Busbar Component Adapters for Modern Industrial Control Panels
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www.moeller.net Busbar Component Adapters for modern industrial control panels Technical Paper Circuit-breakers NZM Dipl.-Ing. Wolfgang Esser Circuit-breakers IZM Switchboard systems Contactors DIL Motor-protective circuit-breakers PKZ Motor-starters MSC For Moeller Electric Sales and Support call KMparts.com (866) 595-9616 Dipl.-Ing. Wolfgang Esser Manager, Product Support Industrial Devices Division Circuit Breakers, Motorstarters and Drives Moeller GmbH, Bonn With grateful acknowledgment of the support from: Mr. Andre R. Fortin, BA Phys. Manager - Codes & Standards International Corporate Advisor – Power Products Moeller Electric Corporation, Millbury, Massachusetts, USA and Mr. Dieter Reiß, Dipl.-Ing. Institute for International Product Safety GmbH, Bonn Differences abound in the types of engineered assemblies encountered throughout the market Busbar Component Adapters • Industrial and commercial distribution sections. Assemblies which – for modern industrial control panel applications, as well as in mainly feature motor starters make assembly in full compliance with • the infra-structure of residential use of a withdrawable drawer design North American market requirements – living complexes. system in a high density configuration, In turn, these various types of engineered from which one or even two loads per assemblies generally feature a different unit can be effectively controlled Different kinds of switching cabinets approach with respect to the way in (MCCs3-Motor Control Centers). This which current or energy is distributed design features complete drawer units The demands placed on modern engi- within their housing or enclosure directly plugged into a set of feeder neered assembly designs, including groupings. Typical for energy distribution vertical busbars. This technology allows mounting and wiring techniques, down assemblies would involve a number of for quick replacement of damaged units to the way in which current within the sections, each reflecting a high degree in down time critical applications such assembly is distributed, are very varied. of standardization in order to more as is encountered in the chemical or raw Major differences are encountered as a easily fulfill the requirements of TSK1- material processing industries. result of: resp. TTA2-Type tested assemblies (Refer to Table 1). In industrial applications, Assemblies with an inherently higher • The end-use application of the a greater mix of motor starter content content of control circuit functionality assembly. and/or serial groupings of smaller (e.g. Electrical apparatus for industrial • Its configuration, geometrical layout components addressing lesser loads machinery) are more likely to require and type of housing. are often encountered in energy individual and customized design • Its maximum rated current, engineering since there is often the • and of course, the physical size of the Type testing for Type tested need for those particular applications components to be mounted within. assemblies (TSk) to take into account specific and safety per IEC/EN 60 439-1 oriented requirements. These would be Generally speaking, they can be broken spelled out in relevant electrical design • Verification of the short circuit down into two distinct groupings standards for machinery, such as IEC/EN withstand strength, 60 204-1 [2] in the IEC world and NFPA • Verification of temperature-rise limits, • Energy Distribution assemblies, or 79 (Electrical Standard for Industrial • Verification of the continuity of the • Electrical apparatus for machinery protective circuit, Machinery) in North America. These (Machines and machine tool • Verification of clearances and creepage particular assemblies, commonly referred controls, with integrated power distances, to as Industrial Control Panels and switching and protective • Verification of the dielectric properties, Industrial Control Panels for Industrial components) • Verification of mechanical operation, Machinery very often need to place • Verification of the degree of protection higher demands on the design and Additional structural differences are • And additional verifications. application versatility of their installed noted in energy distribution assemblies components, particularly in the case Table 1: Necessary Type testing per IEC/EN 60 439-1 falling under the DIN EN 60439-1 [1] of serially built machinery. It’s quite can be made easier for manufacturers of switchgear standard, such as those found in: assemblies by standardizing on distribution board common for those to be built and content. warehoused ahead of time, before an 1 TSK = Typ Tested Assemblies in accordance with EN 60439-1 2 TTA = Type Tested Assemblies 2 3 MCC = Motor Control Center For Moeller Electric Sales and Support call KMparts.com (866) 595-9616 order is actually placed and the final design should be avoided whenever We often see today a differentiation end-use destination can be determined. and wherever possible, if anything so between centralized and de-centralized This puts a premium on the availability that administrative costs can be kept control and energy distribution concepts. of components which incorporate the down to an absolute minimum. The These 2 approaches place different essential features necessary to make busbar systems and adapters described requirements on associated housings them fully compliant with pertinent in the following pages are optimally and are usually configured differently approval agencies world-wide and thus designed to provide modern and with respect to the number of insure their global application without rational solutions for industrial control components per enclosure, as well restriction. Variations in standardized panels used in those applications. as to the magnitude of current levels Application possibilities for energy distribution systems as a function of the size, space requirement and functionality of the equipment Assembly concept Arrange- Centralized De-centralized ment of power switching electrical equipment electrical equipment and protective devices Arrangement Grouped as a unit spatious and/or functionally Close to load, load based spatious and functional separate (e.g. load centers) arrangement Examples: Machinery equipment Water treatment equipment Conveyor belt or roller technology Power rating [kW] Large power demand, with Lesser power requirements, Mostly small individual loads, per Unit (Enclosure) many loads, some of which smaller number of loads, often of the same type can be particularly large noticeable amount of load centers in some cases Energy supply Single point supply source Single point supply source Distributed supply source via cable or bus system via cable or bus system via solid or flexible busway system Current distribution in Preferably via busbar system, Preferably via busbar system, Direct supply of motor starters, individual enclosures partly supplemented with partly supplemented with starter groupings will also bus link connectors bus link connectors feature bus link connectors Mounting of motor starters On busbar adapters, On busbar adapters, On mounting rails, up to 15 kW or mounting rails, or mounting rails, or mounting rail adapters or mounting rail adapters or mounting rail adapters Motor protective switch and On busbar adapters, possible On busbar adapters, possible On mounting rails or circuit breaker mounting up to 550 A, or on mounting up to 550 A, or on mounting mounting rail adapters, and modular plates and modular plates or mounting plates Arrangement of actuating, Local, application oriented Local, application oriented Often integrated in input and display devices decentralized enclosures, also additional centralized operator and display station present Information- and Signalling Increasingly via Increasingly via Primarily via communication exchange communication bus system communication bus system bus system Special advantages Optimum clarity of design, Optimized cabeling Higher level of standardizing, reduced demands on enclosure requirements, higher degree especially useful in cabeling methods of flexibility for changes requirements, higher degree of flexibility for changes, plug technology for all electrical connections is common Table 2: There is more discussion today on the subject of centralized vs. decentralized installation designs. Besides the usual systematic pro and con break- down of aspects from both, a conceptual solution can also be influenced by the way in which varying energy distribution methods and mounting systems can be applied. 3 For Moeller Electric Sales and Support call KMparts.com (866) 595-9616 establishment of a modern and decentralized engineered assembly concept. The new System SmartWire from Moeller brings networking functionality to busbar adapter mounted motor starter combinations from the System xStart line [5] [14] (Photo 1). This very simple networking system serves mainly as replacement for control circuitry wiring (used for energization and signaling) and can be equally functional in both larger decentralized power circuit configurations and centralized custom control panel assemblies. The capability of a quick component exchange is fully maintained using this type of networking design. Indeed, the rapid exchange of parts was a design goal. In the ensuing pages the paper will focus predominantly on electrical machine controls for applications in North America (Emphasis: Industrial Control Panels for Industrial Machinery, Photo 1: The latest networking system Smart Wire from Moeller is used primarily