack and the PLC horizontally in the control cabinet as shown in the following figure.

Terminal assignments

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

Example of power supply wiring

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.

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.

a Kerning > 50 mmb Kerning > 75 mm to

active elementsc Cable duct

c

ba

bab

a

b

a

%IX 0.0%IX 0.1

%IX 0.2%IX 0.3

%IX 0.4%IX 0.5

%IX 0.6%IX 0.7

%QX 0.0%QX 0.1

%QX 0.2%QX 0.3

%QX 0.4%QX 0.5

24 VQ0 VQ

0 V24 V

1-79

Switching, control, visualisationEngineering XC100, XC200


1

Serial interface RS 232

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:

You can use the COM1 or COM2 interface on the PC.

You use the XT-SUB-D/RJ45 programming cable for the physical connection.

CANopen interface

Assignment of the 6-pole Combicon connector:

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

Pin RS232(XC-CPU101/201)

ETH(XC-CPU201)

8 RxD –

7 GND –

6 – Rx–

5 TxD –

4 GND –

3 – Rx+

2 – Tx–

1 – Tx+

+ 24 V H0 V H

+ 24 VQ H0 VQ H

0246024

1357135

1

2

3

4

5

6

7

8

Terminal Signal

6 GND

5 CAN_L

4 CAN_H

3 GND

2 CAN_L

1 CAN_H

Baud

rate

[Kbi

t/s]

Len

gth

[m]

Core

cro

ss-

sect

ion

[mm

2 ]

Loop

resi

stan

ce

[ O/k

m]

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

654321

CAN_H

CAN_GNDCAN_L

CAN_H

CAN_GNDCAN_L

120 O

120 O

1-80


1

1-81


1

1-82


Electronic motor starters and drives

2

Page

General 2-2

Basics of drives engineering 2-7

DS soft starters 2-29

DM soft starters 2-33

DS6 connection examples 2-37

DS4 connection examples 2-40

Connection examples, DM4 2-56

Frequency inverters DF, DV 2-70

DF51, DV51 connecting examples 2-74

DF6 connecting examples 2-80

DV6 connecting examples 2-82

Rapid Link system 2-88

2-1


2

Electronic motor starters and drivesGeneral

The complete power supply and control programme for motors

As the applications differ, so do the requirements made of the electric drives:

• 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.

• 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.

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.

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.

M3~

M3~

M3~

M3~

M3~

Switching

Power distribution

ProtectionShort-circuit,

overloadShort-circuit,

semi-conductor

Frequency-inverter

Motor protectionElectronic

starter

Short-circiuit,overload,

semi-conductor

ElectronicElectro

mechanicalElectro

mechanicalElectro

mechanical

Short-circiuit,overload,

semi-conductor

Switching

Control

Frequent and

silent switching

Softstarting Speed control

2-2



2Three-phase motors have typical starting characteristics, with starting torque MA, pull-up torque MS, pull-out torque MK and rated load torque MN.

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 °.

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

pole pairs and the frequency of the supply voltage. The direction of rotation can be reversed by swapping over two of the supply phases:

ns = Revolutions per minutef = Frequency of voltage in Hzp = Number of pole pairs

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

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.

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

M, I IA

MA

Mk

Ms

MM

MB

ML

MN

IN

nN nS n0

90°0

L1 L2 L3

360°

L1

120° 120° 120°

180°

270°

ns =f x 60

p

Slip speed:

s =ns – n

ns

Speed of an asynchronous machine:

n =f x 60

(1 – s)p

The output power is as follows:

P2 =M x n

h = P2

9550 P1

P1 = U x I xW3x cos vP1 = Electrical rating in kWP2 = Mechanical shaft rating in kWM = Torque in Nmn = Speed in rpmh = Efficiency

2-3



2

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

terminal bolts. There are basically two connection configurations: star and delta.

Notes

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

Motor & Co GmbHTyp 160 l

3 ~ Mot.

S1

Nr. 12345-88

400/690 VyD 29/1715

1430 50Iso.-Kl. IP t

IEC34-1/VDE 0530

0,85ykWU/min Hz

A

54F U1 V1 W1

W2 U2 V2

Star connection Delta connection

ULN = W3 x UW ILN = IW ULN = UW ILN = W3 x IW

V1 W2

U2

V2

W1

U1

L3

L2

ULN

ILN

L1

V1

U2

V2

W1

W2

U1

L3

L2

ULN

ILN

L1

U1 V1 W1

W2 U2 V2

U1 V1 W1

W2 U2 V2

2-4



2

Starting and operating methods The most important starting and operating methods for three-phase asynchronous motors include:

DOL starters (electromechanical)

Star-delta circuit (electromechanical)

M ~ I, n = constant My ~ l Md, n = constant

M3 h

M3 h

D y

IN

MN

nN

IN

y

D

MN

nN

100 %

t

U

100 %

58 %

U

t

D

y

2-5



2

ax

Soft starter and solid state contactor (electronic)

Frequency inverter (electronic)

M ~ U2, n = constant M ~ U/f, n = variable

UBoost = Start pedestal (adjustable)

tRamp = Ramp time (adjustable)

U2 = Output voltage (adjustable)

UBoost = Start pedestal (adjustable)

tRamp = Ramp time (adjustable)

M3 h

M3 h

A

RUN

PRG

Hz

PRGENTER

I O

POWER

ALARM

IN

MN

nN

IN

MN

n0 n1 n2 ... nN ... nm

100 %

30 %

U

U Boost

tt Ramp

100 %

U

U2

U Boost

tt Ramp

2-6


Electronic motor starters and drivesBasics of drives engineering

2

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 contactorsSemiconductor 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 startersSoft 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 invertersFrequency inverters convert the AC or three-phase 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 invertersWhile conventional frequency inverters control three-phase motors using a charactieristic-controlled 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 drives

Designation Part no. Rated operational current

[A]

Mains supply voltage

[V]

Assigned motor rating

[kW]

Semiconductor contactor for resistive and inductive load

DS4-340-M 11–41 3AC 110–500 –

Soft starters DS4-340-M 6–23 3 AC 110 – 500 2.2 –11 (400 V)Soft starter with bidirectional operation

DS4-340-MR 6–23 3 AC 110 – 500 2.2 –11 (400 V)

Soft starter with internal bypass relay

DS4-340-MX 16–23 3 AC 110 – 500 7.5 – 15 (400 V)DS6-340-MX 41–200 3 AC 230 – 460 18.5–110 (400 V)

Soft starter with bypass relay and bidirectional operation

DS4-340-MXR 16–31 3 AC 110 – 500 7.5 – 15 (400 V)

Soft starters (in-line connection type)

DM4-340 16–900 3 AC 230 – 460 7.5 – 500 (400 V)

Soft starters (delta connection type)

DM4-340 16–900 3 AC 230 – 460 11–900 (400 V)

Frequency inverters DF51-322 1.4–10 1/3 AC 230 0.25–2.2 (230 V)DF51-320 15.9–32 3 AC 230 4–7.5 (230 V)DF51-340 1.5–16 3 AC 400 0.37–7.5 (400 V)DF6-340 22–230 3 AC 400 11–132 (400 V)

Vector frequency inverters

DV51-322... 1.6–11 1/3 AC 230 0.18–2.2 (230 V)DV51-320... 17.5–32 3 AC 230 4–7.5 (230 V)DV51-340... 1.5–16 3 AC 400 0.37–7.5 (400 V)DV6-340... 2.5–260 3 AC 400 0.75 – 132 (400

V)

2-8



2

DS4 soft starters DF frequency inverters

DM soft starter DV vector frequency inverters

A

RUN

PRG

Hz

PRGENTER

I O

POWER

ALARM

2-9



2

DOL start

In the simplest case, and especially at low rated output (up to about 2.2 kW), the three-phase 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

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.

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 devicesIf 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

3

4

5

6

7I

Ie

n/nN

I/Ie: 6...10

1

0.25 0.5 0.75 1

1

2

ML

M

MN

M/MN: 0.25...2.5

n/nN

0.25 0.5 0.75 1

2-10



2

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

– 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.

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 star-delta combination from Moeller provides

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

.

Features of star-delta starting• For low- to high-power three-phase

motors• Reduced starting current• Six connection cables

• Reduced starting torque• Current peak on changeover from star to

delta• Mechanical load on changeover from star to

delta

2

3

4

5

6

7I

Ie

I/Ie: 1.5...2.5

n/nN

1

0.25 0.5 0.75 1

1

2

ML

M

MN

M/MN: 0.5

n/nN

0.25 0.5 0.75 1

2-11



2

Soft starters (electronic motor start)

The characteristic curves for DOL and star-delta 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

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.

Features of the soft starters• For low- to high-power three-phase motors• No current peaks• Zero maintenance• Reduced adjustable starting torque

2

3

4

5

6

7I

Ie

I/Ie: 1...5

n/nN

1

0.25 0.5 0.75 1

1

2

ML

M/MN: 0.15...1

M

MN

n/nN

0.25 0.5 0.75 1

2-12



2

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.

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

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

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.

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

F1

MM1 M23

Q11

Q21

L1L2L3

Q1

L1 L2 L3

T1 T2 T3

F12F11

M3

2-13



2

Using a soft starter with pole-changing motors

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

Note

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

Using soft starters for motors with power-factor correction

Caution!

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

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.

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

2-14



2

L1L2

L3

Q1

13

513 14

F1

26

4

24

6

PEU

VW

M 3 M1

13

5Q

11Q

43Q

42Q

412

46

13

51

53

24

62

46

13

5

K L M

U3

V3

W3

U2

V2

W2

R3R2

U1

V1

W2

R1

I >

I >

I >

L1L2

L3

4

15

3

24

6

UV

W

K L M

M 3

I >

I >

I >

F1

26

15

3

Q1

13 14

Q11

Q21

M1

L1L2

L3

T1T2

T3

2-15



2

M 3

L1 L2 L3

Q1 M

1Q11

MM

13

Q11

Q21L1 L2 L3

Q1

L1L2

L3

T1T2

T3

Caut

ion!

Not

per

miss

ible

MM

13

Q11

Q21L1 L2 L3

Q12

TOR

Q1

L1L2

L3

T1T2

T3

2-16



2

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 coordinationIn 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.

Type 2 coordinationIn 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.

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.

F3: Superfast semiconductor fuse

M3

L1L2L3PE

Q1

L1 L2 L3

T1 T2 T3

M1

F3

Q21

I > I > I >

MM1 3

L1L2L3PE

Q1

F3

Q21

L1 L2 L3

T1 T2 T3

I > I > I >

2-17



2

Design and mode of operation of frequency inverters

Frequency inverters provide variable, stepless speed control of three-phase motors.

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

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.

M, nU, f, IU, f, (I)

F

vm

J

M3~

~I M~f n

Pel = U x I x √3 x y M x nPL =

9550

Energy flow

VariableConstant

Mains Electronic actuator Motor Load

Driving Braking

a Rectifierb DC link

c Inverter with IGBTd Open-/closed-loop control

L1, L1

a

d

cb

L2, N

L3

IGBT

M3~

2-18



2

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.

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

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

3

4

5

6

7I

Ie

I/Ie: 0...1.8

n/nN

1

0.25 0.5 0.75 1

I

IN

1

2

ML

M

MN

M

MN

M/MN: 0.1...1.5

n/nN

0.25 0.5 0.75 1

2-19



2

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

The key advantage of sensorless vector technology is that the motor current can be

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

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

In sensorless vector control, the flux-generating current iµ and the torque-generating 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).

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

a Statorb Air gapc Rotord Rotor flow-orientede Stator-oriented

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

R1

a cb

X'2X1

i1 iw

u1 Xhim

R'2s

d

e

i1 iw

im

im

ia

ib

V~

b o

2-20



2

EMC-compliant connection of frequency inverters

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

M3~

3~

F

Q

R

K

T

M

PRGENTER

I O

3

Network

Cable protection

Switching

Main choke

Interference filters

Frequency inverters

Motor cable

Motor

2-21



2

Notes about correct installation of frequency inverters

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.

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 variable-speed electrical drives (PDS = Power Drives System).

The tests and values are based not on individual components but on a typical complete drive system.

Measures for EMC-compliant installation are:

• Earthing measures• Screening measures• Filtering measures• ChokesThey 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 cross-section, 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.

K1 = Radio interference filter

T1 = Frequency invertere

PE

K1T1 Tn Kn

PE

PE

M1

PE PE

M 3h

MnM 3h

2-22



2

Screening measures

L1L2L3PE

ba

e d c

F 300 mm

M

3

Four-core screened motor supply cable:

a Copper screen braid, earth at both ends with large-area connections

b PVC outer sheathc Drain wire (copper, U, V, W, PE)d PVC cable insulation 3 x black,

1 x green/yellowe Textile and PVC fillers

2-23



2

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

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.

Example: Screen attachment for maintenance switch

Note

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 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

o 4.1 o 3.5

MBS-I2

e

f 100

b a

2-24



2

Example for screen earth kit and signal cables:

Filtering measures Radio interference filters and line filters (combinations of radio interference filter and mains choke) protect against conducted high-frequency 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.

Example for a standard connection of frequency inverter DF5, with reference value potentiometer R1 (M22-4K7) and mounting accessories ZB4-102-KS1

2 1 P24H O L

ZB4-102-KS1

15

M4PE

2Cu 2.5 mmPES

PES

1 2

3

M

R1 REV FWD

4K7M

F 2

0 m

I O

2-25



2

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

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 cross-section f 10 mm2, or

• the protective conductor must be open-circuit monitored, or

• an additional conductor must be fitted.

ChokesFitted 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.

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.

M3h

E

L/L1L2N/L3

UV

W

R2S2T2

L1L2L3

L1Z1 G1

L2L3

PE

E

Eee

E

2-26



2

Example: EMC-compliant mounting and connection

a Metal plate, e. g. MSB-I2b Earthing terminalc Maintenance switches

PE

15

PES

PES

PES

W2 U2 V2

U1 V1 W1

PE

a

b

PES

PES

c

2-27



2

Mounting instructions

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

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 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).

Selection aids

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

F 30°F 30°

F 30°

F 30

°

aa

f 1

00f

100

2-28

http://www.moeller.net/en/support/slider/index.jsp


Electronic motor starters and drivesDS soft starters

2

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)

DS6 product features

• 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)

t-Start (s)

12

5

100

0,5

5060

80

10030

40

12

5

100

0,5

U-Start (%)

t-Stop (s)

U-S

tart

U

t-Start t-Stop

t

2-29



2

Example: Setting values and applications

Power section versions

DOL Starters DOL starter with bypass

Reversing starters

Reversing starter with internal bypass

DS4-340-...-M DS4-340-...-MXDS6-340-...-MX

DS4-340-...-MR DS4-340-...-MXR

l 10 st-Start, t-Stop

U-Start

l 1 s

l 30 %

l 60 – 90 %

J l 0

J l L

M3

L1 L2

DS

L3

L1 L2 L3

T1 T2 T3

2-30



2

Connecting star points when using soft starters or semiconductor contactors

Note

DS4 and DS6 soft starters are two-phase controlled.

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

Example DS4:

Danger!

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.

M3

L1

Q21

M1

R1

L2 L3

L1 L2 L3

T1 T2 T3

L1 L3

L1 L3

L2

L2

T1 T2 T3

L1 L3

L1 L3

L2

L2

T1 T2 T3

Caution!Not permissible:

M3 ~

1L1 3L2 5L3 PE

PE2T1 4T2 6T3

2-31



2

LED displays

Example DS4:

Red LED Green LED Function

Lit Lit Init, LEDs lit only briefly, Init itself takes about 2 secondsDepending 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

U

Run- (FWD/REV-) LED

U = 100 %

A1, A2FWD, REV, 0

Error-LED

out

e

Initialization Fault Ready for operation In ramp Top of ramp

2-32


Electronic motor starters and drivesDM soft starters

2

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 user-programmable 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 open-loop 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 moduleThe 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

The application selector switch enables direct assignment without parameter entry.

0 - standard 1 - high torque2 - pump 3 - pump kickstart4 - light conveyor5 - heavy conveyor6 - low inertia fan7 - high inertia fan8 - recip compressor9 - screw compressor

fault

c/l run

supp

lyflash

on

0 - standard 1 - high torque2 - pump 3 - pump kickstart4 - light conveyor5 - heavy conveyor6 - low inertia fan7 - high inertia fan8 - recip compressor9 - screw compressor

a

b

2-34



2

Standard applications (selector switch)

In-delta circuitAs 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:

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

• 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.

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.

2-35



2

II

II

II

M 3 ~

55 k

W40

0 V

55 k

W40

0 V

M 3 ~

100

A

DM4-

340-

55K

(105

A)

DILM

115

NZM

7-12

5N-O

BI

DILM

115

NZM

7-12

5N

U1V1

W1

W2

U2V2

/ 690

V40

010

0 / 5

955

S10.

86ϕ

cos

kW rpm

1410

50 H

zA

U1V1

W1

W2

U2V2

100

A 3

DM4-

340-

30K

(59

A)

ULN

400

VIn

-Lin

eIn

-Del

ta

2-36


Electronic motor starters and drivesDS6 connection examples

2

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 NZM1/2-XAB spacers.

Standard connection of the DS6-340-MX

M3 ~

1L1

3L2

5L3

PEPE 0 V + 24

TOR Ready

- A2 EN + A1 13 14 24

+ 24 V0 V

232T1

4T2

6T3

L1L2L3PE

Q1

Q21

F3

M1

I > I > I >

Q1

2-37



2

Compact motor starter

DS6 soft starter, NZM circuit-breaker and P3 maintenance switch

NZM1

Trip

ON

OFF

DS6

P3 M3 ~

1L1

3L2

5L3

PEPE +24

Ready

EN 13 14 24232T1

4T2

6T3

L1L2L3PE

Q1

Q21

F3

M1

I > I > I >

Q321 3 5 7

2 4 6

U V W

8

Start/Stopp

TOR

+ 24 V0 V

0 V -A2 +A1

2-38



2

DS6-340-…-MX and NZM circuit-breaker with emergency-stop function to IEC/EN 60204 and VDE 0113 Part 1

n Emergency-StopQ1: Power and motor protection

(NZM1, NZM2)Q21:DS6 soft startersM1:motorF3: Superfast semiconductor fuses

(optional)

a Control circuit terminalb Undervoltage release with early-make

auxiliary contact

M3 ~

1L1

3L2

5L3

PEPE 0 V

D2

D1 3.13

3.14

+24

TOR Ready

-A2 EN +A1 13 14 24

+ 24 V

0 V

232T1

4T2

6T3

L1L2L3PE

Q1

Q1

S3

Q21

F3

M1

I >

U>

I > I >

b

a

3 AC, 230 V NZM1-XUHIV208-240ACNZM2/3-XUHIV208-240AC

3 AC, 400 V NZM1-XUHIV380-440ACNZM2/3-XUHIV380-440AC

2-39


2


Linking the overload relay into the control system

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

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)

0: Off/soft stop, 1: Start/soft startn Emergency-Stop

F3

Q1

M3~

1L1

5L3

3L2

2T1

6T3

4T2

M1

Q21

F2

13 14

L1L2L3PE

TOR

I I I

Q21

S3

F2

A1

0 1

A2

2-40



2

Soft

star

ter D

S4-3

40-M

Q1:

Line

pro

tect

ion

Q11

:Mai

ns c

onta

ctor

(opt

iona

l)F2

:M

otor

-pro

tect

ive

rela

y

F3:

Sem

icon

duct

or fu

se fo

r typ

e 2

coor

dina

tion

Addi

tiona

l to

Q1

Q21

: Sof

t sta

rter

M1:

Mot

or

S1:

Q11

off

(ung

uide

d de

cele

ratio

n)S2

:Q

11 o

nb

:Ac

tivat

ion

with

Q11

/K2t

opt

iona

l

F3

Q11

Q1

M 3~1L1

5L33L2

2T1

6T34T2

M1

Q21

F2

1314

L1 L2 L3 PE

II

I

Read

y

K1

b

K2t

Q11

S2S1

K1

Q11

K2t

t >

t Sto

p +

150

ms

Q21K1

A1 A2

F2

L01/

L+

L00/

L–

Soft

Star

tSo

ft St

op

2-41



2

Soft starter without mains contactor

Q1:Line protectionF2: Overload relaysF3: Semiconductor fuse for type 2

coordination, in addition to Q1 (optional)Q21: Soft startersM1: Motor

n Emergency-StopS1: Soft stopS2: Soft start

F3

Q1

M3~

1L1

5L3

3L2

2T1

6T3

4T2

M1

Q21

F2

13 14

L1L2L3PE

TOR

I I I

K1

K1S2

S1

K1

Q21A1

A2

F2

L01/L+

L00/L–

2-42



2

Conn

ectio

n of

sof

t sta

rter

with

mai

ns c

onta

ctor

Q1:

Lin

e pr

otec

tion

Q11

: Mai

ns c

onta

ctor

(opt

iona

l)Q

21: S

oft s

tarte

rsF2

: O

verlo

ad re

lays

F3:

Sem

icon

duct

or fu

se fo

r typ

e 2

coor

dina

tion,

in

add

ition

to Q

1 (o

ptio

nal)

nEm

erge

ncy-

stop

M1:

Mot

or

K1, K

3:co

ntac

tor r

elay

sK2

t:Ti

min

g re

lay

(off-

dela

yed)

S1:

Q11

off

S2:

Q11

on

F3

Q11

Q1

M 3~1L1

5L33L2

2T1

6T34T2

M1

Q21

F2

1314

L1 L2 L3 PE

TOR

II

I

K1Q

21

K1S2S1

K3

A1 A2K3K1

K3

Q11K1

F2

K2t

K2t

t = 1

0 s

L01/

L+

L00/

L–

Soft

Star

t

Soft

Stop

2-43



2

Reversing circuit standard connection, bidirectional rotation

Note:

The device of the DS4-...-M(X)R series have a built-in electronic reversing contactor

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

Minimum connection of DS4-340-M(X)R

Q1:Line protectionQ21: Soft startersF2: Overload relaysF3: Semiconductor fuse for type 2

coordination, in addition to Q1

M1: Motorn: Emergency-Stop0: Off/Soft stop1: FWD2: REV

F3

Q1

M3~

1L1

5L3

3L2

2T1

6T3

4T2

M1

Q21

F2

13 14

L1L2L3PE

TOR

I I I

FWD

0 V

REVQ21

S3

F2

1 0 2

2-44



2

Reve

rsin

g st

arte

r w

itho

ut m

ains

con

tact

or

Q1:

Line

pro

tect

ion

F2:O

verlo

ad re

lays

F3:S

emic

ondu

ctor

fuse

for t

ype

2 co

ordi

natio

n, in

ad

ditio

n to

Q1

Q21

:So

ft st

arte

rsM

1: M

otor

K1, K

2:Co

ntac

tor r

elay

s

n:E

mer

genc

y-St

opS1

:Sof

t sto

pS2

:Sof

t sta

rt FW

DS2

:Sof

t sta

rt RE

V

F3

Q11

Q1

M 3~1L1

5L33L2

2T1

6T34T2

M1

Q21

F2

1314

L1 L2 L3 PE

TOR

II

I

S1F2

K1Q

21

K1

K1

FWD

0 V

K2

K2

K2

K2K1

S2

REV

S3

L01/

L+

L00/

L–

2-45



2

Reversing soft starter with mains contactor

Q1:Line protectionQ11:Mains contactor (optional)Q21:Soft startersF2: Overload relaysF3: Semiconductor fuse for type 2

coordination, in addition to Q1 (optional)M1:Motor

F3

Q11

Q1

M3~

1L1

5L3

3L2

2T1

6T3

4T2

M1

Q21

F2

13 14

L1L2L3PE

TOR

I I I

2-46



2

n:

S1:

S2:

FWD:

REV:

Emer

genc

y-St

opQ

11 O

ff (u

ngui

ded

dece

lera

tion)

Q11

On

Cloc

kwise

rota

tion

Antic

lock

wise

rota

ting

field

K1

K1S2S1

K2t

t = 1

0 s

Q11

K1

F2

K2t

K3Q

21

K3FW

D

K3

FWD

0 V

K4

K4

K4

K4K3

K1

REV

REV

L01/

L+

L00/

L–

Soft

Star

t

Soft

Stop

Soft

Star

t

2-47



2

External bypass, one direction of rotation

Caution!

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

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.

2-48



2

S3:Q1:Q21:Q22:F2:

Soft start/stopCable protectionSoft startersBypass contactorOverload relays

F3:

M1:

Semiconductor fuse forAdditional type 2 coordination in addition to Q1(optional)Motor

F3

Q1

M3~

1L1

5L3

3L2

2T1

6T3

4T2

M1

Q21

F2

13 14

L1L2L3PE

TOR

I<I<I<

Q22

Q21

S3

F2

A1

0 1

A2Q22

A1

A2

Q21TOR

13

14

2-49



2

Pump control, single direction of rotation, continuous operation

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.

Note

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

Pump

Q1:Line protectionQ11:Mains contactor (optional)Q21:Soft startersQ22:Bypass contactorQ31:Motor contactorF2: Overload relaysF3: Semiconductor fuse for

type 2 coordination, in addition to Q1(optional)

M1:MotorF3

Q11

Q1

M3~

1L1

5L3

3L2

2T1

6T3

4T2

M1

Q21

F2

13 14

L1L2L3PE

TOR

I I I

Q22

Q31

2-50



2

Pum

p co

ntro

l, si

ngle

dire

ctio

n of

rota

tion,

con

tinuo

us o

pera

tion

nEm

erge

ncy-

Stop

at >

t-St

op +

150

ms

bEn

able

cHa

ndd

Auto

eSo

ft st

art/s

oft s

top

fRU

Ng

Bypa

ss

b

a

A1 A2Q

21K5S5

K5K5

S4

13 14

K4

K6t

Q22

Q21

TOR

K2

Q31

Q11

K3K4

K3E2 39

Q21

K1S3K1

K1K2

S2

K2K1 K4K3

S1 K2

Q22

K6t

cd

ef

g

Q31

2-51



2

Starting several motors sequentially with a soft starter (cascaded control)

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-StopS1: Q11 OffS2: Q11 Ona Soft start/soft stopb 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 monitoringSet 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 monitoringSet 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 1b Motor 2c Motor ni Switching off individual motorsThe 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



2

Soft

sta

rter

wit

h m

otor

cas

cade

Q21

L1 L2 L3

1L12L23L3

2T14T2

6T3

N PE

Q14

F3

1314

Q13

Q11

M1

M 3~

Q15

Q24

Q23

M2

M 3~

Q25

Qn

Qn3

Mn

M 3~

Qm

TOR

I>I>

I>I>

I>I>

I>I>

I>

Q11

:M

ains

con

tact

or (o

ptio

nal)

F3:

Sem

icon

duct

or fu

se fo

r typ

e 2

coor

dina

tion

(opt

iona

l)Q

21:

Soft

star

ters

M1,

2,..

.:M

otor

2-53



2

Soft

sta

rter

wit

h m

otor

cas

cade

, con

trol

sec

tion

par

t 1

ase

ctio

n "S

tarti

ng s

ever

al m

otor

s se

quen

tially

with

a s

oft s

tarte

r (ca

scad

ed c

ontro

l)", p

age

2-52

ad

c

A1 A2Q

21K213 14

K4K2T

K1T

K4T

K4

K3

Q21

TO

R

K1S2K1

S1

Q14

Q24

K2

K1T

K4

K1K4

K12

K22

Qn1 Kn

2K4

b

K2T

e

Q11

Q1

2-54



2

Soft

sta

rter

wit

h m

otor

cas

cade

, con

trol

sec

tion

par

t 2

ase

ctio

n "S

tarti

ng s

ever

al m

otor

s se

quen

tially

with

a s

oft s

tarte

r (ca

scad

ed c

ontro

l)", p

age

2-52

Q14

Q15

Q15

Q15

K12

K3

Q11

Q14

ab

K12

Q24 Q25

Q25

Q25

K22

K3

K12

Q24

Q41

Q14

K22

K4T

c

Qn

Qm

Qm

Qm

Kn2

K3

K(n-

1)2

Qn

Q(n

-1)1

Kn2

Qn

K4T

ii

i

2-55


2

Electronic motor starters and drivesConnection examples, DM4

Enable/immediate stop without ramp function (e.g. for Emergency-Stop)

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.

Normally the drive is always stopped via a ramp function. When the operating conditions

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.

n Emergency-StopS1: OffS2: OnQ21:Soft starters (E2 = 1 a enabled)

S1

S2

K1E2

39

K1

K1

Q21

2-56



2

Linking the overload relay into the control system

We recommend using an external overload relay instead of a motor-protective circuit-breaker 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-StopS1: Off

S2: On

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.

E2

39Q21K1

S2 K1

K1F1

a b

S1

2-57



2

With separate contactor and overload relay

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

Actuation

Q21

L1L1

2L2

3L3

2T1

4T2

6T3

N

Q11

Q1

F2

F3

T1 T2

~=

M

3~

L2

NL3

PE

L1

I> I> I>

+ T

herm

istor

– Th

erm

istor

S1: Soft startS2: Soft stopF3: Superfast semiconductor fuses

(optional)a Enableb Soft start/soft stop

ba

E1

39Q21

E2

39Q21K1

S2

K1

K1

S1

2-58



2

Without mains contactor

F3: Superfast semiconductor fuses (optional)

a Control voltage through Q1 and F11 or separately via Q2

b See Control sectionc Motor current indication

~=

~=

7

MM1

mot

Q21

F2

3~

L1L2L3NPE

L N E1 E2 39

13

K1;RUN K2;TOR K3 K4

14 23 24 33 34 43

1L1

3L2

5L3

2T1

4T2

6T3

+12 8 17

62 63

PE

0 V

(E1;

E2)

+12

V D

C

REF

1: 0

–10

V

REF

2: 4

–20

mA

T1 T2

F1

⎧ ⎪ ⎨ ⎪ ⎩

Q1 Q2

a

c

b

I

I> I> I> I> I> I>- T

herm

istor

+ T

herm

istor

0 V

Anal

og

Anal

og O

ut 1

Anal

og O

ut 2

0 V

Anal

og

Star

t/Sto

p

Enab

le

2-59



2

Soft starters with separate mains contactor

T1: + ThermistorT2: – ThermistorE1: Start/stopE2: Enable

a See Control sectionb Control voltage through Q1 and F11 or

through Q2c Motor current indication

~=

~=

7

MM1

mot

Q21

F3

3~

L1L2L3NPE

L N E1 E2 39

13

K1;RUN K2;TOR K3 K4

14 23 24 33 34 43

1L1

3L2

5L3

2T1

4T2

6T3

+12 8 17

62 63

PE

0 V

(E1;

E2)

+12

V D

C

REF

1: 0

–10

V

REF

2: 4

–20

mA

T1 T2

F11Q11

⎧ ⎪ ⎨ ⎪ ⎩

I >I > I >

Q1

I >I > I >

Q2

a

b

cI

- The

rmist

or

+ T

herm

istor

0 V

Anal

og

Anal

og O

ut 1

Anal

og O

ut 2

0 V

Anal

og

Star

t/Sto

p

Frei

gabe

2-60



2

Soft starters with separate mains contactor

Actuation

n Emergency-StopS1: Off (unguided deceleration)S2: OnS3: Soft startS4: Soft stop (deceleration ramp)a Enableb Soft start/soft stop

a b

S1

S2

K1E1

39

E2

39

S4

S3

K1

K1

K2K1

Q11

K1 Q21 RUNK2

Q21 K2 Q21 Q11

13

14

33

34

Q1

Q21 OK(no error)

2-61



2

Bypass circuit

T1: + ThermistorT2: – ThermistorE1: Start/stopE2: Enable

a See Control sectionb Control voltage through Q1 and F11 or

through Q2c Motor current indication

~=

~=

7

MM1

mot

Q21

F3

3~

L1L2L3NPE

L N E1 E2 39

13

K1;RUN K2;TOR K3 K4

14 23 24 33 34 43

1L1

3L2

5L3

2T1

4T2

6T3

+12 8

PE

17

62 63

0 V

(E1;

E2)

+12

V D

C

REF

1: 0

–10

V

REF

2: 4

–20

mA

T1 T2

F11

Q11

⎧ ⎪ ⎨ ⎪ ⎩

Q1 Q1

a

b

c

Q22

I> I> I> I> I> I>

I

- The

rmist

or

+ T

herm

istor

0 V

Anal

og

Anal

og O

ut 1

Anal

og O

ut 2

0 V

Anal

og

Star

t/Sto

p

Frei

gabe

2-62



2

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 no-load 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

n Emergency-StopS1: Off (unguided deceleration)S2: Ona Enableb Soft start/soft stop

a b

S2

K1E2

39

E1

39

S4Q22

K1

K1 K1K2

K1

Q21 Q21

K2

K2

Q21 RUN

Q11

13

14

23

24Q21 TOR

Q22

33

34

S1

S3

Q21 OK(no error)

2-63



2

In-delta circuit

a Control voltage through Q1 and F11 or through Q2

b See Control section

c Motor current indicationd Thermistor connection

~=

~=

7

MM1

mot

Q21

F3

3~

L1L2L3NPE

L N E1 E2 39

13

K1;RUN K2;TOR K3 K4

14 23 24 33 34 43

1L1

3L2

5L3

2T1

4T2

6T3

+12 8

PE

17

62 63

0 V

(E1;

E2)

+12

V D

C

REF

1: 0

–10

V

REF

2: 4

–20

mA

T1 T2

F11

Q11

I >I > I >

Q1

I >I > I >

Q2

b

c

a

W1

V1 U1

W2

V2 U2

I

d

+ – 0 V

Anal

og

Anal

og O

ut 1

Anal

og O

ut 2

0 V

Anal

og

Star

t/Sto

p

Enab

le

Ther

mist

or

Ther

mist

or

2-64



2

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

n Emergency-StopS1: OFFS2: ONa Enableb Soft start/soft stopE2: Enable

a b

S1

S2

K1E1

39

E2

39

S4

K1

K1

K2K1 K2

Q21 K2 Q21 Q11

Q21 RUN13

14

33

34

Q1S3

Q21 OK(no error)

2-65



2

Starting several motors sequentially with a soft starter (cascaded control)

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-StopS1: Q11 OffS2: Q11 Ona Soft start/soft stopb RUNc 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 monitoringSet 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 "Control section part 2", page 2-69

a Motor 1b Motor 2c Motor ni Switching off individual motorsThe 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.

2-66



2

Casc

ade

~Q

21

L1 L2 L3

L

1L1

2L2

3L3

2T1

4T2

6T3

N

N

PE

PE

Q1

Q14F3

T1T2

=

F11

Q2

Q13

M1

M 3~

Q15

Q24

Q23

M2

M 3 ~

Q25

Qn4

Qn3

Mn

M 3~

Qn5

I>I>

I>I>

I>I>

I>I>

I>

I>I>

I>

+ Thermistor

– Thermistor

2-67



2

Cont

rol s

ecti

on p

art

1

ase

ctio

n "S

tarti

ng s

ever

al m

otor

s se

quen

tially

with

a s

oft s

tarte

r (ca

scad

ed c

ontro

l)", p

age

2-66

ab

cd

E1 39Q

21K213 14

K4Q21

RU

N

K1T

K4T

K423 24

K3Q21

TO

R

E2 39Q

21K1S2

K1K1

S1Q

14Q

24

K2

K1T

K4

K1K4

Q11

K12

K22

Qn

Kn2

K4

33 34

Q1

Q21

OK(n

o er

ror)

2-68



2

Cont

rol s

ecti

on p

art

2

ase

ctio

n "S

tarti

ng s

ever

al m

otor

s se

quen

tially

with

a s

oft s

tarte

r (ca

scad

ed c

ontro

l)", p

age

2-66

Q14

Q15

Q15

K12

Q15

K3

Q11

Q14

ab

K12

Q24

Q25

Q25

K22

Q25

K3

K12

Q24

Q14

Q24

K22

K4T

c

Qn

Qm

Qm

Kn2

Qm

K3

K(n-

1)2 Qn

Q(n

-1)1

Kn2

Qn

K4T

ii

i

2-69


2

Electronic motor starters and drivesFrequency inverters DF, DV

Features of DF frequency inverters

• 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)

GeneralThe DF and DV frequency inverters are factory-preset for their assigned motor rating, allowing drives to be started immediately after installation.

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, short-circuit, 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.

2-70



2

a DV51 vector frequency inverterb DEX-L2… EMC filter c DF51 frequency invertersd DF6 frequency inverterse DEX-BR1... braking resistors

f DEX-LN… mains choke, DEX-LM… motor choke, SFB… sinusoidal filter

g DEX-CBL-… connection cablesh Keypads DEX-KEY-…

HzA

RUN

POWERALARM

PRGI O

PRGENTER

POWERALARM

RUN

1 2

OFF

OPERBUS

h

d

e

f

cg

b

a

A

RUN

PRG

Hz

PRGENTER

I O

POWER

ALARM

2-71



2

Bloc

k di

agra

m, D

F51,

DV5

1

BR*

DV51

onl

y6*

DV51

onl

y5*

Inpu

t RST

for D

F51

5L

i

*

0 V

+10 V

0 V

PEW

VU

M 3 ~

K11

K12

K14

e

AMH

OO

IL

1211

0...10 V

RUN

FA1

4...20 mA

0...10 V

– +

–+

L+ BRDC–

DC+

R Br

PEL3

L2L1

3 1

PEN

L

2CH

FF2

FF1

REV

FWD

32

16

4P2

4

+24

V

CM2

RJ 4

5M

odBu

s

RST

* PN

U C0

05 =

19

(PTC

)

2-72



2

Bloc

k di

agra

m D

F6

BR*

DF6-

320-

11K,

DF6

-340

-11K

and

DF6

-340

-15K

onl

y

PEW

VU

M 3 ~

K11

K12

K14

e

PLC

CM1

FMAM

IH

OO

IL

O2

AMTH

K23

K34

K24

K33

–+

L+ BR*

DC–

DC+

R Br

PEL3

L2L1

3

RST

AT

FF2

FF1

REV

34

51

2FW

P24

+24

V

FWD

K1K2

K3

RJ 4

5RS

422

SN RP SN SP

RS 4

85

– +

i

PTC

10 V (PWM)

4...20 mA

–10 V...+10 V

0...10 V

+10 V

0 V

0...+10 V

4...20 mA

2-73


2

Electronic motor starters and drivesDF51, DV51 connecting examples

Basic control

Example 1Reference input through potentiometer R1Enable (START/STOP) and direction control through terminals 1 and 2 with internal control voltage

n Emergency-Stop circuitS1: OFFS2: ONQ11: Mains contactorF1: Line protectionPES:Cable screen PE connectionM1:230 V 3-phase motor

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

DILM12-XP1

(4th pole can be broken off)

DILM

Q11

S2

S1

Q11

2

3 5

4 6

A1

A2

1 13

14

2-74



2

Wiring

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

FWD: Clockwise rotating field enableREV: Anticlockwise rotating field

enable

T1 DC+ DC–L+ U V W PE O LH 2 1 P24

PES

PES

PE

PES

PES

MM1

X1

3 ~

e R11

4K7

PE

LNPE

1 h 230 V, 50/60 Hz

L N

Q11

PEF1

M

REV

PES

M

FWD

FWD

f

REV

M

M

t

2-75



2

DF5-340-... frequency inverters with EMC-conformant connection

Actuation

Example 2Setpoint entry via potentiometer R11 (fs) and fixed frequency (f1, f2, f3) via terminal 3 and 4 with internal control voltageEnable (START/STOP) and rotation direction selection via terminal 1

n Emergency-Stop circuitS1: OFFS2: ONQ11:Mains contactorR1: Main chokeK1: RFI filterQ1:Line protectionPES: Cable screen PE connectionM1:400 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

S2

Q1

S1

Q11

2-76



2

Wiring

3 h 400 V, 50/60 Hz

T1

W2

L1 L2 L3 PE

L1L2L3PE

Q11

Q1

V2U2

L1 L2 L3

W1V1U1

R1

K1

PE

PE

DC+ DC–L+ U V W PE O LH 4 3 1 P24

PES

PES

PE

PES

PES

MM1

X1

3 ~

PEIII

e

FF2

FF1

FWD

R11

FF1

FF2

FWD

f1f2

f3fs = fmax

f

2-77



2

Version A: Motor in delta circuit

Motor: P = 0.75 kWMains: 3/N/PE 400 V 50/60 Hz

The 0.75 kW motor described below can be delta-connected 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:

• DF51-322 for 1 AC 230 V• DF51-340 for 3 AC 400 V• Model-specific accessories for

EMC-complaint connection.

PE

LNPE

2

L N

1

R1

PE

PE

1 h 230 V, 50/60 Hz

L

K1

T1

N

Q11

DC+ DC–L+ U V W PE

PES

PES

PES

PES

MM1

X1

3 ~

F1FAZ-1N-B16

DEX-LN1-009

DE51-LZ1-012-V2

DF51-322-075DV51-322-075

230 V4 A

0.75 kW

DILM7+DILM12-XP1

e

U1 V1 W1

W2 U2 V2

/ 400 V230 4.0 / 2.30,75S1 0.67ϕcoskW

rpm1410 50 Hz

A

2-78



2

Version B: Motor in star circuit

3 h 400 V, 50/60 Hz

W2

L1 L2 L3

L1L2L3PE

Q11

Q1

V2U2

L1 L2 L3

W1V1U1

R1

K1

PE

PE

PE

III

U1 V1 W1

W2 U2 V2

T1 DC+ DC–L+ U V W PE

PES

PES

PES

PES

MM1

X1

3 ~

PKM0-10

DEX-LN3-004

DE51-LZ3-007-V4

DF51-340-075DV51-340-075

400 V2.3 A

0.75 kW

DILM7

e

2-79


2

Electronic motor starters and drivesDF6 connecting examples

DF6-340-... frequency inverters

ActuationExample: 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)

n Emergency-Stop circuitS1: OFFS2: ONQ1: Line protectionQ11: Mains contactorPES: Cable screen PE connectionK1: Radio interference suppression filter

Q11

S2

Q1

S1

Q11

2-80

Electronic motor starters and drivesDF6 connecting examples


2

Wiring

3 h 400 V, 50/60 Hz

T1

L1 L2 L3 PE

L1L2L3PE

Q11

Q1

L1 L2 L3

K1 PE

DC+ DC–L+ U V W PE HOI

PID

O L FW P24

PES

PES

PE

4...2

0 m

A

PES

PES

MM1

X1

3 ~

PEIII

e

4K7

R11

PES

M

FWDB1i

50 ˚C

20 ˚C

100 %

20 mA4 mA

40 %

10.4 mA

2-81


2

Electronic motor starters and drivesDV6 connecting examples

Bloc

k di

agra

m D

V6

BR*

DV6-

340-

075,

DV6

-340

-11K

and

DV6

-320

-11K

onl

y

PEW

VU

M 3 ~

K11

K12

K14

e

L+ BR*

DC–

DC+

R Br

PEL3

L2L1

ROTO

3

K1

J51

RST

AT

JOG

FRS

2CH

34

51

26

1314

1511

12

FF2

FF1

REV

78

FWFWD

PLC

CM1

FMAM

IH

OO

IL

O2

AMTH

CM2

–+

P24

+24

V

RJ 4

5RS

422

SN RP SN SP

RS 4

85

– +

i

PTC

10 V (PWM)

4...20 mA

–10 V...+10 V

0...10 V

+10 V

0 V

0...+10 V

4...20 mA

FA1

RUN

OL

QTQ

IP+

24 V

P24

2-82



2

Bloc

k di

agra

m: s

peed

con

trol

circ

uit,

vect

or fr

eque

ncy

inve

rter

DV6

with

enc

oder

inte

rfac

e m

odul

e D

E6-IO

M-E

NC

K REF

V G+

–

K FB

++

V F

PWM

G

APR

ASR

V n–

ACR

FFW

G

V iuu'

i'

FB

o'

ov

v'

e+

+

–

M 3 h

i

2-83



2

DV6-340-... vector frequency inverters with built-in encoder module (DE6-IOM-ENC) and external DE4-BR1-... braking resistor

Actuation

Example:Hoisting gear with speed regulation, control and monitoring through PLCMotor with thermistor (PTC resistor)

n Emergency-Stop circuitS1: OFFS2: ONQ1:Line protectionQ11:mains contactorK2: Control contactor enableRB: Braking resistanceB1: Encoder, 3 channels

PES:Cable screen PE connectionirmesM11:Holding brake

K2 M11

S2

S1

Q11

Q11

Q11 G1

TI

K12

T2

K11

K2

K3

Q1

RB

PLC

Enable

2-84



2

Wir

ing

3 h

400

V, 5

0/60

Hz

T1R B

L1L2

L3PE

L1 L2 L3 PE

Q11

Q1

L1L2

L3

K1PE

DC+

DC–

BRL+

UV

WPE

ThCM

1CM

211

1213

PES

PES

M 3 ~

II

I

e

i

23

81

FWP2

4

CM2

B1

M1

I..

M11

n 1n 2

n 3RE

VFW

D

I..I..

Q..

Q..

Q..

Q..

Q..

P24

EP5DE

6-IO

M-E

NC

EG5

EAPE

ANEB

PEB

NEZ

PEZ

N

T1T2

PE

21DE

4-BR

1...

i

PES

PES

m

a

bEnco

der

2-85



2

Installing encoder interface module DE6-IOM-ENC

3

1

2 4

1

M3 x 8 mm

0.4 – 0.6 Nm

2-86



2

EG5

F 2

0 m

ZB4-102-KS1

15

M4

1 2

3

EG5

Order ZB4-102-KS1 separately!

EP5

5 V H

–

+

TTL (RS 422)A A B B C C

EG5 EAP EAN EBP EBN EZP EZN

M3 h

2-87


2

Electronic motor starters and drivesRapid Link system

System Rapid Link

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

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

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.

.

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

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

a bc d

i

e

i

j

kk

h

f

g

2-88



2

Power and data bus:

e AS interface® flat cablef Link for M12 connector cablesg Flexible busbar for 400 V h and 24 Vh Power feed for flexible busbari Plug-in power link for flexible busbarj Round cable for 400 V h and 24 Vk Plug-in power link for round 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. AS-Interface® 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.

a Piercing pinsb 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:

• 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

a a

b–+

10

6.5

4

2

ML+PENL3L2L1

2-89



2

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

Danger!

• Rapid Link must be operated only on three-phase 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

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 AS-Interface®-/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:

• 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.

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

starter with type “1” coordination. That means that the contactor’s contacts in the RA-MO 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.

e

M3h

1.5 mm2

2.5 mm2 / 4 mm2

3 AC 400 Vh,50/60 Hz 24 V H

RA-DI

Q1

M3hee

M3h

1.5 mm2 1.5 mm2

RA-MO RA-SP RA-MO

M3he

Motor/SpeedControl Units

DisconnectControl Unit RA-DI

F 6 mm2

1.5 mm21.5 mm2 1.5 mm2

1.5 mm2

RA-SP

1.5 mm2

PES

PES

PES

PES

⎧ ⎨ ⎩

2-90



2

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.

• 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.

i dt[A s]

2 A

1 A

0.5 A

10 A13 A16 A20 A25 A32 A40 A

50 A63 A

4 A

3 A

6 A

0.5 1.5 151 2 3 4 5 6 7 8 9 10

103

104

105

8

6

4

2

1.5

8

6

4

2

8

6

4

3

1.5

2

2FAZ-BFAZ-C

FAZ-...-B4HI

Z

Icc rms [kA]

2-91



2

Motor Control Unit

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).

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

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

External sensors are connected through an M12 socket.

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 halogen-free, 8 x 1.5 mm2, unscreened, DESINA-conformant 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

400 VF 2.2 kW

M3 h

3 h 400 V PE50/60 Hz24 V H

M12 plug PIN Function

1 ASi+

2 –

3 ASi–

4 –

PIN Function

1 L+

2 I

3 L–

4 I

1 4 6

3 5 8

PE 7

2-92



2

Motor connection without thermistor:

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.

Motor connection with thermistor:

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 – –

M3h

i

5 8 1 7 3 PE

T1 T2

M 3 h

U V W PE

6 7 1 2 3 *

e

5 8 1 7 3 PE

T1 T2

M 3 h

i

U V W PE

6 7 1 2 3 *

e

2-93



2

Note

The two connections illustrated below apply only for motor control unit RA-MO.

Connecting a 400 V AC brake::

Connecting a 400 V AC brake with rapid braking:

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.

1 7 3 PE

M 3 h

PE

1 2 3 *

e

1 74 6 3 PE

M 3 h

PEWVUB2B1

1 25 4 3 *

e

2-94



2

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.

ConnectionsSpeed control unit RA-SP is supplied ready for connection. The connection to the AS-Interface® data bus and the motor is described below. The connection to the power bus is described in the earlier general section “Rapid Link system”..

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

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 halogen-free 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.

400 V

M3 h

3 h 400 V PE50/60 Hz

M12 plug PIN Function

1 ASi+

2 –

3 ASi–

4 –

1 4 6

3 5 8

PE 7

2-95



2

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

RA-SP2-...

Servo cable SET-M4/...

341-...

400 V AC

341(230)-...

230 V AC

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 – – –

M3h

i

U1, V1, W1, PE

B1/B2 T1/T2

1

2

3

4

2-96



2

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)!

PES

5 8 1 7 3 PE

T1 T2

M 3 hi

U V W PE

e

PES

PES

5 8 1 7 3 PE

T1 T2

M 3 hi

U V W PE

e

PES F 1

0 m

/ 400 V230 3.2 / 1.9 A0.75S1 0.79ϕcoskW

rpm1430 50 Hz

U1 V1 W1

W2 U2 V2/ 690 V400 1.9 / 1.1 A

0.75S1 0.79ϕcoskWrpm1430 50 Hz

U1 V1 W1

W2 U2 V2

PES

5 8 1 7 3 PE

T1 T2 U V W PE

e

PES

M 3 h

PES

5 8 1 7 3 PE

T1 T2

M 3 hi

U V W PE

e

PES

4 6

B1 B2

RA-SP2-341-...RA-SP2-341(230)-...

2-97



2

EMC correct assembly of speed control unit RA-SP

PES

e

PE

2-98


2

2-99


2

2-100


Control circuit devices

3

Page

RMQ 3-2

Signal Towers SL 3-11

LS-Titan® position switches 3-13

Electronic position switches LSE-Titan® 3-24

Analog electronic position switches 3-25

Inductive proximity switches LSI 3-27

Optical proximity switches LSO 3-29

Capacitive proximity switches LSC 3-30

3-1


3

Control circuit devicesRMQ

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.

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,

• Freely programmable switching behaviour on all selector switch actuators: spring-return/stay-put,

• All actuators in illuminated and non-illuminated version,

• Emergency-Stop actuators with pull and turn-to-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

3-2



3

RMQ-Titan® system overview

ATEX

ATEX

3-3



3

RMQ-Titan®

Four-way pushbuttonMoeller 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 pushbuttonThe 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.

Joystick with double contactThe 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.

Selector switch actuatorsThe 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.

LabelsMoeller offers various types of labels for all operating elements. Versions available are:

• 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..

0

1

01

2

3-4



3

Contact versions

Screw terminals

Spring-loaded terminals

Front fixing

Base fixing Contact Contact travel diagram1)

x x x x

M22-(C)K(C)10

x x x –

M22-(C)K(C)01

x x x x

M22-(C)K01D2)

x – x –

M22-K10P

– x x –

M22-CK20

– x x –

M22-CK02

– x x –

M22-CK112)

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

.3

.4

0 2.8 5.5

.1

.20 1.2 5.5

.5

.60 2.8 5.5

.7

.80 1.8 5.5

.3

.4

.3

.40 3.6 5.5

.1

.2

.1

.20 1.2 5.5

.3

.4

.1

.2 0 1.2 3.6 5.5

3-5



3

Terminal markings and function numbers (conventional number/circuit symbol), EN 50013

Voltage versions with series elements

M22-XLED601) Ue FAC/DC

1x 60 V

2x 90 V

3x 120 V

... ...

7x 240 V

M22-XLED220 Ue F

1 x 220 VDC

1) For increasing the voltage AC/DC.

M22-XLED230-T1) Ue F

1x 400 V~

2x 500 V~

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

13

14

13

14

23

24

13

14

23

24

33

34

30

20

10

13

14

13

14

33

34

21

11

21

22

21

22

13

14

12 21

22

31

32

21

22

03 11 21 31

12 22 32

21

22

01

02 11

12

12 – 30 V h/H

Ue h/H

X2X121

M22-XLED60/M22-XLED220

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

2121

X2X1211

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

2

85 – 264 V h, 50 – 60 Hz

Ue h

3-6



3

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.

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

a Test button1) Only for elements 12 to 30 V.

a14

13

X2

X1

14

13

14

13

2 1

4

3

X2

X1

X2

X1

2 1

2 1

M22-XLED-T

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

12 –

240

V h

/H

2

1


2

12

1

2

12

1

2

1M22-XLED60/M22-XLED220


3-7



3

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

a Test button1) For elements 85 to 264 V.

a

L1

N

14

13

X2

X1

14

13

14

13

4

3

2

1

X2

X1

X2

X1M22-XLED230-T

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

85 –

264

V h

/50

– 60

Hz

2 1

2 1

2 1

3-8



3

Labeleditor

Customised inscription of devices using the Labeleditor softwareYou 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.

Ordering examples• M22-XST insert plate for M22S-ST-X legend

plate mount with special inscriptionBasic type: M22-XST-*

* = File name generated by Labelditor

Please order: 1 x M22-XST-RMQ_Titan_xxxxxx.zip

• Button plate in green with special inscriptionBasic type: M22-XDH-*

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-*-*-*

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_xxxxx.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

3-9

http://www.moeller.net/en/support/index.jsp

http://www.moeller.net/en/support/index.jsp



3

ATEX approval

a ATEX equipment code

NoteWhat 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.

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.

The basic devices listed in our Main Catalogue can be ordered with approval in accordance with the ATEX directive 94/9/EC.

• 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

OrderOrder with the designation M22-COMBINATION-* with the suffix M22-ATEX or FAK-COMBINATION-* with the suffix FAK-ATEX.

* 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

http://www.moeller.net/en/support/pdf_katalog.jsp


Control circuit devicesSignal Towers SL

3

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

Control circuit devicesSignal Towers SL


3

Programmability

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.)

BA15d F 7 W

N

1

2

3

4

05

0 5 4 3 2 1

55 �

4 �

3 �

2 �

1 �

4

3

2

1

1...5 Ue = 24 – 230 Vh/H�

3-12


Control circuit devicesLS-Titan® position switches

3

New combinations for your solutions with LS-Titan®

Actuating devices RMQ-Titan® simply snap fittedAnother unique feature is the possibility to combine control circuit devices from the RMQ-Titan range with the position switches LS-Titan. Pushbuttons, selector switches or Emergency-Stop 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°).

a Operating heads in four positions, each turned by 90°, can be fitted subsequently.

a

RMQ-Titan

LS-Titan

3-13



3

Overview

LS, LSM LS4…ZB

LSR… LS…ZB LS…ZBZ

3-14



3

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:

“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.

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.

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)“.

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.

Certification

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).

LS4…ZB LS…ZBZ LS…ZB

LSR-ZB…

BG

PRÜFZERT

Sicherheit geprüfttested safety

ET 06183BG

PRÜFZERT


BGIA 0603010

BG

PRÜFZERT


ET 07014

BG

PRÜFZERT


ET 06165

3-15



3

“Personnel protection” by monitoring the protective device

LS…ZB

LS…ZB LS4…ZB• Door open• LS...ZB disconnects

power• No danger

closed open

a Safety contactb Signalling contact

STOP

21 22

13 14

21 22

13 14

a

b

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

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

3-16



3

"Enhanced personnel protection" with separate signal for door position

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

LS…ZBZ• Stop signal• Waiting time• Machine is stopped• Protective device open• No danger

LS-S02-…FT-ZBZa Safety contactb Signalling contactc Interlockedd Releasede open

STOP

a

b

A1

A221 22

11 12

A1

A221 22

11 12

A1

A221 22

11 12

US US

c d e

Door closed and interlocked

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

Door open a Both contacts in the open positiontamperproof against simple tools

Door released a Apply voltage to coil (A1, A2)e.g. via zero-speed monitorSafety contact (21 – 22) opensSignalling contact (11 - 12) remains closed

Close door a Signalling contact (11 – 12) closes

Door open a Only possible once it is releasedSignalling contact (11 - 12) opens.

Interlock door a Disconnect the voltage from coil (A1, A2)1st actuator interlocked2nd safety contact (21-22) closes

3-17



3

LS-S11-…FT-ZBZa Safety contactb Signalling contactc Interlockedd Releasede open

a

b

US US

A1

A221 22

13 14

A1

A221 22

13 14

A1

A221 22

13 14

c d e


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

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

Door released a Apply voltage to coil (A1, A2)e.g. via zero-speed monitorSafety contact (21 – 22) opensSignalling contact (13-14) remains open

Close door a Signalling contact (13 - 14) opens.

Door open a Only possible once it is releasedSignalling contact (13 - 14) closes.

Interlock door a Disconnect the voltage from coil (A1, A2)1st actuator interlocked2nd safety contact (21-22) closes

3-18



3

"Process protection and enhanced personnel protection" with separate signal for door position

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

LS…ZBZ• Stop signal• Waiting time• Process sequence halted• Protective device open• Product OK

LS-S02-…MT-ZBZa Safety contactb Signalling contactc Interlockedd Releasede open

STOP

A1

A2

21 22

11 12

A1

A2

21 22

11 12

A1

A2

21 22

11 12

a

b

US

c d e


a Voltage on coil (A1, A2)Safety contact (21-22) closedSignalling contact (11 - 12) closed

Door open a Both contacts in the open positiontamperproof against simple tools

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

Close door a Signalling contact (11 – 12) closes

Door open a Only possible once it is releasedSignalling contact (11 - 12) opens.

Interlock door a Apply voltage to coil (A1, A2)1st actuator interlocked2nd safety contact (21-22) closes

3-19



3

LS-S11-…MT-ZBZa Safety contactb Signalling contactc Interlockedd Releasede open

a

b

A1

A2

US

A1

A2

A1

A2

21 22

13 14

21 22

13 14

21 22

13 14

c d e


a Voltage on coil (A1, A2)Safety contact (21-22) closedSignalling contact (13-14) open

Door open a Safety contact (21 - 22) openSignalling 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 a Only possible once it is releasedSignalling contact (13 - 14) closes.

Interlock door a Apply voltage to coil (A1, A2)1st actuator interlocked2nd safety contact (21-22) closes

3-20



3

“Personnel protection” by monitoring of the protective mechanism

LSR…TKG, LSR…TS

LSR…I(A) /TKG LSR…I(A)/TS• Hinged protective

cover open• LSR... disconnects

power• No danger

Closed open

a Safety contactb Signalling contact

STOP

21 22

13 14

21 22

13 14

a

b

Hinged protective cover closed

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

Hinged protective cover open

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

3-21



3

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 0660a 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 • 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

• 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

3-22



3

LS…ZB LS…ZBZ

Standards • IEC 60947, EN 60947,VDE 0660

• IP65

• IEC 60947, EN 60947,VDE 0660

• IP65

Suitable applications




• Approval of German Trade Association




• 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

3-23


3

Control circuit devicesElectronic 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.

The position switch is overload as well as conditionally short-circuit proof and has snap-action 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.

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

Contact travel diagramLSE-11

LSE-02

1 s

fmax F 2 N

LEDadjust

adjust

adjust

fasten

TÜVRheinland

Bauart geprüft

Type approved

Functional

Safety

electron.

+Ue

Q1

0 V

Q2

Q1

Q2

0.5 5.5

default = 3.0

6.10

Q1

0 V

Q2

+Ue

electron.

Q1

Q2

0.5 5.5

default = 3.0

6.10

3-24


Control circuit devicesAnalog electronic position switches

3

Analog electronic position switches

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.

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

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.

Contact travel diagramLSE-AI

LSE-AU

Connection diagram

1000

4

20

S [%]

I [mA]

1000

10

S [%]

U [V]

LSE-AI

F 200 mA

4 – 20 mA

0 V

Q Ue< 400 O

A

+24 V (–15 / +20 %)

+Ue

+Q2

+Q1

0 V

diagnosis

analog

3-25

Control circuit devicesAnalog electronic position switches


3

Contact diagramNormal scenario

Fault scenario

LSE-AU

F 200 mA

F 10 mA

0 V

0 V – 10 V Q UeV

+24 V (–15 / +20 %)

+Ue

+Q2

+Q1

0 V

diagnosis

analog

LSE-AI LSE-AU

Q1 4 – 20 mA 0 – 10 V

Q2 Q Ue Q Ue

LED

t

LED

t

LED

LSE-AI LSE-AU

Q1 0 mA 0 V

Q2 0 V 0 V

LED

Reset

t

LED

t

LED

+Ue

t> 1 s

+Ue

t> 1 s

3-26


Control circuit devicesInductive proximity switches LSI

3

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 Oscillatorb Rectifierc Amplifierd Outpute 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 micro-seconds-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 partThe following correction factors must be used for different materials:

Sn = Rated switching distance

a b

e

cd

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 n0.60 – 1.00 x S

3-27

Control circuit devicesInductive proximity switches LSI


3

AC operating mode

AC inductive proximity switches have two terminals. The load is connected in series with the sensor.

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

UU

U, I N

L1

Sensor

Load

SupplySensor

Load

+

–

R

U U

U, I

Sensor

Load

SupplySensor

Load

3-28


Control circuit devicesOptical proximity switches LSO

3

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

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.

Sd = Operating range

Reflected-light barrier

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.

aa Object

Material Factor app.

Paper, white, matt, 200 g/m2

1 x Sd

Metal, gloss 1.2 – 1.6 x Sd

Aluminium, black, anodized

1.1 – 1.8 x Sd

Polystyrene, white 1 x Sd

Cotton, white 0.6 x Sd

PVC, grey 0.5 x Sd

Wood, untreated 0.4 x Sd

Card, black, gloss 0.3 x Sd

Card, black, matt 0.1 x Sd

b

aa Objectb Reflector

3-29


3

Control circuit devicesCapacitive proximity switches LSC

Working principle

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 high-frequency 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.

a Oscillatorb Evaluation circuitc Amplifierd Outpute Power supplyA, BMain electrodesC Auxiliary electrodes

Effects

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

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.

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.

NoteWhen 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.

A+

B–

a

CB

A

BC

b

e

cd

3-30

Control circuit devicesCapacitive proximity switches LSC


3

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.

60

80

30

10

10 20 40 60 80 1001

er

sr[%]

Material er

Air, vacuum 1Teflon 2Wood 2 to 7Paraffin 2.2Kerosene 2.2Oil of terpentine 2.2Transformer oil 2.2Paper 2.3Polyethylene 2.3Polypropylene 2.3Cable insulation 2.5Soft rubber 2.5Silicone rubber 2.8Polyvinyl chloride 2.9Polystyrene 3Celluloid 3Perspex 3.2Araldite 3.6Bakelite 3.6Silica glass 3.7Hard rubber 4Oil-impregnated paper 4Chipboard 4Porcelain 4.4Laminated paper 4.5Quartz sand 4.5Glass 5Polyamide 5Mica 6Marble 8Alcohol 25.8Water 80

3-31


3

3-32


Rotary switches

4

Page

Overview 4-2

ON-Off switches, main switches, maintenance switches 4-3

Changeover switches, reversing switches 4-5

(Reversing) star-delta switches 4-6

Multi-Speed Switches 4-7

Interlock circuits 4-11

Single-phase starting switches 4-12

Meter selector switches 4-13

Heater switches 4-14

Step switches 4-15

Rotary switches and switch-disconnectors with ATEX approval 4-17

4-1


4

Rotary switchesOverview

Use and mounting forms

Moeller rotary switches and switch-disconnectors are used as:

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.

The following mounting forms are available:

g Flush mounting,h Centre mounting,i Surface mounting,j Service distribution board mounting,k 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.

Basic type

ATEX Iu Use as Mounting form

[A] a b c d e f g h i j k

TM – 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 – – – – + – +

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 current1) In enclosed version (surface mounting), max. 275 A.kDependent on the number of contact units, function and contact sequence.+ Irrespective of the number of contact units, function and contact sequence.

4-2


Rotary switchesON-Off switches, main switches, maintenance switches

4

On-Off switchs, main switches

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

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.

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

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).

T0-2-1P1-25P1-32P3-63P3-100P5-125P5-160P5-250P5-315

Maintenance switches (safety switches) with auxiliary contacts

T0-3-15680

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

1) Load shedding contact

FS 908

ON

OFF

123456

L1

L2

L3

0 1

FS 908

ON

OFFL1

L2

L3

123456789

101112

N

N

0 1

1)

FS 908

ON

OFF

123456NN

13142122

N

L1

L2

L3N

1)

0 1

4-3

Rotary switchesON-Off switches, main switches, maintenance switches


4

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

T0(3)-3-15683 maintenance switch

T0(3)-3-15683 circuit diagram

Function

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.

P1: OnP2: OffQ11: Load shedding

Q11

L2

NL3

L1

F1

Q112

1

4

3

6

5

F2

1 3 5

2 4 6

M3

7 9 11

8 10 12

Q1

U V W

A2Q11

A1

A2P1 P2

F0

95

96

21

22

F2

O

13

14

I13

14

FAZ-B4/1-HS

1-2,3-4,5-6

7-8,11-12

9-10

4-4


Rotary switchesChangeover switches, reversing switches

4

Changeover switches

Reversing switches

T0-3-8212T3-3-8212T5B-3-8212T5-3-8212T6-3-8212T8-3-8212

FS 684

01 2

123456789

101112

01 2L2L1 L3

T0-3-8401T3-3-8401T5B-3-8401T5-3-8401

FS 684

01 2

21 0123456789

10

L2L1 L3

4-5


4

Rotary switches(Reversing) star-delta switches

Star-delta switches

Reversing star-delta switches

T0-4-8410T3-4-8410

T5B-4-8410T5-4-8410

FS 635

Y0

123456789

10111213141516

L1 L2 L3 0 Y Δ

U2

U1

V1V2

W1

W2

T0-6-15877T3-6-15877

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

FS 638

Y0

Y

123456789

10111213141516

L1L2L3

U2

U1

V1V2

W1

W2

1718192021222324

0Y Y

SOND 28 )1

4-6


Rotary switchesMulti-Speed Switches

4

2 speeds, non-reversing

2 separate windings

Tapped windingT0-4-8440T3-4-8440T5B-4-8440T5-4-8440

a without connections

FS 644

01

2

123456789

10111213141516

L1L2L3

1U

1W 1V

2W 2V

2U

1 20

�

T0-3-8451T3-3-8451T5B-3-8451T5-3-8451

FS 644

01

2

123456789

101112

L1L2L31 2

1U

1W 1V

2U

2W 2V

0

4-7



4

2 speeds, reversing

Tapped windingT0-6-15866T3-6-15866

2 separate windings, reversingT0-5-8453T3-5-8453

FS 629

10

12 2

12

2L1 L2 L3

1 0

3456789

1011121314

1 2

151617181920212223241W

2W

1U

1V2U

2V

FS 629

10

12 2

123456789

1011121314151617181920

12 0 1 2

1U

1W 1V

2U

2W 2V

L1L2L3

4-8



4


Tapped winding arrangement, single winding for low speedT0-6-8455T3-6-8455T5B-6-8455T5-6-8455

0-(A)y- (B)d = (B)y y

FS 616

1

0

2

3

0 1 2 3123456789

101112131415161718192021222324

L1 L2 L3

1U

1W 1V

A B

1U

1W 1V

2W 2V

2U

4-9



4


Tapped winding arrangement, single winding for high speedT0-6-8459T3-6-8459

T5B-6-8459T5-6-8459

0-(B)d- (B)y y -(A)y

FS 616

1

0

2

3

FS 420

21

03

0 1 2 3123456789

101112131415161718192021222324

L1 L2 L3

1U

1W 1V

A B

1U

1W 1V

2W 2V

2U

4-10


Rotary switchesInterlock circuits

4

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

Interlock with contactor (SOND 29)Contactor can be energized only when switch is in an operating position

Interlock with contactor (SOND 30)Contactor can be energized only when switch is in an operating position

Q11

Q11

S0

F0

F2

0 21

M3~

Q11

Q1

Circuit as required

Control sectionSOND 27

Power section without mainsdisconnection

Q11

Q11

S0

F0

F2

0 21

M3~

Q11

Q1

Circuit as required


Power section without mainsdisconnection

Q11

S1

S0

F0

F2

0 21

M3~

Q11

Q1

Q11

Circuit as required


Power section Q11

S1

S0

F0

F2

0 21

M3~

Q11

Q1

Q11

Circuit as required


Power section

4-11


4

Rotary switchesSingle-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

Ammeter selector switches

T0-3-80073 x phase to phase3 x phase to neutral with “0” position

T0-2-159223 x phase to neutral without “0” position

T0-5-15925T3-5-15925For direct measurement

L1-L2

FS 1410759

0

L2-L3

L3-L1

L1-N

L2-N

L3-N

L3-L

1

123456789

101112

L2-L

3L1

-L2

0 L1-N

L2-N

L3-N

V

L1L2L3 N L1-L2L2-L3

L3-L1

FS 164854

123456

L3-L

1L2

-L3

L1-L

2

78V

L1L2L3

L1

L2

FS 9440

0

L3 L1L2L30123456789

101112131415161718

L1L2 L3

L1L2L3

A

0

4-12


Rotary switchesMeter selector switches

4

Ammeter changeover switch

Wattmeter selector switches

T0-3-8048T3-3-8048For measurement via transformers, complete rotation possible

L1

L2

FS 9440

0

L3

L1L2L3 00

L1L2L3

123456789

101112

A

T0-5-8043T3-5-8043Two-phase method (Aron circuit) for three-cable installations loaded as required. The total wattage is calculated by adding together the two wattages.

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.

FS 953

0

1 2

W1 20

L1L2L3

123456789

101112131415161718

1 2 3 11

4-13


4

Rotary switchesHeater switches

1-pole disconnection, 3 steps

T0-2-8316T3-2-8316T5B-2-8316

T0-2-15114, complete rotation possible

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.

FS 420

21

03

12345678

L1 L2 L30 1 2 3

1

I II III

2

3

IIIIII

FS 193840

1+2

1

0

2

12345678

0 11+2 2 0

4-14


Rotary switchesStep switches

4

One step closed in each position, complete rotation possible

T0-6-8239T3-6-8239

FS 301

12

3 4 567

891011

12

1 2 3 4123456789

1011

6 7 8 95 1110 12

1314151617181920212223

12

24

4-15

Rotary switchesStep switches


4

Stay-put switches

Changeover switches

On-Off stay-put switches

On-Off stay-put switch1-pole: T0-1-154012-pole: T0-1-154023-pole: T0-2-15403

FS 415

01

10123456

1-pole: T0-1-154212-pole: T0-2-154223-pole: T0-3-15423

1-pole: T0-1-154312-pole: T0-2-154323-pole: T0-3-15433

FS 429

02 1

123456789

101112

0 12

FS 1401

0HAND AUTO

123456789

101112

0 AUTOHAND

1-pole: T0-1-155212-pole: T0-2-155223-pole: T0-3-15523With pulsed contact in the intermediate position

FS 908

ON

OFF 123456789

101112

0 1

4-16


Rotary switchesRotary switches and switch-disconnectors with ATEX approval

4

What does ATEX stand for?

ATmosphéres EXplosibles = ATEX

Explosive atmospheres

Gas Dust

Two standards

For manufacturers: 94/9/EC (binding from 06/2003)

For operators: 1999/92/EC (binding from 06/2006)

Device groups

GroupIII

ApplicationMiningEverything, except mining

Selection of devices by device groups

GroupIIIIIIII

CategoryM1M212 3

SafetyVery highHighVery highHighNormal

Explosion risk assessment

Gas, steam, mistZone 0Zone 1Zone 2

Ex risk

permanent, frequent, long periodsoccasionalnormally not, but then for short time

Dust

Zone 20Zone 21Zone 22

Selection of devices and protective systems by categories

Category

11, 21, 2, 3

Dust

Zone 20, 21, 22Zone 21, 22 Zone 22

Gas, steam, mist Zone 0, 1, 2Zone 1, 2Zone 2

4-17

Rotary switchesRotary switches and switch-disconnectors with ATEX approval


4

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.

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:

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!

• 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!

Current range

T rotary switches

P switch-dis-connectors

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

4-18


Contactors and relays

5

Page

Contactor relays 5-2

SmartWire 5-8

Contactors DIL, overload relays Z 5-24

Contactors DIL 5-30

Overload relays Z 5-35

ZEV electronic motor-protective system 5-38

Thermistor machine protection device EMT6 5-45

CMD contactor monitoring device 5-48

5-1


5

Contactors and relaysContactor 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.

SafetyThe 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.

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.

5-2



5

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.

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 1 Example 2 Example 3DILA-XHI04 DILA-XHI13 DILA-XHI22

+DILA-40

+DILA-31

+DILA-22

q 44 EDILA40/04

q 44 XDILA31/13

q 44 YDILA22/22

51

52

61

62

71

72 82

81 53 61 71 81

82726254 54

53 61

62

71

72

83

84

14

13 33

34

43

44

A1

A2

23

24 14

13 21

22

33

34

43

44

A1

A2 14

13 21

22

31

32

43

44

A1

A2

5-3



5

Coil connections

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

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

The DC operated contactors DILER and DILA have an integrated suppressor circuit.

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.

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.

DILER DILA

A1

A2

A1

A2

5-4


5

5-5



5

Circuit diagram Load current and voltage responses

Proof against incorrect connec-tion also for AC

Addi-tional dropout delay

Induction voltage limiting defined

– Very long 1 V

– Medium UZD

yes Short UVDR

yes Short –

D

+

–

D

+

–0

i I0

u U0

0

U

t1 t2

t0 t

t

D

+

–

ZDu

0

i

t1 t2

t0

I0

U0

U

0t

t

VDRu0

i0

U

t1 t2

I0

U0

t

t

R

C0

t00

T1

I0i

u U0

t

t

5-6



5

Circuit diagram Damping also below ULIMIT

In-creased rating with cir-cuitry

Notes

– – Advan-tages:

Dimensioning uncritical, minimum possible induction voltage, very simple and reliable

Disadvan-tage:

Long drop-out delay


Very short drop-out delay. Dimensioning uncritical. Simple construction

Disadvan-tage:

No damping below UZD


Dimensioning uncritical. High energy absorption. Very simple construction

Disadvan-tage:

No damping below UVDR

yes yes Advan-tages:

HF damping due to stored energy, immediate de-energisation, highly suitable for AC.

Disadvan-tage:

Precise dimensioning required

D

+

–

D

+

–

D

+

–

ZD

VDR

R

C

5-7


5

Contactors and relaysSmartWire

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.

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.

5-8



5

Overview SmartWire

The SmartWire system consists of the following components:

1 Gateway for easyNet and CANopen 2 Gateway for PROFIBUS-DP 3 XI/ON gateway4 SmartWire-I/O module5 DOL starter MSC-D up to 32 A6 DOL starter MSC-D up to 15.5 A7 SmartWire power module8 SmartWire connection cable9 SmartWire module for DILM10 Reversing starter MSC-R up to 12 A

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

I/ON

X

2

8

3

7

9

65

610

4

1

5-9



5

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

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

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

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.

5-10



5

Assembly SmartWire system

a SmartWire module for DILM: SWIRE-DILb Gatewayc SmartWire power module: SWIRE-PFd SmartWire connection cable:

SWIRE-CAB-…e SmartWire end plug: SWIRE-CAB-000f Field busg Programmable logic controllerh Earthi Fusej SmartWire I/O module: SWIRE-4DI-2DO-R

M M MM M MM M M

g bfcj

a

24 V 0 V

24 V 0 V

24 V 0 V

24 V 0 V

24 V 0 V

24 V DC

d

e

d

h

Aux

i

Gate-way

5-11



5

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.

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

Star-delta starters

with 3 SmartWire modules for DILMThey 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 moduleThe 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 relayThe 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

5-12



5

Circ

uit d

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am D

OL

star

ters

-M1

-Q11

3~M

13

5

24

6

UV

WPE

UV

WPE

-Q1

13

51.

13

1.14

I>I>

I>2

46

PEL1 L2 L3

X1

1.21

1.22

-Q1

1.14

A1 A2

1.13

-Q11

X1X2

X3X4 24

V0V DC

INO

UT66

Smar

tWire

Smar

tWire

5-13



5

Circ

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ILM

7 to

DIL

M12

with

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-M1

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3~M

13

5

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13

5

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6

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UV

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-Q1

13

51.

13

1.14

1.21

1.22

I>I>

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PEL1 L2 L3

X1

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A1 A2

1.13

-Q11

X1X2

X3X4 24

V0V DC

INO

UT

-Q11

2221-Q

122221

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INO

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Smar

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Smar

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A1 A2

5-14



5

Circ

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am fo

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ith D

ILM

17 to

DIL

M32

-M1

-Q12

-Q11

3~M

13

5

24

6

13

5

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6

UV

WPE

UV

WPE

-Q1

13

51.

13

1.14

1.21

1.22

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46

PEL1 L2 L3

X1

-Q1

1.14

A1 A2

1.13

-Q11

X1X2

X3X4 24

V0V DC

INO

UT

-Q12

2221-Q

112221

6Sm

artW

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-Q12

X1X2

X3X4 24

V0V DC

INO

UT66

Smar

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A1 A2

Smar

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5-15



5

Circ

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am fo

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tart

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Sm

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M

-M1

-Q12

-Q11

3~M

13

5

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6-Q13

13

5

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6

13

5

24

6

U1V1

W1PE

U1V1

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V2W2U2

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-Q1

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51.53

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46

V2W2U2

PEL1 L2 L3

X1-Q12

X1X2X3X4 24V 0V DC

INOUT

-Q132221

-Q122221

6SmartWire

6SmartWire

-Q13

X1X2X3X4 24V 0V DC

INOUT6

6SmartWire

SmartWire

-Q11

X1X2X3X4 24V 0V DC

INOUT

-Q11.54

1.53

5-16



5

Circ

uit d

iagr

am fo

r sta

r-del

ta s

tart

er w

ith S

mar

tWire

I/O

mod

ule

-M1

-Q12

-Q11

3~M

13

5

24

6-Q13

13

5

24

6

13

5

24

6

U1V1

W1PE

U1V1

W1

V2W2U2

PE

-Q1

13

51.53

1.54

1.61

1.62

I>I>

I>2

46

V2W2U2

PEL1 L2 L3

X1

L01

-K2

V+I1

I4V+

INO

UT

-Q11

1413

6Sm

artW

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Smar

tWire

-Q1

1.62

1.61

6867

-Q13

2122

-Q12

-K1

5857

-Q12

2122

A2A1

A2A1

A2A1-Q

13

-Q1

1.54

1.53

-K2

1413

-Q11

-K1

L02

I3I2

2423

Q2

1413

Q1

-K1

5-17



5

Circ

uit d

iagr

am fo

r sta

r-del

ta s

tart

er w

ith S

mar

tWire

I/O

mod

ule

for D

ILM

and

ETR

4-51

tim

ing

rela

y

-M1

-Q12

-Q11

3~M

13

5

24

6-Q13

13

5

24

6

13

5

24

6

U1V1

W1PE

U1V1

W1

V2W2U2

PE

-Q1

13

51.53

1.54

1.61

1.62

I>I>

I>2

46

V2W2U2

PEL1 L2 L3

X1

L01

2817

-Q13

2122

-Q12

-Q13-K

1-K

11817

-Q12

2122

A2A1

A2A1

A2A1

-Q1

1.54

1.53

-Q11

1413

L02

66

Smar

tWire

Smar

tWire

-Q11

X1X2

X3X4 24

V0V DC

INO

UT

-Q1

1.62

1.61

-K1

5-18



5

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.

a figure, page 5-20 and a figure, page 5-21

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 anda figure, page 5-23

5-19



5

Circ

uit d

iagr

am fo

r saf

ety

pow

er-o

ff

L1 L2 PEL3 -Q01

-T01

-F01

I>I>

I>40

00

240

24V

In Out

Out

NET

-S02

RESE

T RESE

T

POW

ER

CONT

ROL-

LOGI

C

2221 Y1A1

A2Y3

Y213 14

-K02

-K01

Gat

eway

-K03

Pow

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odul

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-K01

13 14

23 24

33 34

41 42

K1 K1

-Q11

X1A1

X2

X3X4

INO

UT

6

A2-Q

12

X1A1

X2

X3X4

INO

UT

A2

6

-Q13

X1A1

X2

X3X4

INO

UT

A2

66

6

-Q14

X1A1

X2

X3X4

INO

UT

A2

6

-Q15

X1A1

X2

X3X4

INO

UT

A2

-Q02

I>I>

I>

0V24

V0V

-K01

23 24 24V

0V

-F03

2hH

-F02

-F04

NET

Smar

tWire

Smar

tWire

Smar

tWire

U Au

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InO

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Pow

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Aux

-S01

NOT

AUS

21 22

5-20



5

Mai

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saf

ety

rele

vant

sw

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offs

PEL1 L2 PEL3

-M1

3~M

UV

WPE

UV

WPE

-Q1

13

5

I>I>

I>2

46

-M1

-Q11

13

5

24

6

-M1

3~M

UV

WPE

UV

WPE

-Q2

13

5

I>I>

I>2

46

-M2

-Q12

13

5

24

6

-M1

3~M

UV

WPE

UV

WPE

-Q3

13

5

I>I>

I>2

46

-M3

-Q13

13

5

24

6

-M1

3~M

UV

WPE

UV

WPE

-Q4

13

5

I>I>

I>2

46

-M4

-Q14

13

5

24

6

-M1

3~M

UV

WPE

UV

WPE

-Q5

13

5

I>I>

I>2

46

-M5

-Q15

13

5

24

6

5-21



5

Cont

rol c

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redu

ndan

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itch-

offs

L1 L2 PEL3 -Q01

-T01

-F01

I>I>

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NOT

AUS

1.31

1.32

1.21

1.22

-Q15

21 22-Q

1422 21

-Q11

21

400

0

240

24V

In Out

Out

NET

22

-Q16

21 22

-S02

RESE

T

RESE

T

POW

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1CH

2

CONT

ROL-

LOGI

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–+

–+

+

13 14 S34

A1A2

-Q13

22 21-Q

1221 22

S35

S31

S22

S12

S12

S21

S33

13 14

-K01

-K02

Gat

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-K03

Pow

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-Q16

13 14-K

0123 24

23 24

33 34

A1 A2

K1 K1

-Q11

X1A1

X2

X3X4

INO

UT

6

A2-Q

12

X1A1

X2

X3X4

INO

UT

A2

6

-Q13

X1A1

X2

X3X4

INO

UT

A2

66

6

-Q14

X1A1

X2

X3X4

INO

UT

A2

6

-Q15

X1A1

X2

X3X4

INO

UT

A2

-Q02

I>I>

I>

0V24

V0V

-K01

33 34 24V

0V

-F02

2hH -F

03-F

04

NET

Smar

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Smar

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U Au

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Pow

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Aux

Smar

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5-22



5Mai

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redu

ndan

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offs

PEL1 L2 PEL3

-M1

3~M

UV

WPE

UV

WPE

-Q1

13

5

I>I>

I>2

46

-M1

-Q11

13

5

24

6

-M1

3~M

UV

WPE

UV

WPE

-Q2

13

5

I>I>

I>2

46

-M2

-Q12

13

5

24

6

-M1

3~M

UV

WPE

UV

WPE

-Q3

13

5

I>I>

I>2

46

-M3

-Q13

13

5

24

6

-M1

3~M

UV

WPE

UV

WPE

-Q4

13

5

I>I>

I>2

46

-M4

-Q14

13

5

24

6

-M1

3~M

UV

WPE

UV

WPE

-Q5

13

5

I>I>

I>2

46

-M5

-Q15

13

5

24

6-Q

16

-F1

13

5

24

6

5-23


5

Contactors and relaysContactors DIL, overload relays Z

Overview of DIL contactors, 3-pole

DILM7 … DILM15 DILM17 … DILM38 DILM40 …DILM72 DILM80 … DILM170

DILM185 … DILM250 DILM300 … DILM500

DILM580 … DILM1000DILH1400

DILM1600DILH2000DILH2200

5-24



5

Overview DILP contactors, 4 pole

DILEM4

DILMP20 DILMP32 … DILMP45 DILMP63 … DILMP80 DILMP125 … DILMP200

Part no. 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 = IeA 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



5

Part no. Auxiliary contact blocks

For surface mounting

For side mounting

DILEEM 02DILEM11DILEM22DILEM

–

DILEM

DILM7 DILA-XHI(V)…DILM32-XHI…

–

DILM9

DILM12

DILM15

DILM17 DILM32-XHI11-S

DILM25

DILM32

DILM32

DILM40 DILM150-XHI(V)…

DILM1000-XHI(V)…

DILM50

DILM65

DILM72

DILM80

DILM95

DILM115

DILM150

DILM170

Rated operating current Ie [A] At 400 V

max. rating [kW] AC-3 Conventional free air thermal current Ith =Ie [A]AC-1 at 60 °C

Part no.

220 V,230 V

380 V,400 V

660 V,690 V

1000 V

6.6 1.5 3 3 – 20 DILEEM

9 2.2 4 4 – 20 DILEM

7 2.2 3 3.5 – 20 DILM7

9 2.5 4 4.5 – 20 DILM9

12 3.5 5.5 6.5 – 20 DILM12

15.5 4 7.5 7 – 20 DILM15

17 5 7.5 11 – 35 DILM17

25 7.5 11 14 – 40 DILM25

32 10 15 17 – 40 DILM32

38 11 18.5 17 – 40 DILM38

40 12.5 18.5 23 – 50 DILM40

50 15.5 22 30 – 65 DILM50

65 20 30 35 – 80 DILM65

72 25 37 35 – 80 DILM72

80 25 37 63 – 90 DILM80

95 30 45 75 – 110 DILM95

115 37 55 90 – 130 DILM115

150 48 75 96 – 160 DILM150

170 52 90 140 – 185 DILM170

5-26



Conventional free air thermal current Ith =Ie [A]AC-1 at 60 °C

Part no.

V, 1000 V

– 20 DILEEM

– 20 DILEM

– 20 DILM7

– 20 DILM9

– 20 DILM12

– 20 DILM15

– 35 DILM17

– 40 DILM25

– 40 DILM32

– 40 DILM32

– 50 DILM40

– 65 DILM50

– 80 DILM65

– 80 DILM72

– 90 DILM80

– 110 DILM95

– 130 DILM115

– 160 DILM150

– 185 DILM170

5

Part no. Auxiliary contact blocks Motor overload relay

Electronic motor protection system ZEV


For side mounting

DILEEM 02DILEM11DILEM22DILEM

– ZE-0.16up toZE-9DILEM

DILM7 DILA-XHI(V)…DILM32-XHI…

– ZB12-0.16up toZB12-16DILM9

DILM12

DILM15 ZEV+ZEV-XSW-25ZEV-XSW-65ZEV-XSW-145ZEV-XSW-820

DILM17 DILM32-XHI11-S ZB32-0.16up toZB32-38DILM25

DILM32

DILM38

DILM40 DILM150-XHI(V)… DILM1000-XHI(V)… ZB65-10up toZB65-75DILM50

DILM65

DILM72

DILM80 ZB150-35up toZB150-175DILM95

DILM115

DILM150

DILM170

5-27



5

Part no. Auxiliary contact blocks


For side mounting

DILM185 – DILM1000-XHI…

DILM225

DILM250

DILM300

DILM400

DILM500

DILM580

DILM650

DILM750

DILM820

DILM1000

DILM1600

DILH1400

DILH2000

DILH2200

Rated operating current Ie [A] At 400 V

max. rating [kW] AC-3 Conventional free air thermal current Ith =Ie [A]AC-1 at 60 °C

Part no.

220 V,230 V

380 V,400 V

660 V,690 V

1000 V

185 55 90 175 108 275 DILM185

225 70 110 215 108 315 DILM225

250 75 132 240 108 350 DILM250

300 90 160 286 132 400 DILM300

400 125 200 344 132 500 DILM400

500 155 250 344 132 700 DILM500

580 185 315 560 600 800 DILM580

650 205 355 630 600 850 DILM650

750 240 400 720 800 900 DILM750

820 260 450 750 800 1000 DILM820

1000 315 560 1000 1100 1000 DILM1000

1600 500 900 1600 1) 1800 DILM1600

1400 – – – – 1400 DILH1400

2000 – – – – 2000 DILH2000

2200 – – – – 2200 DILH2200

1) Please enquire

5-28



Conventional free air thermal current Ith =Ie [A]AC-1 at 60 °C

Part no.

V, 1000 V

108 275 DILM185

108 315 DILM225

108 350 DILM250

132 400 DILM300

132 500 DILM400

132 700 DILM500

600 800 DILM580

600 850 DILM650

800 900 DILM750

800 1000 DILM820

1100 1000 DILM1000

1) 1800 DILM1600

– 1400 DILH1400

– 2000 DILH2000

– 2200 DILH2200

5

Part no. Auxiliary contact blocks Motor overload relay

Electronic motor protection system ZEV


For side mounting

DILM185 – DILM1000-XHI… Z5-70/FF250up toZ5-250/FF250DILM225

DILM250

DILM300 ZW7-63up toZW7-630DILM400

DILM500 ZEV+ZEV-XSW-25ZEV-XSW-65ZEV-XSW-145ZEV-XSW-820

DILM580

DILM650

DILM750 –

DILM820

DILM1000 – –

DILM1600

DILH1400 – –

DILH2000

DILH2200 – –

5-29


5

Contactors and relaysContactors DIL

Accessories

Device DILE(E)M DIL7 to DILM170 DILM185 to DILM500

DILM580 to DILM2000AC DC

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)

Timer module to DILM32 to DILM32

1) Terminal cover to DILM1000.

5-30



5

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 systemDue 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 DCWith all DC contactors DILM a suppressor is integrated in the electronics.

• Plug-in suppressors ACWith 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 DILM170With 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.

• TerminalsUp 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

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:

• 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.

Universal voltage coilsThe DILM17 to DILM170 DC actuated contactors cover the entire DC control voltage range with only 4 control voltage variants.

Voltage toleranceContactors 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.

Rated actuation voltage

RDC24 24…27 V DC

RDC60 48…60 V DC

RDC130 110…130 V DC

RDC240 200…240 V DC

5-32



5

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 dimensionsThe 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.

Pick-up and holding powerThe 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.

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.

Rated power 1)

Contac-tor

Power consumption

Pick-up Hold-ing

7.5…15 kW

DILM17DILM25DILM32DILM38

12 W 0.5 W

18.5…37 kW

DILM40DILM50DILM65DILM72

24 W 0.5 W

37…45 kW

DILM80DILM95

90 W 1.3 W

55…90 kW

DILM115DILM150DILM170

149 W 2.1 W

1) AC-3 at 400 V

5-33



5

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.

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.

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).

5-34


Contactors and relaysOverload relays Z

5

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

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).

Normal operation (no fault) Three phase overload One phase drops outa Trip bridge b Differential barc Differential travel

97S

95

98 96

97 95

98 96

97 95

98 96

�

�

�

5-35



5

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

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.

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.

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.

2h100604020106421

4020106421

0.6

ZB12, ZB32, ZB65, ZE

1 1.5 2 3 4 6 8 10 15 20x Setting current

2-phaseSeco

nds

Min

utes

3-phase

2h100604020106421

4020106421

0.6

ZB150

6 8 1015 20 3 41 1.5 2x Setting current

2-phaseSeco

nds

Min

utes

3-phase

5-36



5

2 h100604020106421

4020106421

1 1.5 2 3 4 6 8 10 15 200.6

ZW7

Min

utes

Seco

nds

x Setting current

Minimum

Maximum

5-37


5

Contactors and relaysZEV 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.

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.

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.

5-38



5

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 faultThe 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 device1 to 820 A

Current sensors 1 to 25 A3 to 65 A10 to 145 A

Sensor belt40 to 820 A

5-39



5

Tripping characteristics Tripping characteristics for 3 phase loads

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 %.

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

20

CLASS 40

25

15

CLASS 510

tA100

50

20

10

5

2

1

20

10

5

2

10.7 1 2 5 8

3035

x Ie

ZEV

Min

utes

Seco

nds

5-40



5

Electronic motor-protective system ZEV with earth-fault protection and thermistor monitored motor

a Faultb Programmable contact 1c Programmable contact 2d Current sensor with A/D transducer e 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

L1L2L3N

96 06 0898

95 05 07A1 A2Y1 Y2 PEC1

Z1

Z2

C2

T2

T1 <

>

M3~

Reset

S1

S2 Q11

Q11

~=

97

I µP

Mode

Class

TestReset

Up

Down

L1

A

D

L2 L3

%

PE

Q11

a

f

d

e

b

c

5-41



5

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.

TNF= Nominal response temperature

a Tripping range IEC 60947-8b Re-switch on range IEC 60947-8c Tripping at 3200 O g 5 %d 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

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.

TNF–20°

TNFTNF–5°

750

4000

12000

1650

TNF+5°

TNF+15°

a

b

c

d

R [ ]

i [°C]

5-42



5

Electronic motor-protective system ZEV with short-circuit monitoring at the thermistor input

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.

a

L1L2L3N

96 06 0898

95 05 07A1 A2Y1 Y2 PEC1

Z1

Z2

C2

T1

T2 <

>

M3~

Reset

S1

S2 Q11

Q11

~=

97

I µP

Mode

Class

TestReset

Up

Down

L1

A

D

L2 L3

%

PE

IN1

M

IN2 IN3 11

A1 A2 12 14

S3

Q11

K1

5-43



5

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.

ZEV mounting and current sensor

• 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 conductorsDue to the fixing band the Rogowski sensor ZEV-XSW-820 is particularly easy to mount. And this saves the user time and money.

Wrap the band around the current conductors.

Engage the fixing pin.

Pull the fixing band tight and close with the velcro fastener.

Attaching the sensor coils a following diagram.

1123

1

2

3

5-44


Contactors and relaysThermistor machine protection device EMT6

5

EMT6 for positive temperature coefficient thermistor

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

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.

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.

Since all the units use the closed-circuit principle, they also respond to a broken wire in the sensor circuit.

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.

US

A1

A2

PTC

N

T1 T2

21 13

22 14

L

Power Tripped

US

A1

A2

PTC

N

T1 T2

21Y2Y1 13

22 14

L

+24

VPower Tripped

Rese

t

5-45



5

EMT6 as contact protection relay

Application example

Control of a storage tank heater

a Control circuitb Heater

Q11: Heater protection

Functional description

For this see circuit page 5-47.

Switching on the heaterThe 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.

Switching off the heaterThe 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.

L13 400 V 50 Hz

L2L3N

-Q1

L1

-Q11A2

A1 1 3 5

2 4 6

U V W

I > I > I >

400 V 50 Hzb

a

5-46



5

Open-circuit protectionA safety thermostat ensures fault isolation in the event of an open circuit in the sensor circuit of

K3. If, for example, limit value Tmax is not detected, the thermostat’s N/C contact F4 opens to switch off the power.

a Contact thermometer changeover contact

I-II position at T F Tmin

I-III position at T F Tmax

K1: Control voltage "On"

K2: Switch-on at T F Tmin

K3: Switch-off at Tmax

S0: Off

S1: Start

F4: Safety thermostat

230 V 50 Hz

-S0

-S1

-F4

-K1

-K2 -Q11

-Q11-K21313

1414

-K3

-K3EMT6 EMT6A2

T1 T2 A1 T2 T1 A1

A2

A1

21

22

A2-K1

N

A1 X1

X2A2- H1

II III

L1

-F1 4A

F

-K1

1424

1323

a

5-47


5

Contactors and relaysCMD contactor monitoring device

Operating principle

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

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

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

5-48



5

Circ

uit f

or D

OL

star

ters

aSw

itchi

ng b

y sa

fety

rela

y or

safe

ty P

LCb

Sign

al c

onta

ct to

PLC

eva

luat

ion

I >I >

I >

U <

M 3˜

-Q1

-Q1 -K

-S1-F1

-Q11

-X1 -M

1L1L2

L31.

13 21 22

1.14

-Q1113 14

-Q11

33 34

-Q11

21 22

-F2

CMD

-Q1D1 D2

D2

A1 A2

LS2

1S2

2S1

3S1

4S3

1S3

2

-Q11

A1 A2

T1 13

5

24

6

T2T3

L1L0

1L0

1

L02

L02

L2 PEU

VW

PEPE

L3

L1 L2 L3

-S2

13 14

-S3

21 22

13 14

a

b

TEST

5-49



5

Circ

uit f

or re

vers

ing

star

ters

aSw

itchi

ng b

y sa

fety

rela

y or

safe

ty P

LCb

Sign

al c

onta

ct to

PLC

eva

luat

ion

L1 L2 L3

L1 L2 L3

-Q1

-Q1 -K

-S1-F

1

-Q11

-X1 -M

1

-Q12

-Q11

-Q12

-Q11

-Q11

-Q12

-Q11

-F2

CMD

-Q12

-Q1

-Q11

L01

L01

L02

L02

PEPE

-F3

CMD

-S2

-S3

-S4

TEST

-Q12

-Q12

I >I >

I >

U <

M 3˜

L1L2

L31.

13 21 22

1.14

13 1413 14 21 22

13 14

43 4421 22

31 32

31 32 A1 A2

D1 D2

D2D1

D2

A1A1

A2

LL

S21

S22

S13

S14

S31

S32

A1 A2

T1 13

5

24

6

13

5

24

6

T2T3

UV

WPE

A2

13 14 21 22

21 22

13 14

a

b

43 4421 22

S21

S22

S13

S14

S31

S32

5-50


5

5-51


5

5-52


Motor-protective circuit-breakers

6

Page

Overview 6-2

PKZM01, PKZM0 and PKZM4 6-4

PKZM01, PKZM0 and PKZM4 – auxiliary contacts 6-7

PKZM01, PKZM0 and PKZM4 – releases 6-8

PKZM01, PKZM0 and PKZM4 – operating principle schematics 6-9

PKZ2 – overview 6-12

PKZ2 – remote operator 6-14

PKZ2 – release 6-16

PKZ2 – auxiliary switches, trip-indicating auxiliary contacts 6-17

PKZ2 – operating principle schematics 6-18

6-1


6

Motor-protective circuit-breakersOverview

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

PKZM01The 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

PKZM4The 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

PKZM0The 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.

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.

PKZ2PKZ2 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.

6-2

Motor-protective circuit-breakersOverview


6

PKZM01Circuit-breakerin surface mounting enclosure

PKZM0Circuit-breaker

PKZM4Circuit-breaker

PKZ2Circuit-breaker

PKZ2Compact starter

MSC-D DOL Starters

MSC-RReversing starters

6-3


6

Motor-protective circuit-breakersPKZM01, PKZM0 and PKZM4

The motor-protective circuit-breakers PKZM01, PKZM0 and PKZM4

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.

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.

6-4



6

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-TThe 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-...-CThe 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-PKZ0The 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

Individual and group protection with CL-PKZ0

Examples:

Use the BK25/3-PKZ0 for terminals > 6/4 mm2

For grouped connection with three-phase commoning link B3...PKZ0.Note utilization factors to IEC/EN 0660 500.

Iu = 63 A

l> l> l> l> l> l> l> l> l>

l> l> l>

PKZM0-16,PKZM4-16or

PKZM0-16/20,PKZM4-16/20or

PKZM0-20,PKZM4-20or

PKZM0-25,PKZM4-25

4 x 16 A x 0.8= 51.2 A

2 x (16 A + 20 A)x 0.8 = 57.6 A

3 x 20 A x 0.8= 50 A

3 x 25 A x 0.8= 60 A

6-6


Motor-protective circuit-breakersPKZM01, PKZM0 and PKZM4 – auxiliary contacts

6

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.

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.

Side mounted:

Integrated:

1.14 1.22

1.13 1.21

I >

1.13

1.14 1.22

1.21 1.31

1.32

1.13 1.21 1.33

1.14 1.22 1.34

1.53

1.54

1.61

1.62

1.53

1.54

I >

I >

"+"4.43 4.13

"I >"

4.44 4.14

4.21"I >""+"

4.31

4.32 4.22

6-7


6

Motor-protective circuit-breakersPKZM01, 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

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!

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.

U <

D1

D2

C1

C2

6-8


Motor-protective circuit-breakersPKZM01, PKZM0 and PKZM4 – operating principle schematics

6

Motor-protective circuit-breakers PKZM01, PKZM0 and PKZM4

Manually operated motor-starter

I > I > I >

L1 L2 L3

T1 T2 T3

-Q1

6-9



6

Motor-protective circuit-breakers with auxiliary switches and trip-indicating auxiliary contacts

PKZM01(PKZM0-...)(PKZM4...) + NHI11-PKZ0 + AGM2-10-PKZ0

For differential fault message(Overload or short-circuit)

I > I >I >

L1 L2 L3

-Q1

1.13 1.21

T1 T2 T3

4.44 4.32 4.22 4.14

4.43 4.31 4.21 4.13

1.14 1.22

E1: circuit-breaker ONE2: circuit-breaker OFF

E3: general fault, overload releaseE4: short-circuit release

4.43

4.44

X2

L1

-Q11.13

1.14

-Q11.21

1.22

-Q1 -Q14.13

4.14

-X1 1

X1 X1 X1 X1

-X1 2 -X1 3 -X1 4

-E1 -E2 -E3 -E4X2 X2 X2

-X1 5

N

6-10



6

Remote switch off via shunt release

High-capacity compact starter with auxiliary contact and shunt release

PKZM0-.../S00-.. + A-PKZ0Q11: Contact module

S1: OffS2: OnS3: Circuit-breaker On

I > I >I >

L1 L2 L3

21

22

13

14

A1

A2-Q11

-Q1

1.13 1.21

I>> I>>I>>

C2

C1 1.14 1.22

-X1PE

T1 T2 T3

-M1

U1 V1 W1

M3

1 2 3

L1

-Q1

-S1

1.13

1.14

21

22

13

14

-S2 -K113

14

A1

A2-Q11

N

13

14

-S3

C1

C2

-Q1

6-11


6

Motor-protective circuit-breakersPKZ2 – 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:

• 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

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:

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!

For an EEx e application, the normally closed contact 95–96 must be used to shed the contact module or contactor, to achieve disconnection.

6-12

Motor-protective circuit-breakersPKZ2 – overview


6

(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:

• 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.

• 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.

(High-capacity) contact module for 24 V DC control voltage

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.

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.

A1 13 21

2T1

4T2

6T3

A2 14 22

A1 13 21

2T1

4T2

6T3

A2 14 22

2T1

4T2

6T3

A1

A2

13

14 +24

V

2T1

4T2

6T3

I >> I >> I >>

6-13


6

Motor-protective circuit-breakersPKZ2 – 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:

• 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

f 15

f 300

f 15 t (ms)

F 30 F 30

t (ms)

t (ms)

0

I

0

I

0

I

CONTROL

CONTROL

CONTROL

LINE

ON

OFFMain contact

ON

ON

OFF/RESETOFF/RESET

6-14

Motor-protective circuit-breakersPKZ2 – remote operator


6

Remote operator RE-PKZ2

Remote operator RS-PKZ2

Off and Reset separate Off equals Reset

Off equals Reset

I >

L 72 74

T A20 A40 B20

72 74

L(+) N(-)

A20 A40 B20

33

34

I 0

72 74

L(+) N(-)

A20 A40 B20I 0

33

34

LINE

CONTROL

ON OFF RESET

LINE

CONTROL

ON OFF RESET

I >

L 72 74

T A20

72 74

L(+) N(-)

A20

33

34

72 74

L(+) N(-)

A20I 0

33

34

A30 A0

A30 A0

24 V

–

+

A30 A0

ON

LINE

CONTROL

OFF/RESETON

LINE

CONTROL

OFF/RESET 24 V~/

6-15


6

Motor-protective circuit-breakersPKZ2 – release

Voltage releases

Undervoltage release UUndervoltage 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.

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.

Shunt release A

U <

D1

D2 2.14

2.13 2.23

2.24

U <

D1 2.13

2.14D2

Shunt releases trip the circuit-breaker when a voltage is applied. These are an economic option for switching off remotely.

Shunt releases are suitable for AC and DC, and one version covers a wide voltage range.

C1

C2

6-16


Motor-protective circuit-breakersPKZ2 – auxiliary switches, trip-indicating auxiliary contacts

6

NHI standard auxiliary contacts

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.

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.

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.

NHI22

NHI11

1.13

1.14

1.21

1.22

1.211.13

1.14 1.22

1.31

1.32

1.43

1.44

PKZ 2(4)/ZM...

I >

or

I >

13

PKZ 2(4)/ZM.../S

A1

14

21

22A2

NHI 2-11SNHI 11S NHI 22S

1.131.13 1.21 1.13 1.31 311.21 431.431.21

1.141.14 1.22 1.14 1.32 321.22 441.441.22

I >>

"I >"

4.43 4.31 4.21 4.13

4.44 4.32 4.22 4.14PKZ 2(4)/ZM... AGM 2-11

"+"

I >

6-17


6

Motor-protective circuit-breakersPKZ2 – operating principle schematics

Motor-protective circuit-breaker consisting of:

• PKZ2 basic unit • Plug-in trip block Z

Compact starter, consisting of:

• Basic device• Trip block• Contact module SE1A...-PKZ2, which can be

attached and has the same contours, for operational switching

High-capacity compact starter, consisting of:

• Basic device• Trip block• High-capacity contact module fitted with

same contour profile

Circuit-breaker with current limiter fitted

-Q1

L1 L2 L3

I > I > I >

T1 T2 T3

–Q1

L1 L2 L3

T1

A1

A2

13

14

21

22

I > I > I >

T2 T3

-Q1

L1 L2 L3

T1

A1

A2

13

14

21

22

I >>

I >> I >> I >>

I >> I >>

T2 T3

-Q1

L1 L2 L3

T1

I > I > I >

T2 T3

I >> I >> I >>

6-18



6

On-off switching with remote operator

Separate actuation of OFF and RESET Circuit-breaker with remote operator, standard version.

Example 1: PKZ2/ZM-.../RE(...)

a Separate actuation of OFF and Resetb Resetc OFFd ONActuation by control circuit devices (for example pushbuttons NHI, AGM, VS3, EK...SPS with floating contacts).

Auxiliary switch for signalling the manual/automatic position of the remote operator. Indicates the automatic position when closed.

L1

�

� � �

N

-X11 2

72 74

-Q1

A20 A40 B20

-X14 5 6

-X13

-S1113

14-S01

13

14

-S2113

14

-X17

33

34

-X18

A20 A40 B20

72 74 33

34

-Q1

L1 L2 L3

T1 T2 T3

I > I > I >

-Q1

6-19



6

Common actuation of OFF and RESET Circuit-breaker with remote operator, standard version.

Example 2: PKZ2/ZM-.../RS(...)

a Off = Resetb Off/Resetc ONActuation by control circuit devices (for example pushbuttons NHI, AGM, VS3, EK...SPS with floating contacts).

Auxiliary switch for signalling the manual/automatic position of the remote operator. Indicates the automatic position when closed.

L1

N

-X19 10

72 74

-Q2A20 A40 B20

-X112 13

-X111

-S1213

14-S02

13

14

-X114

33

34

-X115

A20 A40 B20

72 74 33

34

-Q2

L1 L2 L3

T1 T2 T3

I > I > I >

-Q2

� �

�

6-20



6

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(...)

Actuation by PLC with 24 V DC electronic outputs.Auxiliary switch for signalling the manual/automatic position of the remote operator.

Indicates the automatic position when closed.

L1

N

-X21 2

72 74

-Q3

A20 A30 B20

-X23

ON

-X25

33

34

-X26

A20 A40 B20

72 74 33

34

-Q3

L1 L2 L3

T1 T2 T3

I > I > I >

-Q3

4

24 V

OFF/RESET

6-21



6

Circuit-breaker with remote operator

Actuation by control circuit devices. Example 4: PKZ2/ZM-.../RS(...)

S22: OnS23: Off/ResetActuation 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.

L1

N

-X27 8

72 74

-Q4

A20 A30 A0

-X29 10

-S22 -S2313

14 34

13

14

-X1 11

33

-X212

A20 A40 B20

72 74 33

34

-Q4

L1 L2 L3

T1 T2 T3

I > I > I >

-Q124 V

~/

6-22



6

Indication by auxiliary switches

Circuit-breaker with auxiliary contact and trip-indicating auxiliary contact.

Example: PKZ2/ZM-... + NHI11-PKZ2 + AGM2-11-PKZ2

For differential fault indication.

E1: Circuit-breaker OnE2: Circuit-breaker OffE3: General fault, Overload trippingE4: Short-circuit tripping

I > I > I >

-Q1

L1 L2 L3 1.13 1.21

1.14 1.22

4.43 4.31 4.21 4.13

4.44 4.32 4.22 4.14

T1 T2 T3

L1

-Q1 -Q1 -Q1 -Q1

-X1 -X1 -X1 -X11 2 3 4

X1X1X1X1

X2 X2 X2 X2

-E1 -E2 -E3 -E4

-X15

N

1.13

1.14

1.21

1.22

4.43

4.44

4.13

4.14

6-23



6

Use of the undervoltage release in the Emergency-Stop circuit

Motor-protective circuit-breaker with auxiliary contact and undervoltage release.

Example: PKZ2/ZM... + NHI22-PKZ2 + UHI-PKZ2

All poles of the Emergency-Stop circuit are isolated from the mains supply in the event of a power failure.

S1: Emergency-StopS2: Emergency-Stop

I > I >I >

L1 L2 L3

-Q1

1.13 1.21

1.14 1.22

-X1PE

T1 T2 T3

-M1

U1 V1 W1

M3

1 2 3

1.31 1.43

1.32 1.44

D2 2.14

U >

D1 2.13

L1

2.13

2.14

-Q1

D1

-S1

-S2

N

21

22

21

22

-Q1U <

D2

6-24



6

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

S1: OffS2: OnS3: Circuit-breaker Off

I > I >I >

L1 L2 L3

21

22

13

14

A1

A2

-Q1

1.13 1.21

I>> I>>I>>

C2

C1 1.14 1.22

-X1PE

T1 T2 T3

-M1

U1 V1 W1

M3

1 2 3

-Q11

L1

1.13

1.14-Q1

C1

-S1

-S2

N

21

22

A1

A2

-Q1

C2

-S3

-Q11

13

14

6-25



6

High-capacity compact starter with maximum number of auxiliary contacts fitted

Example: PKZ2/ZM.../S-PKZ2 + NHI2-11S-PKZ2

K1: Circuit-breaker OnK2: Circuit-breaker OffK3: Contact module Off

K4: Contact module OnK5: Contact module OnK6: Contact module Off

I > I >I >

I>> I>> I>>

L1 L2 L3

-Q1

1.13 1.21

1.14 1.22

-X1PE

T1 T2 T3

-M1

U1 V1 W1

M3

1 2 3

31 43

32 44

A1

A2-Q11

13 21

14 22

L1

-Q1 -Q1 -Q1 -Q11.13

1.14

1.21

1.22

43

44

13

14-Q11

21

22-Q11

-K1A1

A2-K2

A1

A2-K3

A1

A2-K4

A1

A2-K5

A1

A2-K6

A1

A2

N

13213143

14223244

13213143

14223244

13213143

14223244

13213143

14223244

13213143

14223244

13213143

14223244

31

32

6-26



6

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

Example: PKZ2/ZM.../RE + NHI11-PKZ2 + AGM2-11-PKZ2

S1: OnS2: OffS5: ResetQ1: Auxiliary contact, indication: manual-autoK1: Circuit-breaker OnK2: Circuit-breaker OffK3: Overload indicationK4: Short-circuit indication

I > I >I >

L1 L2 L3

-Q1

1.13 1.21

1.14 1.22

T1 T2 T3

72 74 33

A20 A40 B20 34

4.43 4.31 4.21 4.13

4.44 4.32 4.22 4.14

L1

1.13

1.14-Q1

1.21

1.22-Q1

4.43

4.44-Q1

-K1A1

A2-K2

A1

A2-K3

A1

A2-K4

A1

A2N

13212243

14313244

13212243

14313244

13212243

14313244

13212243

14313244

13

14

13

14-S1

13

14

-S2 -Q121

22A20 A40

72 74

B20

-Q14.13

4.14

-S2-S5

6-27



6

Circuit-breaker with current limiter in separate mounting

Example: PKZ2/ZM... + NHI11-PKZ2 with CL/EZ-PKZ2

K1: Circuit-breaker OnK2: Circuit-breaker Off

Q2: Current limiter, separate mounting

I > I >I >

L1 L2 L3

-Q1

1.13 1.21

I>> I>>I>>

1.14 1.22

-Q2

PE

T1 T2 T3

-M1

U1 V1 W1

M3

1 2 3

L1 L2 L3

T1 T2 T3

-X1

L1

-Q11.13

1.14-Q1

1.21

1.22

-K1A1

A2-K2

A1

A2

13

21

31

43

14

22

32

44

N

13

21

31

43

14

22

32

44

6-28



6

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

circuit-breaker thumb-grip remains in the “On” position. Circuit-breaker with trip block ZMR, high-capacity contact module S and NHI11-PKZ2.

Q11: ShutdownE1: Overload indication

Q11: High-capacity contact module

I > I >I >

L1 L2 L3

21

22

13

14

A1

A2

-Q1

1.13 1.21

I>> I>>I>>

1.14 1.22

-X1PE

T1 T2 T3

-M1

U1 V1 W1

M3

1 2 3

-Q11

T1 T2 T3

95

96

97

98

L1

-Q1 -Q195

96

-X1

-E1

N

-Q1

-Q11A1

A2

1.13

1.14

97

98

4

-X15

X2

X1

6-29


6

6-30


Circuit-breakers

7

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

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


7

Circuit-breakersOverview

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.

Switch-disconnectors without overload or tripping units are available in the same sizes as the circuit-breakers and can be fitted with

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.

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.

NZM1 NZM2 NZM3 NZM4

7-2

Circuit-breakersOverview


7

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.

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:

• 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.

IZM1 IZM2 IZM3

7-3


7

Circuit-breakersShunt releases

Shunt releases A (Q1)

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.

L1(L+)

-Q1

-S11

C1

C1C2

Q1

E1 -Q1

0

C2

N(L-, L2)

7-4


Circuit-breakersUndervoltage releases

7

Undervoltage release U (Q1)

Off-delayed undervoltage release UV (Q1)

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.

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.

N(L-, L2)

L1(L+)

D1

D2-Q1

-Q1

D1D2

E1

Q1 U<

U<

0-S11

L1(L+)

-S110

N(L-, L2)

-Q1

D2D1

D2

D1U<

Q1

-Q1E1

U<

7-5


7

Circuit-breakersContact diagrams of the auxiliary contacts

Auxiliary contact – standard HIN

Auxiliary contact – trip-indicating HIA

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

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).

0 r ISwitch-on0 R ISwitch-off+ R ITripQ contacts closedq contacts opened

L1L2L3

HIN

L1L2L3

HIN

L1L2L3

HIN

I

I

+ I

+

+

+

L1L2L3

HIA

L1L2L3

HIA

L1L2L3

HIA

+

+

+I

I

+I

7-6

Circuit-breakersContact diagrams of the auxiliary contacts


7

Auxiliary contact – early make HIV

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).

0 r ISwitch-on0 R ISwitch-off+ R ITripQ contacts closedq contacts opened

L1L2L3

HIV

I

I

++

+

+

I

L1L2L3

HIV

L1L2L3

HIV

NZM 1, 2, 3NZM1, 2, 3, 7

L1L2L3

HIV

L1L2L3

HIV

L1L2L3

HIV

I

I

+ I

+

+

+

NZM 10

I

I

++

+

+

I

L1L2L3

HIV

L1L2L3

HIV

L1L2L3

HIV

NZM 4

7-7


7

Circuit-breakersInternal circuit diagrams

NZM1

Maximum configuration:

NZM2

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.

1.11L1 L2 L3

T1 T2 T3

1.13

4.11

3.13

3.23

1.14

4.13

4.14

1.12

4.12

3.14

3.24

HIN

-Q1

HIA HIVI> I> I>

4.21

4.22

4.23

4.24

1.21

1.22

1.23

1.24

NZM

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

Details about the auxiliary contacts: a section "Maximum configuration:", page 7-8

L1 L2 L3

T1 T2 T3

1.13

4.21

3.13

3.23

1.14

4.23

4.24

4.22

3.14

3.24

HIN

1.41

1.43

1.44

1.42

-Q1

HIA HIVI> I> I>

1.11

1.12

...... 4.11

4.12

4.13

4.14

7-8



7

NZM3

NZM4

NZM7



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.

L1 L2 L3

T1 T2 T3

1.13

4.21

3.13

3.23

1.14

4.13

4.14

4.22

3.14

3.24

HIN

4.11

4.12

1.61

1.62

-Q1

HIA HIVI> I> I>

1.11

1.12

4.23

4.24

1.63

1.64

......

L1 L2 L3

T1 T2 T3

1.13

4.41

3.13

3.23

1.14

4.13

4.14

4.43

4.44

4.42

4.11

4.12

3.14

3.24

HIN

1.61

1.62

-Q1

HIA HIVI> I> I>

1.11

1.12

1.63

1.64

...... ... ...

L1 L2 L3

1.13

1.11

4.11

3.13

3.33

1.14

1.12

4.12

3.14

3.34

NHI RHI VHII> I> I>

-Q1

7-9



7

NZM10

NZM14

L1 L2 L3

1.13 1.21

1.43

1.31

4.13

4.21

4.43

4.31

3.21

3.13

3.33

1.14

1.22

1.44

NHI

I>

ZM(M)-

RHI VHI1.

32

4.14

4.22

4.44

4.32

3.22

3.14

3.34

-Q1

L1 L2 L3

1.12

1.11

1.21

4.11

1.14

1.22

1.24

4.12

4.14

NRHI003

I>

I>

-Q1

7-10


Circuit-breakersRemote switch-off with voltage releases

7

Remote switch-off with undervoltage releases

Remote switch-off with shunt releases

Terminal designation with NZM14

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.

N(L-, L2)

L1(L+)

L1(L+)

N(L-, L2)

-S.

-S.

D1D2

D2-Q1 U<

D1

-Q1

N(L-, L2)

L1(L+)

L1(L+)

N(L-, L2)

-S.

-S.

C1C2

1.131.14 -Q1

C1

-Q1HIN

1.13

1.14

C2

-Q1

-Q11.12

1.141.11

7-11

Circuit-breakersRemote switch-off with voltage releases


7

Main switch application in processing machines with Emergency-Stop function conform to the standard IEC/EN 60204-1, VDE 0113 part 1

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.

-S.

NZM

L1 L2 L3 N

-Q1E1

-Q1 U<

HIV-Q1

D1

D2

L1 L2 L3

HIV-Q1

E1

-Q1 U<

-Q1

NZM

D1

D2

-S.

3.14

3.13

7-12


Circuit-breakersApplication of the undervoltage release

7

Switch-off of the undervoltage release

Starting interlock of the undervoltage release

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.

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.

L1(L+)

N(L-, L2)

L1(L+)

N(L-, L2)

-Q1

-Q1

HIVD1D2

D1

D2

3.13

3.14

U<3.133.14

-Q1

L1(L+) L1

(L+)

N(L-, L2)

-S5

-Q1 U<

-S6 -Q11.14

D1

D2

1.13

-S6 -S5

N(L-, L2)

D1D2

1.131.14

7-13


7

Circuit-breakersShutdown of the undervoltage release -

Interlocking of several circuit-breakers using an undervoltage release

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.

Terminal marking for NZM14

D1

-Q1

D21.211.22

D1

-Q2

D21.211.22

L1(L+)

N(L-, L2)

-Q2

-Q1D1

D2U<

1.21

1.22-Q1

-Q2D1

D2U<

1.21

1.22

L1(L+)

N(L-, L2)

-Q1/Q21.12

1.141.11

7-14


Circuit-breakersIndication of the switch position

7

ON and OFF indication with auxiliary contact – standard HIN (Q1)

Tripped indication using trip-indicating auxiliary contact HIA (Q1)

P1: OnP2: Off

Trip-indicating auxiliary contacts for mesh network switches

P1: Tripped

Terminal designation with NZM14

L1(L+)

L1(L+)

N(L-, L+)

N(L-, L+)

-F0

1.13

1.14

X1

-P1 -P2X2

X1

X2

-Q1

L1(L+)

-F0

1.11

1.12

X1

-P1 -P2X2

X1

X2

1.141.22

1.21

-F0

1.21X1 X2

X1 X2-P1

-P2

1.131.14

1.22-Q1

N(L-, L2)

N(L-, L+)

L1(L+)

-P1X1

X2

-P1X1

X2

L1(L+)

N(L-, L2)

-F0

-Q1

-F0

4.134.14

4.13

4.14

-Q1

4.11

4.12

4.14

-Q1

7-15


7

Circuit-breakersShort-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.

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


0, 10, 50, 100, 150, 200, 300, 500, 750, 1000 ms

NZM14-... S(H)Standard circuit-breakers

NZM14-...S

NZM14-...H


100, 150, 200, 250, 300 msI>

I>

L1 L2 L3

-Q1

7-16


Circuit-breakersMesh network circuit-breakers

7

NZM1, NZM2, NZM3, NZM4, NZM7, NZM10, NZM14

Circuit with capacitor unit and shunt release 230 V, 50 Hz.

The capacitor unit which provides the energy for the shunt release of the mesh network

circuit-breaker can be configured independently of the circuit-breaker.

Connect NZM-XCM to the supply side!

a Mesh network relay

b Mesh network relay with low power contacts

18

19

20

2122

23

24

19

18

20L1

N 21

24

23

22

51 (C1)

a

HIN-NZM...

53 (C2)

230 V50/60 Hz

NZM-XCM

b

19USt24 V H

18

20

21

24

23

22

51 (C1)

HIN-NZM...L1

N

53 (C2)230 V50/60 Hz

NZM-XCM

7-17


7

Circuit-breakersRemote 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

NZM14

L1(L+)

N(L-, L2)

0P1

75

70 71

74

72

NZM-XR

I

L1(L+)

N(L-, L2)

P10

I

75

70 71

74

72

NZM-XR

L1(L+)

N(L-, L2)

P10

75

I

70 71

74

72

NZM-XR

HIA

L1(L+)

N(L-, L2)

0

70 71

74

72

R-NZM14

I

L1(L+)

N(L-, L2)

R-NZM14

70 71

74

72

0

I

L1(L+)

N(L-, L2)

RHI

R-NZM14

70 71

74

72

0

I

7-18


Circuit-breakersas a transformer switch

7

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

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 shunt releases Q1 Circuit-breakers with undervoltage releases Q1

L1(L+) L1

(L+)

N(L-, L2)

C1C2

Q1

N(L-, L2)

-S7-S7

C1

C2-Q1

L1(L+) L1

(L+)

N(L-, L2)

D1D2

Q1

N(L-, L2)

-S7-S7

D1

D2U<-Q1

7-19


7

Circuit-breakerswith 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:

• Persons against direct contact (basic protection),

• Persons against indirect contact (fault protection),

• Dangers of an earth fault (fire etc.)

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.

Part no. Rated current range

Ue IDn tv Sensi-tivity

A V A ms

NZM1(-4)-XFI30(R)(U) 15 – 125 200 – 415 0.03 – pulsat-ing cur-rentNZM1(-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 – AC/DC

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



7

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.

a Test button (T)b NZM1-(4)..., NZM2-4...c +NZM2-4-XFId NZM1-(4)-XFI

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…

NZM2-4-XFI…

0 + I

N L1 L2 L3

Q1

n tI v

I> I> I> I>

a

a

b

c

d

M22-K10 M22-K02

6.13

6.14

6.21

6.22

7-21



7

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:

• 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.

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.

230 V AC g 20 % 50/60 Hz3 V A

50/60 Hz 250 V AC 6 A

LOAD

N

NO C NC

L

L1 L2 L3 N

1S2

1S1

5 6 7 8

1 2 3 4

> 3 m – 50 m

7-22



7

Trip of circuit-breakers with shunt release and possible external reset of the relay by a pushbutton (NC contact)

5 6 7 8

1 2 3 4

L1

1S1

6 A

1S2

L2 L3N

PFR-W

LOAD

NZM.-XA... C2

C1

-S.

7-23



7

Trip of circuit-breakers with undervoltage release and possible external reset of the relay by a pushbutton (NC contact)

5 6 7 8

1 2 3 4

L1

1S1

6 A

1S2

L2 L3N

PFR-W

LOAD

NZM.-XU... D2

D1

-S.

U <

7-24


7

7-25


7

Circuit-breakersIZM circuit-breakers

Term

inal

ass

ignm

ent o

f the

con

trol

circ

uit p

lug

Cont

rol c

ircui

t plu

g IZ

M-X

KL(-A

V) fo

r cus

tom

er c

onne

ctio

nCo

ntro

l circ

uit p

lugs

X8,

X7,

X6,

X5

are

iden

tical

X8: O

ptio

nal c

ontr

ol c

ircui

t plu

g(S

tand

ard

for I

ZM...

-U...

XFR

rem

ote

rese

tL/

L+an

d IZ

M...

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)U

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tran

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mer

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tran

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e.g.

1)

a E

lect

roni

cIZ

M-X

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) N c

urre

nt tr

ansf

orm

erJu

mpe

r with

no

over

load

rele

ase

IZM

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(C) N

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rent

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mer

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onve

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mer

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rL1

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tern

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rnal

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mer

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24V

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24 V

DC

Pow

er su

pply

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em b

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em b

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ing

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tor,

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odul

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: Opt

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ith

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ase

X814 13 12 11 10 9 8 7 6 5 4 3 2 1

X714 13 12 11 10 9 8 7 6 5 4 3 2 1

DPWrite Free Free Close OpenOUTXA,XU

XEIN

1 2 3 4 5 6 7 8 9ExternalInternal

Enable – + – + – +

a

Inte

rnal

Term

inal

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7-26



7

X6: S

tand

ard

cont

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rst s

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ase

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”

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cut

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switc

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SN/

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X6 14 13 12 11 10 9 8 7 6 5 4 3 2 1 X5 14 13 12 11 10 9 8 7 6 5 4 3 2 1

Ma

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7-27



7

Auxi

liary

sw

itche

s

Wir

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iona

l aux

iliar

y sw

itch

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rd a

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swit

ches

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inal

s

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rnal

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e no

.

Term

inal

s

Leit

ungs

num

mer

XHI1

1(22

)(31)

: S3,

XH

I22:

S4

oder

XH

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S7,

XH

I40:

S8

opti

onal

e Zu

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, XH

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-Hilf

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Klem

men

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rn

Leit

ungs

num

mer

Klem

men

7-28



7

Sign

allin

g sw

itche

s

XHIB

XHIF

XHIS

1XH

ISXH

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XHIB

XHIF

XHIS

XAXH

IS1

XA1

XU

XUV

XHIA

de-energized

energized

de-energized

energized

X7.14

X7.12

X7.1

X7.3

X7.4

X7.6

X7.10

X6.6

X7-10

X6-6

Term

inal

s

Sign

al 1

st v

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ge r

elea

seen

ergi

zed

Sign

al 2

nd v

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ge r

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1, X

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V en

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zed

Wir

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.

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inal

s

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.

Inte

rnal

color color

“Rea

dy t

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ose”

sign

al

“Spr

ing

char

ged”

sign

al

Bell

swit

chal

arm

de-energized

energized

de-energized

energized

Klem

men

Mel

desc

halt

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ster

Spa

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slös

er X

AM

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scha

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zwei

ter

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nung

saus

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rXA

1, X

U o

der

XUV

Leit

ungs

num

mer

Klem

men

Leit

ungs

num

mer

Inte

rn

Eins

chal

t-be

reit

scha

fts-

mel

dung

Spei

cher

-zu

stan

ds-

mel

dung

Aus

gelö

st-

Mel

de-

scha

lter

Farbe / Farbe /

Reset

Trip

7-29



7

Volta

ge re

leas

e/el

ectr

ical

man

ual r

eset

Emer

genc

y-St

op o

r sho

rt te

rmin

als

XHIS

XAXH

IS1

XA1

XUXU

V

XA

Wir

e no

.

Wir

e no

.

Term

inal

s

Term

inal

s

Inte

rnal

color

1 st

shu

nt r

elea

seO

ptio

n: 2

nd s

hunt

rel

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or

unde

rvol

tage

rel

ease

or

unde

rvol

tage

rel

ease

wit

h de

lay

Leit

ungs

num

mer

Leit

ungs

num

mer

Klem

men

Klem

men

Inte

rnFarbe /

Opt

iona

l: XA

1 zw

eite

r A

rbei

tsst

rom

ausl

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erst

er A

rbei

tsst

rom

ausl

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nter

span

nung

saus

löse

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V U

nter

span

nung

saus

löse

r, ve

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7-30



7

Clos

ing

rele

ase/

elec

tric

al O

N

XEE

XE

XEE

XE

34

Term

inal

s

Wir

e no

.

Term

inal

s

Inte

rnal

Elec

tric

al "

ON

"Cl

osin

g re

leas

e

Wir

e no

.

Klem

men

Leit

ungs

num

mer

Klem

men

Inte

rn

Elek

tris

ch "

EIN

"Ei

nsch

altm

agne

t

Leit

ungs

num

mer

7-31



7

Mot

or o

pera

tor,

rem

ote

rese

t mag

net

XMS

XFR

XMXM

color

Mot

or o

pera

tor

Char

ging

mot

orop

tion

al: m

otor

cut

-off

sw

itch

XM

S

XFR

rem

ote

rese

t co

ilS

13 c

ut-o

ff s

wit

ch fo

rre

mot

e re

set

coll

color

Wir

e no

.

Term

inal

s

Inte

rnal

Wir

e no

.

Term

inal

s

Farbe /

Mot

oran

trie

bM

otor

antr

ieb

Opt

iona

l: M

otor

abst

ells

chal

ter

XMS

Leit

ungs

num

mer

Klem

men

Inte

rn

Leit

ungs

num

mer

Klem

men

XFR

Fern

-Rüc

kset

zmag

net

S13

Abs

tells

chal

ter

für

Fern

-Rüc

kset

zung

Farbe /

7-32



7

Prot

ectiv

e ci

rcui

ts fo

r ove

rcur

rent

rele

ase

with

bre

aker

sta

tus

sens

or a

nd m

eter

ing

mod

ule

1)Te

rmin

atio

n re

sisto

r on

X8-1

/X8-

2, if

no

exte

rnal

syst

em b

us m

odul

e.2)

Whe

n no

met

erin

g m

odul

e an

d al

so n

o BS

S m

odul

e is

used

: dire

ct c

onne

ctio

n X8

to X

ZM...

XZM

...

1)

+

-

- +

S42/

S43

S45

Trip

mag

net

for

over

curr

ent

rele

ase

Ove

rcur

rent

rele

ase

Inte

rnal

Term

inal

s

Internal system bus

Brea

ker

Stat

us S

enso

rIn

tern

al s

yste

m b

usM

eter

ing

mod

ule

Met

erin

g m

odul

e

Volta

ge tr

ansf

orm

er

BSS

mod

ule

G s

enso

rN

sen

sor

N-W

andl

erG

-Wan

dler

Aus

löse

mag

net

für

Übe

rstr

omau

slös

ung

Elek

tron

isch

erÜ

bers

trom

ausl

öser

Inte

rn

Klem

men

Interner Systembus

Inte

rner

Sys

tem

bus

Mes

smod

ul

Mes

smod

ul

Span

nung

swan

dler

BSS-

Mod

ul

7-33



7

Prot

ectiv

e ci

rcui

ts fo

r ove

rcur

rent

rele

ase,

met

erin

g m

odul

e on

ly

1)Te

rmin

atio

n re

sisto

r on

X8-1

/X8-

2, if

no

exte

rnal

syst

em b

us m

odul

e (a

figur

e, p

age

7-26

).

XZM

...

1)

- +

+

-

Inte

rnal

Term

inal

s

Internal system bus

Trip

mag

net

for

over

curr

ent

rele

ase

Ove

rcur

rent

rele

ase

Inte

rnal

sys

tem

bus

Met

erin

g m

odul

e

Met

erin

g m

odul

e

Volta

ge tr

ansf

orm

erG

sen

sor

N s

enso

r

Inte

rn

Klem

men

Interner Systembus

Aus

löse

mag

net

für

Übe

rstr

omau

slös

ung

Elek

tron

isch

erÜ

bers

trom

ausl

öser

Inte

rner

Sys

tem

bus

Mes

smod

ul

Mes

smod

ul

Span

nung

swan

dler

G-W

andl

erN

-Wan

dler

7-34



7

Prot

ectiv

e ci

rcui

ts fo

r ove

rcur

rent

rele

ase,

bre

aker

sta

tus

sens

or o

nly

1)Te

rmin

atio

n re

sisto

r on

X8.1

/X8.

2, if

no

exte

rnal

syst

em b

us m

odul

e (a

figur

e, p

age

7-26

).

XZM

...

1)

+

-

- +In

tern

al

Term

inal

s

Trip

mag

net

for

over

curr

ent

rele

ase

Ove

rcur

rent

rele

ase

BSS

mod

ule

Inte

rnal

sys

tem

bus

Brea

ker

Stat

us S

enso

r

Internal system bus

G s

enso

rN

sen

sor

Inte

rn

Klem

men

Aus

löse

mag

net

für

Übe

rstr

omau

slös

ung

Elek

tron

isch

erÜ

bers

trom

ausl

öser

BSS-

Mod

ul

Inte

rner

Sys

tem

bus

Brea

ker

Stat

us S

enso

r

Interner Systembus

N-W

andl

erG

-Wan

dler

7-35


7

7-36


All about Motors

8

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


8-2

All about Motors

8

Page

Three-phase current-automatic stator starters 8-91

Three-phase automatic rotor starters 8-96

Switching of capacitors 8-100

Duplex pump control 8-104

Fully automatic pump control 8-106

Off position interlock of the loads 8-110

Fully automatic main transfer switch with automatic reset 8-111


All about MotorsMotor protection

8

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

8-3

http://www.moeller.net/en/support/slider/index.jsp



8

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.

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.

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.

8-4



8

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.

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.

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.

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).

1 pole 2 pole

8-5



8

Pick-up times

Response limits of time-delayed overload relays at all-pole load.

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.

Type of overload relay

Multiple of current setting Refer-ence ambi-ent temper-ature

At > 2 h starting from cold state of relay

Bt F 2 h

CTripping class

10 A102030

Tripping time in minutesF 2F 4F 8F 12

DTripping class

10 A102030

Tripping time in seconds

2 < T F 104 < T F 106 < T F 209 < T F 30

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

8-6



8

Response limits of 3-pole thermal overload relays at 2-pole load

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.

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.

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

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.

Type of thermal overload relay

Multiple of current setting Reference ambient temperature

At > 2 h, starting from cold state of relay

Bt F 2 h

Ambient temperature compensated, without phase-failure sensitivity

3 poles 1.0 2 poles1 pole

1.320

+ 20 °C

Non-ambient temperature compensated, without phase-failure sensitivity

3 poles 1.0 2 poles1 pole

1.250

+ 40 °C

Ambient temperature compensated, with phase-failure sensitivity

2 poles1 pole

1.00.9

2 poles1 pole

1.150

+ 20 °C

8-7



8

Type 1 coordinationIn 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 coordinationIn 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

Heavy starting dutyAn 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 ZW7The ZW7 consists of three special saturable core current transformers, supplying an overload

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 currentThe setting ranges quoted in the Moeller Main Catalogue, Industrial Switchgear apply when the incoming cable is looped once through the transformer relay.

8-8



8

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 directionChangeover time with overload relay in positionA: < 15 s B: > 15 < 40 s C: > 40 s

Setting of the overload relay0.58 x Ie 1 x Ie 0.58 x IeFull motor protection in Y (star) position

Only partial motor protection in y position

Motor not protected in Y (star) position

-Q11A

-Q15 -Q13

Ie

-Q11

B

-Q15 -Q13

Ie

-Q11 -Q15 -Q13

Ie

C

8-9



8

Heavy starting duty

Multi-speed switches2 speeds2 separate windings

One tapped winding 3 speeds1 x tapped winding+ 1 winding

Attention must be paid to short-circuit protection of the overload relays.Separate supply leads should be provided if required.

-Q17 -Q21 -Q17-Q23 -Q21 -Q17-Q23 -Q21-Q11

Current transformer-operated overload relays ZW7

Bridging of motor protection during starting

Bridging during starting using bridging relay

For medium and large motors

For small motors; no protection during starting

Automatic cut out

-Q11 -Q11 -Q12 -Q11 -Q12

8-10



8

Individually compensated motor

Capacitor connected

Ie = Rated motor operational current [A] Iw = Iw = Active current Proportion of motor

Ib =Ib = Reactive current rated operational current [A]Ic = Rated capacitor current [A] Ic =

IEM = Setting current of overload relay [A] Ic = cos v = Motor power factorUe = Rated operational voltage [V]Pc = Rated capacitor output [kvar]C = Capacitance of capacitor [mF]

Iexy A[ ]

} Ie2

Iw2– A[ ]

Ue 3 2πf C 10 6– A[ ]××××Pc 103×

3 Ue×------------------

to contactor terminals to motor terminals

Setting IEM of overload relay

Capacitor does not relieve loading of cable between contactor and motor.

Capacitor relieves loading of cable between contactor and motor; normal arrangement.

-Q11PC

IEM

-Q11

PC

IEM

IEM 1 Ie×= IEM Iw2 Ib Ic–( )+ 2=

8-11



8

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.

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 motorsMotors 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.

• Rotor-critical motorsSquirrel-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.

8-12



8

Protection of current and temperature-dependent motor-protective devices

+ Full protection(+) Partial protection- No protection

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 – + +

8-13


8

All about MotorsEngineering notes

Three-phase automatic startersAutomatic stator starters three-phase current with startup resistorsSingle 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 transformersThis 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 resistorsResistors 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.

I: Line currentMd: Torquen: Speeda Reduction of the line currentb Reduction of the torque

a

b

20 40 60 80n

100 %

II

I'

Md

Md

M'd

a

20 40 60 80 100 %

b

n

II

I'Md

Md

M'd

20 40 60 80 100 %n

I Md

8-14



8

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

Switching of capacitors

DIL contactors for capacitors – individual switching

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

less than 50 V within a minute of the capacitor being switched off.

Individual compensation Group compensation

L1...3

-F1

-Q11 -Q31

-M1

-C1M3

L1...3

-F1

-Q11

-M1

-C1 M3

M3

M3

-M2 -M3

8-16



8

Contactor for capacitor DILK… – Individual and group compensation

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 reactorsFrequently 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.

Group compensation

a Additional inductance with standard contactor

L1...3

-F1

-Q11

M3

-F2 -F3

-Q12 -Q13

-Q1

M3

M3

-Q31 -Q32a

-C0 -C1 -C2

-M1 -M2 -M3

I >

8-17


8

All about MotorsCircuit 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 purpose

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.

Classification according to the type of representation

Simplified or detailed

• Single-line or multi-line representation• Connected, semi-connected or separate

representation• Topographical representationIn 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

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.

8-18

All about MotorsCircuit documents


8Wiring 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”.

Circuit diagram: 1-pole and 3-pole representation

M3 ~

Q1

Q11 Q121 3 5

2 4 6

1 3 5

2 4 6

M3 ~

U V W

PE

Q12

1 3 5

2 4 6

L1L2L3

13

14Q

Q11

L1, L2, L3

I > I > I >I >

8-19


8

All about MotorsPower supply

4-conductor system, TN-C-Sa Protective earth conductor

Protective earth terminal in enclosure (not totally insulated)

Overcurrent protective device in the supply is required for compliance to IEC/EN 60204-1

5-conductor system, TN-Sa Protective earth conductor

Protective earth terminal in enclosure (not totally insulated)

Overcurrent protective device in the supply is required for compliance to IEC/EN 60204-1

L1 L2 L3 N PEN

PE

NL31L21L11

�

NL31L21L11

L1 L2 L3 N PE

�

8-20



8

3-conductor system, IT

Overcurrent protective device is required in the supply for compliance to IEC/EN 60204-1For all systems: use the N conductor only with the agreement of the user

Separate primary and secondary protection

Earthed control circuit. In non-earthed control circuit, remove link and provide insulation monitoring.

L31L21L11

L1 L2 L3

PE

1

L1L3

5

2

3

64I�

L01L02

0

I� I�

8-21



8

Combined primary and secondary protection

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).

L1L3

1 5

2

3

64

I> I> I>

L01L02

0

8-22


All about MotorsControl circuit supply

8

Separate primary and secondary protection, with insulation monitoring on the secondary side

a Clear buttonb Test button

DC power supply with three-phase bridge rectifier

L1

L3

1 5

2

3

64

I. I. I.

L011

PE

0

L02

L01

A1

R <

A1

L 15

A2

15 S1 S2 E

E

E

16

16 18

18 L A2

ab

L2

L1

L3

1 5

2

3

64I� I� I�

L2

Yy0

– +

8-23


8

All about MotorsContactor 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

contactor with anticlockwise rotation for high speed).

The following table shows the marking used in this Wiring Manual and in Moeller circuit documentation.

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.

Type of component

Mains contactors Step contactors

Standard motor 2 speed/4 speed

3 speed

One speed Low speed High speed

For-ward Up Hoist

Re-verse Down Lower

For-ward Up Hoist

Re-verse Down Lower

For-ward Up Hoist

Re-verse Down Lower

Star Delta Start-ing stage

Notes

DIL (/Z) Q11

DIUL (/Z) Q11 Q12

SDAINL (/Z) Q11 Q13 Q15

SDAIUL (/Z) Q11 Q12 Q13 Q15

UPIL (/Z/Z) Q17 Q21 Q23

UPIUL (/Z/Z) Q17 Q18 Q21 Q22 Q23

UPSDAINL (/Z) Q17 Q21 Q23 Q19

U3PIL (/Z/Z/Z) Q11 Q17 Q21 Q23

UPDIUL (/Z) Q17 Q21

ATAINL (/Z) Q11 Q13 Q16 to Qn

1-n start-ing stages

DAINL Q11

DDAINL Q11

DIL + discharge resistors

Q11 Q14

DIGL + discharge resistors

Q11

8-24


All about MotorsDirect-on-line start of three-phase motors

8

Typical circuits with DIL contactors

Fuseless without overload relayShort-circuit protection1) and overload protection by means of PKZM motor-protective circuit-breaker or NZM circuit-breaker.

Fuses with overload relayShort-circuit protection2) for contactor and overload relay by means of fuses F1.

Short-circuit protection3) for contactor by means of fuses F1.

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)

L1 L3

1 5

2

3

64

L2

13

14

1 53

2 64

-Q1

PE

U V W

-Q11

M3

-M1

I > I > I >

L1 L3L2

1 53

2 64

PE

U V W

-Q11

M3

-M1

-F1

-F22 64 96

9597

98

L1 L3L2

1 53

2 64

PE

U V W

-Q11

M3

-M1

-F1

-F2

96

9597

98

8-25



8

Typical circuit with bridging of overload relay during starting

Control circuit device I: ON0: OFFFor 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

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.

Without overload relay with overload relay

The short-circuit capacity of the contacts in the circuit has to be considered when selecting F0.Double actuator

L1(Q11/1)

-Q113

14

21

220

-S1113

14

13

14-Q11

A1

A2

-Q11

N

-F0

I

L1(Q11/1)

95

96

21

22

13

14

-F2

0

-S11

I

13

14-Q11

A1

A2-Q11

N

-F0

21 22

131496

1413 141321 22

Q11 Q11F2

0 I

A B

8-26



8

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 L3

2 64

L2

1 53

2 64

-F1

PEU V W

-Q11

M3

-M1

-F2

2 64

1 53

9698

97 95

-Q14

8-27



8

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

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.

Q14:Bridging contactorK1: Timing relaysQ11:Mains contactor

Control circuit deviceI: ON0: OFFFor connection of further control circuit devices a section "Pulse encoder", page 8-37

-Q11

-Q14 -Q14 -Q11

-K1

-K1

L1 (Q11/1)

-F295

96

21

22

0

-S11

16

15

13

14

-Q11A1

A2-Q14

N

-F0

13

14-Q1

13

1413

14 43

44

21

22

A1

A2

A1

A2

I

Q14 Q1196 2214

13 14

21

22

13 14

21 22

F2

0

-S11

I

A B

8-28



8

Two directions of rotation, DIUL reversing contactor

Fuseless without overload relayShort-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.

Fuses with overload relaysShort-circuit protection1) for contactor and overload relay by means of fuses F1.

Short-circuit protection1) for contactor by means of fuses F1.

1) Fuse size in accordance with data on the rating plate of the overload relay F2

L1 L3L2

1 53

2 64

U V W

M3

-M1

-Q1

1 53

2 64

1 53

2 64-Q11 -Q12

13

14

PE

I > I > I >

L1 L3L2

1 53

U V W

M3

-M1

2 64-Q11 -Q12

1 53

2 64

2 64

-F1

-F2

PE

96

97 95

98

L1 L3L2

U V W

M3

-M1

2 64-Q12

1 53

2 64

-F1

PE

-F2

-Q111 53

8-29



8

Changing direction of rotation after actuation of the 0 push-button

Changing direction of rotation without actuation of the 0 push-button

Q11: Mains contactor, clockwiseQ12: Mains contactor, anticlockwise

Control circuit device(three-way pushbutton)I = Clockwise0 = StopII = Anticlock-wise

-Q11 -Q12

-Q11

-Q11

-Q12

95

96

21

22

13

14

21

22

13

14

13

1413

14

21

22

13

14

A1

A2

A1

A2

21

22

21

22

L1(Q11/1)

0

-S11

-Q12

N

-F0

-Q1

I

I

II

-F2

II

-Q11 -Q12

-Q11

-Q11

-Q12

95

96

21

22

13

14

13

1413

14

21

22

A1

A2

A1

A2

21

22

21

22

13

14

21

22

13

14

L1(Q11/1)

0

-S11

-Q12

N

-F0

-Q1

I

I

II

-F2

II

Q12

0

-S11

I

Q12

21 22

13 14Q11

96F2

1413 1413

21 22

A B

1413

C

21 22

13II

Q12 Q12Q111314Q11

96F2

13 14

-S11 21

221413 1413

21

22

A B

1413

C

21 22

0I II

8-30



8

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 speedRETRACT: high speed onlySTOP: tapped winding

1 53

L1 L3L2

-F1

2 64

PE

M3

-M1

97 95

98 96

1 53

2 64

1 53

2 64

2 64 2 64

2 64

1 53

-F297 95

98 96

-F21

-Q23

1U

1V

1W

2U

2V

2W

-Q17 -Q22 -Q21

8-31



8

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.

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.

0: StopI : Low speed – FORWARD

(Q17)II: High speed – FORWARD

(Q21 + Q23)III: High speed – BACK

(Q22 + Q23)

Q17: Feed forwardQ21: High speed forwardQ23: Star contactorK1: Contactor relayQ22: Retract high speed

L1 (Q17/1)

-F2/F2195

96

21

22

0

-S11

13

14

A1

A2N

-F0

13

14

44

21

22

III

21

22

13

14

22

21

I13

I

II

14

21

-Q22

-Q21

-Q23

-Q17 -Q21

-Q23

31

32

-Q17 -Q17

-Q22

-Q23A1

A2

22

21

A1

A2

13

14

-Q17

22

21-K1 -Q21

-K1

-K1

13

14

A1

A2-Q22

-Q23

-K1

A1

A2

43

43

44

31

32

31

32

21

22

-Q2113

14-Q22

13

14

21

22

III

22

II

8-32


All about MotorsDirect switch-on with PKZ2 motor-protective circuit-breaker

8

Reversing

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.

L1 L3L2

U V W

M3

-M1

-Q1

-Q11

I > I > I >

13

14

T1 T3T2

L1 L3L2

T1 T3T2

L1 L3L2

-Q1213

14

21

22

I>> I>>I>>

A1

A2

21

11

T1 T3T2

A1

A2

I>> I>> I>>

8-33



8

a Stop

a remove links with position switches

Q12Q12 Q12

L1(Q11/1)

-Q1

21

220

-S11

13

14

I

A1

A2

-Q11

-F0

-Q12

-Q11

-Q11

-Q12

21

22

-S11

Q11

21

22

13Q11

1413

1313Q11

13Q1214

0I 0I II

-S11

A B C

II

141321

22

21

221413

1.13

1.14

II21

22

13

14

13

14

13

14

21

22

21

22

A1

A2

-Q12

Q11.14 14 14

L1(Q11/1)

A B C

21

221413 1413

21

22

21

221413

-Q1

21

220

-F01.13

1.14

-S11

21

22II

21

22

13

14

21

22

13

14

I

-Q11 -Q1213

14

13

14

-Q12 -Q1121

22

A1A1

A2A2

-Q12-Q11

N N

a a

S11 RMQ-Titan, M22-…

Q1 PKZ2/ZM-…

Q12 S/EZ-PKZ2

Q11 S/EZ-PKZ2

F0 FAZ

-Q11

-Q12

14 14

13 13

22 22

21 21-Q11

-Q12

a

8-34



8

Two speeds

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.

-Q1

M3

-M1

1U

1V

1W

2U

2V

2W

L1 L3L2

-Q21

T1 T3T2

-Q17A1

A2

2113

L1 L3L2 1.13 1.21

1.14 1.22

L1 L3L2 1.13 1.21

1.14 1.22

-Q2

2214

T1 T3T2

A1

A2

2113

2214

T1 T3T2

I > I >I >I > I > I >

I>> I>>I>> I>> I>>I>>

n < n >

1W 1V

1U

2W 2V

2U

8-35



8

Version 1 Version 2Q21

13Q17

13Q2114

Q21.14

0I II

Q213

Q17

0I II1.14

L1(Q17/1)

-F0

-Q1

0

-S11

I

II

21

22

1.13

1.14

21

22 21

22

13

14

-Q1713

14

21

221413

-S11

A B1413

21

22

1413

13

14

13

14

21

22

A1

A2

N

-Q21.13

1.14

22

21

n>

n<-Q21

-Q21

-Q17

-Q17

-Q21

21

22

A1

A2

n>n<

C

L1(Q17/1)

-F0

-Q1

-Q2

021

22

1.13

1.14

1.13

1.14

-S11

Q1714

Q2114

Q21

21 221413

A B

141321

22

1413

22

21

C

-S11 II

n>

I

n<

21

22 21

22

13

1413

14

-Q1713

14

13

14

-Q21

-Q21 21

22

-Q1721

22

-Q17A1

A2

-Q21A1

A2

N

n>n<

13

Stop Stop

S11 RMQ-Titan, M22-… –

Q1, Q2 PKZ2/ZM-…/S –

Q21 S-PKZ2 n >

Q17 S-PKZ2 n <

S11 RMQ-Titan, M22-… –

8-36


All about MotorsControl circuit devices for direct-on-line start

8

Typical example of circuits with contactors DILM…

Pulse encoder

Illuminated pushbutton actuators

Two two-way pushbuttons

Double actuator pushbutton with indicator light

T0-1-15511 spring-return switch with automatic return to position 1

T0-1-15366 spring-return switch with automatic return to rest position

Maintained contact sensors

Changeover switch T0-1-15521 with fleeting contact in the intermediate position

MCS pressure switches

0 IQ11

21

1314Q11

96F2

13 14

Q11A2

13 14

2122 22

X1 X2

0 I

Q111314Q11

96F2

13 14

21 22

-S11

I 0

-S11

13 14

21 22 21 22 21 22

13 14 13 14

A B BA

0

Q111314Q11

96F2

1314

2122

I

2122

1314

A B C

Q11A2

0

Q111314

Q1196F2

1

01

21

34

S11

Start

Start

Q111314

Q1196F2

0 1

21

34

I

0 1I

S11

Start

Q111314Q11

96F2

21

34

I ON0OFF

0 1

S11

Q11A1

F296

-S12

2

1

4IP >

8-37


8

All about MotorsStar-delta switching of three-phase motors

Star-delta starters with overload relay

Arrangement in the motor lineIn 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 lineInstead 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.

1 53

U1 V1 W1

2 64-Q11

2 64-F2

96

97 95

98

2 64-Q11

-F296

97 95

98

-F1

2 64

1 53

U1 V1 W1

8-38



8

Configuration in the delta circuitInstead 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.

2 64

-Q15

-F296

97 95

98

2 64

1 53

U2W2V2

-Q131 53

2 64

8-39



8

Automatic star-delta starters SDAINL

Arrangement and rating of protective devices

Rating of switchgearQ11, Q15 = 0.58 x IeQ13 = 0.33 x Ie

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

M3

-M1

U1

V1

W1

W2

U2

V2

L1 L3L2

2 64-Q15

-F296

97 95

98

2 64

1 53

-Q131 53

-F1

1 53

2 64

1 53

2 64

-Q11

B

-Q1

A

PE

2 64

13

14

21

22

I > I >I >

8-40



8

Further notes on the configuration of the overload relay a section "Automatic star-delta starters SDAINL", page 8-40.

SDAINLM12 to SDAINLM55Pushbutton actuators

K1: Timing relay approx. 10 sQ11: Mains contactorQ13: Star contactorQ15: Delta contactorDouble actuator

FunctionPushbutton 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.

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.

SDAINLM70 to SDAINLM260

S110

(–)N

Q11

Q13

Q13

Q15

K1

I

Q11

Q11

Q15Q13

K1

Q15

N Y

K1

21

22

13

14

A2

A1

A2

A1

53

54

22

21

28

1717

18

14

13

53

54

53

54

A2

A1

A2

A1

22

21

S110

(–)N

Q11

Q13

Q13

Q15

K1

I

Q11

Q11

Q15Q13

K1

Q15

N Y

K1

21

22

13

14

A2

A1

A2

A1

13

14

22

21

28

1717

18

14

13

13

14

43

44

A2

A1

A2

A1

22

21

8-41



8

SDAINLM12 to SDAINLM260 Two-wire control

Double actuatorControl circuit deviceI = ON0 = OFF

For connection of further control circuit devices a section "Control circuit devices for star-delta starting", page 8-51

44

2

43 13

14

L1 (Q11/1)

-F0

95

96-F2

13

14

13

14

-S14

-Q11 -Q13 -Q15

-Q11

-S14MCSP >

24

1

SWQ

1

Q11

21 22

1314Q11

96F2

0 I

1413 141321 22

A B

-S11

HAND

8-42



N

8

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

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.

Automatic star-delta starters SDAINL EM

Pushbutton actuators Maintained contact sensors

K1: Timing relay approx. 10 sQ11: Mains contactorQ13: Star contactorQ15: Delta contactor

Double actuatorControl circuit deviceI = ON0 = OFF

L1 (Q11/1)

-F295

96

0

-S11

13

14

A1

A2

-F0

44

21

22

2

13

14

I

-Q11

-Q15

-K1A1

A2

A1

A2

A1

A2-Q15-Q13

43

44

43-Q11 -Q13

-F0

95

96

-F2

13

14

-S14

13

1413

14

-Q1

-Q1114

13

22

21-Q13

-Q11

-S14MCS

24

1

SWQ

-K1

22

21

16

15

18 -Q13

1

L1 (Q11/1)

Q11

21

22

4414Q11

96F2

0 I

1413 141321 22

A B-S11

-Q11

P >

HAND

8-43



8


FunctionPushbutton 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.

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.

8-44



8

Automatic reversing star-delta starter SDAIUL

Reversing

Rating of switchgearQ11, Q12: Ie

F2, Q15 : 0,58 x IeQ13 : 0,33 x IeThe 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

Standard version: Relay current = motor rated current x 0.58

For other arrangements of overload relay a section "Star-delta starters with overload relay", page 8-38

M3

-M1

U1

V1

W1

W2

U2

V2

L1 L3L2

2 64-Q12

-F296

97 95

98

2 64

-Q151 53

-F1

1 53

2 64

1 53

2 64-Q11

-Q1

PE

2 64

131 3 5

14

21

22

-Q131 53

2 64

I > I > I >

8-45



8

Changing direction of rotation after actuation of the 0 pushbuttonThree-way pushbuttonControl circuit devicesI = Clockwise0 = StopII = Anticlockwise

L1 (Q11/1)

-F2

0

-S11

A1

A2

N

-F0

44

13

14

II

-Q11 -K1A1

A2-Q15-Q13

43

44

43-Q11

-Q1

-Q11

-Q11

I

21

22

95

96

21

22

-Q12

13

14

13

14-Q12

-K1-K1

-Q1213

14

13

14

II

I21

22

21

22

A1

A2

-Q15 -Q1321

22

-Q12A1

A2

A1

A2

21

22

21

2218

17

28

17

0

Q1213 14Q11

96F2

13 14

21 22

I

13 14

A B C

13Q12

II

13 14

21 22 21 22

-S11

8-46



8


FunctionPushbutton 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.

Changing direction of rotation without actuation of the 0 pushbuttonThree-way pushbuttonControl circuit devicesI = Clockwise0 = StopII = Anticlockwise

L1 (Q11/1)

-F2

0

-S11

A1

A2

N

-F0

44

13

14

II

-Q11 -K1A1

A2-Q15-Q13

43

44

43-Q11

18

17

-Q1

-Q11

-K1

-Q11

I

21

22

95

96

21

22

-Q12

13

14

13

14-Q12 -Q12 13

14

13

14

II

I21

22

21

22

A1

A2

-K1

-Q15 -Q1321

22

-Q12A1

A2

A1

A2

21

22

21

2228

17

21

22

13 14 96

1413 1413

Q11Q11 F2

0I

A B

13Q12

14Q12

II

-S11 21 22 21 221413

C

8-47


8

All about MotorsStar-delta starting with motor-protective circuit-breakers PKZ2

With Icc > Icn short-circuit proof installation required.

L1 L2 L3

L1

-Q1

L2 L3

T1 T2 T3

L1 L2 L3

T1

13 21

14-Q11 -Q15 -Q13

22

13 21

14 22

T2 T3

1U

1V

1W

2V

2W

2U

-M1

L1 L2 L31 3 5

2 4 6

T1 T2 T3

Q13A1 13 21

14A2 22

L1

U F 690 V

U F 500 V

L2 L3

T1 T2 T3

1.13 1.21

1.14 1.22

A1

A2

A1

A2

M3

I>> I>> I>>

I>> I>> I>> I>> I>>I>>

I > I > I >

8-48



8

2 x RMQ-Titan, M22-… with indicator light M22-L… T0-1-8 rotary switch

L1(Q11/1)

-F0

1.13

1.1421

22

13

14

14

13

14

13

44

43

A1

A2

-Q1

-S11 -Q11

-Q11

-K1A1

A2

A1

A2

A1

A2-Q11

22

21

22

15

1816

21

-Q13

-Q13

-Q15

-Q15

10 s N YN

-Q13 -K1

A2

0

I

S11

1413

2221

1413

2221

A B

Q1

0 I1.14Q11 Q11 Q1143 A214 44

0 1

S11

Q1144

Q11.14

1234

Q1114

8-49



8

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

8-50


All about MotorsControl circuit devices for star-delta starting

8

Automatic star-delta starters SDAINL

Pulse encoder

Illuminated pushbutton actuators Two two-way pushbuttons

Double actuator pushbutton with indicator light

Spring-return switch T0-1-15511 with automatic return to position 1.

Spring-return switch T0-1-15366 with automatic return to rest position.

Two-wire control

Changeover switch T0-1-15521 with fleeting contact in the intermediate position

e.g. selector switch Rotary switch T LS position switchesMCS pressure switches

F2 Q11 Q11 Q11 Q11

212213 14 13 14

2122

96 13

X1 X2

14

-S11

44 A20 I

F2

-S11 -S112113 14 13 14 13 14 13 14

22

21

22

21

22

21

22

0

A B A B

I 0 I96Q1114

Q1144

22

96 13

1321

14 13 14

21 22

A2 14 44F2

-S11

Q11 Q11 Q11 Q11

A B C

1

0

Q111314

Q1196F2

1

01

21

34

S11

Start

Start

Q111314

Q1196F2

0 1

21

34

I

0 1I

S11

Start

Q111314Q11

96F2

21

34

I ON0OFF

0 1

S11

Q1114

Q1144

F2

S14

96

8-51

All about MotorsControl circuit devices for star-delta starting


8

Three-phase reversing contactor DIULRRReversing star-delta starter SDAIUL

Two-way pushbutton1) without self-maintaining circuit (inching) for use only with reversing contactors

Three-way pushbutton with indicator light. Reversing after actuation of pushbutton 0

Spring-return switch1) T0-1-8214, without self-maintaining circuit (inching)automatic return to 0 only for reversing contactors

Changeover switch1) Switch T0-1-8210 remains in position 1 or 2

Spring-return switch T0-2-8177 with automatic return to position 1 or 2

Position switchesConnected by removing the links between contactor terminals Q11/13 and Q12/22 and between Q12/13 and Q11/22 and interposing the position switches.

1) Overload relays always with manual reset

-S11

22211413

22211413

I II

BA

13Q12

13Q11

96F2

13

-S11

22211413

22211413

22211413

I

A B D EC

Q11A2 21 96Q12

21 IIQ11

14Q12

13Q12F2

0

234

01 2

1

Q1213

F296

Q1113

FS 4011

01 2

FS 684

01 2

2

123456

01 STARTSTART

78

Q11F296 13

Q1213

Q1214

FS 140660

01 2

START START

Q11/13Q12/22

Q12/13Q11/22

8-52


All about MotorsPole-changing motors

8

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:

The various tapped winding configurations give differential output ratios for the two speeds

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).

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.

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:

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.

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

Type of connection d/y y y/y yOutput ratio 1/1,5–1,8 0,3/1

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

8-53



8

Motor circuit

3 speedsThe 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:

Circuit A

Selection of low and high speed only from zero. No return to low speed, only to zero.

Circuit B

Selection of either speed from zero. Switching from low to high speed possible. Return only to zero.

Circuit C

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

Speeds 1000/1500/3000 750/1000/1500 750/1500/3000 = separate winding (in the circuit diagrams)

Number of poles

6/4/2 8/6/4 8/4/2

Connection

X Y Z

8-54



8

Motor circuit

4 speedsThe 1:2 speeds - tapped windings - can follow in sequence or overlap, as the following examples show:

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).

Circuit A

Selection of any speed only from zero. Return only to zero.

Circuit B

Selection of any speed from zero and from low speed. Return only to zero.

Circuit C

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)

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

8-55


8

All about MotorsMotor windings

Tapped winding3 speedsMotor circuit X2 windings, medium and high speed – tapped winding

Motor circuit Y2 windings, low andspeed – tapped win

2 2

or 2 or 2

Low speed Separate winding1

Medium speed Separate winding1

a figure, page 8-83 a figure, page 8-8

2U

2W 2V

3W

3V3U

1U

1W

3W

3V3U

2U

2W 2V

3W 3V

3U

1U

1W 1

3W 3V

3U

1W 1V

1U

2W

2U

Tapped winding2 speeds

Motor circuit2 speeds2 separate windings

Tapped windingwith yd starting at low speed

Low speed d Low speed y Low speed Low speed y

High speed yy High speed yy High speed Low speed d

a figure, page 8-61 a figure, page 8-61 a figure, page 8-65

High speed yy

a figure, page 8-74

1U

1W 1V

2W 2V

2U

1U

1W 1V

2W

2V2U

1W 1V

1U 1U

1W 1V

2W1

2U22V12V22U1

2W2

1U

2U

1V1W

2W 2V

1U

2U

1W

2V

1V

2W2W 2V

2U

1V

1W

2W2 1U

2V12V2

2U2

2W12U1

1U 2V2

2U1

1V1W

2W1 2V1

2W22U2

8-56

All about MotorsMotor windings


Motor circuit2 speeds2 separate windings

Tapped windingwith yd starting at low speed

Low speed Low speed y

High speed Low speed d

a figure, page 8-65

High speed yy

a figure, page 8-74

V1W 1V

1U 1U

1W 1V

2W1

2U22V12V22U1

2W2

2W 2V

2U

1V

1W

2W2 1U

2V12V2

2U2

2W12U1

1U 2V2

2U1

1V1W

2W1 2V1

2W22U2

8

Tapped winding3 speedsMotor circuit X2 windings, medium and high speed – tapped winding

Motor circuit Y2 windings, low and high speed – tapped winding

Motor circuit Z2 windings, low and medium speed – tapped winding

2 2 2

or 2 or 2 or 2

Low speed Separate winding1

Medium speed Separate winding1

High speedSeparate winding1

a figure, page 8-83 a figure, page 8-85 a figure, page 8-87

2U

2W 2V

3W

3V3U

1U

1W 1V

3W

3V3U

1U

1W 1V

2W

2V2U

2U

2W 2V

3W 3V

3U

1U

1W 1V

3W 3V

3U

1U

1W 1V

2W 2V

2U

1W 1V

1U

2W 2V

2U

3W 3V

3U

8-57


8

8-58


All about MotorsMulti-speed contactors

8

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.

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

indexing facilities of rotary switches allow for these possibilities. Multi-speed contactor starters can achieve these circuits by interlocking with suitable control circuit devices.

Fuse protection of the overload relaysWhen 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.

L1

-F11

-Q17 -Q21

-F21 -F2

1 3 5

2 4 6

2 4 6

1 3 5

2 4 6

2 4 6

97

98

95

96

L2 L3

97

98

95

96

-F1

8-59

All about MotorsMulti-speed contactors


8

Fuseless surface mounting

Multi-speed motors can be protected against short circuits and overloads by motor-protective circuit-breakers PKZ or circuit-breakers NZM,

which provide all the advantages of a fuseless circuit. Normally, the fuse in the supply line protects the switches from welding.

L1

-Q1

-Q17 -Q21

1

I > I > I >

3 5

1 3 5

2 4 6

1 3 5

2 4 6

2 4 6

13

14

L2 L3

-Q2

1

I > I > I >

3 5

2 4 6

13

14

8-60


All about MotorsMulti speed switches of three-phase motors

8

Tapped winding, non-reversing, 2 speeds

Multi-speed contactors UPILFuseless, without overload relay, with motor-protective circuit-breaker or circuit-breaker.

a section "Motor windings", page 8-56

Synchronous speedsOne multi-speed winding

L1

-Q1

-Q21 -Q17

PE

M

-M1

2U

2V

2W

1U

1V

1W3

1

I > I > I >

3 5

1 3 5

2 4 6

1 3 5

2 4 6-Q23

1 3 5

2 4 6

2 4 6

13

14

L2 L3

-Q2

1

I > I > I >

3 5 13

14

8-61



8

Rating of switchgear

Q2, Q17: I1 (low speed)Q1, Q21: I2 (high speed)Q23: 0.5 x I2

Motor terminals 1U, 1V, 1W 2U, 2V, 2W

Number of poles 12 6

rpm 500 1000

Number of poles 8 4

rpm 750 1500

Number of poles 4 2

rpm 1500 3000

Contactors Q17 Q21, Q23

8-62



8

Circuit A (a figure, page 8-55) One three-way pushbutton

For connection of further control circuit devices a figure, page 8-69, a figure, page 8-70, a figure, page 8-71

FunctionPushbutton 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.

Three-way pushbuttonI: Low speed (Q17)0: StopII: high speed

(Q21 + Q23)Q17: Mains contactor, low speedQ23: Star contactorQ21: Mains contactor, high speed

L1(Q11/1)

-F0

-Q1

-Q2

0

II

-S11

-Q17

-Q17 -Q23

N

-Q23

-Q21

I

13

14

13

14

21

22

21

22

14

13

14

13

21

2222

21A1

A2

A1

A2-Q21

-Q17

-Q23

-Q21

22

21

13

14

A1

14

II

I

22

14

13

21

13

A2

-S11

14 1313I II0

A B C

96

21 22

13 14

21 22

13 14

21 22

13 14

Q17 F21 Q21 Q21

8-63



8

Circuit C (a figure, page 8-55) One three-way pushbutton

For connection of further control circuit devices a figure, page 8-72

Three-way pushbuttonI: Low speed (Q17)0: StopII: High speed (Q21 + Q23)

Q17: Mains contactor, low speedQ23: Star contactorQ21: Mains contactor, high speed

L1(Q11/1)

-F0

-Q1

-Q2

0

II

-S11

-Q17

-Q17 -Q23

N

-Q23

-Q21

I

13

14

13

14

21

22

21

22

14

13

14

13

22

2121

22A1

A2

A1

A2-Q21

-Q23

-Q17

-Q21

22

21

13

14

A1

14

II

I

22

14

13

21

13

A2

14

-S11

Q1714Q21

13Q21

13I II0

A B C

Q1796F21

21

22

13 14

21

22

13 14

21 22

13 14

8-64



8

Two separate windings, non-reversing, two speeds

Multi-speed contactor UPDIUL, fuseless without overload relay


Q1, Q17 = I1 (low speed)Q2, Q21 = I2 (high speed)

Motor windings a section "Motor windings", page 8-56.

L1

-Q1

-Q17 -Q21

PE

M

-M1

1U

1V

1W

2U

2V

2W3

1

I > I > I >

3 5

1 3 5

2 4 6

1 3 5

2 4 6

2 4 6

13

14

L2 L3

-Q2

1

I > I > I >

3 5

2 4 6

13

14

8-65



8


Multi-speed contactor UPDIUL, with fuses and overload relay

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.


L1

F1

F1

F21 F2

M1

1W

1V

1U

2W

2V

2U

Q17 Q211 3 5

2 4 6

9698

9597

9698

9597

2 4 6

1 3 5

2 4 6

2 4 6

L2 L3

M3

8-66



8

Circuit A (a figure, page 8-55)One three-way pushbutton

Circuit C (a figure, page 8-55)One three-way pushbutton

Q17: Mains contactor, low speedQ21: Mains contactor, high speed

Three-way pushbuttonI: Low speed (Q17)0: StopII: High speed (Q21 + Q23)

For connection of further control circuit devices a figure, page 8-73.

L1

FO

F2

F21

Q113

1413

21

2221

2214

13

14

13

22

21

A1

A2

A1

13

14

14

1321

22

95

9695

96

21

A2

14Q2

0S11

Q17

Q21 Q17

Q21

I

II

Q17 Q21

N

II

I

22

L1(Q17/1)

-F0

0-S11

A1

A2

A1

A2

II

I II

22

21

-Q21

22

21

95

96

22

21

22

21

14

13

-Q21

-Q17

-Q21

-Q17

14

13

N

-F21

-F2

FL1

14

13

14

13

-Q1

-Q2

95

96

14

13

-Q1722

21

14

13

I

-S11

14Q21

13Q21

13I II0

A B C

Q1796F21

21 22

13 14

21 2213 14

21 22

13 14

13 14

21 22-S11

A

Q2113

Q2114

Q1714

I 0 II

F2196

Q1713

B C

21 22

13 14

21 22

13 14

8-67



8

Operating principleActuation 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.

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.

8-68


All about MotorsControl circuit devices for UPDIUL multi-speed contactors

8


Circuit A (a figure, page 8-55)

One three-way pushbutton with indicator lights


I : Low speed (Q17)0: StopII : High speed (Q21)

-F0

L1

0

A1

A2

A1

A2

II

I

22

21

-Q21

22

21

22

21

14

13

-Q21

-Q17

-Q21

14

13

N

95

96

14

13-Q17

14

13

I

-Q1722

21

II

-F2/F21

22

21

A

B D

B

-S11

I 021 II13

A B C D E

21 21

13

22 22 22

14 13

211314 14

Q17A2

Q2121

Q1714

Q2113Q21

96F21

8-69



8

Circuit A (a figure, page 8-55)

Two three-way pushbuttons


I: Low speed (Q17)0: StopII: High speed (Q21)Remove existing links and rewire

-F0

L1

95

21

2221

22

21

22

22

21

22

21

21

14

13

14

13

22

21

13

1413

14

22

22

21

13

14

13

14

96-F2/F21

0a

0b

IIb

Ib

IIa

IIbIIa

-Q17

-Q21

-Q21

-Q17A B

IaIb

Ia

13

A

96

B C BA C

-S11 -S11

Ia

21

221413 1413 1413

21

22

21

22

21

221413 1413 1413

21

22

21

22

IIa0a Ib IIb0b

Q2113Q17

14Q21F21

8-70



8

Circuit A (a figure, page 8-55) T0-1-8210 changeover switchAlways set overload relay to manual reset

Circuit B (a figure, page 8-55)

One three-way pushbutton

L1

95

96-F2/F21

-S12

-Q17

-Q21 -Q17

-Q21

-S12

A B

1 2

1 3

14

13

22

14

13

21

22

21

2 4

-F0

S12

Q2113

F296

Q1713

1 0 21234

L1

95

9621

22

21

22

14

13

14

13

13

14

14

13

22

21

A1

A2

A1

A2

22

21

-F0

-F2/F21

0

II

I

A B

II

N

-Q21 -Q17

-Q17 -Q21

-Q17 -Q21

8-71



8

Circuit B(a figure, page 8-55)


Control circuit device for circuit B

-F0

L1

0a

-Q21

22

21

22

21

14

13-Q2114

13

95

96

-Q17

IIb

IIa

-F2(1)

22

21B

0b

2221

Ib

21

22

Ia IIa IIb14

1314

13

A

14

13

-Q1722

21

14

13

A

Q2113

F2196

B C

Q1714

Q1713

Ia

S11 S11

Q2114

0a IIa Ib 0b IIb

21 22

13 14

21 22

13 14

21 22

13 14

21 22

13 14

21 22

13 14

21 22

13 14

A B C

8-72



8

Circuit C (a figure, page 8-55)


Control circuit device for circuit C

-F0

L1

0a

-Q21

22

21

22

21

14

13-Q21

14

13

95

96

14

13-Q17

IIb

-Q17

IIa

-F2(1)

22

21A B

0b

22

21

Ib22

21

Ia22

21

14

13IIa

Ib

Ia

IIb14

13

14

13

22

2122

21

-S11

A

Q2113

F2196

B C

Q1714 13

Ia

-S11

Q2114

0a IIa

21 22

13 14

21 2213 14

21 2213 14

Ib 0b IIb

A B C

21 22

13 14

21 2213 14

21 2213 14

8-73


8


Tapped winding, non-reversing, 2 speeds

Multi-speed contactors UPSDAINLStar-delta starting at low speed

FuselessWithout overload relay

Rating of switchgearQ1, Q17 = I1

(low speed)Q2, Q21 = I2

(high speed)Q19, Q23 = 0,5 x I2

L1

PE

Y

-M1

3 2W1

2V1

2U1

1W1V1U

1 3 5

2 4

L2 L3

3 5

2 4 6

2 4 6-Q17

-Q23

-Q21

6

2W2

2V2

2U2

1 3 5

1

1 3 5

2 4 6

3 5

2 4 6

1

13

14

-Q1

-Q19

2 4 6

-Q214

131 3 5

I > I > I > I > I > I >

8-74



8

With fuses and overload relays

Rating of switchgearF2, 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.


L1

PE

Y

-M1

3

2W1

2V1

2U1

1W1V1U

L2 L3

5

2 4 6

-Q17

-Q23

-Q21

2W2

2V2

2U2

1 3 5

1

1 3 5

2 4 6

3 5

2 4 6

1

-F1

-Q19

2 4 6

-F21-F22 4 6

97 95

98 96

3

97 95

98 962 4 6

8-75



8

FunctionActuation 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.

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.

Circuit

Low speed selected only from zero, high speed only via low speed without actuation of the Stop button.Three-way pushbuttonI: Low speed (Q17,

Q19)0: StopII: High speed (Q21,

Q19, Q23)

Q17: Mains contactor, low speed

K3: Timimg relaysQ23: Star contactor

Q19: Delta contactorQ21:Mains contactor,

high speed

-F0

-F21

-Q1

-Q2-S11

-Q17

-Q21

-Q17

-Q17

21

21

A1

A2

N

22

22-Q21

-Q21

-Q21

-Q17

-Q23 -Q19

-Q19

-Q23

-Q19

-Q19

-K3

-K3A1

A2

A1

A2

A1

A2

31

32 21

22

21

A1

A2

21

22

44

43

22

13 15

1614

13

14

13

14

13

14

43

44

L1(Q17/1)

0

II

I

-Q23

14

13

22

21

95

9695

9614

13

14

13

14

13

II

-S11

A

Q1713

Q1944 14

F2196

B C

21 22

13 14

Q1743

Q1714

I 0 II

Q2122

21 22

13 14

21 22

13 14

8-76



8

Tapped winding, reversing, 2 speeds(direction preselected)

Multi-speed contactors UPIULOverload relays F2 and F21 are not used on multi-speed contactors without motor protection.

Rating of switchgearQ11, Q12 = I2 (low and high speed)F2, Q17 = I1 (low speed)F1, Q21 = I2 Q23 = 0.5 x I2 (high speed)

L1

PE

-M1

2W

2V

2U

1 3 5

2 4

L2 L3

-F1

2 4 6

2 4 6-Q11

97

-Q17

6

1W

1V

1U

1 3 5

-F2198

95

96 2 4 6

97

98

95

96-F2

2 4 6

1 3 5

2 4 6

1 3 5

2 4 6

1 3 5

M

3

-Q12

-Q21

-Q23

8-77



8

FunctionContactor 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

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.

Five-way pushbutton

ConnectionChange of direction FORWARD–REVERSE after actuation of Stop button, optionally followed by SLOW–FAST with no return to low speed.

Control circuit device0: StopI: Forward (Q11)II: Back (Q12)III: Slow (Q17)IV: Fast (Q21 + Q23)

L1(Q11/1)

-F0

0-S11

A1

A2

A1

A2

-Q17

-Q17A1

A2

A1

A2N

-F21

-F2

III

II

14

13

22

21

-Q11

-Q17

-Q11 -Q21

14

13

22

21

95

96

2222

21

14

13

44

43-Q11

-Q21

95

96

21

A1

A2

22

21I

22

21

-Q1114

13

IV22

21

14

13III

22

21-Q23-Q12

-Q23

-Q23

21

22

14

13

-Q12

-Q2114

13IV

III21

22

-Q1244

43-Q1214

13

14

13

Q1113

I

F2196

13 14

21 22

-S11

A C

0

B D

Q1213

Q1214

Q1713

Q1143

Q1714

Q1721

II III IV

E

13 14

21

22

13 14

21

22

13 14

21 22

13 14

21

22

8-78



8

Tapped winding, reversing, 2 speeds(Direction and speed selected simultaneously)

Multi-speed contactor UPIUL Fuseless without overload relay


Q1, Q17, Q18 = I1 (low speed)

Q2, Q21, Q22 = I2

Q23 = 0.5 x I2 (high speed)

L1

PE

M

-M1

3 1W

1V

1U

2W

2V

2U

-Q23

1 3 5

2 4 6

L2 L3

-Q1I> I> I>

-Q2

1 3 5

2 4 6

1 3 5

2 4 6

1 3 5 1 3 5 1 3 5

1 3 5

2 4 6

2 4 6 2 4 6 2 4 6-Q17

I> I> I>

13

14

-Q18 -Q21 -Q22

13

14

8-79



8

Multi-speed contactor UPIUL

With fuses and overload relays


F2, Q17, Q18 = I1 (low speed)

F21, Q21, Q22 = I2Q23 = 0.5 x I2 (high speed)

Overload relays F2 and F21 are not used on multi-speed contactors without motor protection

L1

PE

M

-M1

3 1W

1V

1U

2W

2V

2U

1 3 5

2 4 6

L2 L3

-F2

1 3 5

2 4 6

1 3 5

2 4 6

-Q17

-F1

-Q18

97 95

98 96

-Q23

97 95

98 96

-F212 4 6

2 4 6-Q21 -Q22

1 3 5

2 4 6

1 3 5

2 4 6

8-80



8

Circuit

Simultaneous selection of direction and speed via one pushbutton. Always operate Stop button before changeover.

Q17:Slow forwardQ18:Slow backQ21:Fast forwardQ23:Star contactorK1: Contactor relayQ22:Fast back

L1(Q17/1)

N

-F0

0

-S11I

-Q18

A1

A2

A1

A2

-Q21

21

22

-Q21

14

13

22

21

95

96

II

22

21

-Q17

21

II

21

22

22

-Q23

21

-Q17

-Q22-Q23

-Q22

-Q21

-Q23

A1

A2

A1

A2

-Q23

-Q22

-Q18-Q17

22

-Q22

14

14

13

III

95

96

-F2

-F2114

13

-Q2

-Q1

-Q1713

31

32

-Q21

22

2122

21

-K1

I

14

13 14

13

IV

14

13

22 21 14

21 22 13-Q18 -K1

-K1A1

A2

14

13

44

43

A1

A2

-K143

44

14

13

32

31

III

IV

21

22

-Q1831

32

31

3214

13

14

13

8-81



8

FunctionDesired 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.

Five-way pushbuttonControl circuit device0: StopI: Slow forward (Q17)II: Slow back (Q18)III: Fast forward (Q21 + Q23)IV: Fast back (Q22 + Q23)

Q1822

13 14

21 22

-S11

A

Q2121

Q2322

Q1721

I0 II

F2196

Q2314

Q1832

Q2232

III IV

B C D E

13 14

21 22 21 22

13 14

21 22

13 14

21 22

13 14

8-82



8

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

Synchronous speed


Q2, Q11 : I1 (low speed)

Q1, Q17 : I2 (medium speed)

Q3, Q21 : I3 (high speed)

Q23 : 0.5 x I3

L1

PE

M

-M1

3 3W

3V

3U

2W

2V

2U

1 3 5

2 4

L2 L3

-Q1I> I> I>

-Q2

1 3 5

2 4 6

1 3 5

2 4 6

1 3 5 1 3 5

1 3 5

2 4 6

2 4 6 2 4 6

-Q17

I> I> I>

13

14

-Q23

-Q11 -Q21

13

14

6

1W1V1U

13

14

2 4 6

I> I> I>-Q3

1 3 5

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

8-83



8

FunctionPushbutton 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

motor-protective circuit-breaker or circuit-breaker can also switch off.

Circuit of motor winding: XCircuit A

Circuit ASelection of any speed only from zero. No return to low speed, only to zero.

Circuit BSelection of any speed from zero or from low speed. Return only to zero.

Q11: Low speed winding 1Q17: Medium speed winding 2Q23: High speed winding 2Q21: High speed winding 2

4-way pushbutton0: StopI: Low speed (Q11)II: Medium speed (Q17)III: High speed (Q21 + Q23)

L1(Q17/1)

-F0

0

-S11

A1

A2

A1

A2

21

22

22

21

-Q17

21-Q23

-Q17

-Q23 -Q21A1

A2

A1

A2

-Q23

N

-Q17

14

13

III

14

13

-Q2-Q1

31

32

-Q3

III22

21

14

13

II14

13I

II

14

13

-Q1114

13

13

14

22

21

22

21

-Q2121

22

22

-Q11

-Q21

31

3232

31

-Q11 -Q17

-Q11

-Q21

-Q23

32

31

14

13

13 14

21 22

A

Q2113

Q1114

Q1714

I0 II

F2296

Q2114

III

B C D

13 14

21 22 21 22

13 14

21 22

13 14

13 14

21 22-S11

A

Q2113

Q1114

Q1714

I0 II

F2296

Q2314

III

B C D13 14

21 22 21 22

13 14

Q1113

Q1713

21 22

13 14

8-84



8

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

Synchronous speed


F2, Q17: I1 (low speed)

F3, Q11: I2 (medium speed)

F4, Q21: I3 (high speed)

Q23: 0.5 x I3

L1 L2 L3

1 3 5

M1

2 4 6

F1

97 95

98 96

Q17 Q111 3 5

2 4 6

F22 4 6

F397 95

98 962 4 6

Q211 3 5

2 4 6

F497 95

98 962 4 6

1 3 5

Q231 3 5

2 4 6

3U 3V 3W

2U

2V

2W

1U

1V

1W

M3

1 3 51 3 5

Winding 2 1 2

Motor terminals

1U, 1V, 1W

2U, 2V, 2W

3U, 3V, 3W

Number of poles

12 8 6

rpm 500 750 1000

Number of poles

8 6 4

rpm 750 1000 1500

Contactors Q17 Q11 Q21, Q23

8-85



8

FunctionPushbutton 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.

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.

Circuit of motor winding: YCircuit A

Circuit ASelection of any speed only from zero. No return to low speed, only to zero.

Circuit BSelection of any speed from zero or from low speed. Return only to zero.4-way pushbutton0: StopI: Low speed (Q17)II: Medium speed (Q11)III: High speed (Q21 + Q22)

Q17: Low speed winding 1Q11: Medium speed winding 1Q23: High speed winding 2Q21: High speed winding 2

L1

F0

0

S2

S1

S3

S0

A1

A2

A1

A2

Q17

21

Q17 Q21

A1

A2

A1

A2

Q23

N

III

14

13

F3F2

F4

III

II

I

II

14

13

14

13

22

21

22

2121

2222

Q11

31

32

32

31

Q11 Q11

Q21

Q23

14

13

22

21

95

96

22

21

22

21

14

13

14

13

Q11

31

32Q21

Q23 Q2332

31

Q17 Q21

Q17

14

13

Q1714

13 14

21 22

-S11

A

Q2113

Q1114

I0 II

F2296

Q2114

III

B C D

21 22

13 14

21 22

13 14

21 22

13 14

Q2114

Q1713

Q2113

Q1113

Q1714

F2296 0 I II

-S11

13 14

21

22

13 14

21

22

13 14

21

22

13 14A B C D

Q1114

21

22

III

8-86



8

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

Synchronous speed


F2, Q17: I1 (low speed)

F4, Q21: I2 (medium speed)

F3, Q11: I3 (high speed)

Q23: 0.5 x I3

L1 L2 L3

1 3 5

M1

2 4 6

F1

97 95

98 96

Q17 Q111 3 5

2 4 6

F22 4 6

F397 95

98 962 4 6

Q211 3 5

2 4 6

F497 95

98 962 4 6

1 3 5

Q231 3 5

2 4 6

3U 3V 3W

2U

2V

2W

1U

1V

1W

M3

1 3 51 3 5

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

8-87



8

FunctionPushbutton 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.

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.

Circuit of motor winding: ZCircuit A

Circuit ASelection of any speed from zero. No return to low speed, only to zero.

Circuit BSelection of any speed from zero or from low speed. Return only to zero.

Q17: Low speed winding 1Q23: Medium speed winding 2Q21: Medium speed winding 2Q11: High speed winding 1

4-way pushbutton0: StopI: Low speed (Q17)II: Medium speed (Q21 + Q23)III: High speed (Q11)

L1(Q17/1)

N

-F0

0

-S11

I

-Q11

A1

A2

A1

A2

-Q21

21

22

-Q21

14

13

22

21

-F2-F21-F22

95

96

III

II22

21

-Q1714

1322

21

14

13

II

21

2222

-Q2321

-Q17 -Q23 -Q21

-Q11

-Q17

-Q23A1

A2

A1

A2

-Q23

-Q11

-Q21

-Q17

14

13

32

31

32

31

22

21

32

31

32

31

-Q1114

13

14

13

14

13III

Q2113

Q1714

Q1114

F2296 0 I II III

13 14

21

22

A B C D

Q2114

21

22

21

22

21

22

13 14 13 14 13 14

-S11

II III0 I14

Q2313

Q2314

Q1713

Q1714

Q1113

Q1114

F2296

-S11

1321

22

13 14

21

22

13 14

21 22

13 14

A B C D

21 22

8-88


All about MotorsMulti speed switch with motor-protective circuit-breakers PKZ2

8

L1 L2 L3

-Q1

1 3 5

2 4 6-Q21

2U

2V

2W

1U

1V

1W

-Q2

U F 690 V

I> I> I>

L1 L2 L3 1.13 1.21

1.14 1.22

A1

A2

13

14

21

22I>>

T1 T2 T3

-Q17A1

A2

-M1

I>> I>>

I> I> I>

T1 T2 T3

-Q23

T1 T2 T3

L1 L2 L3 1.13 1.21

1.14 1.22

I>> I>> I>>

13

14

21

22

A1

A2-Q23

13

14

21

22

L1 L2 L3

I>> I>> I>>

U F500 V

M3 h

Number of poles 12 6

rpm 500 1000

Number of poles 8 4

rpm 750 1500

Number of poles 4 2

rpm 1500 3000

8-89

All about MotorsMulti speed switch with motor-protective circuit-breakers PKZ2


8

Circuit Aa figure, page 8-55 Circuit Ca figure, page 8-55

L1(Q17/1)

-Q21

13

14

21

22

-F0

II

I

-Q17

-Q23

-Q1

-S11

1.13

1.141.13

1.14-Q2

21

220

-S11

n >

n <

13

14

21

22

21

22

-Q17 -Q23A1

A2

N

-Q21

-Q23A1

A2

n >n <

A1

A2

13

14

-Q1721

22

-Q2113

14

13

14

21

22

-S11

21

22

13 14A

Q1713

21

22

13 14

21

22

13 14

B C

Q21.14

Q2114

Q2113

I 0 II

Q1713

Q21.14

Q2114

Q2113

L1(Q17/1)

-F0

-Q1

-Q2

0

II

I

n >

n <

1.13

1.141.13

1.1421

22

13

14

21

22

-Q1713

14

21

22

21

22

A1

A2

-Q21

-Q23

-Q17

A B C

21

22

13 14

21 22

13 14

21

22

13 14

I 0 II

13

14

21

22

-Q1721

22

-Q2113

14

-Q2313

14

-Q23A1

A2

A1

A2

n >n <

N

-S11

Q1714

-Q21

Stop Stop

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


All about MotorsThree-phase current-automatic stator starters

8

Three-phase automatic stator resistance starter DDAINL with mains contactor and resistors, 2-stage, 3-phase version

When using F1 instead of Q1, use F2.

L1 L2 L3

-Q1

1 2 3

I> I> I>

2 4 6

13

14-F1

1 53

2 4 6-Q11 -Q17

-R2X

Y

Z

-F2

PEU V W

M3

-M1

1 53

2 4 6-Q16

2 4 6

1 3 5

-R1U1 U2

V2

W2

V1

W1

42 6

97 95

98 96

Rating of switchgear:Starting voltage: 0.6 x UeInrush current: 0.6 x direct switching systemTightening torque: 0.36 x direct switching systemQ1, Q11: IeQ16, Q17: 0.6 x Ie

8-91



8

DDAINL three-phase automatic stator resistance starter with mains contactor and resistors, 2-stage, 3-phase version

Q16: Step contactorK1: Timing relayQ17: Step contactor

K2: Timing relayQ11: Mains contactor

Two-wire control

Always set overload relay to manual reset

-Q1-F2

L1(-Q11)

N

-F0

13

14

95

96

021

22-S11

I 13

14

21

22

-Q11

-Q16A1

A2-K1

A1

A2-Q17

A1

A2

-K115

18

-K2

-Q17

A1

A2-Q11

A1

A2

-K213

14

13

14

-Q16

13

14

15

18

-Q11

32

31-Q11

-F0

-Q113

14

-S12

-Q1132

31-Q11

L1(Q11/1)

22

21

8-92



8

FunctionPushbutton 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.

Three-wire controlDouble actuatorI = ON0 = OFF

Two-wire control

-S11

Q1132

2221

Q1121

F296

2221

1413 1413

0 I

A B

F296

Q1122

Q1132

-S12

8-93



8

Three-phase automatic stator resistance starter ATAINL with mains contactor and starting transformer, 1-stage, 3-phase

When using F1 instead of Q1, use F2. Rating of switchgear

L1 L2 L3

4

1 53

2 4 6

U V W

1 53

2 4 6

a

U2 V2 W2

1U1

2W1

2V1

2U1

1V1

1W1

M3

M1

F1

2 6

1 53

Q113

14

Q111 53

2 4 6K1

Q13

2 4 6 97 95

98 96

I > I > I >

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



8

FunctionPressing 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.

Two-wire control

Always set overload relay to manual reset (automatic reset)

Q16: Step contactorK1: Timing relayQ11: Mains contactorQ13: Star contactor

Three-wire controlI: ON0: OFF

Two-wire control

L1

Q1

F0

13

14

95

96F2

21

S110

I13

14K1

13

14

13

14

Q13

Q16

N

A1

A2K1

Q13

A1

A2Q11

K1

A1

A2

K1

Q11

Q13

22

21A1

A2

22

21

67

68

55

56

22

L1(Q11/1)

-F0

95

96-F2

-S12

-K1 -K155

96

67

68

-S11

K113

2221

F296

2221

1413 1413

0 I

A B

K114

-S12

F296

K155

8-95


8

All about MotorsThree-phase automatic rotor starters

DAINL three-phase automatic rotor starters

Three stage, rotor three phase

When using F1 instead of Q1, use F2.

L1 L2 L3

-Q1

1 3 5

I > I > I >

13

14-F1

2 64

2 4 6

PEU V W

M3

-M1

-Q12

2 4 6

97 95

98 96

1 3 5-Q11

-F2

2 4 6

1 3 5 1 53

2 4 6-Q13 -Q142 4 6

1 3 5

K

L

M

U3

V3

W3

U2

V2

W2

-R3 -R2U1

V1

W2

-R1

8-96



8

2-stage, rotor 2-phase

When using F1 instead of Q1, use F2.Rating of switchgear

L1 L2 L3

1 3 5 13

14

I> I> I>

2 64

1 3 5

2 4 6

PEU V W

M3

-M1

-Q111 3 5

-F2

2 4 6

-R2U1

V1

-R1

-Q1

-F1

97 95

98 96

K

L

M

-Q12 -Q142 4 6

1 3 5

U2

XY

V2

2 4 6

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



8

With mains contactor, style 3-stage, rotor 3-phase

Q11: Mains contactorK1: Timing relayQ14: Step contactorK2: Timing relay

Q12: Step contactorQ13: Final step contactorK3: Timing relay

Q1 F2

L1

N

F0

0

S11

I

Q11A1

A2

A1

A2

K1

K2

Q14

A1

A2

13

14

13

14

95

96

21

22

13

14Q11

13

14

K1 Q14A1

A2

15

18K2

Q12

14

13A1

A2

15

18A1

A2Q13

Q13 Q1332

31

14

13U3

A1

A2U3

15

18Q12

Q1144

43

Double actuatorI: ON0: OFF

For connection of further control circuit devices: a section "Control circuit devices for star-delta starting", page 8-51

F296

Q1114

Q1113

0 I

-S11

21 22 21 22

13 14 13 14

A B

8-98



8

FunctionPushbutton 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.

8-99


8

All about MotorsSwitching of capacitors

Contactors for capacitors DIL

Individual circuit without quick-discharge resistors

Individual circuit with quick-discharge resistors

R1 discharge resistors fitted in capacitorR1 discharge resistors fitted to contactor

L3

-F1

1 3 5

2 4 6-Q11

-R1

-C1

-R1

-R1

L1 L2 L3

-F1

1 3 5

2 4 6-Q11

-R1-C1

-R1

L1 L2

21

22-Q11 -Q11

31

32

8-100



8

Double actuatorFor connection of further control circuit devices: a section "Control circuit devices for star-delta starting", page 8-51

L1(Q11/1)

-F0

21

22

-S11

0

I13

14

13

14

-Q11

-Q11A1

A2

N

22

L1

21

0 IQ1114

A B

Q1113

1413

2221

1413

Maintained contact sensorsIn 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.

FunctionPushbutton 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.

L1

-S12

Q11A1

8-101



8

Capacitor contactor combination

Capacitor contactor with pilot contactor and series resistors. Individual and parallel circuit

with and without discharge resistors and with series resistors.

On the version without discharge resistors, resistors R1 and the connections to the auxiliary contacts 21–22 and 31–32 are omitted.

L3L1 L2

-F1

1 3 5

2 4 6-Q14

-R1

-C1

-R1

21

22

-Q1131

32

43

44

13

14

21

22

A1

A2

31

32

43

44

1 3 5

2 4 6

A1

A2

13

14

-R2

8-102



8

FunctionActuation 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.

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.

Q11: Mains contactorQ14: Pilot contactorActuation by two-way pushbutton S11 Actuation by selector switch S13, two-wire

control S12 (power factor correction relay) and two-way pushbutton S11

-F0

0

I

-S11

L1(Q11/1)

-Q14

21

22

-Q11A1

A2

13

14 -Q1113

14

13

14

-Q14A1

A2

N

-F0

0

I

-S12

L1(Q11/1)

-Q14

21

22

13

14-Q11

13

14

13

14

A1

A2

-S12

-Q14A1

A2-Q11

N

T0 (3)-1-15431

1

234

1

0 2

8-103


8

All about MotorsDuplex pump control

Fully automatic control with two pumps

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)

P1 Auto = Pump 1 constant load, Pump 2 peak load

P2 Auto = Pump 2 constant load, Pump 1 peak load

P1 + P2 = Direct operation independent of float switches (or pressure switches)

a Cable with float, counterweight, pulleys and clamps

b Storage tankc Inlet d Pressure pipee Outlet

f Centrifugal or reciprocating pumpg Pump 1h Pump 2i Suction pipe with filterj Well

L1 L2 L3

-Q1

-F22

-Q11

U V W

M3

-M1

-M2 M3

F7-F11 -F21

-F12

-Q12

U V W

F8

b

d

F7 Q

Q

a

a

F8

c

e

f

f

i

h

g

0

0

I

I

F7: 0

F7: IF8: 0

F8: I

j

I > I > I >

8-104

All about MotorsDuplex pump control


8

Floa

t sw

itch

F7 c

lose

s bef

ore

F8Q1

1:Pu

mp

1 m

ains

con

tact

orQ

12:P

ump

2 m

ains

con

tact

or

Func

tion

The

dupl

ex p

ump

cont

rol i

s des

igne

d fo

r ope

ratio

n of

tw

o pu

mp

mot

ors M

1 an

d M

2. C

ontro

l is v

ia fl

oat

switc

hes F

7 an

d F8

.O

pera

ting

mod

e se

lect

or sw

itch

S12

in p

ositi

on P

1 au

to:

The

syst

em o

pera

tes a

s fol

low

s:W

hen

the

wat

er le

vel in

the s

tora

ge ta

nk fa

lls o

r rise

s, F7

sw

itche

s pum

p 1

on o

r off

(bas

ic lo

ad).

If th

e w

ater

leve

l dr

ops b

elow

the

rang

e of

F7 (d

ischa

rge

is gr

eate

r tha

n in

take

), F8

star

ts p

ump

2 (p

eak

load

). W

hen

the

wat

er

leve

l rise

s aga

in, F

8 is

deac

tivat

ed. P

ump

2 co

ntin

ues r

unni

ng u

ntil

F7 st

ops b

oth

pum

ps.

The

oper

atin

g se

quen

ce o

f pum

ps 1

and

2 ca

n be

de

term

ined

usin

g op

erat

ing

mod

e se

lect

or sw

itch

S12:

Pos

ition

P1

auto

or P

2 au

to.

In p

ositi

on P

1 +

P2, b

oth

pum

ps a

re in

ope

ratio

n,

inde

pend

ent o

f the

floa

t sw

itche

s (Ca

utio

n! Ta

nk m

ay

poss

ibly

over

flow

).O

n th

e ver

sion

of d

uple

x pum

p co

ntro

l with

aut

omat

ic lo

ad sh

arin

g (T

0(3)

-4-1

5915

), S1

2 ha

s a fu

rther

po

sitio

n: th

e se

quen

ce o

f ope

ratio

ns is

aut

omat

ically

re

vers

ed a

fter e

ach

cycle

.

F11

F0

-F12

-F22

95 96

95 96-F

7Q

2 1-S

1114 13

-F8

Q-S

212 1

14 13-Q

1214 13

-Q11

14 13

NEO

-Q11

A1 A2-Q

12A1 A2

-S12

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

13

0

P 1, P 2

P 1 AutoP 2 Auto

T0(3

)-4-1

5833

8-105


8

All about MotorsFully automatic pump control

With pressure switch for air tank and domestic water supply without water failure (run dry) safety device

With 3-pole pressure switch MCSN (main circuit)

F1: Fuses (if required)Q1: Motor-protective switch, manual (z. B. PKZ)F7: Pressure switch MCSN, 3-poleM1:Pump motora Air or pressure tankb Non-return valvec Pressure piped Centrifugal (or reciprocating) pumpe Suction pipe with filterf Well

L1L2L3

-F1

-Q1

a

bd

c e

f

U V W

-M1

M3

P-F7

I > I >I >

8-106



8

With single-pole pressure switch MCS (control circuit)

F1: FusesQ11:Contactor or automatic star-delta starterF2: Overload relay with reclosing lockoutF7: Pressure switch MCS, 1-poleM1:Pump motora Air or pressure tankb Non-return valvec Centrifugal (or reciprocating) pumpd Pressure pipee Suction pipe with filterf Well

3 5

2 4 695

96

-M1

M3

U V W

L1L2L3

-F1

-F2a

bc

de

f

P

N

-Q11 1

-F7

8-107



8

With 3-pole float switch SW (main circuit)

F1: Fuses (if required)Q1: Motor-protective circuit-breakers,

manual (z. B. PKZ)F7: Float switch 3-pole (circuit: pump full)M1:Pump motorHW:Highest levelNW:Lowest valuea Cable with float, counterweight,

pulleys and clampsb Storage tankc Pressure piped Centrifugal (or reciprocating) pumpe Outlet f Suction pipe with filterg Well

U V W

L1L2L3

-F1

-F7

I

0

HW

NW-Q1

-M1

Q

M3

a

c

b

de

f

g

I > I >I >

8-108



8

With 1-pole float switch SW (control circuit)

F1: Fuses Q11:Contactor or automatic star-delta

starterF2: Overload relay with reclosing

lockoutF8: Float switch 1-pole (circuit: pump

full)S1: Changeover switch

MANUAL-OFF-AUTOF9: Float switch 1-pole (circuit: pump

full)M1:Pump motora Cable with float, counterweight,

pulleys and clampsb Storage tankc Pressure piped Centrifugal (or reciprocating)

pumpe Outlet f Suction pipe with filterg Water-failure monitoring by

means of a float switchh Well

L1

U V W

L2L3N

-F1

-F2

-Q11 1 3 5

2 4 695

96

-F8

0

H A

-M1

S1

HW

NW

M3

-F9

I

0

Q

Q

a

b

c

de

h

f

g

0

I

8-109


8

All about MotorsOff 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.

-S3

-R1 -R2

51 52

U <

-Q1

I > I > I >

I > I > I >-Q2I > I > I >-Q3 I > I > I >-Q4

8-110


All about MotorsFully automatic main transfer switch with automatic reset

8

Off position interlock for control or master switches by means of auxiliary contacts VHI (S3),

NHI (S1) and undervoltage release. Cannot be used with motor operator.

a Emergency-Stopb Off position interlock contacts

on the control or master switches

-S3

a

V

95

96

U <

-Q1-S1

51

52

1011

1011

1011

b

b

b

I > I > I >

8-111

All about MotorsFully automatic main transfer switch with automatic reset


8

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 Uan = 0,95 x Un Drop-out voltage Ub = 0,85 x Uan

FunctionMain switch Q1 is closed first, followed by main switch Q1.1 (auxiliary supply).

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

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.

a Main supplyb Auxiliary supply

c To load

L1L2L3N

-Q1

-F01

21

22

14

21

21

22

2211

11

12 14

12 14

R

R S

S

T

T

-F02

5 6

3 4

1 2

5 6

3 4

1 2

-Q1.1

-Q11

-K2

-Q12

-Q12

-Q11

-K2

-Q12

-Q11 -K2

-K1

A1

A2

A1

A2

A1

A2

L2.1L3.1

N

L1.1

13

a b

c

I > I > I >I > I > I >

8-112


Export to the world market and to North America

9

Page

Approvals and certificates 9-2

Fuses for circuits in North America 9-4

Approval authorities 9-6

Test authorities and approval stamps 9-10

Marking of electrical equipment for North America 9-12

Circuit symbols, European – North America 9-21

Circuit diagram examples to North American specifications 9-33

North American classification for control switches 9-36

Rated motor currents for North American motors 9-38

Protection types for electrical equipment for North America 9-39

North American cable cross-sections 9-41

9-1


9

Export to the world market and to North AmericaApprovals and certificates

Approvals for switching and protective devices or for power distribution systems are national, regional or application-specific approvals for the use of these products.

• 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

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.

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.

9-2

http://www.moeller.net/en/support/pdf_katalog.jsp

Export to the world market and to North AmericaApprovals and certificates


9

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 motor-protective 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

Industrial control equipmentUL 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

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

9-3

http://www.moeller.net/en/company/news/publications/index.jsp


9

Export to the world market and to North AmericaFuses for circuits in North America

Fields of application Notes

Primarily domestic Types H, Ktherefore they may

fast:

Protection from resistive and inductive loads.

Circuits for heating, lighting, feeders and branches for mixed loads.

slow:

Protection from inductive and highly inductive loads.

Circuits for motors, transformers, lighting etc.

ExtremelyCurrent-l

Compact Current-lAll other f

Compact Current-lAll other f

Not curreIn the USAreplaced b

Current-lAll other f

Current-lTypes RK1fuse typesRK1 fuses

_ ExtremelyCurrent-lAll other f

Selection and application of fuses suitable for circuits (feeder and branch circuits) in North America.

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.

Type or design in: Standards UL, CSA

Fuse characteristics

SCCR Typical values in A

USA Canada

Class H, "Code"

Class H, No. 59 "Code"

UL 248-6/7, C22.2 248-6/7

fast 10 kA, 250 VAC 0…600

10 kA, 600 VAC

Class CC Class CC UL 248-4, C22.2 248-4

fastslow

200 kA, 600 VAC 0.5…30

Class G Class G UL 248-5, C22.2 248-5

fastslow

100 kA, 480 VAC 21…60

100 kA, 600 VAC 0.5…20

Class J Class JHRCI-J

UL 248-8, C22.2 248-8

fastslow

200 kA, 600 VAC 1…600

Class KK1, K5

Class KK1, K5

UL 248-9, C22.2 248-9

fastslow

50 kA/100 kA/200 kA, 600VAC

0…600

Class L Class L UL 248-10, C22.2 248-10

fastslow

200 kA, 600 VAC 601…6000

Class RRK1, RK5

Class RHRCI-R RK1, RK5

UL 248-12, C22.2 248-12

fastslow

50 kA/100 kA/200 kA, 600VAC

0…600

Class T Class T UL 248-15, C22.2 248-15

fast 200 kA, 300 VAC200 kA, 600 VAC

0…1200

9-4

Export to the world market and to North AmericaFuses for circuits in North America


Tripping characteristic

SCCR Typical values in A

fast 10 kA, 250 VAC 0…600

10 kA, 600 VAC

fastslow

200 kA, 600 VAC 0.5…30

fastslow

100 kA, 480 VAC 21…60

100 kA, 600 VAC 0.5…20

fastslow

200 kA, 600 VAC 1…600

fastslow

50 kA/100 kA/200 kA, 600VAC

0…600

fastslow

200 kA, 600 VAC 601…6000

fastslow

50 kA/100 kA/200 kA, 600VAC

0…600

fast 200 kA, 300 VAC200 kA, 600 VAC

0…1200

9

The NA fuse types are largely tested and suitable for DC circuits in accordance with UL and CSA.

Fields of application Notes

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.

fast:

Protection from resistive and inductive loads.

Circuits for heating, lighting, feeders and branches for mixed loads.

slow:

Protection from inductive and highly inductive loads.

Circuits for motors, transformers, lighting etc.

Extremely compact design!Current-limiting to UL/CSA!

Compact design.Current-limiting to UL/CSA!All other fuse types do not fit into bases.

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.

9-5


9

Export to the world market and to North AmericaApproval authorities

Code Full title Country

ABS American Bureau of ShippingShip classification association

USA

AEI Assoziazione Elettrotechnica ed Elettronica ItalianaItalian electrotechnical industry organisation

Italy

AENOR Asociacion Española de Normalización y Certificación, Spanish organisation for standards and certification

Spain

ALPHA Gesellschaft zur Prüfung und Zertifizierungvon Nieders-pannungsgerätenGerman test laboratories association

Germany

ANSI American National Standards Institute USA

AS Australian Standard Australia

ASA American Standards AssociationAmerican association for standards

USA

ASTA Association of Short-Circuit Testing AuthoritiesAssociation 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 ItalianoItalian standards organisation

Italy

CEI Commission Electrotechnique InternationaleInternational electrotechnical commission

Switzerland

CEMA Canadian Electrical Manufacturers’ AssociationVerband der Kanadischen Elektroindustrie

Canada

CEN Comité Européen de NormalisationEuropean standards committee

Europe

CENELEC Comité Européen de coordination de Normalisation Élec-trotechnique, European committee for electro-technical standards

Europe

9-6



9

CSA Canadian Standards AssociationCanadian standards association, Canadian standard

Canada

DEMKO Danmarks Elektriske MaterielkontrolDanish material control for electrotechnical products

Denmark

DIN Deutsches Institut für Normung German institute for standardisation

Germany

DNA Deutscher Normenausschuss German standards commit-tee

Germany

DNV Det Norsk VeritasShip classification association

Norway

EN European standard Europe

ECQAC Electronic Components Quality Assurance CommitteeCommittee for components with a verified quality

Europe

ELOT Hellenic Organization for StandardizationGreek organization for standardization

Greece

EOTC European Organization for Testing and CertificationEuropäische Organisation für Konformitätsbewertung

Europe

ETCI Electrotechnical Council of IrelandIrish organization for standardization

Ireland

GL Germanischer LloydShip classification association

Germany

HD Harmonization document Europe

IEC International Electrotechnical CommissionInternational Electrotechnical Commission

–

IEEE Institute of Electrical and Electronics Engineers Verein der Elektro- und Elektronik-Ingenieure

USA

IPQ Instituto Portoguês da QualidadePortuguese quality institute

Portugal

ISO International Organization for Standardization Internationale Organisation für Normung

–


9-7



9

JEM Japanese Electrical Manufacturers AssociationElectrical industry association

Japan

JIC Joint Industry ConferenceGesamtverband 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 AssociationElectrical 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



9

PRS Polski Rejestr Statków Ship classification association

Poland

PTB Physikalisch-Technische Bundesanstalt German physi-cal/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 cer-tification

Luxemburg

SEMKO Svenska Elektriska Materielkontrollanstalten Swedish test institute for electrotechnical products

Sweden

SEV Schweizerischer Elektrotechnischer Verein Swiss electro-technical 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 acci-dent 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, Informationstech-nik (Verband Deutscher Elektrotechniker)Association of electrical, electronics and information technology

Germany

ZVEI Zentralverband Elektrotechnik- und Elektronikindustrie Central association of the electrical and electronic industry

Germany


9-9


9

Export to the world market and to North AmericaTest 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

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 Characters

Belgium Comité Electrotechnique BelgeBelgisch Elektrotechnisch Comité (CEBEC)

Denmark Danmarks Elektriske Materielkontrol (DEMKO)

Germany Verband Deutscher Elektrotechniker (VDE)

Finland FIMKO

France Union Technique de l’Electricité (UTE)

v

9-10

Export to the world market and to North AmericaTest authorities and approval stamps


9

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

Listing

Recognition

Canada Canadian Standards Association (CSA)

Country Test authority Characters

9-11


9

Export to the world market and to North AmericaMarking 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

9-12



9

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

9-13



9

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

Code letter Device or Function

9-14



9

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 CageInduction MotorSynchro, General• Control transformer• Control transmitter• Control Receiver• Differential Receiver• Differential Transmitter• Receiver• Torque Receiver• Torque TransmitterSynchronous MotorWound-Rotor Induction Motor or Induction Frequency Convertor

BT Battery

C Capacitor• Capacitor, General• Polarized CapacitorShielded Capacitor

CB Circuit-Breaker (all)

9-15



9

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 AnnunciatorLight Emitting DiodeLamp• Fluorescent Lamp• Incandescent Lamp• Indicating Lamp

E Armature (Commutor and Brushes)

Lightning ArresterContact• Electrical Contact• Fixed Contact• Momentary ContactCore• Magnetic CoreHorn GapPermanent MagnetTerminalNot Connected Conductor

Code letter

Device or Function

9-16



9

F Fuse

G Rotary Amplifier (all)A.C. GeneratorInduction Machine, Squirrel CageInduction Generator

HR Thermal Element Actuating Device

J Female Disconnecting DeviceFemale Receptacle

K Contactor, Relay

L Coil• Blowout Coil• Brake Coil• Operating CoilField• Commutating Field• Compensating Field• Generator or Motor Field• Separately Excited Field• Series Field• Shunt FieldInductorSaturable Core ReactorWinding, General

LS Audible Signal Device• Bell• Buzzer• Horn

M Meter, Instrument

Code letter

Device or Function

9-17



9

P • Male Disconnecting Device• Male Receptable

Q Thyristor• NPN-Transistor• PNP-Transistor

R Resistor• Adjustable Resistor• Heating Resistor• Tapped Resistor• RheostatShunt• Instrumental Shunt• Relay Shunt

S Contact• Time Closing Contact• Time Opening Contact• Time Sequence Contact• Transfer Contact• Basic Contact Assembly• Flasher

Code letter

Device or Function

9-18



9

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 SwitchThermostat

Code letter

Device or Function

9-19



9

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• ShieldedConductor, General

X Tube Socket

Code letter

Device or Function

9-20


Export to the world market and to North AmericaCircuit symbols, European – North America

9

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

or or

Connection of conductors (node)

Terminal

Terminal strip/block

Conductors

03-02-04 03-02-05

03-02-01

03-02-02

03-02-03

1 2 3 4 1 2 3 4

03-01-01

9-21



9

Conductor (for later expansion)

Line of application, general symbol

Line of application, optional, denoting small interval

Separation between two fields

Line of separation between functional units

Shielding

Earth, general symbol Ground, general symbol

Protective earth Protective ground

Connector with plug and socket

or

Isolating point, lug, closed


103-01-01

02-12-01

02-12-04

02-01-06

02-01-06

02-01-07

02-15-01GRD

02-15-03

03-03-05 03-03-06

03-03-18

9-22



9

Passive components

Resistor, general symbol or or

Resistor with fixed tappings or

Variable resistor, general

Adjustable resistor

Resistor with sliding contact, potentiometer

Winding, inductance, general or

Winding with fixed tapping

Capacitor, general symbol or or

Variable capacitor


04-01-02 04-01-02RES

04-01-09

RES

04-01-03RES

RES

04-01-07

RES

04-03-01 04-03-02

04-03-06

04-02-01 04-02-02

104-02-01

9-23



9


Visual indicator, general symbol

*with colour stated

Indicator light, general symbol or or

*with colour stated

Buzzers or

Horn, claxon

Drives

Manual operation, general use

Operated by pushing

Operated by pulling

Operated by turning

Operated by key

Operated by rollers, sensors


08-10-01

08-10-1108-10-10

ABU

08-10-05

HN

02-13-01

02-13-05

02-13-03

02-13-04

02-13-13

02-13-15

9-24



9

Stored energy mechanism, general symbol

Switch mechanism with mechanical release

Operated by motor

Emergency switch

Operated by electromagnetic overcurrent protection

Operated by thermal overcurrent protection

Electromagnetic operation

Control by fluid level

Electromechanical, electromagnetic operating devices

Electromechanical operating device, general symbol, relay coil, general symbol

or or

x device code letter a table, page 9-13

Operating device with special features, general symbol

or or



02-13-20

102-05-04

M

02-13-26

MOT

02-13-08

02-13-24

02-13-25

OL

02-13-23

02-14-01

07-15-01

×

×

9-25



9

Electromechanical operating device with On-delay

or or


Electromechanical device with Off-delay

or or


Electromechanical device with On- and Off-delay

or or


Electromechanical device of a thermal relay or

Contacts

N/O contact or or

N/C contact or

Changeover contact with interruption

or

Early-make N/O contact of a contact assembly

TC or TDC

Late-break N/C contact of a contact assembly

T0 or TD0


07-15-08

×

07-15-07

×

07-15-09

×

07-15-21

07-02-01 07-02-02

07-02-03

07-02-04

07-04-01

07-04-03

9-26



9

N/O contact, delayed when closing

or

N/C contact, delayed when reclosing

or

Control devices

Push-button (not stay-put)

Spring-return switches with N/C contact, manually operated by pushing, e.g. push-button

Spring-return switches with N/O and N/C contacts, manually operated by pushing

Spring-return switches with latching position and one N/O contact, manually operated by pushing

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)

Position switches (N/C contacts)Limit switches (N/C contacts)

Spring-return switches with N/O contacts, mechanically operated, N/O contacts closed


07-05-02 07-05-01T.C.

07-05-03 07-05-04T.C.

07-07-02

PB

PB

PB

PB

07-08-01

LS

07-08-02

LS

LS

9-27



9

Spring-return switches with N/C contacts, mechanically operated, N/C contacts open

Proximity switches (N/C contacts), actuated by the proximity of iron

Proximity switches, inductive, N/O contacts

Proximity switches, block diagram

Under-pressure relays, N/O contacts

or

Pressure switches, N/C contact or

Float switches, N/O contact

Float switches, N/C contact


LS

Fe

07-20-04

Fe

07-19-02

07-17-03

P< P

P > P

9-28



9

Switchgear

Contactors (N/O contacts)

x code letter

Three-pole contactor with bimetal relay (3 thermal elements)

x code letter

Three-pole switch-disconnector

Three-pole circuit-breaker

Three-pole breaker with switch mechanism with three thermoelectric overcurrent releases, three electromagnetic overcurrent releases, motor-protective circuit-breaker

Fuse, general symbol

Transformers, current transformers

Transformers with two windings

or


07-13-02

OL

07-13-06

DISC

07-13-05

CB

107-05-01

l > l > l >

x x x

07-21-01

FU

06-09-02 06-09-01X1 X2

H1 H2

9-29



9

Autotransformer or or

Current transformer or or

Machines

Generator or

Motor, general symbol or

DC motor, general symbol

AC motor, general symbol

Three-phase asynchronous motor with squirrel-cage rotor

or

Three-phase asynchronous motor with slip-ring rotor


06-09-07

06-09-06

06-09-11 06-09-10

CT

(H1)(X1)

G

06-04-01

G GEN

M

06-04-01

M

06-04-01

MOT

M

06-04-01

M

06-04-01

M~

M3~

06-08-01

M

M3~

06-08-03

9-30



9

Semiconductor components

Static input

Static output

Static input with negation

Static output with negation

Dynamic input, change of status from 0 to 1 (L/H)

Dynamic input with negation, change of status from 1 to 0 (H/L)

AND gate, general symbol

OR gate, general symbol

NOT gate, inverter

AND with negated output, NAND

OR with negated output, NOR


12-07-01

12-07-02

12-07-07

12-07-08

&

12-27-02

A

� 1

12-27-01

OR

1

12-27-11

OR

&12

1312-28-01

A

� 134512-28-02

OR

9-31



9

Exclusive OR gate, general

RS flip-flop

Monostable gate, cannot be triggered during the output pulse, general symbol

Delay, variable with indication of delay values

Semiconductor diode, general symbol

Limiting diode Zener diode

Light-emitting diode (LED), general symbol

Bi-directional diode, diac

Thyristor, general symbol

PNP transistor or

NPN transistor, in which the collector is connected to the enclosure

or


= 1

12-27-09

OE

SR

12-42-01

S FF 1TC 0

1

12-44-02

SS

02-08-05

TPAdj.m/ms

05-03-01

(A) (K)

05-03-06

05-03-02

05-03-09

(T) (T)

05-04-04

(A) (K)

05-05-01

(A) (K) (E) (C)

(B)

05-05-02

(A)(K) (E) (C)

(B)

9-32


Export to the world market and to North AmericaCircuit diagram examples to North American specifications

9

Direct motor starters, fuseless with circuit-breakers

Control circuit with fuse

Control circuit, fuseless

L1

L2

L3

CB L1L2

L3

T1T2

T3

H3

H1 H4

1 4H2

X1 X2

1FU 2FU

M

M

X1 X2

A1 A2W

2 PB

M1313

1414

M

1211

1 PBSTOP

START

L1

L2

L3

CB L1L2

L3

T1T2

T3

H31 4H2

X1 X2

M

M

H1 H4

H1 H4

9-33

Export to the world market and to North AmericaCircuit diagram examples to North American specifications


9

Mot

or s

tart

ers

to U

L

aFe

eder

Circ

uit

bBr

anch

Circ

uit 1

cBr

anch

Circ

uit 2

dPo

wer

Tra

nsfo

rmer

eCo

ntro

l Circ

uit T

rans

form

erf

Clas

s 2 T

rans

form

er

gCl

ass 2

Circ

uit

1 DI

SCL

1L

1T

11

FU-1

1 M

-110

L

2 M

-1

2 M

-1

2 M

-12 PB

-22

PB-1

2 PB

-21

LS

20 L

MTR

1

MTR

2

a

1 FU

-21

FU-3

4 FU

-1

5 FU

-1

5 FU

-2

3 FU

-2

3 T

2 FU

-2

2 FU

-1

4 FU

-2

1 PB

-11

PB-2

1 M

-1

1 M

-21

SOL

1 M

-11

M-2

1 M

-1

1 FS

1 CR

-1

1 CR

-1

L 2

L 2

T 2

L 3

L 3

T 3

1 T

2 T

d

b

f g

c

e

9-34


9

9-35


9

Export to the world market and to North AmericaNorth American classification for control switches

Switching capacity

Rated voltage V Make A Break A

120240480600

60301512

631.51.2

120240480600

30157.56

31.50.750.6

120240480600

157.53.753

1.50.750.3750.3

120240

3.61.8

0.60.3

125250301 – 600

2.21.10.4

2.21.10.4

125250301 – 600

1.10.550.2

1.10.550.2

125250301 – 600

0.550.270.10

0.550.270.10

125250301 – 600

0.220.11–

0.220.11–

Classification DesignationAt maximum rated voltage of

Thermal uninter-rupted cur-rent

AC voltage 600 V 300 V 150 V A

Heavy Duty A600A600A600A600

A300A300––

A150–––

10101010

Standard Duty B600B600B600B600

B300B300––

B150–––

5555

C600C600C600C600

C300C300––

C150–––

2.52.52.52.5

––

D300D300

D150–

11

DC voltage

Heavy Duty N600N600N600

N300N300–

N150––

101010

Standard Duty P600P600P600

P300P300–

P150––

555

Q600Q600Q600

Q300Q300–

Q150––

2.52.52.5

–––

R300R300–

R150––

1.01.0–

to UL 508, CSA C 22.2-14 and NEMA ICS 5

9-36

Export to the world market and to North AmericaNorth American classification for control switches


ed voltage ofThermal uninter-rupted cur-rent

300 V 150 V A

A300A300––

A150–––

10101010

B300B300––

B150–––

5555

C300C300––

C150–––

2.52.52.52.5

D300D300

D150–

11

N300N300–

N150––

101010

P300P300–

P150––

555

Q300Q300–

Q150––

2.52.52.5

R300R300–

R150––

1.01.0–

9

Switching capacity

Rated voltage V Make A Break A Make VA Break VA

120240480600

60301512

631.51.2

7200720072007200

720720720720

120240480600

30157.56

31.50.750.6

3600360036003600

360360360360

120240480600

157.53.753

1.50.750.3750.3

1800180018001800

180180180180

120240

3.61.8

0.60.3

432432

7272

125250301 – 600

2.21.10.4

2.21.10.4

275275275

275275275

125250301 – 600

1.10.550.2

1.10.550.2

138138138

138138138

125250301 – 600

0.550.270.10

0.550.270.10

696969

696969

125250301 – 600

0.220.11–

0.220.11–

2828–

2828–

9-37


9

Export to the world market and to North AmericaRated 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 V120 V

230 V3) 240 V

460 V480 V

575 V600 V

1/23/41

4.46.48.4

2.23.24.2

1.11.62.1

0.91.31.7

11/223

1213.6

6.06.89.6

3.03.44.8

2.42.73.9

571/210

15.22228

7.61114

6.1911

152025

425468

212734

172227

304050

80104130

405265

324152

6075100

154192248

7796124

627799

125150200

312360480

156180240

125144192

250300350

302361414

242289336

400450500

477515590

382412472

1) Source: 1/2 – 200 HP250 – 500 HP

= NEC Code, Table 430-250= UL 508, Table 45.2

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.

3) For motor full-load currents of 208 V motors/200 V motors, use the appropriate values for 230 V motors, increased by 10 – 15 %.

9-38


Export to the world market and to North AmericaProtection types for electrical equipment for North America

9

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.

1) NEMA = National Electrical Manufacturers Association

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 1General purpose

IP20 UL/CSA type 4 Xdust-tight, water-tight,corrosion-resistant, rain-tight

IP66

UL/CSA type 2Drip-tight

IP22 UL/CSA type 5drip-tight, dust-tight

IP53

UL/CSA type 3Dust-tight, rain-tight, resistant to sleet and ice

IP55 UL/CSA type 6rain-tight, water-tight, immersible, resistant to hail and ice

IP67

UL/CSA type 3 RRain-proof, resistant to sleet and ice

IP24 UL/CSA type 12For use in industry, drip-tight, dust-tight

IP54

UL/CSA type 3 SDust-tight, rain-tight, resistant to sleet and ice

IP55 UL/CSA type 13dust-tight, oil-tight, drip-tight

IP54

UL/CSA type 4dust-tight, water-tight, rain-tight

IP66

9-39

Export to the world market and to North AmericaProtection types for electrical equipment for North America


9

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

9-40


Export to the world market and to North AmericaNorth American cable cross-sections

9

Conversion of North American cable cross sections into mm2

USA/Canada Europe

AWG mm2

(exact)

mm2

(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 35

1 42.41

1/0 (0) 53.49 50

2/0 (00) 67.43 70

3/0 (000) 85.01

4/0 (0000) 107.2 95

9-41

Export to the world market and to North AmericaNorth American cable cross-sections


9

USA/Canada Europe

kcmil mm2

(exact)

mm2

(nearest standard size)

250 127 120

300 152 150

350 177 185

400 203

450 228

500 253 240

550 279

600 304 300

650 329

700 355

750 380

800 405

900 456

1,000 507 500

In addition to “circular mills”, cable sizes are often given in “MCM”: 250 000 circular mills = 250 MCM

9-42


9

9-43


9

9-44


Standards, formulae, tables

0
1
Page

Marking of electrical equipment 10-2

Protective measures 10-5

Overcurrent protection of cables and conductors 10-13

Electrically critical equipment of machines 10-21

Measures for risk reduction 10-26

Degrees of protection for electrical equipment 10-28

Utilisation categories for contactors and motor starters 10-34

Utilisation categories for switch-disconnectors 10-38

Rated motor currents 10-40

Conductors 10-43

Formulea 10-50

Standard international units 10-54

10-1


10

Standards, formulae, tablesMarking 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 company-specific stipulations for implementing the standard, which deviate from the standard to some extent.

• 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.

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.

10-2



0
1
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

10-3



10

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

Code letter old Example for electrical equipment Code letter new

10-4


Standards, formulae, tablesProtective measures

0
1
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 contactThese 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 contactThis is the protection of personnel and working animals from dangers which may arise from accidental contact with components or extraneous conductive parts.

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).

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

Protective insulation (Total insulation) k

Protection by partitioning Protection by non-conduc-tive spaces

Protection by distancing Protection by non-earthed local equipotential bond-ing

Protective separation

10-5



10

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

a System earthb Chassisc Impedance

Earth continuity type systems Meaning of designation

TN systemT: Direct earthing of a point (system earth)N:Chassis directly connected to the system earth

TT systemT: Direct earthing of a point (system earth)T: Chassis directly earthed, independent of the

earthing of the power supply (system earth)

IT networkI: All live parts isolated from earth or one point

connected to earth via an impedanceT: Chassis directly earthed, independent of the

earthing of the power supply (system earth)

L2

N

L1

L3

PE

b

a

L2

N

L1

L3

PE

b

a

L2L1

L3

c b

PE

10-6



0
1
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 Description so far

Condition for dis-connection

Overcurrent protective device

TN-S systemseparated neutral and earth con-ductors throughout the system

Zs X Ia F U0 Zs = Impedance of the fault circuitIa = current, which causes disconnec-tion in:• F 5 s• F 0.2 sin circuits up to 35 A with sockets and hand-held compo-nents which can be movedU0 = rated voltage against earthed con-ductor

FusesMiniature cir-cuit-breakersCircuit-break-ers

TN-C systemNeutral conductor and protection functions are combined throughout the system in a single PEN conduc-tor.

Protective multiple earthing

L2

N

L1

L3

PE

L2

PEN

L1

L3

10-7



10


* a table, page 10-12


TN system

Protection with


Condition for dis-connection


TN-C-S systemNeutral conductor and protection functions are in a part of the system combined in a single PEN conductor

Residual-cur-rent protec-tive device

Residual-current protective circuit

Zs X IDn F U0 IDn = Rated fault current U0 = Maximum per-missible touch volt-age*:(F 50 V AC, F 120 V DC)

Residual volt-age protec-tion device (in special case)

Insulation monitoring device

L2L1

L3NPE(N)

L2L1

L3NPE(N)

10-8



0
1



TT system

Protection with Circuit principle Description so far

Conditions for indica-tion/disconnection


FusesMiniature cir-cuit-breakersCircuit-break-ers

Protective earth

RA X Ia F UL RA = Earthing resist-ance of conductive parts of the chassisIa = Current which causes automatic dis-connection in F 5 sUL = Maximum per-missible touch volt-age*:(F 50 V AC, F 120 V DC)

Residual-cur-rent protective device

Residual-cur-rent protec-tive circuit

RA X IΔn F UL IΔn = Rated fault cur-rent

Residual-volt-age protective device (for spe-cial cases)

Residual-voltage pro-tective circuit

RA: max. 200 O

L2

PE

L1

L3NPE

PE

L2

PE

L1

L3N

L2L1

L3N

PE PE

F1 F1 F1

L2

N

L1

L3

PE

FU

10-9



10




TT system

Protection with

Circuit principle Descrip-tion so far



–


Feed back to protec-tive multi-ple earth-ing

RA X Id F UL (1)ZS X Ia F Uo (2)RA = Earthing resist-ance of all conductive parts connected to an earthId = 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 itUL = Maximum per-missible touch volt-age*:F 50 V AC, F 120 V DC

L2

PE

L1

L3

10-10



0
1



IT network

Protection with



Residual cur-rent protec-tive device

Residual-current pro-tective cir-cuit

RA X IΔn F UL

IΔn = Rated fault cur-rent

Residual volt-age protective device (for special cases)

Residual-voltage pro-tective cir-cuit

RA: max. 200 O


a additional potential equalisation

Protective-conductor system

R X Ia F UL

R = Resistance between components and extraneous con-ductive parts which can be touched simul-taneously

L2

PE

L1

L3

PE

F1 F1

L2L1

L3

FU

PE

FU

PE

L2

PE

L1

L3

Z<

�

10-11



10

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

5.0

2.0

1.0

0.5

0.2

0.1

0.05

0.0250 100 200 300 400

U [V]

t [s]Anticipated touch voltage Max. per-

missible dis-connection time

AC eff

[V]DC eff

[V] [s]

< 50 < 120 ·50 120 5.0

75 140 1.0

90 160 0.5

110 175 0.2

150 200 0.1

220 250 0.05

280 310 0.03

10-12


Standards, formulae, tablesOvercurrent protection of cables and conductors

0
1
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.

For the protection of conductors against overload the following conditions must be fulfilled (source: DIN VDE 0100-430)

IB Anticipated operating current of the circuit IZ Current carrying capacity of conductor or

cableIn Rated current of protective device

Note:

For adjustable protective devices, In corresponds to the value set.

I2 The current which causes tripping of the protective device under the conditions specified in the equipment regulations (high test current).

Arrangement of protection devices for overload protectionProtection 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.

IB F In F IZI2 F 1,45 IZ

IA

1.45 � Iz

Charactistics ofprotective device

Operational current

Rated

- or s

etting

curre

nt I n

Tripp

ing cu

rrent

I 2

Current-carrying capacity Iz

Reference values

of conductor IB

10-13



10

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 short-circuit 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:

or

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 Ak: 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

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 short-circuit current-carrying capacity is reduced unless a protective device fitted upstream can ensure the necessary protection in the event of a short circuit.

t kxS

T--⎝ ⎠

⎛ ⎞2

= I2 x t = k2 x S2

10-14



0
1
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 conductorsOvercurrent 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 conductorWhere 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

Curr

ent-

carr

ying

cap

acity

and

pro

tect

ion

of c

able

s an

d co

nduc

tors

with

PVC

in

sula

tion

to D

IN V

DE

0298

-4, a

t 25

°C a

mbi

ent t

empe

ratu

re

Type

of c

able

or

cond

ucto

rN

YM, N

YBUY

, NHY

RUZY

, NYI

F,H0

7V-U

, H07

V-R,

H07

V-K,

NYI

FYN

YY, N

YCW

Y, N

YKY,

NYM

, N

YMZ,

NYM

T, N

YBUY

, N

HYRU

ZY

Type

of

inst

alla

tion

A1B1

B2C

EO

n or

und

er th

e w

all s

urfa

ce, u

nder

pla

ster

In h

eat-i

nsul

atin

g w

alls,

in

con

duit

unde

r the

su

rface

In e

lect

rical

con

duit

or c

able

cha

nnel

Dire

ct in

stal

latio

nex

pose

dSi

ngle

-cor

e ca

ble

Mul

ti-co

re c

able

Mul

ti-co

re c

able

und

er

the

surfa

ceSi

ngle

wire

s in

cond

uit o

n th

e w

all s

urfa

ce

Mul

ti-co

re c

able

in

cond

uit o

n th

e w

all

surfa

ce o

r on

the

floor

Mul

ti-co

re c

able

Sp

ur w

iring

in th

e w

all o

r und

er p

last

er

Num

ber o

f cor

es2

32

32

32

32

3Cu

rrent

-car

ryin

g ca

pacit

y Iz in

A fo

r 25

C am

bien

t te

mpe

ratu

re a

nd 7

0 C

oper

atin

g te

mpe

ratu

re.

For t

he a

lloca

tion

of o

verc

urre

nt p

rote

ctiv

e de

vice

s app

ly th

e fo

llow

ing

cond

ition

s Ib F

I n F

I z

and

I 2 F

1.4

5 I z

t. F

or o

verc

urre

nt p

rote

ctio

n de

vice

s with

a tr

ippi

ng c

urre

nt o

f I2 F

I n o

nly

appl

y th

e co

nditi

on:

I b F

I n F

I z (I

b: Op

erat

ing

curre

nt o

f the

circ

uit).

Circ

uit-b

reak

ers a

nd sw

itch-

disc

onne

ctor

s ful

fil th

is co

nditi

on. F

or o

verc

urre

nt p

rote

ctiv

e de

vice

s with

oth

er tr

ippi

ng

curre

nts,

only

the

follo

win

g co

nditi

on a

pplie

s:

� 0

.3 d

d

� 0

.3 d

d

I n F

; =

1,

45 x--------

--I n⋅

I z I n

10-16



0
1
Cont

inue

Type

of

inst

alla

tion

A1B1

B2C

E

Num

ber o

f co

res

23

23

23

23

23

Copp

er

cond

ucto

r cr

oss-

sect

ion

in

mm

2

I zI n

I zI n

I zI n

I zI n

I zI n

I zI n

I zI n

I zI n

I zI n

I zI n

1.5

16.5

1614

1318

.516

16.5

1616

.516

1513

2120

18.5

1621

2019

.516

2.5

2120

1916

2525

2220

2220

2020

2825

2525

2925

2725

428

2525

2534

3230

2530

2528

2537

3535

3539

3536

35

636

3533

3243

4038

3539

3535

3549

4043

4051

5046

40

1049

4045

4060

5053

5053

5050

5067

6363

6370

6364

63

1665

6359

5081

8072

6372

6365

6390

8081

8094

8085

80

2585

8077

6310

710

094

8095

8082

8011

910

010

210

012

512

510

710

0

3510

510

094

8013

312

511

810

011

710

010

110

014

612

512

612

515

412

513

412

5

5012

612

511

410

016

016

014

212

5–

––

––

––

––

––

–

7016

016

014

412

520

420

018

116

0–

––

––

––

––

––

–

9519

316

017

416

024

620

021

920

0–

––

––

––

––

––

–

120

223

200

199

160

285

250

253

250

––

––

––

––

––

––

For o

verc

urre

nt p

rote

ctiv

e de

vice

s who

se ra

ted

curre

nt In

doe

s not

con

form

to th

e va

lues

giv

en in

the

tabl

e, se

lect

the

next

low

er a

vaila

ble

rate

d cu

rrent

val

ue.

10-17



10

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 con-ductors

Insulated power cables

0,6/1-kV cable with 4 conduc-tors

Protected Unprotected2)

mm2 mm2 mm2 mm2 Cu Al

mm2 Cu

up to

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 1851) 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



0
1
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.

1) Higher ambient temperatures in accordance with information given by the manufacturer

Insulation material1) NR/SR PVC EPR

Permissible operational tempera-ture

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

10-19



10

Converstion factors to VDE 0298 part 4

Grouping of several circuits

Arrangement Number of circuits

1 2 3 4 6 9 12 1516

20

1 Embedded or enclosed

1.00 0.80 0.70 0.700.65

0.550.57

0.50 0.45 0.400.41

0.400.38

2 Fixed to walls or floors

1.00 0.85 0.800.79

0.75 0.700.72

0.70 – – –

3 Fixed to ceilings 0.95 0.800.81

0.700.72

0.700.68

0.650.64

0.600.61

– – –

4 Fixed to cable trays arranged horizontally or vertically

1.000.970.90

0.870.80

0.770.75

0.730.75

0.720.70 – – –

5 Fixed to cable trays or consoles

1.00 0.840.85

0.830.80

0.810.80

0.790.80

0.780.80

– – –

10-20


Standards, formulae, tablesElectrically critical equipment of machines

0
1
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).

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.

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

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.

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. Star-delta, reversing and multi-speed switches are not permissible for use as mains isolating devices.

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 contactThis 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

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 contactThis 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 failureWhen 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.

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 motor-protective circuit-breakers with undervoltage releases also reliably prevent automatic restarting on return of voltage.

Overcurrent protectionNo 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 single-phasing.

Overload protection of motorsContinously 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.

10-22



0
1
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 deviceEvery machine which could potentially cause danger must be equipped with an Emergency-Stop 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 de-energization 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 mushroom-head 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 operationsThe term Emergency-Stop is short and concise, and should continue to be used for general usage.

It is not clear however from the term Emergency-Stop 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-StopThis 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

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)

10-24



0
1
Colours of indicator lights and their meanings

To IEC/EN 60073, VDE 0199, IEC/EN 60204-1 (VDE 0113 Part 1)

Colours of illuminated push-buttons and their meanings

Both tables are valid for illuminated push-buttons, Table 1 relating to the function of the actuators.

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

10-25


10

Standards, formulae, tablesMeasures for risk reduction

Risk avoidance in a malfunction

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 IEC/EN 60204 1 specifies a range of measures which can be taken to reduce danger in the event of a fault.

The use of proven circuits and components

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

f Chassis earth connection of the control circuit for operational purposes (not used as a protective measure)

RedundancyThis means the existence of an additional device or system which takes over the function in the event of a fault.

L01

0

K1

K1I

⎧⎪⎪⎪⎪⎨⎪⎪⎪⎪⎩

⎧⎪⎨⎪⎩

L1

L2

L02

�

�

�

�

�

�

10-26

Standards, formulae, tablesMeasures for risk reduction


0
1
Diversity

The construction of control circuits according to a range of function principles or using various types of device.

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 circuite Safety barrier closed

Performance testsThe correct functioning of the equipment can be tested either manually or automatically.

c

ed

K1 K2

K1

K2

13

14

21

22

a

b

10-27


10

Standards, formulae, tablesDegrees 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

First nu-meral

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



0
1
Protection against contact and foreign bodies

First numeral



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 opera-tion of the equipment or with safety.

6 Protection against the ingress of dust

Dust-tight

Protection against contact with live parts with a wire.The entry probe, 1.0 mm diameter, must not penetrate.

No entry of dust.

Example for stating degree of protection: IP 4 4

Characteristic letterFirst numeralSecond numeral

10-29



10

Protection against water

Sec-ond nu-meral



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 splash-ing 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 power-ful water jets

Water projected in powerful jets against the enclosure from any direction shall have no harmful effect.

7 Protected against the effects of occa-sional submer-sion

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



0
1
8 Protected against the effects of sub-mersion

Ingress of water in harmful quantities must not be possible when the equipment is continuously submerged in water under condi-tions which are subject to agreement between manufacturer and user.These conditions must be more stringent than those for charac-teristic numeral 7.

9K* Protected during cleaning using high-pres-sure/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 barWater temperature of 80 °C

* This characteristic numeral originates from DIN 40050 9.

Sec-ond nu-meral



10-31



10

Abnorm

Switch off Switch

c c

0.9 1 1 0.9 –

0.65 1 1 0.65 10

0.3 1 1 0.3 6

0.3 1 1 0.3 10

t0,95 T0,95

1 ms 1 1 1 ms –

6 x P1) 1 1 6 x P1) 1.1

15 ms 1 1 15 ms 10

1) The value “6 x P” results from an empirical reloads to an upper limit of P = 50 W, i.e. 6 [ms]/[Wgreater than 50 W are assumed to consist of smaan upper limit, irrespective of the power consum

I

Ie

U

Ue

I

Ie

I

Ie

U

Ue

I

Ie

Type of current

Utilisation catorgory

Typical applications: Normal condi-tions of use

I = Switch-on current, Ic = Switch-off current,Ie = Rated operational current, U = Voltage,Ue = Rated operational voltageUr = 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

Switch on

Alternat-ing cur-rent

AC-12 Control of resistive and solid state loads as in optocoupler input circuits

1 1

AC-13 Control of solid state loads with transformer iso-lation

2 1

AC-14 Control of small electromagnetic loads (max. 72 VA)

6 1

AC-15 Control of electromagnetic loads (above 72 VA) 10 1

Direct current

DC-12 Control of resistive and solid state loads as in optocoupler input circuits

1 1

DC-13 Control of electromagnets 1 1

DC-14 Control of electromagnetic loads with economy resistors in the circuit

10 1

to IEC 60947-5-1, EN 60947-5-1 (VDE 0600 part 200)

I

Ie

U

Ue

I

Ie

U

Ue

10-32



0

s: Normal condi-tions of use

ent, Ic = Switch-off current,onal current, U = Voltage,onal voltageage,until 95 % of the steady-state eached.ed power in Watts

Switch on

and solid state loads as in circuits

1 1

te loads with transformer iso- 2 1

ectromagnetic loads (max. 72 6 1

magnetic loads (above 72 VA) 10 1

and solid state loads as in circuits

1 1

magnets 1 1

magnetic loads with economy uit

10 1

t 200)

I

Ie

U

Ue

I

Ie

U

Ue

1

Abnormal conditions of use

Switch off Switch on Switch off

c c c c

0.9 1 1 0.9 – – – – – –

0.65 1 1 0.65 10 1.1 0.65 1.1 1.1 0.65

0.3 1 1 0.3 6 1.1 0.7 6 1.1 0.7

0.3 1 1 0.3 10 1.1 0.3 10 1.1 0.3

t0,95 T0,95 T0,95 T0,95

1 ms 1 1 1 ms – – – – – –

6 x P1) 1 1 6 x P1) 1.1 1.1 6 x P1) 1.1 1.1 6 x P1)

15 ms 1 1 15 ms 10 1.1 15 ms 10 1.1 15 ms

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.

I

Ie

U

Ue

I

Ie

U

Ue

I

Ie

U

Ue

I

Ie

U

Ue

I

Ie

U

Ue

I

Ie

U

Ue

10-33


10

Standards, formulae, tablesUtilisation categories for contactors and motor starters

Verification of

Switch off Switch on

c c

0.95 1 1 0.95 All val-ues

1

0.65 2.5 1 0.65 All val-ues

4

0.650.35

11

0.170.17

0.650.35

Ie F 100Ie > 100

88

0.650.35

66

11

0.650.35

Ie F 100Ie > 100

11

3

1.

1

8

6

6

8

Ic

Ie

Ur

Ue

Ie

A

I

I

Type of current

Utilisation catorgory

Typical applications:I = Switch-on current, Ic = Switch-off current,Ie = Rated operational current, U = voltage,Ue = Rated operational voltageUr = Recovery voltage

Verification of elec-trical lifespan

Switch on


AC-1 Non-inductive or slightly inductive loads, resistance furnaces

All val-ues

1 1

AC-2 Slip-ring motors: starting, switch-off All val-ues

2.5 1

AC-3 Squirrel-cage motors: stating, switch-off, switch-off during running4)

Ie F 17Ie > 17

66

11

AC-4 Sqirrel-cage motors: starting, plugging, reversing, inching

Ie F 17Ie > 17

66

11

AC-5A Switching of electric discharge lamp con-trols

AC-5B Switching of incandescent lamps

AC-6A3) Switching of transformers

AC-6B3) Switching of capacitor banks

AC-7A Slightly inductive loads in household appli-ances and similar applications

Data as sup-plied by the manufacturer

AC-7B Motor load for household appliances

AC-8A Switching of hermetically enclosed refriger-ant compressor motors with manual reset of overload releases5)

AC-8B Switching of hermetically enclosed refriger-ant compressor motors with automatic reset of overload releases5)

AC-53a Switching of squirrel-cage motor with semi-conductor contactors

Ie

A

I

Ie

U

Ue

10-34



0

s:nt, ent,nal current,

onal voltageage

Verification of elec-trical lifespan

Switch on

ghtly inductive loads, All val-ues

1 1

arting, switch-off All val-ues

2.5 1

rs: stating, switch-off, unning4)

Ie F 17Ie > 17

66

11

: starting, plugging, Ie F 17Ie > 17

66

11

c discharge lamp con-

descent lamps

ormers

tor banks

ads in household appli-pplications

Data as sup-plied by the manufacturer

sehold appliances

tically enclosed refriger-tors with manual reset s5)

tically enclosed refriger-tors with automatic leases5)

el-cage motor with ntactors

Ie

A

I

Ie

U

Ue

1

Verification of switching capacity


c c c c

0.95 1 1 0.95 All val-ues

1.5 1.05 0.8 1.5 1.05 0.8

0.65 2.5 1 0.65 All val-ues

4 1.05 0.65 4 1.05 0.8

0.650.35

11

0.170.17

0.650.35

Ie F 100Ie > 100

88

1.051.05

0.450.35

88

1.051.05

0.450.35

0.650.35

66

11

0.650.35

Ie F 100Ie > 100

1010

1.051.05

0.450.35

1010

1.051.05

0.450.35

3.0 1.05 0.45 3.0 1.05 0.45

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) 6.0 1.05 1)

6.0 1.05 1) 6.0 1.05 1)

8.0 1.05 0.35 8.0 1.05 0.35

Ic

Ie

Ur

Ue

Ie

A

I

Ie

U

Ue

Ic

Ie

Ur

Ue

10-35



10

Verification of sw

Switch off Switch on

L/R ms

L/R ms

1 1 1 1 All values 1

2 2.5 1 2 All values 4

7.5 2.5 1 7.5 All values 4

1

4) Devices for utilization category AC-3 may be ulimited period such as for setting up a machinoperations must not exceed a total of five per

5) Hermetically enclosed refrigerant compressor a motor both of which are housed in the samethe motor running in the refrigerant.

Ic

Ie

Ur

Ue

Ie

A I

Type of 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

Switch on

Direct current

DC-1 Non-inductive or slightly inductive loads, resistance furnaces

All values 1 1

DC-3 Shunt motors: starting, plugging, revers-ing, inching, dynamic braking

All values 2.5 1

DC-5 Series motors: starting, plugging, revers-ing, inching, dynamic braking

All values 2.5 1

DC-6 Switching of incandescent lamps

To IEC/EN 947 4-1-60947, VDE 0660 Part 102

1) c = 0,45 for Ie F 100 A; c = 0,35 for Ie > 100 A.2) Tests must be carried out with an incandescent lamp load connected.3) 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.

Ie

A

I

Ie

U

Ue

10-36



0

:nt, ent,nal current,

onal voltage,ge

Verification of electrical endurance

Switch on

ghtly inductive loads, All values 1 1

ng, plugging, revers-ic braking

All values 2.5 1

ng, plugging, revers-ic braking

All values 2.5 1

escent lamps

Ie > 100 A.t lamp load connected.AC-3 or AC-4 test values in accordance with

Ie

A

I

Ie

U

Ue

1



L/R ms

L/R ms

L/R ms

L/R ms

1 1 1 1 All values 1.5 1.05 1 1.5 1.05 1

2 2.5 1 2 All values 4 1.05 2.5 4 1.05 2.5

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)

4) 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.

5) 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.

Ic

Ie

Ur

Ue

Ie

A

I

Ie

U

Ue

Ic

Ie

Ur

Ue

10-37


10

Standards, formulae, tablesUtilisation categories for switch-disconnectors


Switch on Switch o

c

All values 1) 1) 1)

All values 1.5 1.05 0.95 1.5 1

All values 3 1.05 0.65 3 1

Ie F100Ie > 100

1010

1.051.05

0.450.35

8 8

11

L/Rms

All values 1) 1) 1) 1) 1)

All values 1.5 1.05 1 1.5 1

All values 4 1.05 2.5 4 1

All values 4 1.05 15 4 1

Ie

A

I

Ie

U

Ue

Ic

Ie

U

U

Ie

A

I

Ie

U

Ue

Ic

Ie

U

U

Type of 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


AC-20 A(B)1) Making and breaking without load

AC-21 A(B)1) Switching resistive loads including low overloads

AC-22 A(B)1) Switching mixed resistive and inductive loads including low over-loads

AC-23 A(B)1) Switching motors and other highly inductive loads

Direct current

DC-20 A(B)1) Making and breaking without load

DC-21 A(B)1) Switching resistive loads including low overloads

DC-22 A(B)1) Switching mixed resistive and inductive loads, including low over-loads (e.g. shunt motors)

DC-23 A(B)1) Switching highly inductive loads (e.g. series motors)

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

Standards, formulae, tablesUtilisation categories for switch-disconnectors


0

ons:rrent,urrent,tional current,

ational voltage,oltage

aking without load

ve loads including low overloads

resistive and inductive loads including low over-

s and other highly inductive loads

aking without load

ve loads including low overloads

resistive and inductive loads, including low over- motors)

inductive loads (e.g. series motors)

tion.

tors and switch-fuse units to

ing motors are also tested according to the ies for contactors and motor starters",

1


Switch on Switch off

c c

All values 1) 1) 1) 1)

All values 1.5 1.05 0.95 1.5 1.05 0.95

All values 3 1.05 0.65 3 1.05 0.65

Ie F100Ie > 100

1010

1.051.05

0.450.35

8 8

1.051.05

0.450.35

L/Rms

L/Rms

All values 1) 1) 1) 1) 1) 1)

All values 1.5 1.05 1 1.5 1.05 1

All values 4 1.05 2.5 4 1.05 2.5

All values 4 1.05 15 4 1.05 15

Ie

A

I

Ie

U

Ue

Ic

Ie

Ur

Ue

Ie

A

I

Ie

U

Ue

Ic

Ie

Ur

Ue

10-39


10

Standards, formulae, tablesRated motor currents

Rated motor currents of three-phase motors (guideline values for cage motors)

Smallest possible short-circuit protection for three-phase motorThe 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.

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.

D.O.L. starting: Maximum starting current: 6 x rated current Maxi-mum starting time: 5 sec.

y/d starting: Maximum starting current: 2 x rated current Maxi-mum starting time: 15 sec.Motor overload relay in phase current: set to 0.58 x rated current.

10-40



0
1
Motor rating 230 V 400 V

Rated motor current

Fuse Rated motor current

Fuse

Direct starting

y/d Direct starting

y/d

kW cos v h [%] A A A A A A

0.060.090.120.18

0.70.70.70.7

58606062

0.370.540.721.04

2244

––22

0.210.310.410.6

2222

––––

0.250.370.550.75

0.70.720.750.79

62666974

1.422.73.2

461010

2444

0.81.11.51.9

4446

2224

1.11.52.23

0.810.810.810.82

74747880

4.66.38.711.5

10162025

6101016

2.63.656.6

661016

44610

45.57.511

0.820.820.820.84

83868787

14.819.626.438

32325080

16253240

8.511.315.221.7

20253240

10161625

1518.52230

0.840.840.840.85

88889292

51637196

100125125200

638080100

29.3364155

636380100

32405063

37455575

0.860.860.860.86

92939394

117141173233

200250250315

125160200250

688199134

125160200200

80100125160

90110132160

0.860.860.870.87

94949595

279342401486

400500630630

315400500630

161196231279

250315400400

200200250315

200250315400

0.870.870.870.88

95959696

607–––

800–––

630–––

349437544683

5006308001000

400500630800

450500560630

0.880.880.880.88

96979797

––––

––––

––––

769–––

1000–––

800–––

10-41



10

Motor rating 500 V 690 V

Rated motor current

Fuse Rated motor current

Fuse

Direct starting

y/d Direct starting

y/d

kW cos v h [%] A A A A A A

0.060.090.120.18

0.70.70.70.7

58606062

0.170.250.330.48

2222

––––

0.120.180.240.35

2222

––––

0.250.370.550.75

0.70.720.750.79

62666974

0.70.91.21.5

2244

–222

0.50.70.91.1

2244

––22

1.11.52.23

0.810.810.810.82

74747880

2.12.945.3

661016

4446

1.52.12.93.8

461010

2444

45.57.511

0.820.820.820.84

83868787

6.8912.117.4

16202532

10161620

4.96.58.812.6

16162025

6101016

1518.52230

0.840.840.840.85

88889292

23.428.93344

50506380

25323250

1720.923.832

32325063

20252532

37455575

0.860.860.860.86

92939394

546579107

100125160200

638080125

39475878

8080100160

506363100

90110132160

0.860.860.870.87

94949595

129157184224

200250250315

160160200250

93114134162

160200250250

100125160200

200250315400

0.870.870.870.88

95959696

279349436547

400500630800

315400500630

202253316396

315400500630

250315400400

450500560630

0.880.880.880.88

96979797

615–––

800–––

630–––

446491550618

630630800800

630630630630

10-42


Standards, formulae, tablesConductors

0
1
Wiring and cable entries with grommets

Cable entry into closed devices is considerably simplified and improved by using cable grommets.

Cable grommetsFor direct and quick cable entry into an enclosure and as a plug.

Detailed information on material properties a table, page 10-45.

Membrane grommets metric

Cable entry

Hole diamter

Cable external diameter

For use with NYM/NYY cables, 4-core

Cable grom-met

mm mm mm2

• IP66, with integrated push-through diaphragm

• PE and thermoplastic elastomer, halogen free

M16 16.5 1 – 9 H03VV-F3 x 0.75NYM 1 x 16/3 x 1.5

KT-M16

M20 20.5 1 – 13 H03VV-F3 x 0.75NYM 5 x 1.5/5 x 2.5

KT-M20

M25 25.5 1 – 18 H03VV-F3 x 0.75NYM 4x 10

KT-M25

M32 32.5 1 – 25 H03VV-F3 x 0.75NYM 4 x 16/5 x 10

KT-M32

10-43



10

Wiring and cable entries with cable glands

Metric cable glands to EN 50262with 9, 10, 12, 14 or 15 mm long thread.

Detailed information on material properties a table, page 10-45.

Cable glands Cable entry

Hole diamter

Cable exter-nal diame-ter

For use with NYM/NYY cables, 4-core

Cableg-landsType

mm mm mm2

• With lock nut and built-in strain relief

• IP68 up to 5 bar, polyamide, halogen-free

M12 12.5 3 –7 H03VV-F3 x 0.75NYM 1 x 2.5

V-M12

M16 16.5 4.5 – 10 H05VV-F3 x 1.5NYM 1 x 16/3 x 1.5

V-M16

M20 20.5 6 – 13 H05VV-F4 x 2.5/3 x 4NYM 5 x 1.5/5 x 2.5

V-M20

M25 25.5 9 – 17 H05VV-F5 x 2.5/5 x 4NYM 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.

10-44



0
1
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

10-45



10

External diameter of conductors and cables

NYM: sheathed conductor NYY: plastic-sheathed cable H05RR-F: light rubber-sheathed flexible cable (NLH + NSH)

NYCY: cable with concentric conductor and plastic sheathNYCWY: cable with concentric wave-form conductor and plastic sheath

Number of conductors

Approximate external diameter (average of various makes)NYM NYY H05 H07 NYCY

RR-F RN-F NYCWYCross-section mm mm mm mm mmmm2 max. max. max.2 x 1.5 10 11 9 10 122 x 2.5 11 13 13 11 143 x 1.5 10 12 10 10 133 x 2.5 11 13 11 12 143 x 4 13 17 – 14 153 x 6 15 18 – 16 163 x 10 18 20 – 23 183 x 16 20 22 – 25 224 x 1.5 11 13 9 11 134 x 2.5 12 14 11 13 154 x 4 14 16 – 15 164 x 6 16 17 – 17 184 x 10 18 19 – 23 214 x 16 22 23 – 27 244 x 25 27 27 – 32 304 x 35 30 28 – 36 314 x 50 – 30 – 42 344 x 70 – 34 – 47 384 x 95 – 39 – 53 434 x 120 – 42 – – 464 x 150 – 47 – – 524 x 185 – 55 – – 604 x 240 – 62 – – 705 x 1.5 11 14 12 14 155 x 2.5 13 15 14 17 175 x 4 15 17 – 19 185 x 6 17 19 – 21 205 x 10 20 21 – 26 –5 x 16 25 23 – 30 –8 x 1.5 – 15 – – –10 x 1.5 – 18 – – –16 x 1.5 – 20 – – –24 x 1.5 – 25 – – –

10-46



0
1
Cables and wiring, type abbreviation

Examples for complete cable designationPVC-sheathed wire, 0.75 mm2 flexible, H05V-K 0.75 black

Heavy rubber-sheathed cable, 3-core, 2.5 mm2 without green/yellow protective conductor A07RN-F3 x 2.5

Identification of specificationHarmonized specification HRecognized national type A

Rated operational voltage UO/U300/300V 03300/500V 05450/750V 07

Insulating materialPVC VNatural and/or synthetic rubber RSilicon rubber S

Sheathing materialPVC VNatural and/or synthetic rubber RPolychloroprene rubber NFibre-glass braid JTextile braid T

Special construction featureFlat, separable conductor HFlat, non-separable conductor H2

Type of conductorSolid -UStranded -RFlexible with cables for fixed installation -KFlexible with flexible cables -FHighly flexible with flexible cables -HTinsel cord -Y

Number of cores ...Protective conductorWithout protective conductors XWith protective conductors G

Rated conductor cross-section ...

10-47



10

690/40

4 % 6 %

Short-circuit current

Rated cu

IK’’ In

A A A

1498 – 42

1888 1259 53

2997 1998 84

3746 2497 105

4795 3197 134

5993 3996 167

7492 4995 209

9440 6293 264

11987 7991 335

14984 9989 418

18879 12586 527

– 15983 669

– 19978 837

– 24973 1046

– 31965 1339

– 39956 1673

– 49945 2092

Rated operational currents and short-circuit currents for standard transformers

Rated voltage

400/230 V 525 V

Un

Short-circuit voltage UK

4 % 6 %

Rating Rated current Short-circuit current

Rated current

In IK’’ In

kVA A A A A

50 72 1967 – 55

63 91 2478 1652 69

100 144 3933 2622 110

125 180 4916 3278 137

160 231 6293 4195 176

200 289 7866 5244 220

250 361 9833 6555 275

315 455 12390 8260 346

400 577 15733 10489 440

500 722 19666 13111 550

630 909 24779 16519 693

800 1155 – 20977 880

1000 1443 – 26221 1100

1250 1804 – 32777 1375

1600 2309 – 41954 1760

2000 2887 – 52443 2199

2500 3608 – 65553 2749

10-48



0

525 V

6 %

rcuit Rated current

In

A A

– 55

1652 69

2622 110

3278 137

4195 176

5244 220

6555 275

8260 346

10489 440

13111 550

16519 693

20977 880

26221 1100

32777 1375

41954 1760

52443 2199

65553 2749

1

690/400 V

4 % 6 % 4 % 6 %

Short-circuit current

Rated current Short-circuit current

IK’’ In IK’’

A A A A A

1498 – 42 1140 –

1888 1259 53 1436 958

2997 1998 84 2280 1520

3746 2497 105 2850 1900

4795 3197 134 3648 2432

5993 3996 167 4560 3040

7492 4995 209 5700 3800

9440 6293 264 7182 4788

11987 7991 335 9120 6080

14984 9989 418 11401 7600

18879 12586 527 14365 9576

– 15983 669 – 12161

– 19978 837 – 15201

– 24973 1046 – 19001

– 31965 1339 – 24321

– 39956 1673 – 30402

– 49945 2092 – 38002

10-49


10

Standards, formulae, tablesFormulea

Ohm's Law

Resistance of a piece of wire

Copper:

l = Length of conductor [m] Aluminium:

z = Conductivity [m/Omm2] Iron:

A = Conductor cross section [mm2] Zinc:

Resistors

Transformer

Capacitors

Impedance

L = Inductance [H] f = Frequency [Hz] C = Capacitance [F] v = Phase angle XL = Inductive impedance [O]XC = Capacitive impedance [O]Parallel connection of resistances

With 2 parallel resistances: With 3 parallel resistances:

General calculation of resistances:

U I R V[ ]×= I UR--- A[ ]= R U

I--- Ω[ ]=

R lχ A×------------ Ω[ ]= χ 57 m

Ωmm2---------------=

χ 33 m

Ωmm2---------------=

χ 8,3 m

Ωmm2---------------=

χ 15,5 m

Ωmm2---------------=

XL 2 π f L Ω[ ]×××=

XC1

2 π f C×××----------------------------- Ω[ ]=

Z R2 XL XC–( )2+= Z Rcosv----------- Ω[ ]=

RgR1 R2×R1 R2+---------------- Ω[ ]= Rg

R1 R2× R3×R1 R2 R2 R3 R1 R3×+×+×--------------------------------------------------------------- Ω[ ]=

1R--- 1

R1----- 1

R2----- 1

R3----- ... 1 Ω⁄[ ]+ + += 1

Z-- 1

Z1---- 1

Z2---- 1

Z3---- ... 1 Ω⁄[ ]+ + +=

1X--- 1

X1----- 1

X2----- 1

X3----- ... 1 Ω⁄[ ]+ + +=

10-50



0
1
Electric power

Mechanical force between 2 parallel conductors

Mechanical force between 3 parallel conductors

Power Current consumption

Direct current

Single-phase AC

Alternating current

2 conductors with currents I1 and I2

s = Support spacing clearance [cm]

a = Support spacing clearance [cm]

3 conductors with current I

P U I× W[ ]= I PU--- A[ ]=

P U I cosϕ×× W[ ]= I PU cosϕ×--------------------- A[ ]=

P 3 U I cosϕ××× W[ ]= I P3 U cosϕ××

---------------------------------- A[ ]=

F20,2 I1 I2 s×××

a----------------------------------- N[ ]= I1

I2

s

a

F3 0,808 F2 N[ ]×=

F3 0,865 F2 N[ ]×=

F3 0,865 F2 N[ ]×=

10-51



10

Voltage drop

Calculation of cross-section from voltage drop

Known power Known current

Direct current

Single-phase AC

Alternating current

Direct current Single-phase AC Alternating current

Known power

Known current

Power loss

Direct current Single-phase AC

Alternating current

l = Single length of conductor [m];A = Conductor cross section [mm2];z = Conductivity (copper: z = 57; aluminium: z = 33; iron: z = 8.3 )Du = Voltage drop

UΔ 2 l× P×z A× U×---------------------- V[ ]= UΔ 2 l× l×

z A×------------------ V[ ]=

UΔ 2 l× P×z A× U×---------------------- V[ ]= UΔ 2 l× l×

z A×------------------ cos× ϕ V[ ]=

UΔ l P×z A× U×---------------------- V[ ]= UΔ 3 l l×

z A×------------ cos× ϕ V[ ]×=

A 2 l× P×z Δu× U×-------------------------- mm2[ ]= A 2 l× P×

z Δu× U×-------------------------- mm2[ ]= A l P×

z Δu× U×-------------------------- mm2[ ]=

A 2 l× l×z Δu×------------------ mm2[ ]= A 2 l× l×

z Δu×------------------ cosϕ mm2[ ]×= A 3 l l×

z Δu×----------------× cos× ϕ mm2[ ]=

PVerl2 l× P× P×z A× U× U×-------------------------------- W[ ]= PVerl

2 l× P× P×z A× U× U× cosv× cosv×------------------------------------------------------------------- W[ ]=

PVerll P× P×

z A× U× U× cosv× cosv×------------------------------------------------------------------- W[ ]=

mOmm2---------------

10-52



0
1
Power of electric motors

Output Current consumption

Direct cur-rent

Single-phase AC

Alternating current

P1 = Rated mechanical power at the motor shaft P2 = Electrical power consumption

Efficiency

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

Synchronous speed = approx. no-load speed

P1 U l× h× W[ ]=l

P1

U h×------------- A[ ]=

P1 U l× cosv× h× W[ ]=l

P1

U cosv× h×------------------------------- A[ ]=

P1 (1,73) U× l× cosv× h× W[ ]=l

P1

(1,73) U× cosv× h×-------------------------------------------------- A[ ]=

hP1

P2----- (100 %)×= P2

P1

h----- W[ ]=

10-53


10

Standards, formulae, tablesStandard international units

International Unit System (SI)

Factors for conversion of old units into SI units

Basic parameters Physical parame-ters

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 sub-stance

n mole (Mol) Gmol, Mmol, kmol, mmol, mmol

Light intensity Iv cd (Candela) Mcd, kcd, mcd

Conversion factors

Size Old unit SI unit exact Approximate

Force 1 kp1 dyn

9.80665 N1·10-5 N

10 N1·10-5 N

Momentum of force

1 mkp 9.80665 Nm 10 Nm

Pressure 1 at1 Atm = 760 Torr1 Torr1 mWS1 mmWS1 mmWS

0.980665 bar1.01325 bar1.3332 mbar0.0980665 bar0.0980665 mbar9.80665 Pa

1 bar1.01 bar1.33 bar0.1 bar0.1 mbar10 Pa

Tension

Energy 1 mkp1 kcal1 erg

9.80665 J4.1868 kJ1·10-7 J

10 J4.2 kJ1·10-7 J

1 kp

mm2---------- 9,80665 N

mm2---------- 10 N

mm2----------

10-54



0
1
Power

1.163 W 1.16 W

1 PS 0.73549 kW 0.74 kW

Heat transfer coefficient

dynamic viscosity

1 Poise

1 Poise 0.1

Kinetic viscosity 1 Stokes

Angle (flat) 1

1 gon

1

1 gon

57,296 1 rad

63,662 gon 1 rad

Conversion factors

Size Old unit SI unit exact Approximate

1kcalh

-------- 4,1868kJh---- 4,2kJ

h----

1kcalh

--------

1 kcal

m2h°C--------------- 4,1868 kJ

m2hK------------ 4,2 kJ

m2hK------------

1 kcal

m2h°C--------------- 1,163 W

m2K--------- 1,16 W

m2K---------

1 10 6– kps

m2--------⋅ 0 980665, 10 5– Ns

m2------⋅ 1 10 5– Ns

m2------⋅

0,1 Ns

m2------ 0,1 Ns

m2------

Pa s⋅

1 10 4– m2

s------⋅ 1 10 4– m2

s------⋅

1360--------pla 2 78, 10 3– pla⋅

1400--------pla 2 5 10 3– pla⋅,

π180-------- rad 17 5 10 3– rad⋅,

π200-------- rad 15 7, 10 3– pla⋅

10-55



10

Conversion of SI units, coherences

Conversion of SI units and coherences

Size SI units name

Symbol Basic unit Conversion of SI units

Force Newton N

Force momentum

Newton-metre

Nm

Pressure Bar bar

Pascal Pa

Energy, heat Joule J 1 J = 1 Ws = 1 Nm

Power Watt W

Tension

Angle (flat) DegreeGon

1gon

360° = 1 pla = 2p rad 400 gon = 360°

Radian rad

Full circle pla 1 pla = 2p rad = 360°Voltage Volt V

Resistor Ohm O

Conductivity Siemens S

Electric charge

Coulomb C 1 · A · s

1 kg m⋅

s2--------------⋅

1 kg m2⋅

s2----------------⋅

105 kg

m s2⋅------------- 1 bar 105Pa 105 N

m2------= =

1 kg

m s2⋅-------------⋅ 1 Pa 10 5– bar=

1 kg m2⋅

s2----------------⋅

1 kg m2⋅

s3----------------⋅ W 1= J

s-- 1N m⋅

s------------=

N

mm2---------- 106 kg

m s2⋅------------- 1 N

mm2---------- 102 N

cm2--------=

1mm----

1 kg m2⋅

s3 A⋅----------------⋅ 1 V 1= W

A----⋅

1 kg m2⋅

s3 A2⋅----------------⋅ 1 Ω 1= V

A--- 1 W

A2-----⋅=⋅

1 s3 A2⋅

kg m2⋅----------------⋅ 1 S 1= A

V--- 1= A2

W-----⋅ ⋅

10-56



0
1
Decimal powers (parts and multiples of units)

Capacity Farad F

Field strength

Flux Weber Wb

Flux density Tesla T

Inductance Henry H

Power Prefix Symbol Power Prefix Symbol

10–18 Atto a 10–1 Deci d

10–15 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

10–2 Centi c 1012 Tera T

Conversion of SI units and coherences

Size SI units name

Symbol Basic unit Conversion of SI units

1 s4 A⋅

kg m2⋅----------------⋅ 1 F 1= C

V---⋅ 1 s A2⋅

W------------⋅=

Vm---- 1 kg m⋅

s3 A⋅--------------⋅ 1 V

m---- 1 W

A m⋅------------⋅=

1 kg m2⋅

s2 A⋅----------------⋅ 1 Wb 1= V s 1 W s⋅

A-----------⋅=⋅ ⋅

1 kg

s2 A⋅------------⋅ 1 T

Wb

m2------ 1 V s⋅

m2---------⋅ 1 W s⋅

m2A-----------⋅= = =

1 kg m2⋅

s2 A2⋅----------------⋅ 1 H

Wb

A------ 1 V s⋅

A---------⋅ 1 W s⋅

A2-----------⋅= = =

10-57



10

Physical units

Mechanical force

Pressure

Obsolete units

SI unit: N (Newton) J/m (Joule/m)

Previous unit: kp (kilopond) dyn (Dyn)

1 N = 1 J/m = 1 kg m/s2 = 0.102 kp = 105 dyn

1 J/m = 1 N = 1 kg m/s2 = 0.102 kp = 105 dyn

1 kg m/s2 = 1 N = 1 J/m = 0.102 kp = 105 dyn

1 kp = 9.81 N = 9.81 J/m = 9.81 kg m/s2 = 0.981 106 dyn

1 dyn = 10–5 N = 10–5 J/m = 10–5 kg m/s2 = 1,02 10–5 kp

SI unit: Pa (Pascal) bar (Bar)

Previous unit:

at = kp/cm2 = 10 m WsTorr = mm Hgatm

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

1 bar = 105 Pa = 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



0
1
Work

Power

SI unit: J (Joule) Nm (Newtonmeter)

SI unit:(as before)

Ws (Wattsecond) kWh (Kilowatthour)

Previous unit: kcal (Kilocalorie) = cal · 10–3

1 Ws = 1 J = 1 Nm 107 erg

1 Ws = 278 · 10–9 kWh = 1 Nm = 1 J = 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 = 1 J = 0.102 kpm = 0.239 cal

1 J = 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

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

kcal/h (Kilocalorie/hour.) = cal/h · 106

kpm/s (Kilopondmetre/Sec.)

PS (metric horsepower)

1 W = 1 J/s = 1 Nm/s

1 W = 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



10

Magnetic field strength

Magnetic field strength

Magnetic flux density

SI unit:

Previous unit: Oe = (Oerstedt)

= 0.01256 Oe

= 12.56 Oe

1 Oe

Am---- Ampere

Meter-----------------

1 Am---- 0= 001 kA

m-----,

1 kAm----- 1000= A

m----

79= 6 Am----, 0= 0796 kA

m-----,

SI unit Wb (Weber)mWb (Microweber)

Previous unit: M = Maxwell

1 Wb = 1 Tm2

1 Wb = 106 mWb = 108 M

1 mWb = 10–6 Wb = 100 M

1 M = 10–8 Wb = 0.01 mWb

SI unit: T (Tesla)mT (Millitesla)

Previous unit: G = Gauss

1 T = 1 Wb/m2

1 T = 103 mT = 104 G

1 mT = 10–3 T = 10 G

1 G = 0,1–3 T = 0,1 mT

10-60



0
1
Conversion of Imperial/American units into SI units

Length 1 in 1 ft 1 yd 1 mileLand mile

1 mileSea 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 1 knot

0.447 0.5144 0.3048 5.080 ·10–3

Pressure 1 in Hg 1 ft H2O 1 in H2O

bar 65.95 · 10-3 33.86 · 10-3 29.89 · 10-3 2.491 · 10-3

Energy, Work

1 HPh 1 BTU 1 PCU

J 2.684 ·106 1.055 · 103 1.90 · 103

1mileh

--------- 1fts--- 1 ft

min--------

ms----

1 lbsq.in---------- 1 psi

10-61



10

Conversion of Imperial/American units into SI units

Length 1 cm 1 m 1 m 1 km 1 km

0.3937 in 3.2808 ft 1.0936 yd 0.6214 mile (land mile)

0.5399 mile (sea mile)

Weight 1 g 1 kg 1 kg 1 t 1 t

15.43 grain 35.27 ounce 2.2046 lb. 0.9842 long ton

1.1023 short ton

Area 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

Volume 1cm3 1 l 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)

Force 1 N 1 N 1 N 1 N

0.2248 lb 0.1003 · 10–3 long ton (UK)

0.1123 · 10–3 short ton (US)

7.2306 pdl (poundal)

Speed 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

Pressure 1 bar 1 bar 1 bar 1 bar

14.50 psi 29.53 in Hg 33.45 ft H2O 401.44 in H2O

Energy, Work

1 J 1 J 1 J

0.3725 · 10–6 HPh 0.9478 · 10–3 BTU 0.5263 · 10–3 PCU

10-62


Index

1
1
AAC/DC sensitive ................................................................... 7-20Accessories contactors ......................................................... 5-30Air circuit-breakers ................................................................ 7-3Analog inputs, easy ..................................................1-23…1-26Analog output, easy ............................................................ 1-31Approval authorities worldwide ............................................. 9-6AS-Interface® data bus ....................................................... 2-89Asynchronous motor .............................................................. 2-2ATEX approval ..................................................................... 3-10

EMT6 .............................................................................. 8-12Motor protection system ZEV ......................................... 5-39Overload relays .............................................................. 5-35PKZM0, PKZM4 ................................................................ 6-4RMQ-Titan ...................................................................... 3-10Rotary switches, switch-disconnectors ........................... 4-17Thermistor relay for machine protection EMT6 ............... 5-45

Automatic stator startersEngineering starting resistor ........................................... 8-14Engineering starting transformer .................................... 8-14Example resistors ........................................................... 8-91Example starting transformer ......................................... 8-94

Auxiliary contact module ....................................................... 5-2Auxiliary switch

PKZ2 .............................................................................. 6-17Auxiliary switches

Early make ....................................................................... 7-7PKZM01, PKZM0, PKZM4 ................................................ 6-7Standard, trip-indicating ................................................... 7-6Trip-indicating .................................................................. 7-6

BBasic circuits

Delta, star ......................................................................... 2-4easy .....................................................................1-54…1-59

BimetalMotor protection ............................................................ 8-13Motor-protective circuit-breakers ..................................... 6-4Overload relay ................................................................ 5-35

Braking oversynchronous ..................................................... 8-59Braking resistance ............................................................... 2-84Break-Down Service ............................................................... 0-9

11-1

IndexMoeller Wiring Manual 02/08

11

Bridging during startingHeavy starting duty .........................................................8-10Motor contactor ................................................................8-9Overload relays ...............................................................8-26

Busbar system ......................................................................0-22

CCables ................................................................................10-43Cage Clamp .........................................................................5-31CANopen ................................................................. 1-39…1-41Capacitor

Central compensation, use of reactors ............................8-17Single, group compensation ...........................................8-16

Capacitor group compensation ............................................8-17Cascade control ...................................................................2-52Changeover circuit ...............................................................1-56Changeover contact

Wattmeter ......................................................................4-13Changeover switch

Ammeter .........................................................................4-12Voltmeter ........................................................................4-12

Changeover switches .............................................................4-5Circuit diagram auxiliary protection .......................................5-6Circuit diagram Internal circuit diagrams Circuit-breaker .......7-8Circuit documents general ....................................................8-18Circuit documents wiring diagram .......................................8-19Circuit examples

Bridging during starting ..................................................8-26Contactors DIL ................................................................8-25

Circuit for overload relay 1-pole, 2-pole .................................8-5Circuit-breaker

Internal circuit diagrams ...................................................7-8Meshed network circuit-breakers ....................................7-17Remote operation with motor operator ..........................7-18Residual current device ...................................................7-20Switch position ...............................................................7-15Transformer switches ......................................................7-19

Circuit-breaker remote switching .........................................7-11Classification types of soft starters .......................................2-17Coil functions .......................................................................1-52Coils .....................................................................................1-50COM-LINK connection ..........................................................1-47Compact circuit-breakers .......................................................7-2

11-2


1
1
Compact PLC, PS4 ............................................................... 1-68Compensated motor ............................................................ 8-11Connecting examples

DF51, DV51 .........................................................2-74…2-79DF6 .....................................................................2-80…2-81DM4 ....................................................................2-56…2-69DS4 ................................................................................ 2-55DS6 .....................................................................2-37…2-39DV6 .....................................................................2-82…2-87

Connection RA-MO to AS-Interface® .................................. 2-92Connection RA-SP to AS-Interface® .................................... 2-95Contact module PKZ2 .......................................................... 6-13Contact protection relay ...................................................... 5-46Contactor for capacitor ...................................................... 8-102Contactor relays circuit diagrams ........................................... 5-6Contactor relays reference letters .......................................... 5-3Contactor, marking .............................................................. 8-24Contactors

DC operated ................................................................... 5-32DILM .............................................................................. 5-31Overview .............................................................5-24…5-25SmartWire ...................................................................... 5-10

Contacts .............................................................................. 1-50Control circuit devices

For direct-on-line start .................................................... 8-37For multi-speed contactors ..................................8-69…8-73For star-delta .................................................................. 8-51RMQ ................................................................................. 3-2

Control circuit supply motor ................................................. 8-23Control relays

Basic circuits ................................................................... 1-54Overview ........................................................................ 1-12

Control relays a easyRelays .............................................. 1-12Co-ordination type motor protection ..................................... 8-8Core-balance transformer .................................................... 5-38Current Limiter

a Current limiter PKZ2 ................................................ 6-28a Current limiters PKZM0, PKZM4 ................................ 6-5

Current limiter PKZ2 ............................................................ 6-28Current limiter PKZM0, PKZM4 .............................................. 6-5Current monitoring relays ...................................................... 1-6Current transformer-operated overload relays ZW7 ............... 8-8

11-3


11

DDarwin ..................................................................... 0-11…0-13DC motors ..............................................................................8-5Degrees of protection for electrical equipment ...................10-28Delta circuit, motor ..............................................................2-78Delta connection ....................................................................2-4Digital inputs, easy

AC devices ......................................................................1-21DC devices ......................................................................1-22

Direct-on-line starterMotor-protective circuit-breakers ......................................6-3

Disconnect Control Unit .......................................................2-91DOL starters

Features ..........................................................................2-10SmartWire .......................................................................5-12Three-phase asynchronous motors ...................................2-5With bypass ....................................................................2-30

Double-frame terminal .........................................................5-31Drives engineering basics .......................................................2-7

EEarly-make auxiliary switches .................................................7-7Earth-leakage circuit-breaker ...............................................7-22easy ......................................................................................1-12easy expansion ......................................................... 1-32…1-43easy expansion units for networking ....................................1-42easy inputs ............................................................... 1-21…1-27easy inputs, MFD

Analog ............................................................................1-23easy local expansion ............................................................1-32easy modem operation .........................................................1-49easy outputs ............................................................. 1-28…1-31easy power supply ................................................................1-20easy printer connection ........................................................1-48easy remote expansion .........................................................1-32easy system overview ............................................... 1-12…1-19easyControl ..........................................................................1-16easyHMI ...............................................................................1-14easyNet .................................................................... 1-34…1-38easyRelay .............................................................................1-12EEx e motors

Overload relays ...............................................................5-35PKZM0, PKZM4 ................................................................6-4

11-4


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1
Electrical connector ................................................................ 6-4Electrical isolation .................................................................. 5-2Electronic Catalogue .............................................................. 0-8Electronic safety relays ......................................................... 1-10Electronic timing relays .......................................................... 1-2EMC compliant connection .................................................. 2-21EMC measures frequency inverters ...................................... 2-22Emergency-Stop function ..................................................... 7-12EMR4 measuring and monitoring relays ................................ 1-6Encoder ............................................................................... 2-84Engineering

easy .....................................................................1-20…1-49EM4, LE4 ........................................................................ 1-78Motor ..................................................................8-14…8-17PS4 ................................................................................. 1-75Switching of capacitors .................................................. 8-16Three-phase automatic starters ...................................... 8-14XC100, XC200 ............................................................... 1-79

Ethernet module .................................................................. 1-46Explosive atmospheres ........................................................ 4-17

FFault current ........................................................................ 5-38Fault indication, differential ................................................. 6-10Flat band conductor ............................................................. 2-89Floor-standing enclosure ..................................................... 0-21Free-wheel diode suppressor ................................................. 5-4Frequency generators .......................................................... 1-27Frequency inverters, features ............................................... 2-70FU a Frequency inverter ..................................................... 2-7Function blocks .................................................................... 1-50Functions easy ..................................................................... 1-18Fuseless, Reversing contactor DIUL ...................................... 8-29

GGerman Trade Association ................................................... 3-22Graphic operator panel ........................................................ 1-72Group compensation ........................................................... 8-16Group protection Motor-protective circuit-breakers ............... 6-6

HHamburg circuit, off position interlock ............................... 8-110Hazard reduction ................................................................. 1-10

11-5


11

Heater switches ....................................................................4-14Heavy starting duty

Bridging during starting ..................................................8-10Example ..........................................................................8-27Motor protection ...............................................................8-8

High-capacity compact starters ............................................6-18High-speed counter ..............................................................1-27HMI systems .........................................................................1-72Housing ...................................................................... 0-18, 0-21

IImpulse relays ......................................................................1-57Incremental encoders ...........................................................1-27In-delta circuit ......................................................................2-35Indication of tripping circuit-breaker ....................................7-15Individual compensation ......................................................8-16In-line circuit ........................................................................2-35Insulation monitoring relays ...................................................1-8Interface assignment, XC100/XC200 RS ..............................1-80Interlock circuits, rotary switches .........................................4-11IZM terminal assignment .....................................................7-26

LLabeleditor .............................................................................3-9Let-through energy ...............................................................2-91Level monitoring relay ............................................................1-7Load-shedding contact ...........................................................4-4Low-voltage switchgear systems ..........................................0-14

MMain switches ......................................................................7-12Main transfer switch ..........................................................8-111Maintenance switches, rotary switches ..................................4-4Markings, contactor .............................................................8-24Master switch, off position interlock ..................................8-111Mechanical interlock ............................................................5-32Mesh network circuit-breaker ..............................................7-17MFD-Titan ............................................................................1-12Mirror contact ......................................................................5-34Modular PLC ........................................................................1-70

11-6


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Moeller .................................................................................. 0-4Electronic Catalogue ........................................................ 0-8Field Service ..................................................................... 0-9Low-voltage switchgear systems .................................... 0-14Support Portal .................................................................. 0-4

Monitoring relays ................................................................... 1-6Motor

Circuit documents .......................................................... 8-18Control circuit devices for direct-on-line start ................. 8-37Control circuit supply ...................................................... 8-23Engineering .........................................................8-14…8-17Mains changeover ........................................................ 8-111Motor windings .............................................................. 8-56Multi speed switch PKZ2 ................................................ 8-89Multi-speed contactors ................................................... 8-59Pole-changing .....................................................8-53…8-55Power supply .................................................................. 8-20Separate windings .......................................................... 8-53Star-delta of three-phase motors .........................8-38…8-47Star-delta with PKZ2 ...........................................8-48…8-50Starting with PKZ2 ..............................................8-33…8-36Switching of capacitors .................................. 8-100…8-103Switching on three-phase motors ........................8-25…8-32Tapped winding ............................................................. 8-53

Motor connection ................................................................ 2-95Motor Control Unit .............................................................. 2-92Motor feeder ......................................................................... 2-2Motor full-load current ...................................................... 10-40Motor operator circuit-breaker ............................................ 7-18Motor overload relay, motor protection ............................... 5-35Motor power supply ............................................................ 8-20Motor protection ........................................................8-3…8-13Motor protection system ZEV ....................................5-38…5-44Motor rating ........................................................................ 5-31Motor windings ................................................................... 8-56Motor-protective circuit-breaker

Operating principle schematics PKZM01, PKZM0, PKZM4 6-9Motor-protective circuit-breakers

For starter combinations .................................................. 6-5Operating principle schematics PKZ2 ..................6-18…6-29Operating principle schematics PKZM01, PKZM0, PKZM4 .....6-9….............................................................................. 6-11

Motor-protective circuit-breakers, overview .......................... 6-1

11-7


11

Motor-starter combination MSC .............................................6-4SmartWire .......................................................................5-10

Multi-function displayOverview .........................................................................1-12

Multi-function display a easyHMI .....................................1-14Multi-speed contactors .........................................................8-59

Control circuit devices ......................................... 8-69…8-73Star-delta ........................................................................8-74

Multi-speed switch Bridging during starting .........................8-10Multi-speed switch for three-phase motors

Star-delta ............................................................ 8-74…8-88Multi-speed switch of three-phase motors ............... 8-61…8-68Multi-speed switch with PKZ2 ..............................................8-89Multi-speed switches

Rotary switches .................................................................4-7Multi-speed switching, marking ...........................................8-24

NNegation ..............................................................................1-54Networking display and operating devices ...........................1-74Networking easy ...................................................... 1-32…1-43Networking PS40 and XC series ...........................................1-73

OOff-delayed undervoltage release ...........................................7-5Off-position interlock

Loads ............................................................................8-110Off-postion interlock

Hamburg circuit ............................................................8-110Master switch ...............................................................8-111

Ohm's Law .........................................................................10-50Operands .............................................................................1-50Operating frequency ...............................................................8-4Operating principle schematic PKZ2 ......................... 6-18…6-29Operating principle schematics PKZM01, PKZM0, PKZM4 6-9…6-11Overload motor ....................................................................5-38Overload motor-protective circuit-breaker ..............................6-2Overload protection contactor ..............................................8-25Overload protection, Rapid Link ...........................................2-90Overload relay

Tripping ............................................................................8-4Overload relay a Motor protection overload relay ............5-35

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Overload relay function ....................................................... 6-12Overload relay function PKZ2 .............................................. 6-29Overload relay time-delayed .................................................. 8-6Overload relays .................................................................... 2-57

In delta circuit ................................................................ 8-39In motor circuit, in mains line ......................................... 8-38

Oversynchronous braking .................................................... 8-59Overvoltage ......................................................................... 2-57

PParallel circuit ...................................................................... 1-55Permanent contact .............................................................. 1-57Personnel protection

Enhanced ....................................................................... 3-17LS ................................................................................... 3-16LSR ................................................................................. 3-21

Phase failure ........................................................................ 5-38Phase imbalance relay ........................................................... 1-7Phase monitoring relays ........................................................ 1-6Phase sequence relays ........................................................... 1-7Phase-failure sensitivity ....................................................... 5-35Point-to-point connection .................................................... 1-47Pole-changing motors ...............................................8-53…8-55Power bus ............................................................................ 2-89Power electronics .................................................................. 2-7Process protection ............................................................... 3-19Programmable contacts ....................................................... 5-39Programming easy ....................................................1-50…1-66Protective measures ............................................................. 10-5Proximity switches ....................................................3-27…3-31Pt100/Ni1000 inputs, easy .................................................. 1-26PTC Thermistor, Thermistor machine protection relay .......... 5-45PTC-Thermistor, motor protection ....................................... 8-12Pump control ....................................................................... 2-50

Float switches .............................................................. 8-108Pressure switches ......................................................... 8-106Two pumps .................................................................. 8-104

Pushbutton control circuit devices ....................................... 8-69Push-through sensor ZEV ..................................................... 5-39

QQuick-discharge resistor .................................................... 8-100

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RRapid Link ............................................................................2-88RC suppressor ........................................................................5-4Reclosing lockout ...................................................................8-4Reference letter contactor relays ............................................5-3Reflected-light barrier, reflected-light beam .........................3-29Relay outputs, easy ..............................................................1-28Remote display .....................................................................1-44Remote operator circuit-breaker ...........................................7-18Remote operator PKZ2 .........................................................6-14Remote switch off PKZ2 .......................................................6-25Remote switch off PKZM01, PKZM0, PKZM4 .......................6-11Residual-current protection ..................................................7-20Residual-current protection relays ........................................7-22Residual-current release circuit-breaker ...............................7-20Reversing combination a Reversing contactor ..................8-29Reversing contactor ..............................................................8-29Reversing soft starter ...........................................................2-45Reversing star-delta

2 directions of rotation ...................................................8-45Direction change .............................................................8-46Rotary switches .................................................................4-6

Reversing starterMotor-protective circuit-breakers ......................................6-3SmartWire .......................................................................5-12Soft starters ....................................................................2-30

Reversing switches .................................................................4-5Risk reduction .......................................................... 1-10, 10-26Rogowski principle ...............................................................5-38Rogowski sensor ..................................................................5-44Root -3 circuit ......................................................................2-65Rotary switches

ATEX approval ................................................................4-18Changeover switches, reversing switches .........................4-5Heater switches ..............................................................4-14Interlock circuits ..............................................................4-11Main switch, maintenance switch .....................................4-3Meter selector switches ..................................................4-12Multi speed switches ........................................................4-7Speed switching ..............................................................8-59Star-delta, reversing star-delta ..........................................4-6Step switches ..................................................................4-15Use, mounting forms ........................................................4-2

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Rotor automatic starterEngineering starting resistor ........................................... 8-14Properties of slipring rotor .............................................. 8-15Slipring rotor .................................................................. 8-96

Rotor-critical motors ............................................................ 8-12

SSafety category .................................................................... 5-19Safety of machines .............................................................. 1-10Safety position switches ...................................................... 3-15Safety relays ........................................................................ 1-10Safety technology ................................................................ 1-10SASY60 ................................................................................ 0-22Screening measures ..................................................2-23…2-25Sealing power ...................................................................... 5-31Selectivity a time selectivity .............................................. 7-16Self-latching ......................................................................... 1-56Semiconductor contactors ..................................................... 2-7Sensor belt ZEV .................................................................... 5-39Separate windings

Multi speed switch ..............................................8-65…8-68Speeds ............................................................................ 8-53

Separation galvanic ............................................................... 5-2Series circuit ........................................................................ 1-55Shift register ........................................................................ 1-63Short-circuit current, maximum ........................................... 2-91Short-circuit monitoring ....................................................... 5-43Short-circuit protection ........................................................ 8-25Short-circuit protection, RA-MO .......................................... 2-90Short-circuit rating ................................................................. 8-7Short-circuit releases .............................................................. 6-4Shunt releases

Circuit-breaker remote tripping ........................................ 7-4Circuit-breakers .............................................................. 7-19Operating principle schematics PKZ2 ............................. 6-25PKZM01, PKZM0, PKZM4 ................................................ 6-8Remote switch off PKZ2 ................................................. 6-16Remote switch-off .......................................................... 7-11

Single phase motors .............................................................. 8-5Single-phasing sensitive ........................................................ 6-4SL signal towers ................................................................... 3-11Slipring rotor a Rotor automatic starter ............................ 8-96

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SmartWireGateway easyNet/CANopen ...........................................1-43Gateway PROFIBUS-DP .....................................................5-9Modules ..........................................................................5-10System .................................................................. 5-8…5-23

Soft starters ............................................................................2-7Classification types .........................................................2-17DM4 ...............................................................................2-33DS4, DS6 .........................................................................2-29Examples ........................................................................2-13Features ..........................................................................2-12

Soft starting a Soft starters .................................................2-7Special purpose relays ............................................................1-2Speed Control Unit ...............................................................2-95Speeds, separate windings ...................................................8-53Spring-loaded terminal .........................................................5-31Stairwell lighting ..................................................................1-60Standard auxiliary contact, ON-OFF indication .....................7-15Standard auxiliary switch .......................................................7-6

PKZ2 ...............................................................................6-17Star connection ......................................................................2-4Star connection, motor .........................................................2-79Star-delta

Bridging during starting ....................................................8-9easy ................................................................................1-58Marking ..........................................................................8-24Motor start .....................................................................2-11Multi-speed contactors ...................................................8-74Rotary switches .................................................................4-6SDAINL ............................................................... 8-40…8-44Three-phase asynchronous motors ...................................2-5Three-phase motors ............................................ 8-38…8-47With PKZ2 ........................................................... 8-48…8-50

Star-delta starters, with overload relays ...............................8-38Starting with PKZ2 ................................................... 8-33…8-36Stator automatic starters

Properties of squirrel cage rotor ......................................8-15Support Portal ........................................................................0-5Suppressor circuit ...................................................................5-4Suppressor circuit integrated, pluggable ..............................5-31Switch position indication ......................................................4-4Switch position indication circuit-breaker .............................7-15Switch-disconnectors Use, mounting forms ............................4-2Switch-disconnectors with ATEX approval ...........................4-18

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Switching of capacitors ........................................ 8-100…8-103Switching on three-phase motors .............................8-25…8-32System Range xEnergy ......................................................... 0-14System-protective circuit-breakers ......................................... 6-2

TTapped winding ................................................................... 8-10

Feed drive ....................................................................... 8-31Four speeds .................................................................... 8-55Marking .......................................................................... 8-24Multi speed switch ..............................................8-61…8-64Multi speed switch star-delta ..............................8-74…8-88Pole-changing motors .................................................... 8-53Rotary switches .....................................................4-7…4-10Three speeds .................................................................. 8-54

Temperature compensated .................................................... 6-4Temperature monitoring ...................................................... 8-12Test authorities and approval stamps .................................. 9-10Text display, easy ................................................................. 1-65Text operator panel ............................................................. 1-72Thermal overload relays ....................................................... 5-35Thermistor ........................................................................... 8-12Thermistor motor protection ................................................ 5-42Thermistor overload relay for machine protection EMT6 ...... 5-45Thermistor protection .......................................................... 5-42Three-phase asynchronous motor .......................................... 2-2Three-phase automatic rotor starters ........................8-96…8-99Three-phase automatic starters ........................................... 8-14Three-phase automatic stator starters ......................8-91…8-95Three-phase current-automatic stator starters ..................... 8-91Three-phase motors Multi speed switch ...................8-61…8-68Three-phase motors star-delta Multi speed switch ...8-74…8-88Time selectivity circuit-breaker ............................................. 7-16Timing relay, on-delayed ..................................................... 1-57Timing relays, functions ......................................................... 1-2Transformer switch circuit-breaker ....................................... 7-19Transformer-protective circuit-breaker ................................... 6-5Trip-indicating auxiliary contact circuit-breaker ..................... 7-6Trip-indicating auxiliary contact PKZ2 .................................. 6-17Trip-indicating auxiliary contacts PKZM01, PKZM0, PKZM4 .. 6-7Tripping characteristics motor protection system ................. 5-40Tripping characteristics Overload relays ............................... 5-36Tripping CLASS .................................................................... 5-38

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UU/f inverters a Frequency inverters .....................................2-7Unbalanced current consumtion ..........................................5-38Undervoltage release

Circuit-breakers ..............................................................7-19Interlocking of multiple switches ....................................7-14Off-delayed .......................................................................7-5PKZ2 ...............................................................................6-16PKZM01, PKZM0, PKZM4 .................................................6-8Remote switch-off ...........................................................7-11Starting interlock ............................................................7-13Switch-off .......................................................................7-13

Use or reactor capacitor .......................................................8-17Utilisation categories contactors, motor starters ................10-34Utilisation categories for switch-disconnectors ...................10-38

VVaristor suppressor ................................................................5-4Vector control ......................................................................2-70Visualisation, easyHMI .........................................................1-66Voltage releases

Interlock with undervoltage releases ..............................7-14Off-delayed undervoltage release .....................................7-5PKZ2 ...............................................................................6-16PKZM01, PKZM0, PKZM4 .................................................6-8Remote switch-off ...........................................................7-11Shunt releases ..................................................................7-4Starting interlock Undervoltage releases .........................7-13Undervoltage releases ......................................................7-5

WWall-mounting distribution system .......................................0-21Wall-mounting enclosure .....................................................0-18Wiring examples for PS4 .......................................... 1-75…1-77

XxEnergy ................................................................................0-14XSoft ....................................................................................1-71

ZZEV motor protection system ................................... 5-38…5-44

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11-16

L1

L2

L3

CB L1L2

L3

T1T2

T3

H31 4H2

X1 X2

M

M

H1 H4

H1 H4

-Q11.14

A1

A2

1.13

-Q11

X1 X2 X3 X424V0VDC

IN OUT

66SmartWire SmartWire

Wiring Manual | 2008Automation and Power Distribution

Wir

ing

Man

ual

| 20

08

Eaton’s electrical business is a globalleader in electrical control, powerdistribution, uninterruptible power supply and industrial automationproducts and services.

Eaton’s global electrical brands,including Cutler-Hammer®, MGE OfficeProtection Systems™, Powerware®,Holec®, MEM®, Santak and Moeller,provide customer-driven PowerChainManagement® solutions to serve thepower 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)228 602-3640Fax +49(0)228 602-61400

E-Mail: [email protected]: www.moeller.net/fieldservice

Moeller addresses worldwide:www.moeller.net/address

E-mail: [email protected]: www.moeller.net www.eaton.com

Issued by Moeller GmbHHein-Moeller-Str. 7-11D-53115 Bonn

© 2008 by Moeller GmbH, GermanySubject to alterationsFB0200-004EN_(02/08) ip/Ins/CPIPrinted in Germany (11/08)Article No.: 119816

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