Wiring Manual Automation and Power Distribution

Moeller addresses worldwide: www.moeller.net/address Wiring Manual E-mail: [email protected] Internet: www.moeller.net L1 L2 L3 21 1 3 5 13 -Q1 L 14 22 N Issued by Moeller GmbH B -F1 I > I > I > Hein-Moeller-Str. 7-11 2 4 6 D-53115 Bonn ~

+12 V 0 V

© 2006 by Moeller GmbH, Germany 1 3 5 1 3 5 1 3 5 L01h -Q11 -Q15 -Q13 F1 Subject to alteration 2 4 6 2 4 6 2 64 N01 h FB0200-004GB-INT MDS/Doku/ 02/05 97 95 A -F2 Printed in the Federal Republic of 2 4 6 98 96

Germany (04/06) PE

Article No.: 106254 U1 V2 V1 M W2 W1 3 U2 L N NI1 I7 I8

-M1

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1st edition 2000, 12/99 2nd updated edition 2006, publication date 02/05

All the circuits are designed according to our best expertise and have been carefully tested. They serve as practical examples. Moeller GmbH refuses to accept liability for any errors.

All rights reserved, including those of the translation. No part of this manual may be reproduced in any form (printed, photocopy, microfilm or any other process) or processed, duplicated or distributed by means of electronic systems without the written permission of Moeller GmbH, Bonn, Germany.

Subject to alterations without notice.

Printed on bleached cellulose, 100 % free from chlorine and acid.

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chapter Automation Systems 1 Electronic motor starters and drives 2 Command and signalling devices 3 Rotary Switches 4 Contactors and Relays 5 Motor-protective circuit-breaker 6 Circuit-breakers 7 All about Motors 8 Specifications, Formulae, Tables 9 Alphabetical index 10

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Page Programmable logic controllers PLCs 1-2 1 xSystem 1-4 Modular I/O system XI/ON 1-6 Networkable motor starters xStart-XS1 1-8 Networking PS40 series 1-10 Networking xSystem 1-11 Networking display and operating devices 1-12 Networking embedded HMI-PLCs 1-13 Engineering XC100/XC200 1-14 Engineering PS4 1-16 Engineering EM4 and LE4 1-19

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Programmable logic controllers The programmable (logic) controller (PLC) is an The most important specifications of a PLC are its electronic device for machine or process control. maximum number of inputs/outputs, its memory 1 The PLC receives signals via inputs, processes size and its processing speed. them according to the instructions of a program, The PS40 Series and the new xSystem are the two and transfers signals to the outputs. automation systems offered by Moeller. These are The program is created using programming described below. software which is able to link inputs and outputs in any required sequence, to measure time, or even carry out arithmetic operations.

PS40 Series Compact PLCs Modular PLCs The PS4 compact PLCs have the following system The PS416 modular PLC has the following key characteristics: features: • Standard programming • High processing speed • Remote and local expansion options • Compact size • Integrated fieldbus interface (Suconet) • Wide range of networking options • Plug-in screw terminals • Extensive memory • Small, compact in size Sucosoft programming software The controllers in this range are very versatile with Sucosoft is the name of the software for a wide range of features, such as integrated programming the PS40 PLCs. setpoint potentiometers, analog inputs/outputs or Program examples are provided in the PLC memory expansion modules (from PS4-150). Beginners' Guide “Automation with Programmable Logic Controllers” (FB2700-017).

Moellers' entire PLC range is described in the Main Catalogue for Automation Systems and Drives, as well as in the Product overview for automation.

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PS4/EM4: LE4: Compact PLC or expansion module Local expansion

PS416: Modular PLC

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xSystem xSystem is Moeller's latest modular automation The XSoft software combines programming, system. It can be configured for the individual configuring, testing, commissioning and 1 requirements of small or large applications. visualization functions in a single tool designed for xSystem reduces the hardware and software the entire xSystem product range. interfaces required. The system features IT functions that are already integrated.

F1 F2 F3 F4 F5 F6 F7 F8 F10 F11 F9 +/- 7 8 9 F12 F13 , 4 SHIFT 5 6 F14 F15 0 1 2 3 ESC CLEAR ENTER

180˚ 1 2

F1 1 F5 2 3 A B C F2 D E F F6 4 5 G H I 6 J K L M N O F3 SHIFT 7 F7 8 P Q R S 9 T U V F4 W X Y Z F8 0 . +/- ESC CLEAR ENTER

0 1 2 3 4 5 6 0 7 1 2 3 4 5 14 15 0 XC-CPU101 1 2 3 4 5 6 7 8 9 0 10 11 1 2 3 12 13 14 4 15 5 6 7 DC INPUT 8 9 EH-X 10 11 0 1 2 D16 12 13 3 14 15 4 5 6 DC INPUT 8 7 EH 9 10 11 -XD16 12 13 14 15 3 DC INPUT EH-XD16 8

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

0 1 2 3 4 5 6 7 8 9 0 10 11 1 2 3 12 13 14 4 15 5 6 7 DC INPUT 8 9 10 0 1 EH-XD16 11 2 3 12 13 14 4 15 5 6 7 DC INPUT 8 9 EH-X 10 11 0 1 2 D16 12 13 3 14 15 4 5 6 DC INPUT 8 7 EH 9 10 11 -XD16 12 13 14 15 DC INPUT EH-XD16 3 0 1 2 3 4 5 6 0 7 1 2 3 4 5 14 15 XC-CPU 201

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System components Refer to the following product overview and • Modular PLCs manuals for further information: – XC100 h – Automation product overview 8 DI, 6 DO, CANopen, RS 232, 4 interrupt (AWB2700-7546) 1 inputs – XC100 hardware and engineering Slot for multimedia memory card, (AWB2724-1453) 64 – 256 KByte program/data memory, – XC200 hardware and engineering 4/8 KByte for retentive data, (AWB2724-1491) 0.5 ms/1000 instructions – XI/OC hardware and engineering – XC200 g (AWB2725-1452) 8 DI, 6 DO, CANopen, RS 232, Ethernet, – XV100 hardware and engineering 2 counters, 2 interrupt inputs, WEB/OPC (AWB2726-1461) server, USB, locally expandable with XI/OC – xStart-XS1 hardware and engineering I/O modules, 256 – 512 KByte program/data (AWB2700-1426) memory, 0.05 ms/1000 instructions – XSoft PLC programming (AWB2700-1437) • Text display PLCs – Function blocks for XSoft (AWB2786-1456); – Modular text display PLCs a including data handling function blocks for Consisting of XC100, up to 3 XI/OC modules text display PLCs and LCD text display with 4 x 20 or x 8 40 lines/characters The latest edition is available from – Compact text display PLC b http://www.moeller.net/support: Enter the Minimum mounting dimensions and high numbers shown in brackets, e.g. interface integration density (10 DI, 8 DO, “AWB2725-1452G”, as a search term. 8 DIO, 2 AI, 2 AO, 2 counter inputs, 2 interrupt inputs, 1 encoder input) • XI/OC input/output modules c – Can be fitted to the XC100/200 (max. 15 modules) – Plug-in terminals with screw or springloaded terminal •XSoft – Programming, configuring, testing/commissioning in a single tool

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XI/ON – the concept XI/ON is a modular I/O system for use in industrial A complete XI/ON structure counts as a single bus automation applications. It links sensors and station in any fieldbus structure and therefore only 1 actuators on the field level with the higher-level requires one bus address. The individual XI/ON controller. Fieldbus protocols PROFIBUS-DP, peripheral modules are therefore independent of CANopen and DeviceNet are supported. the higher-level fieldbus. XI/ON offers modules for virtually every The I/O modules consist of a combination of a application: base module designed as a terminal block, and a • Digital input and output modules plug-in electronics module. • Analog input and output modules The XI/ON peripheral modules are linked to the • Technology modules fieldbus via the XI/ON gateway. This is used for A XI/ON station consists of a gateway, power the communication between the XI/ON station supply modules and I/O modules. and the other fieldbus stations. b c d a

g e f

a Gateway e End plate b Power supply module f Base module in slice design c Electronics module in block design g Base module in block design d Electronics module in slice design

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Flexibility modules can then be plugged simply onto the Each XI/ON station can be adapted exactly for the assigned base module. required number of channels since the modules The base modules are available as terminal blocks. are available in different levels of granularity. They are wired either with spring-loaded or screw 1 For example, digital input modules with 2, 4, 16 or terminals. The electronic modules can be fitted or 32 channels are available in slice or block design. removed during commissioning or for A XI/ON station can contain modules in any maintenance without disturbing the wiring. combination. This enables the system to be A design coding feature ensures that the adapted to virtually any application in industrial electronic modules can only be fitted at the correct automation. locations provided. Compact design I/Oassistant diagnostics and engineering The narrow mounting width of the XI/ON modules software (gateway 50.4 mm; slice 12.6 mm, block The I/Oassistant provides support during the 100.8 mm) and the low mounting height make entire planning and implementation phase of an the system ideal for use in applications where I/O system. It provides help for engineering the space is at a premium. stations, the configuration and for setting the Simple handling parameters. The software is used for Apart from the gateway, all XI/ON modules commissioning systems and carrying out tests and consist of a base module and an electronics diagnostics on the stations. module. The entire documentation for the station, The gateway and the base modules can be including a parts list for ordering, can be snap-fitted on mounting rails. The electronics generated after the engineering phase.

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xStart-XS1 xStart-XS1 is the modular, networkable version of The xStart-XS1 modules consist of a base module the tried and tested motor starter from Moeller. It and a power module that contains the tried and 1 connects the motors with the XI/ON system and tested PKZM0 motor-protective circuit-breaker thus ensures flexible availability between systems, and one or two DILEM contactors. They enable the irrespective of the fieldbus in use. connection of assigned motor ratings up to 4.0 kW xStart-XS1 offers DOL and reversing starters in at a rated operational voltage Ue of 400 V AC. different ratings and available with or without a trip-indicating auxiliary contact (AGM).

de d bc b c a

a XI/ON gateway b Supply module c XI/ON I/O modules d xStart-XS1 DOL starter module e xStart-XS1 reversing starter module

Flexibility Mounting You can adapt xStart-XS1 exactly to the The complete module is mounted by simply requirements of the system used. snap-fitting it onto two top-hat rails. You can also xStart-XS1 can be used at any position on a XI/ON simply mount the base module and add the power station so that you can organise your station section at a later time. Mounting and removal are conveniently into system areas. carried out without any tools. The motor can be disconnected at the machine by using the rotary handle.

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3 1

125

Power supply accessories are available for power can be fed via a distribution system. This reducing wiring costs. If several xStart-XS1 power distribution is available for an operating modules are mounted next to each other, the current of up to 63 A.

L1 L2 L3 a b

a Incoming terminal for three-phase commoning link b Three-phase commoning link for up to 4 DOL starters without trip-indicating auxiliary contact AGM c DOL starter without AGM trip-indicating auxiliary contact

PE M PE M M PE M PE 3 h 3 h 3 h 3 h

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1 Part No. Interface Memory Suconet PROFIBUS-FMS Modbus PROFIBUS-DP

PS4-141-MM1 Suconet K + RS 232 64 kByte PS4-151-MM1 Suconet K + RS 232 64 kByte

PS4-201-MM1 Suconet K + RS 232 64 kByte PS4-271-MM1 Suconet K + RS 232 64 kByte PS4-341-MM1 Suconet K + RS 232 512 kByte

PS416-BGT... PS416-CPU... PS416-POW... PS416-INP... PS416-OUT... PS416-AIN... PS416-AIO... PS416-CNT-200 PS416-TCS-200 PS416-NET... Suconet K (M/S) PS416-COM-200 serial interface

PS40 Range PS416-MOD-200 Modbus(SI)

EM4-101-... Suconet K/K1 EM4-111-... Suconet K/K1

EM4-201-DX2 Suconet K EM4-204-DX1 PROFIBUS-DP

max. 6 LE4 LE4-104-XP1 LE4-108-... LE4-116-... LE4-206-... LE4-308-... LE4-622-CX1 2 x 3 counter LE4-633-CX1 3 x 3 path measurement LE4-501-BS1 Suconet K LE4-503-BS1 PROFIBUS-FMS (Slave)

CM4-504-GS1 Suconet K, PROFIBUS-DP CM4-505-GS1 Gateway ZB4-501-UM4 interface converter

S40 Programming software

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1 CANopen PROFIBUS-DP Modbus Suconet K Ethernet

XC600

XC100 + XIOC xSystem

XC100-XV + XV100

XC200 + XIOC

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1 Part no Resolution Code Display CANopen PROFIBUS-DP Suconet DeviceNet Ethernet Text operator panel M14

MI4-110-KC1 120 X 32 11 LCD monochrome MI4-110-KD1 120 X 32 19 LCD monochrome MI4-110-KG1/2 120 X 32 35 LCD monochrome MI4-140-KF1 120 X 64 27 LCD monochrome MI4-140-KI1 240 X 64 46 LCD monochrome MI4-140-KJ1 240 X 64 46 LCD monochrome

Graphic operator panel M14

MI4-150-KI1 320 X 240 56 Monochrome MI4-450-KI1 320 X 240 56 STN colour MI4-570-KH1 640 X 480 50 TFT

Touch operator panel M14 (Resistive)

MI4-130-TA1 320 X 240 – Monochrome

HMI (Display and operating device) HMI (Display and operating MI4-140-TA1 320 X 240 – Monochrome MI4-450-TA1 320 X 240 – STN colour MI4-550-TA1 320 X 240 – TFT colour MI4-160-TA1 640 X 480 – Monochrome MI4-570-TA2 640 X 480 – TFT MI4-580-TA1 800 X 600 – TFT MI4-590-TA1 1024 X 768 – TFT Touch operator panel MV4 (Infra-red)

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1 Part no Resolution Touch Display CANopen PROFIBUS-DP Suconet DeviceNet Ethernet

MC-HPG-230 320 X 240 Infra-red STN colour MC-HPG-230-DP MC-HPG-300 640 X 480 Infra-red TFT MC-HPG-300-DP

XVH-340-57CAN 320 X 240 Infra-red STN colour XVH-330-57CAN 320 X 240 Resistive STN colour Embedded HMI-PLC XV-442-57CQB-x-13-1 320 X 240 Infra-red STN colour XV-432-57CQB-x-13-1 320 X 240 Resistive STN colour

XV-440-10TVB-x-13-1 640 X 480 Infra-red TFT XV-430-10TVB-x-13-1 640 X 480 Resistive TFT

XV-440-12TSB-x-13-1 800 X 600 Infra-red TFT XV-430-12TSB-x-13-1 800 X 600 Resistive TFT

XV-440-15TXB-x-13-1 1024 X 768 Infra-red TFT XV-430-15TXB-x-13-1 1024 X 768 Resistive TFT

Note: The XVH- ... devices are also available with RS 232 or MPI interface.

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Device arrangement Install the rack and the PLC horizontally in the control cabinet – as shown in the following figure. 1 c a Clearance > 50 mm b Clearance > 75 mm from active elements ba c Cable duct

a a b b ba

Terminal assignment Wiring example of power supply unit The terminals for the power supply and the local The voltage terminal 0VQ/24VQ is only used for I/O have the following assignment: the power supply of the local 8 inputs and 6 outputs, and is potentially isolated from the bus. The outputs 0 to 3 can be loaded with 500 mA and the outputs 4 and 5 with 1 A, each with a 100 % duty factor (DF) and a simultaneity factor %IX 0.0 of 1. %IX 0.1 %IX 0.2 The wiring example shows the wiring with a %IX 0.3 separate power supply for the PLC and the IO %IX 0.4 %IX 0.5 terminals. If only one power supply is used, the %IX 0.6 following terminals must be connected: %IX 0.7 %QX 0.0 24 V to 24VQ and 0 V to 0VQ. %QX 0.1 %QX 0.2 %QX 0.3 %QX 0.4 %QX 0.5 24 VQ 0 V 24 V Q 0 V

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You use the XT-SUB-D/RJ45 programming cable for the physical connection. 0 1 2 CANopen interface 4 3 1 6 5 Assignment of the 6-pole Combicon connector: 0 7 2 1 Terminal Signal 4 3 5 6 GND 6 5 CAN_L + 24 V H 5 0 V H 4 4 CAN_H + 24 V H Q 3 3 GND 0 VQ H 2 2 CAN_L 1 1 CAN_H RS 232 serial interface Only use a cable that is permissible for CANopen This interface is used by the XC100 to with the following properties: communicate with the PC. The physical O connection is implemented via an RJ 45 interface. • Surge impedance 108 to 132 The interface is not isolated. The connector has • Capacitance per unit length < 50 pF/m the following assignment: CAN_H CAN_H

Pin Designation Description 120 O CAN_L 120 O CAN_L CAN_GND CAN_GND 1 2 3 4 5 6 ] 7 2

8 [Kbit/s] Baud rate Length [m] Cable cross section [mm Loop resistance [ O /km] 20 1000 0.75 – 0.80 16 4 GND Ground 125 500 0.50 – 0.60 40 5 TxD Transmit Data 250 250 0.50 – 0.60 40 7 GND Ground 500 100 0.34 – 0.60 60 8 RxD Receive Data 1000 40 0.25 – 0.34 70 You can use the COM1 or COM2 interface on the PC.

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PS4-151-MM1 compact PLC • Wiring for a 230 V AC supply circuit • 24 V DC inputs from an external power supply • Relay contacts with different potentials: 230 V unit, earthed operation 1 AC and 24 V DC Q1 L1 L2 L3 N PE 1153 Q2 1 F2 I > I > I > 2 2246 L1 NPE

T1 T2 ** MM * * 1 +24 V 0 V F1 2 +24 V 0 V +24 V 0 V

B1 B2 2.5 mm 2 A A X1 N .1 .1 .0 .2 .3 .4 .5 .6 .7 .0 .2 .3 .4 .5 .6 .7 L1 0 V 0 V

II 24 V I 24 V PRG Suconet K IA/QA R R 0 V .0 .1 U0 U1 U10 .2 .3 .4 .5 .6 .7 1 2 A1

A1 F3 F4 F5 F6 F7 M1 A2

X1 A1 P1 P2 A1 X2 A1 A2 A1 A1 Q11 Q12 Q13 Q14 A2 A2 A2 A2

* Insulation monitoring must be provided ** IEC/EN 60204-1 specifies that a control where the control circuits are not earthed. transformer is required. (EN 60204-1 and VDE 0100-725)

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PS4-201-MM1 compact PLC • Shared power supply for PLC and • Non-earthed operation with insulation inputs/outputs monitoring L1 1 L2 L3 N PE 1153 1 Q1 F2 1 1 C1 F1 C1 2 F3 I > I > I > 21 2246 2 S1 2 13 23 33 43 22 A1 Q11 Q11 13 12 14 14 24 34 44 P1 L1 L2 L3 PE L1 N PE S2 P1 * 3 14 11 T1 T2 A1 Q11 A2 +24 V 0 V +24 V 0 V A2 +24 V 0 V

1 1 F4 F5 2 2

+24 V 0 V 13 13 S3 B4 14 14 A .1 .0 .2 .3 .4 .5 .6 .7 0 V 0 V 24 V A1 24 V II PRG Suconet K Q U10 0 V .1 U1 .0 .2 .3 .4 .5 U0 1 2

A1 A1 A1 Q12 Q13 M1 A2 A2 A2

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

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PS4-341-MM1 compact PLC • Shared power supply for PLC and • Non-earthed operation with insulation inputs/outputs monitoring 1 L1 L2 L3 N PE 1153 1 Q1 F2 1 1 C1 F1 C1 2 F3 I > I > I > 21 2246 2 S1 2 13 23 33 43 22 A1 Q11 Q11 13 12 14 14 24 34 44 P1 L1 L2 L3 PE a L1 N PE S2 P1 * 3 14 11 T1 T2 A1 Q11 A2 +24 V 0 V +24 V 0 V A2

+24 V 0 V

F4 F5 F6 I I .1 .1 .2 .3 .2 .3 .5 .5 .7 .7 .0 .4 .6 .6 .0 .4 0 V 0 V 0 V

24 V Digital Input Digital Input PRG Suconet K Digital Output Digital Input Digital Output A Q 0 1 10 0 V 0 V 24 V .2 .5 .2 .5 U U U .3 .4 .3 .4 .6 .7 .1 .1 .0 .0 1 2

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

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EM4-201-DX2 expansion module and LE4-116-XD1 local expansion • Inputs and outputs have a separate power • Earthed operation supply 1 Q1 L1 L2 L3 N PE 1 3 5 1 3 5 Q2 Q3

I > I > I > I > I > I > 2 4 6 2 4 6

L1 N PE L1 N PE T1 * T2 * +24 V 0 V +24 V 0 V 1 F2 2 1 F1 2

15 13 11 11 A1 A1 K1 Q15 Q16 Q17 K1 Q12 18 14 12 12 A2 A2 .1 .1 .0 .2 .3 .4 .5 .6 .7 .0 .2 .3 .4 .5 .6 .7 0 V 0 V A1 0 V

Q 24 V 24 V II Suconet K1/K I Q .9 .8 .10 .11 .12 .13 .14 .15 24 V 0 V .9 .8 .10 .11 .12 .13 .14 .15 1 2

13 13 A1 X1 Q18 Q19 Q14 P1 14 14 A2 X2

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

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Page General 2-2 Basics of drives engineering 2-7 Soft starters DS4 2-19 2 Soft starters DM4 2-22 Frequency inverters DF5, DV5, DF6 and DV6 2-26 Connection examples DS4 2-38 Connection examples DM4 2-54 Connection examples DF5, DV5 2-69 Connection examples DF6 2-77 Connection examples DV6 2-80 Rapid Link system 2-86

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The complete power supply and control programme for motors As the applications differ, so do the requirements • During DOL starting (star-delta, reversing made of the electric drives: starter or pole-switching), unwanted current • In the simplest case, the motor is switched with and torque peaks occur. Soft starters eliminate an electromechanical contactor. Combinations these to ensure gentle starting and prevent an 2 consisting of motor protection and line excessive burden on the power source. protection are termed motor starter. • Where an infinitely adjustable speed or a torque • If frequent and/or silent switching is required, adjustment is necessary, frequency inverters contactless semiconductor contactors are used. (U/f inverters, vector frequency inverters, servo) In addition to conventional line, short-circuit are used today. and overload protection, superfast As a general rule, the application determines the semiconductor fuses are required for type “2” drive. coordination and may be needed for type “1” coordination.

Frequent Soft Switching and Speed control starting silent switching

Power distribution

Short-circiuit, Short-circiuit, Short-circuit, Short-circuit, Protection overload overload, overload, semi-conductor semi-conductor semi-conductor

Electro Electro Electro Switching Electronic mechanical mechanical mechanical

Frequenz- Electronic Control umrichter starter Motorschutz

M M M M M 3~ 3~ 3~ 3~ 3~

Three-phase asynchronous motors 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.

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The three-phase asynchronous motor is the The effect of induction produces the rotating field world’s most common electric motor. Its and a torque in the rotor winding. The motor popularity is the result of a rugged, simple speed is determined by the number of pole pairs construction, high degrees of protection, and the frequency of the supply voltage. The standardized sizes and low cost. direction of rotation can be reversed by swapping over two of the supply phases: 2 f x 60 ns = p

n = Revolutions per minute Three-phase motors have typical starting s f = Frequency of voltage in Hz characteristics, with tightening torque M , A p = Number of pole pairs pull-out torque MK and rated-load torque MN. M, I Example: 4-pole motor (number of pole pairs = 2), IA Mk mains frequency = 50 Hz, n = 1500 r.p.m. MA (synchronous speed, speed of rotating field) Ms Because of the induction effect, the asynchronous

MN motor’s rotor can not reach the rotating field’s synchronous speed even at idle. The difference MB M between synchronous speed and rotor speed is M termed slip. ML IN Slip speed: 0 nN nS n ns – n S = ns The three-phase motor contains three phase windings that are offset from one another by Speed of an asynchronous machine: 120 °/p (p = number of pole pairs). To generate a f x 60 rotating field in the motor, a voltage is applied to n = (1 – s) p each phase in turn at a time delay of 120 °. The output power is as L1 L2 L3 follows:

M x n P2 P2 = h = 90˚ 180˚ 270˚ 360˚ 9550 P2 0 P1 = U x I xW3 – p.f.

P2 = Shaft rating in kW M = Torque in Nm n = Speed in r.p.m. 120˚ 120˚ 120˚

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The motor’s electrical and mechanical rating are As a rule, three-phase asynchronous motors are recorded on its nameplate. connected to their power supply with six terminal bolts. There are basically two connection Motor & Co GmbH configurations: star and delta.

Typ 160 l W2 U2 V2 2 3 ~ Mot. Nr. 12345-88 yD 400/690 V 29/17 A S1 15 kW y 0,85 1430 U/min 50 Hz Iso.-Kl. F IP 54 t U1 V1 W1 IEC34-1/VDE 0530

Star connection Delta connection L3 W1 L3 V2 V1 W2 V1 W1 L2 V2 L2 U2 ULN U LN U2 W2 L1 U1 L1 I U1 LN ILN

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

U1 V1 W1 U1 V1 W1

W2 U2 V2 W2 U2 V2

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

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

DOL starting Star-delta circuit (electromechanical) (electromechanical) 2

D y

M M 3 h 3 h

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

IN IN

MN MN y

nN nN

U U D 100 % 100 %

58 % y

t t

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Soft starter and semiconductor contactor Frequency inverter (electronic) (electronic)

POWER

Hz ALARM A

RUN IOPRG

PRG ENTER

M 3 h M 3 h

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

IN IN M N MN

nN n0 n1 n2 ... nN ... nmax

U U 100 % 100 %

U Boost U Boost 30 %

t Ramp t t Ramp t

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

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Power electronics devices The power electronics devices provide infinitely Frequency inverters variable adjustment of physical variables – such as Frequency inverters convert the AC or three-phase speed or torque – to the application process. The system with its constant voltage and frequency power is drawn from the electrical mains, into a new, three-phase system with variable converted in the power electronics apparatus and voltage and frequency. This voltage/frequency fed to the consumer (i.e. the motor). control enables stepless speed control of 2 Semiconductor contactors three-phase motors. The controlled drive can be Semiconductor contactor allow fast, silent operated at rated-load torque even at low speeds. switching of three-phase motors and resistive Vector frequency inverters loads. Switching takes place automatically at the While conventional frequency inverters control ideal point in time and suppresses unwanted three-phase motors using a current and voltage peaks. charactieristic-controlled U/f (voltage/frequency) Soft starters relationship, vector frequency inverters work Soft starters ramp the voltage fed to the motor up using a sensorless, flow-oriented control of the to mains voltage, so that the motor starts almost motor’s magnetic field. The controlled variable is jolt-free. The voltage reduction leads to a the motor current. This allows an opimized control square-law torque reduction in relation to the of the torque for demanding applications (mixers motor’s normal starting torque. Soft starter are and agitators, extruders, transport and conveying therefore especially well suited to starting loads installations). with a square-law speed or torque characteristic (such as pumps or fans).

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Moeller drives

Designation Model Rated current Mains supply Assigned motor [A] voltage rating [V] [kW]

2 Semiconductor DS4-140-H 10–50 1 AC 110–500 – contactor for resistive and inductive load Soft starter DS4-340-M 6–23 3 AC 110–500 2.2–11 (400 V) Soft starter with DS4-340-MR 6–23 3 AC 110–500 2.2–11 (400 V) bidirectional operation Soft starter with bypass DS4-340-MX, 16–46 3 AC 110–500 7.5–22 (400 V) relay DS4-340-M + DIL Soft starter with bypass DS4-340-MXR 16–31 3 AC 110–500 7.5–15 (400 V) relay and bidirectional operation Soft starters (in-line DM4-340... 16–900 3 AC 230 – 460 7.5–500 (400 V) connection type) Soft starters (delta DM4-340... 16–900 3 AC 230 – 460 11–900 (400 V) connection type) Frequency inverters DF5-322... 1.4–10 1 AC 230 0.18–2.2 (230 V) 3 AC 230 Frequency inverters DF5-340... 1.5–16 3 AC 400 0.37–7.5 (400 V) Frequency inverters DF6-340... 22–230 3 AC 400 11–132 (400 V) Vector frequency DV5-322... 1.4–11 1 AC 230 0.18–2.2 (230 V) inverters 3 AC 230 Vector frequency DV5-340... 1.5–16 3 AC 400 0.37–7.5 (400 V) inverters Vector frequency DV6-340... 2.5–260 3 AC 400 0.75–132 (400 V) inverters

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POWER

Hz ALARM A

RUN IOPRG

PRG ENTER 2

Semiconductor contactors DS4-… Frequency inverters DF5-… Vector frequency inverters DV5-…

Frequency inverters DF6-320-… Vector frequency inverters DV6-320-…

Soft starters DM4-…

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DOL starting

In the simplest case, and especially at low rated synchronous speed [ns ~ f]. output (up to about 2.2 kW), the three-phase Due to rotor slippage, The operating speed [n] motor is connected directly to mains voltage. In deviates from this value in relation to the rotating most applications, the connection is made with an field [n = ns x (1 – s)], slippage being 2 electromechanical contactor. [s = (ns – n)/ns]. In this control mode, – on the mains at fixed On starting (s = 1), a high starting current occurs, voltage and frequency – the asynchronous reaching up to ten times the rated current Ie. motor’s speed is only slightly below the I 7 M 2 Ie MN 6

4 1 ML 3

0.25 0.5 0.75 1 0.25 0.5 0.75 1 n/nN n/nN

I/Ie: 6...10 M/MN: 0.25...2.5

Features of DOL starting If an application demands frequent and/or silent • For low- and medium-power three-phase switching, or if adverse environmental conditions motors prevent the effective use of electromechanical • Three connection lines (circuit layout: star or switching elements, electronic semiconductor delta) contactors are required. In addition to short-circuit • High starting torque and overload protection, the semiconductor • Very high mechanical load contactor must be protected with a superfast fuse. • High current peaks According to IEC/EN 60947, type “2” • Voltage dips coordination requires the use of a superfast • Simple switching devices semiconductor fuse. For type “1” coordination, – the majority of cases – a superfast semiconductor fuse is not necessary. Here are a few examples:

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• Building services management: • Other applications: Non-motor-driven loads, – Reversing drive for lift doors such as – Starting heat-exchanger units – Heater elements in extruders – Starting conveyor belts – Heater elements in kilns • In critical atmospheres: – Controlling lighting systems. – Controlling filling station petrol pump motors – Controlling pumps in paint processing plants. 2

Motor start in star-delta configuration The star-delta circuit layout is the most commonly motor control. The customer saves on expensive used configuration for starting three-phase wiring and installation time and reduces the motors. likelihood of faults. The completely factory prewired SDAINL star-delta combination from Moeller provides convenient

. I 7 M 2 Ie M 6 N

4 1 ML 3

0.25 0.5 0.75 1 0.25 0.5 0.75 1 n/nN n/nN M/M : 0.5 I/Ie: 1.5...2.5 N

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

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Soft starters (electronic motor start) The characteristic curves for DOL and star-delta The ideal scenario of a smooth torque build-up starting show current and torque step changes, and a controlled current reduction in the starting which have a number of negative effects, phase is made possible by the electronic soft especially at medium and high motor ratings: starter. Providing infinitely variable control of the 2 • High mechanical machine loads three-phase motor’s supply voltage in the starting • Rapid wear phase, it matches the motor to the load behaviour • Increased servicing costs of the driven machine and accelerates it smoothly. • High supply costs from the power supply This avoids mechanical jolting and suppresses companies (peak current calculation) current peaks. Soft starters present an electronic • High mains and generator load alternative to the conventional star-delta switch. • Voltage dips with a negative effect in other consumers I 7 M 2 I MN e 6

4 1 ML 3

0.25 0.5 0.75 1 0.25 0.5 0.75 1 n/nN n/nN M/M : 0.15...1 I/Ie: 1...5 N

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

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Parallel connection of several motors to a single soft starter L1 L2 You can also use soft starters to start several L3 motors connected in parallel. This does not, however, allow the behaviour of the individual motors to be controlled. Each motor must be F1 separately fitted with suitable overload 2 protection. Q1

Note: The total current consumption of the connected motors must not exceed the soft starter’s rated Q11 operational current Ie.

Note: L1 L2 L3 Each motor must be individually protected with a thermistor and/or overload relay. Q21

Caution! T1 T2 T3 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’ F11 F12 ratings (for example 1.5 kW and 11 kW): The lower-rated motors may not be able to reach the required torque due to the relatively large ohmic M M M1 M2 resistance of these motors’ stators, requiring a 3 3 higher voltage during starting.

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

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Using soft starters with pole-changing Using soft starters for motors with motors power-factor correction Soft starters can be connected in the supply line Caution! before pole-changing, a section No capacitive loads must be connected at the soft “Pole-changing motors”, page 8-51). starter’s output. 2 Note: Power-factor corrected motors or motor groups All changeovers (high/low speed) must take place must not be started with soft starters. Mains-side at standstill. compensation is permissible when the ramp time The start signal must be issued only when a (starting phase) has completed (i.e. the TOR (Top contact sequence has been selected and a start of Ramp) signal has been issued) and the signal for pole-changing was set. capacitors exhibit a series inductance. Control is comparable to cascade control with the difference that the changeover is made not to the Note: next motor but to the other winding (TOR = If electronic devices (such as, soft starters, top-of-ramp signal). frequency inverters or UPS), use capacitors and correction circuits only with a choke fitted Using soft starters with three-phase upstream. slipring motors When upgrading or modernizing older a page 2-16. 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 page 2-15).

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2 13 14 K L M 6 6 5 5 W I > 4 4 3 3 I > M 3 M1 2 1 2 1 UV L1 L2 L3 T1 T2 T3 I > L1 L2 L3 Q11 Q21 Q1 R1 6 5 W2 4 3 V1 2 1 U1 Q41 R2 6 5 3 4 W2 V2 2 1 U2 Q42 R3 6 5 4 3 W3 V3 2 1 F1 U3 Q43 13 14 K L M PE 5 6 6 W 5 I > 3 4 4 V 3 I > M L2 L3 3 M1 2 2 1 1 U I > L1 Q11 Q1 For Immediate Delivery call KMParts.com at (866) 595-96162-15 Moeller Wiring Manual 02/05 Electronic motor starters and drives Basics of drives engineering Q12 2 TOR M 3 L1 L2 L3 T1 T2 T3 Q11 M1 L1 L2 L3 Q1 Q21 Caution! Not permissible M 3 L1 L2 L3 T1 T2 T3 Q11 M1 L1 L2 L3 Q21 Q1 M 3 Q11 M1 L1 L2 L3 Q1

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Connecting star points when using soft starters or semiconductor contactors Caution! The connection of the star point to the PE or N conductor is not permissible when using controlled semiconductor contactors or soft starters. This applies especially to 2 two-phase-controlled starters.

L1 L2 L3 L1 L2 L3 L1 L2 L3

Q21

T1 T2 T3 T1 T2 T3 T1 T2 T3

M1 M 3

Caution! R1 Not permissible

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Soft starters and classification type to Type “2” coordination IEC/EN 60947-4-3 In type “2” coordination, the contactor or soft The following classification types are defined in starter must not endanger persons or the IEC/EN 60947-4-3, 8.2.5.1: installation in the event of a short-circuit and must be capable of continued use without repairs Type “1” coordination or parts replacements. For hybrid control devices 2 In type “1” coordination, the contactor or soft and contactors, there is a risk of contact welding. starter must not endanger persons or the In this case the manufacturer must provide installation in the event of a short-circuit and appropriate maintenance instructions. does not have to be capable of continued use The coordinated short-circuit protection device without repairs or parts replacements. (SCPD) must trip in the event of a short-circuit. Blown fuses must be replaced. This is part of normal operation (for the fuse), also for type “2” coordination.

L1 L1 L2 L2 L3 L3 PE PE

Q1 Q1 I> I> I> I> I> I>

F1 F1

L1 L2 L3 L1 L2 L3

Q21 Q21

T1 T2 T3 T1 T2 T3

M M M1 3 M1 3

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Product attributes • Construction, mounting and connection as for contactor • Automatic control voltage detection –24VDC g 15 % 110 to 240 V AC g 15 % – Safe starting at 85 % Umin • Operation indication by LED 2 • 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)

2 1

5 0,5 t-Start (s) 0 10 60 50

80 40 U-Start (%) 30 100 2 1

5 0,5 t-Stop (s) 0 10

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LED displays The LEDs indicate the operational states as follows:

Red LED Green LED Function Lit Lit Init, LEDs lit only briefly, Init itself takes about 2 seconds 2 Depending on device: – All devices: LED briefly lit once – DC devices: after a brief pause, the LEDs briefly light up again Off Off Device is off Off Flashing at 2 s Ready for operation, power supply OK, but no start signal intervals Off Flashing at 0.5 s Device in operation, ramp is active (soft start or soft stop); on M(X)R interval 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 Off Fault 0.5 s interval U

A1, A2 FWD, REV, 0

Uout = 100 %

Run- (FWD/REV-) LED

Error-LED

Initialization Fault Ready for operation In ramp Top of ramp

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Power section versions DOL starters DOL starters Reversing starters Reversing starters with bypass with bypass L1 L2 L3 DS4-340-...-M DS4-340-...-MX DS4-340-...-MR DS4-340-...-MXR 2 L1 L2 L3

DS4

T1 T2 T3

M 3

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Product attributes • Configurable, communications-capable soft Instead of the keypad, intelligent interfaces can starter with plug-in control signal terminals and also be used: interface for optional units: • Serial RS 232/RS 485 interface (configuration – Operator control and programming unit through PC software) 2 – Serial interface • Suconet K fieldbus module (interface on every – Fieldbus module Moeller PLC) • Application selector switch with • PROFIBUS DP fieldbus module user-programmable parameter sets for 10 The DM4 soft starters provide the most convenient standard applications method of implementing soft starting. Because – • I2t controller in addition to phase failure and motor current – Current limitation monitoring – the motor winding temperature is – Overload protection signalled through the built-in thermistor input, the – Idle/undercurrent detection (e.g. belt break- soft starters eliminate the need for additional, age) external components, such as motor protective • Kickstarting and heavy starting relays. DM4 conforms to the IEC/EN 60947-4-2 • Automatic control voltage detection standard. • 3 relays, e.g. fault signal, TOR (top of ramp) With the soft starter, reducing the voltage results Ten default parameter sets for typical applications in a reduction of the high starting currents of the can be simply called up with a selector switch. three-phase motor, although the torque is also 2 Additional plant-specific settings can be defined reduced [Istartup ~ U] and [M ~ U ]. After starting, with an optional keypad. the motor reaches its rated speed with all of the In three-phase regulator control mode, for solutions described above. For starting motors at example, three-phase resistive and inductive loads rated-load torque and/or for motor operation at a – heaters, lighting systems, transformers – can be motor speed that is independent of the supply controlled with the DM4. Both open-loop and – frequency, a frequency inverter is required. with measured value feedback – closed-loop control are possible.

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

0 - standard flash fault supply 1 - high torque on a 2 - pump c/l run 3 - pump kickstart 4 - light conveyor 5 - heavy conveyor 6 - low inertia fan 7 - high inertia fan b 8 - recip compressor 9 - screw compressor

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Standard applications (selector switch)

Labelling on Indication on Meaning Notes device keypad Standard Standard Standard Default settings, suitable without adaptation 2 for most applications High torque1) High Torque High breakaway Drives with higher friction torque at standstill torque Pump Pump Small pump Pump drives up to 15 kW Pump Pump.w.Kick Large pump Pump drives over 15 kW Longer deceleration Kickstart times. Light LightConvey Light conveyor conveyor Heavy HeavyConvey Heavy-duty conveyor conveyor Low inertia LowInert.fan Low-inertia fan Fan drive with relatively small mass inertia fan moment of up to 15 times the motor’s inertia moment High inertia HighInertfan High-inertia fan Fan drive with relatively large mass inertia fan moment of over 15 times the motor’s inertia moment Longer ramp-up times. Recip RecipCompres Reciprocal Higher start pedestal, p.f. optimization compressor compressor matched Screw ScrewCompres Screw Increased current consumption, no current compressor compressor limitation 1) For the “High Torque” setting, the soft starter must be able to supply 1.5 times the motor’s rated current. Delta circuit Note: Normally, soft starters are connected directly in The delta connection is more cost-effective at series (in-line) with the motor. The DM4 soft motor ratings over 30 kW and when replacing starters also allow a delta connection. star-delta switches. Advantage: • This is a less expensive alternative since the soft starter has to deliver only 58 % of the motor’s rated 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 phase, so that additional motor protection must be fitted in the parallel phase or in the supply cable. For2-24 Immediate Delivery call KMParts.com at (866) 595-9616 Moeller Wiring Manual 02/05 Electronic motor starters and drives Soft starters DM4 W2 U2 V2 U1 V1 W1 2 595-9616 In-Delta M 3 ~ (866) 55 kW 400 V at III A 3 0.86 50 Hz KMParts.com ϕ 100 A DILM115 cos 100 / 59 NZM7-125N 400 V call DM4-340-30K (59 A) kW rpm 55S1 1410 / 690 V LN Delivery U 400 100 A NZM7-125N-OBI DILM115 DM4-340-55K (105 A) III Immediate M 3 ~ 55 kW 400 V For W1 V1 W2 U2 V2 In-Line U1

2-25 Moeller Wiring Manual 02/05 Electronic motor starters and drives Frequency inverters DF5, DV5, DF6, DV6

Design and mode of operation Frequency inverters provide variable, stepless speed control of three-phase motors.

Energy flow 2 F U, f, I U, f, (I) M M, n m v 3~ Constant Variable J

Mains Electronic actuator Motor Load

IM~ M x n P = U x I x √3 x y P = el fn~ L 9550 Frequency inverters convert constant mains almost only active power (p.f. ~ 1) from the voltage and frequency into a DC voltage, from supplying mains. The reactive power needed for which they generate a new three-phase supply motor operation is supplied by the DC link. This with variable voltage and frequency for the eliminates the need for p.f. correction on the three-phase motor. The frequency inverter draws mains side. a b c IGBT

L1, L1 L2, N M 3~ L3

a Rectifier c Inverter with IGBT b DC link d Open-/closed-loop control

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The frequency-controlled three-phase motor is The possibilities for individual or plant-specific today a standard component for infinitely variable coordination are determined by the specific speed and torque regulation, providing efficient, features of the inverters and by the modulation energy-saving power either as an individual drive procedure used. or as part of an automated installation. 2 I 7 M 2 Ie 6 MN

5 M 4 MN 1 ML 3 I 2 IN

0.25 0.5 0.75 1 0.25 0.5 0.75 1 n/nN n/nN I/I : 0...1.8 e M/MN: 0.1...1.5

Modulation procedure of inverters An inverter basically consists of six electronic circuit switches the IGBTs on and off according to switches and is today usually made with IGBTs various principles (modulation procedures) to (insulated gate bipolar transistors). The control change the frequency inverter’s output frequency.

Sensorless vector control The switching patterns for the inverter are In flow-regulated vector control, the active and calculated with the PWM (pulse-width reactive current components are calculated from modulation) switching patterns. In voltage vector the measured motor currents, compared with the control mode, the amplitude and frequency of the values from the motor model and, if necessary, voltage vector are controlled in dependence of corrected. The amplitude, frequency and slippage and load current. This allows large speed inclination of the voltage vector are controlled ranges and highly accurate speeds to be achieved directly. This allows operation at the current limit without speed feedback. This control method (U/f and the achievement of large speed ranges and control) is the preferred method for parallel highly accurate speeds. Especially noteworthy is operation of several motors with one frequency the drive’s dynamic output at low speeds, for inverter. example in lifting and winding applications.

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The key advantage of sensorless vector The following illustration shows a simplified technology is that the motor current can be equivalent circuit diagram for the asynchronous regulated to match the motor’s rated current. This motor and associated current vectors: allows dynamic torque regulation to be implemented for three-phase asynchronous motors. 2 X1 R1 X'2 R'2 / s bo

i1 iw i1 iw

u im X d 1 h im~ V ib

im e acb ia

a Stator i1 = Stator current (phase current) b Air gap iµ = Flux-generating current component c Rotor iw = Torque-generating current component d Rotor flow-oriented R’2 /s = Slip-dependent rotor resistance e Stator-oriented

In sensorless vector control, the flux-generating The physical motor data required for the model is current iµ and the torque-generating current iw are formed from the entered and measured calculated from the measured stator voltage u1 (self-tuning) parameters. 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).

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Characteristics of frequency inverters DF5, DF6 • Infinitely variable speed control through Individual settings can be made with an optional voltage/frequency control (U/f) keypad. Various control modes can be selected • High starting and acceleration torque and configured in a number of layers, • Constant torque in motor’s rated range For applications with pressure and flow control, all • EMC measures (optional: radio interference devices contain a built-in PID controller that can 2 filter, screened motor cable) be matched to any system. Additional features of sensorless vector A further advantage of the frequency inverters is control for frequency inverters DV5 and DV6 that they eliminate the need for external • Infinitely variable torque control, also at zero components for monitoring and motor protection. speed On the mains side, only a fuse or circuit-breaker • Low torque control time (PHKZ) is needed for line and short-circuit • Increased concentricity and constancy of speed protection. The frequency inverter’s inputs and • Speed control (options for DV6: control module, outputs are monitored internally by measurement pulse generator) and control circuits, such as overtemperature, The DF5, DF6, DV5 and DV6 frequency inverters earth fault, short-circuit, motor overload, motor are factory-preset for their assigned motor rating, blockage and drive belt monitoring. Temperature allowing drives to be started immediately after measurement in the motor winding can also be installation. incorporated in the frequency inverter’s control circuit through a thermistor input.

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Frequency inverter, installing Electronic devices such as soft starters and F 30˚ frequency inverters must normally be fitted F 30˚ vertically. F 30˚ To ensure adequate air circulation for cooling, a F 30˚ 2 clear space of at least 100 mm should be maintained both above and below the device. At the sides of the device, the clear space should be at least 10 mm for DF5 and DV5 and 50 mm for DF6 and DV6. Note that the front enclosure elements of the DF5 and DV5 devices open to the side for electrical connection. Make sure that the free space in the area of the front hinged covers is at least 80 mm to the left side and at least 120 mm to the right side. f 100

f 80 f 120 f 100

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EMC-compliant connection of frequency inverters

Mains 2 Contactor F

Switching Q

Mains choke R

Suppressor filter K

Frequency inverter T 3~

Motor cable

M Motor M 3~

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

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Notes about correct installation of frequency inverters For an EMC-compliant installation, observe the Measures for EMC-compliant installation are: following information. Electrical and magnetic • Earthing measures disturbance fields can be limited to the required • Screening measures levels. The necessary measures work only in • Filtering measures 2 combination and should be taken into • Chokes consideration at the engineering stage. To They are described in more detail below. subsequently modify an installation to meet EMC Earthing measures requirements is possible only at considerable These must be implemented to comply with the additional cost. legal standards and are a prerequisite for the effective use of further measures such as filters EMC measures and screening. All conducting metallic enclosure The EMC (electromagnetic compatibility) of a sections must be electrically connected to the device is its ability to withstand electrical earth potential. For EMC, the important factor is interference (i.e. its immunity) while itself not not the cable’s cross-section, but its surface, since emitting excessive electromagnetic interference this is where high frequency current flows to into the environment. earth. All earthing points must be low-impedance, The IEC/EN 61800-3 standard describes the limit highly conductive and routed directly to the values and test methods for emitted interference central earthing point (potential equalization bar and noise immunity for variable-speed electrical or star earth). The contact points must be free drives (PDS = Power Drives System). from paint and rust. Use galvanized mounting The tests and values are based not on individual plates and materials. components but on a typical complete drive system.

T1 K1 Tn Kn M1 Mn M M 3h 3h K1 = Radio interference filter PE T1 = Frequency inverter PE PE PE PE

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Screening measures

L1 M L2 L3 3 PE 2

F 300 mm

a b

Four-core screened motor supply cable:

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

edc

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Screening reduces emitted interference (noise Note: immunity of neighbouring systems and devices Maintenance switches at of frequency inverter against external influences). Cables laid between outputs must be operated only at zero current. the frequency inverter and the motor must be screened, but the screen must not be considered a Control and signal lines must be twisted and may replacement for the PE cable. Four-wire motor be double-screened, the inner screen being 2 cables are recommended (three phases plus PE). connected to the voltage source at one end and The screen must be connected to earth (PES) at the outer screen at both ends. The motor cable both ends with a large-area connection. Do not must be laid separately from the control and connect the screen with pigtails. Interruptions in signal lines (>10 cm) and must not run parallel to the screen, such as terminals, contactors, chokes, any power cables. 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 ba (PES, screen terminal). Free, unscreened cables should not be longer than about 100 mm. Example: Screen attachment for maintenance switch

MBS-I2

f 100

a Power cables: mains, motor, internal DC link, braking resistance b Signal cables: analog and digital control signals

4.2 x 8.2 Inside control panels, too, cables should be e screened if they are more than 30 cm long.

o 4.1 o 3.5

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Example for screening control and signal cables:

1 2

H O L 2 1 P24

15 3 2 PES 2 Cu 2.5 mm F 20 m M4 PE ZB4-102-KS1

PES 4K7 M M R1 REV FWD Example for a standard connection of frequency inverter DF5, with reference value potentiometer R1 (M22-4K7) and mounting accessories ZB4-102-KS1 Filtering measures Note: Radio interference filters and line filters The mounting surfaces of frequency inverters and (combinations of radio interference filter and radio interference filters must be free from paint mains choke) protect against conducted and must have good HF conductivity. 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. IO

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Filters produce leakage currents which, in the Chokes event of a fault (such as phase failure or load Fitted on the frequency inverter’s input side, unbalance), can be much larger than the rated chokes reduce the current-dependent phase effect values. To prevent dangerous voltages, the filters and improve the power factor. This reduces the must be earthed. As the leakage currents are current harmonics and improves the mains high-frequency interference sources, the earthing quality. The use of mains chokes is especially 2 connections and cables must have a low recommended where several frequency inverters resistance and large contact surfaces. are connected to a single mains supply point when other electronic devices are also connected to the Z1 G1 same supply network. L1 L1 R2 L/L1 U L2 S2 L2 V M A reduction of the mains current interference is L2 3h L3 L3 T2 N/L3 W also achieved by installing DC chokes in the e e E frequency inverter’s DC link. PE At the frequency inverter’s output, chokes are E E E used if the motor cables are long and if multiple motors are connected in parallel to the output. For leakage currents above 3.5 mA, one of the They also enhance the protection of the power following must be fulfilled according to EN 60335: semiconductors in the event of an earth fault or • the protective conductor must have a short-circuit, and protect the motors from cross-section greater than 10 mm2, excessive rates of voltage rise (> 500 V/µs) • the protective conductor must be open-circuit resulting from high pulse frequencies. monitored, or • an additional conductor must be fitted.

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Example: EMC-compliant mounting and connection

2 15

PES PE PES

a PES

b PES PES W2 U2 V2 U1 V1 W1 c PE

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

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Linking the overload relay into the control system We recommend using an external overload relay In the event of a fault, the soft starter decelerates instead of a motor-protective circuit-breaker with for the set ramp time and stops. built-in overload relay. This allows controlled ramping down of the soft starter through the Standard connection, unidirectional 2 control section in the event of an overload. rotation Note: In standard operation the soft starter is connected Connecting the motor directly to mains power can into the motor supply line. A central switching cause overvoltage and destruction of the soft element (contactor or main switch) with isolating starter’s semiconductors. properties to isolate the mains according to Note: EN 60947-1 section 7.1.6 and for working on the The overload relay’s signalling contacts are linked motor is required according to EN 60204-1 into the On/Off circuit. section 5.3. No contactors are required to operate individual motor feeders. Minimum connection of DS4-340-M(X)

L1 L2 L3 PE

Q1 F1 I I I

01 F1 S3 F2 3L2 5L3 1L1 TOR Q21

2T1 14

4T2 13 6T3 A1 Q21 M A2 M1 3~ 0: Off/soft stop, 1: Start/soft start

For2-38 Immediate Delivery call KMParts.com at (866) 595-9616 Moeller Wiring Manual 02/05 Electronic motor starters and drives Connection examples, DS4 A1 A2 2 K1 Q21 595-9616 r contactor On/Off HLS Start/Stop (866) at Q11 K2t b + 150 ms S1: Q11 OffS1: Q11 OnS2: Q11 b : Control with Q11/K2t optional HLS = Semiconducto Stop Stop t > K1

K2t KMParts.com Q11 call S1 F1 S2 K1 L01/L+ L00/L– Delivery F2 = Semiconductor fuse for type “2” coordination, in addition to Q1 Q21 = Semiconductor contactor M1 = Motor semiconductorcontactor 14 Immediate 13 Ready

For

6T3 5L3

4T2 I 3L2

2T1 I 1L1 M 3~ I F2 F1 Q11 M1 Q21 Q1 L1 L2 L3 PE Connection of DS4-340-M as Q1 =Q11 =Mains contactor (optional) Line protection relay F1 = Motor-protective 2-39 Moeller Wiring Manual 02/05 Electronic motor starters and drives Connection examples, DS4

Connection as soft starter without separate mains contactor

L1 L01/L+ L2 L3 PE 2 K1

Q1 I I I F1

F1 S1

F2 3L2 5L3 1L1 TOR S2 K1 T1

2T1 13 14 4T2 6T3

A1 K1 T1 A2 M1 M 3~ L00/L– Q1: Line protection n Emergency-Stop F1: Overload relay S1: Soft stop F2: Semiconductor fuse for type “2” S2: Soft start coordination, in addition to Q1 T1: Semiconductor contactor M1: Motor

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2 K1 K3 595-9616 Soft Stop Soft Start Emergency-Stop (866) n S1: Off Q11 S2: On Q11 K2t t = 10 s at K1 Q11 K1 KMParts.com K2t call S1 F1 S2 K1 in addition to Q1 Delivery L00/L– L01/L+ F2 = Semiconductor fuse for type “2” coordination, T1 = Soft starter = Motor M1 14 Immediate

TOR 13

6T3 5L3 For

4T2

I 3L2

2T1 I 1L1 M 3~ I F2 F1 Q11 T1 M1 Q1 L1 L2 L3 PE Connection of soft starter with mains contactor Q1 = Line protection Q11 = Mains contactor (optional) F1 = relay Motor-protective 2-41 Moeller Wiring Manual 02/05 Electronic motor starters and drives Connection examples, DS4

Reversing circuit standard connection, rating the DS4 is not available with built-in bidirectional rotation reversing contactor function. In this case make Note: sure that direction reversal takes place only with The device of the DS4-...-M(X)R series have a the DS4 in stop state. Use an external controller to built-in electronic reversing contactor function. implement this functionality. In soft starter You need to only specify the required direction of operation, you can use a TOR relay to control an 2 rotation. The DS4 then internally ensures the off-delayed relay for this purpose, whereby the correct control sequence. deceleration time must be t-Stop + 150 ms or At ratings over 22 kW, a conventional reversing higher. circuit layout must be used, because above this Minimum connection of DS4-340-M(X)R L1 L2 L3 PE

Q1 F1 I I I

F1 102 S3 F2 3L2 5L3 1L1 TOR T1

2T1 13 14 4T2 6T3

FWD REV T1 M 0 V M1 3~ Q1: Line protection T1: Soft starter Q11: Mains contactor (optional) M1: Motor F1: Overload relay n: Emergency-Stop F2: Semiconductor fuse for type “2” 0: Off/Soft stop coordination, in addition to Q1 1: FWD 2: REV

For2-42 Immediate Delivery call KMParts.com at (866) 595-9616 Moeller Wiring Manual 02/05 Electronic motor starters and drives Connection examples, DS4 REV 2 K2 0 V FWD 595-9616 K1 T1 K2 (866) at K1 S3 K2 n : Emergency-Stop S1: Soft stop S2: FWD Soft start S2: REV Soft start K1 KMParts.com S1 F1 K2 S2 K1 call contactor L01/L+ L00/L– T1: Semiconductor M1: Motor Delivery starter without mains contactor 14 Immediate

TOR 13

6T3 5L3 For

4T2

I 3L2

2T1 I 1L1 M 3~ I F1 F2 T1 M1 Q1 addition to Q1 L1 L2 L3 PE Connection of reversing soft Q1: Line protection F1: relay Overload F2: coordination, in for type “2” Semiconductor fuse 2-43 Moeller Wiring Manual 02/05 Electronic motor starters and drives Connection examples, DS4

Connection of reversing soft starter with mains contactor

L1 L2 L3 2 PE

Q1 I I I

Q11

F2 3L2 5L3 1L1 TOR T1

2T1 14

4T2 13 6T3

M M1 3~

Q1: Line protection Q11: Mains contactor (optional) F1: Overload relay F2: Semiconductor fuse for type “2” coordination, in addition to Q1 T1: Semiconductor contactor M1: Motor

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REV 2 K4 0 V FWD 595-9616 K3 T1 (866) K4 at K3 K4 REV Soft Start K3 KMParts.com K4 K1 K3 FWD call Soft Stop Soft Start Delivery K2t t = 10 s K1 Q11 Immediate For K1 K2t S1 F1 S2 K1 L01/L+ L00/L– n : Emergency-Stop S1: Off Q11 S2: On Q11 2-45 Moeller Wiring Manual 02/05 Electronic motor starters and drives Connection examples, DS4

Bypass connection, single direction of rota- function is mapped to relay 13/14. The soft starter tion controls the bypass contactor so that no further Caution! user action is required. Because the bypass The DS4-...-MX(R) devices have built-in bypass contactor is switched only at zero current and contacts. The examples below therefore apply does not, therefore, have to switch the motor only for DS4-...-M. If an external bypass for load, an AC1 layout can be used. Suitable bypass 2 devices with reversing function (DS4-...-MR) is to contactors are listed in appendix “Technical be fitted, you must include an additional bypass data”. contactor is required the second direction of If an Emergency-Stop requires an immediate rotation as well as additional interlocks to prevent disconnection of the voltage, the bypass may have a short-circuit through the bypass contactors. to switch under AC3 conditions (for example if the The bypass connection allows a direct connection Enable signal is removed with a command or the of the motor to the mains to suppress heat soft stop ramp time is 0). In this case, the circuit dissipation through the soft starter. The bypass must be laid out so that either a higher-priority contactor is actuated once the soft starter has isolating element trips first or the bypass must be completed the acceleration phase (i.e. once mains laid out to AC3. voltage is reached). By default, the Top-of-Ramp

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L1 L2 L3 PE

Q1 2 I I I F1 F1

F2 01 S3 3L2 5L3 1L1 TOR Q21 T1 13 T1 14

2T1 14

4T2 13 6T3

A1 A1 T1 Q21 M A2 A2 M1 3~ S3 = Soft start/stop F2 = Semiconductor fuse for type “2” coordination, in addition to Q1 Q1 = Line protection T1 = Semiconductor contactor Q21 = Bypass contactor M1 = Motor F1 = Overload relay

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Pump connection, single direction of rota- interlocks ensure that changeovers take place only tion after a stop. In pump applications the bypass contactor is often required to provide emergency operation Note: capability. This is achieved with a service switch In contrast to simple bypass operation, the bypass that allows a changeover from soft starter contactor must be laid out to AC3 here. For a 2 operation to DOL starting through the bypass suitable contactor, see our recommended mains contactor. In the latter setting the soft starter is contactor in appendix “Technical data”. fully bypassed. But because the output circuit must not be opened during operation, the

Pump L1 L2 Q1: Line protection L3 Q11: Mains contactor (optional) PE Q21: Bypass contactor Q31: Contactor F1: Overload relay Q1 F2: Semiconductor fuse for type “2” I I I coordination, in addition to Q1 T1: Semiconductor contactor F1 M1: Motor

Q11 3L2 5L3 1L1 TOR Q21 T1

2T1 14

4T2 13 6T3 Q31

M M1 3~

For2-48 Immediate Delivery call KMParts.com at (866) 595-9616 Moeller Wiring Manual 02/05 Electronic motor starters and drives Connection examples, DS4 13 14 2 Q21 T1 TOR K2 595-9616 K4 K6t a (866) at K6t A1 A2 e f g RUN Bypass T1 f g KMParts.com S4 S5 K5 K5 K5 call Q31 Delivery K3 K4 Q11 Hand Auto stop Soft start/soft c d e K2 K3 K1 cd Immediate K3 K4 K1 K2 For K2 S1 Q21 E2 39 b K1 T1 K1 Emergency-Stop 150 ms t > t-Stop + Enable S2 S3 K1 Pump control n a b 2-49 Moeller Wiring Manual 02/05 Electronic motor starters and drives Connection examples, DS4

Starting several motors sequentially with a d Off-time monitoring soft starter (cascaded control) Set the timing relay K1T so that the soft starter When starting several motors one after the other is not thermally overloaded: calculate the time using a soft starter, keep to the following from the soft starter’s permissible operating changeover sequence: frequency or select a soft starter that allows • Start using soft starter the required time to be reached. 2 • Switch on bypass contactor • Disable soft starter e Changeover monitoring • Switch soft starter output to the next motor Set the timing relay to a return time of about • Restart 2 s. This ensures that the next motor branch can not be connected as long as the soft starter is running. a page 2-52 n Emergency-Stop a S1: Q11 Off page 2-53 S2: Q11 On i Switching off individual motors a Soft start/soft stop The Off switch results in all motors being switched off at the same time. To switch off individual b Simulation of RUN relay motors, you need to make use of N/C contact i. Timing relay K2T simulates the RUN signal of the DS4. The set off-delay time must be Observe the thermal load on the soft starter greater than the ramp time. To be on the safe (starting frequency, current load). If motors are to side, use 15 s. be started at short intervals, you may have to select a soft starter with a higher load cycle. c RUN

For2-50 Immediate Delivery call KMParts.com at (866) 595-9616 Moeller Wiring Manual 02/05 Electronic motor starters and drives Connection examples, DS4 Qm 2 I > ~ I > M 3 595-9616 I > Qn Mn (866) at Qn3 Q32 Q11 = Mains contactor (optional) = Mains contactor Q11 coordination fuse for type “2” = Semiconductor F2 = Soft starter T1 2,... = Motor M1, KMParts.com I > ~ I > M 3 call I > Q31 M2 Q33 Delivery 14 Q22

TOR

6T3 3L3

2L2 4T2 Immediate

1L1 2T1 M 3 For Q21 Q11 M1 F2 T1 L1 L2 L3 N PE Q23 Soft starters with motor cascade 2-51 Moeller Wiring Manual 02/05 Electronic motor starters and drives Connection examples, DS4 e K4 2 K4 595-9616 K1T K4T c (866) K4 K2T at 13 14 K3 T1 TOR b K2T A1 KMParts.com A2 ad

K2 T1 call Qn1

Kn2 Delivery K4 Q31

K22 Q21 K12 K2 Immediate K1T For K1 K4 Q11 S1 S2 K1 K1 Soft starter with motor cascade, control section part 1 2-52 Moeller Wiring Manual 02/05 Electronic motor starters and drives Connection examples, DS4 QmQm Kn2 2 595-9616 c i

K3 Qn Qm Qn (866) at Qn Kn2 K4T Q(n-1)1 K(n-1)2 K22 Q32 KMParts.com Q32 Switching off individual motors”, page off individual motors”, i Switching 2-50 call i K3 Q32 Q31 section “ Motor n a Q31 c i Delivery Q21 K22 Q31 K12 K4T K12 Q22 Immediate Q22 ab For i K3 Q21 Q22 K12 Motor 1 Motor 2 Q11 Q21 Soft starter with motor cascade, control section part 2 a b 2-53 Moeller Wiring Manual 02/05 Electronic motor starters and drives Connection examples, DM4

Enable/immediate stop without ramp function (e.g. for Emergency-Stop) The digital input E2 is programmed in the factory an immediate de-energization, this is effected via so that it has the "Enable" function. The soft the enabling signal. starter is enabled only when a High signal is Caution! applied to the terminal. The soft starter cannot be You must in all operating conditions always first 2 operated without enabling signal. stop the soft starter ("Run“ relay scanning), In the event of wire breakage or interruption of before you mechanically interrupt the power the signal by an Emergency-Stop circuit, the conductors. Otherwise a flowing current is regulator in the soft starter is immediately blocked interrupted – thus resulting in voltage peaks, and the power circuit disconnected, and after that which in rare cases may destroy the thyristors of the "Run“ relay drops out. the soft starter. Normally the drive is always stopped via a ramp function. When the operating conditions require n: Emergency-Stop S1: Off S2: On T1: (E2 = 1 a enabled)

S1 K1

S2 K1

E2 K1 T1 39

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Linking the overload relay into the control system We recommend using an external overload relay Caution! instead of a motor-protective circuit-breaker with Connecting the motor directly to mains power can built-in overload relay. This allows controlled cause overvoltage and destruction of the soft ramping down of the soft starter through the starter’s semiconductors. control section in the event of an overload. There are two options, which are shown in the 2 following diagram: n: Emergency-Stop S1: Off S2: On K1 T1: Enable (E2 = 1 h enabled) F1 a The signalling contacts of the overload relay are linked into the On/Off circuit. In the event ab of a fault, the soft starter decelerates for the set ramp time and stops. b The signalling contacts of the overload relay S1 are linked into the enabling circuit. In the event of a fault, the soft starter’s output is immediately de-energized. Although the soft starter shuts off its output, the mains contactor remains energized. To de-energize the mains contactor as well, include a second S2 K1 contact of the overload relay in the On/Off circuit.

E2 K1 T1 39

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DM4 with overload relay Standard connection For isolation from the mains, either a mains L1 contactor upstream of the soft starter or a central L2 switching device (contactor or main switch) is L3 N necessary. 2 PE Control section

Q1 K1 > > > I I I S2

Q11

S1 K1 F1

E2 E1 F2 K1 T1 T1 39 39 ba L 1L1 2L2 3L3 N S1: Soft start S2: Soft stop ~ a Enable = b Soft start/Soft stop T1 – Thermistor + Thermistor T1 T2 2T1 4T2 6T3

M 3~

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DM4 without separate mains contactor

L1 L2 L3 N PE 2

Q1 Q2

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

F1 b F2 ⎩ ⎪ ⎨ ⎪ ⎧

1L1 3L2 5L3 L N E1 E2 39 7 +12 8 1 Enable

~ +12 V DC Start/Stop 0 V Analog 0 V (E1;E2)

= REF 1: 0–10 V REF 2: 4–20 mA T1 = K1;RUN K2;TOR K3 K4 ~

PE Analog Out 1 Analog Out 2 - Thermistor + Thermistor 0 V Analog

T1 T2 13 14 23 24 33 34 43 7 62 63 2T1 4T2 6T3

Imot c M M1 3~

a Control voltage through Q1 or F1 or through Q2 b See control section c Motor current indication

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DM 4-340 with separate mains contactor Control section

2 K1

S3 Q11 S1

13 K1 S4 K2 K2 K2 T1 RUN 14

S2 K1

33 T1 OK (no error) 34

E2 E1 K1 T1 K2 T1 Q11 39 39

ab n Emergency-Stop S1: Off S2: On a Enable b Soft start/Soft stop

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DM4-340 with separate mains contactor

L1 L2 L3 N PE 2

Q1 Q2

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

Q11 F1 b F2 ⎩ ⎪ ⎨ ⎪ ⎧

1L1 3L2 5L3 L N E1 E2 39 7 +12 8 1 Enable

~ +12 V DC Start/Stop 0 V Analog 0 V (E1;E2)

= REF 1: 0–10 V REF 2: 4–20 mA T1 = K1;RUN K2;TOR K3 K4 ~

PE Analog Out 1 Analog Out 2 - Thermistor + Thermistor 0 V Analog

T1 T2 13 14 23 24 33 34 43 7 62 63 2T1 4T2 6T3

Imot c M M1 3~

a Control voltage through Q1 or F1 or through Q2 b See Control section c Motor current indication

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Bypass connection After the run-up (full mains voltage reached) the The bypass contactor is now switched to a no-load DM4 soft starter actuates the bypass contactor. state and can therefore be AC-1 rated. Thus, the motor is directly connected with the If an immediate de-energization is required in the mains. event of an Emergency-Stop, then the bypass 2 Advantage: contactor must also switch the motor load. In this • The soft starter’s heat dissipation is reduced to case it must be AC-3 rated. the no-load dissipation. • The limit values of radio interference class "B“ are adhered to. Control section

13 23 S1 K1 Q21 S4 K2 K2 K1 T1 RUN T1 TOR 14 24

S2 K1

T1 OK 33 (no error) 34 E2 E1 K1 T1 K2 T1 Q11 Q21 39 39

a b n Emergency-Stop S1: Off S2: On a Enable b Soft start/Soft stop

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DM4-340 with bypass L1 L2 L3 N PE 2

Q1 Q1

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

Q11 a

F1 b F2 ⎩ ⎪ ⎨ ⎪ ⎧

1L1 3L2 5L3 L N E1 E2 39 7 +12 8 1 Enable

~ +12 V DC

Start/Stop 0 V Analog PE 0 V (E1;E2)

= REF 1: 0–10 V Q21 REF 2: 4–20 mA G1 = K1;RUN K2;TOR K3 K4 ~ Analog Out 1 Analog Out 2 - Thermistor + Thermistor 0 V Analog

2T1 4T2 6T3 T1 T2 13 14 23 24 33 34 43 7 62 63

Imot c M M1 3~

a Control voltage through Q1 or F1 or through Q2 b See Control section c Motor current indication

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Delta connection A delta connection allows the use of a soft starter For this you have to connect the motor in delta with a lower rating than the motor it is used to and the voltage in this connection method must control. Connected in series with each motor agree with the mains voltage. For 400 V mains winding, the current the soft starter needs to voltage the motor must therefore be marked with supply is reduced by a factor of W3. This layout has 400 V/690 V. 2 the drawback that six motor supply cables are needed. Apart from that there are no restrictions. All soft starter functions remain available. Control section

S3 Q11 S1

13 K1 S4 K2 K2 T1 RUN 14

S2 K1

33 T1 OK (no error) 34

E2 E1 K1 T1 K2 T1 Q11 39 39

ab n Emergency-Stop S1: Off S2: On a Enable b Soft start/Soft stop E2: Enable T1: +thermistor T2: –thermistor

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DM4-340 Delta L1 L2 L3 N PE 2

Q1 Q2

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

Q11 a

F1 b F2 ⎩ ⎪ ⎨ ⎪ ⎧

L N E1 E2 39 7 +12 8 1 1L1 3L2 5L3

+12 V DC PE Start/Stop Enable 0 V Analog = 0 V (E1;E2) REF 1: 0–10 V REF 2: 4–20 mA T1 = K1;RUN K2;TOR K3 K4 ~ Analog Out 1 Analog Out 2 Thermistor Thermistor 0 V Analog

T1 T2 13 14 23 24 33 34 43 7 62 63 2T1 4T2 6T3 V1 U1 W1 c I mot M M1 3~ V2 U2 W2

a Control voltage through Q1 or F1 or through Q2 b See Control section c Motor current indication

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Starting several motors sequentially with a soft starter When starting several motors one after the other using a soft starter, keep to the following sequence when changing over: • Start using soft starter 2 • Switch on bypass contactor • Block soft starter • Switch soft starter output to the next motor • Restart

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2 Qm I > I > M 3~ I > Qn Mn Qn3 F1 Q32 I > I > I > I > ~ I > M 3 I > Q32 M2 Q2 Q33 Q22 PE

N T2 – Thermistor – =

L T1 + Thermistor +

6T3 3L3

I > 2L2 4T2

I > 1L1 2T1 M 3~ I > Q1 F2 Q21 M1 T1 L1 L2 L3 N PE Q23 DM4-340 cascade For Immediate Delivery call KMParts.com at (866) 595-96162-65 Moeller Wiring Manual 02/05 Electronic motor starters and drives Connection examples, DM4 d K4 2 c K4 595-9616 K1T K4T 13 14 K4 T1 RUN (866) 23 at 24 K3 T1 TOR E1 39 K2 T1 KMParts.com Qn Kn2 call K22 K4 Delivery K12 K2 Q21 Q31 K1T 33 34 Immediate K1 K4 Q11 For T1 OK (no error) E2 39 ab K1 T1 S1 S2 K1 K1 Control section part 1 2-66 Moeller Wiring Manual 02/05 Electronic motor starters and drives Connection examples, DM4 Qm Kn2 2 Qm 595-9616 c S3 K3 Qn Qm (866) Qn at Kn2 Qn K4T Q(n-1)1 K(n-1)2 KMParts.com Q32 K22 call Q32 S3 K3 Q31 Q32 Q31 Delivery K22 Q31 K12 Q21 K4T Q22 K12 Set the timing relay so that the soft starter is not thermally overloaded. The appropriate time relates to the time relates The appropriate overloaded. is not thermally that the soft starter relay so Set the timing required the so that starter the soft select Alternatively, starter. soft the selected of frequency operating admissible be attained. times can about 2of a return time relay to Set the timing be connected motor branch can not ensures that the next s. This off motors time. To switch off at the same all motors S1 switches is running. N/C contact the soft starter as long make use of N/C contact S3. you need to individually, Immediate c d Q22 For ab S3 K3 Q21 Q22 K12 Emergency-Stop Enable stop Soft start/Soft Q11 Q21 DM4-340 cascade, control section part 2 n S1: Off S2: On a b 2-67 Moeller Wiring Manual 02/05 Notes

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Connection examples, DF5 and DV5 FA1 2

RJ 45

RS 422 RUN 595-9616

(866) + – 0 V 0 P24

+24 V

4...20 mA 4...20

0...10 V 0...10 – V +10 +

KMParts.com

FWD

FM H(PWM) V 10 O OI L CM2 12 11 REV

call

FF1 321

0 V 0

FF2

RST 5* L PTC 6* 4

Delivery RST K11 e K12 K14 1 3 PEN PEL3L2L1 PEWVU Immediate M 3 ~ For L L+ BR* DC– DC+ Br R Block diagram, DF5 and DV5 BR* DV5 only only 6* DV5 RST for DF5 5* Input 2-69 Moeller Wiring Manual 02/05 Electronic motor starters and drives Connection examples, DF5 and DV5

Basic control Example 1 Reference input through potentiometer R1 Enable (START/STOP) and direction control through terminals 1 and 2 with internal control 2 voltage n: Emergency-Stop circuit S1: Off S2: On Q11: Mains contactor F1: Line protection PES: Cable screen PE connection M1:Motor, 3-phase 230 V

S1 Note: For EMC-conformant mains connection, suitable radio interference suppression measures must be implemented according to S2 Q11 product standard IEC/EN 61800-3.

Q11

DILM12-XP1

(4th pole can be broken off) DILM A1 1 3513

A2 2 4 6 14

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Wiring

1 h 230 V, 50/60 Hz f L N M PE t 2 F1 M PE

FWD Q11 REV

L N PE

L+ H T1 DC+ DC– U V W PE O L 2 1 P24 PES PES PES X1 PES

PES PE

M1 M 4K7 3 ~ M M e R11 REV FWD

– Single-phase frequency inverter DF5-322-... FWD: Clockwise rotating field enable – Directional control through terminals 1 and 2 REV: Anticlockwise rotating field enable – External reference input from potentiometer R1

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DF5-340-... frequency inverters with EMC-conformant connection Control section Example 2 Reference input through potentiometer R11 (fs) and fixed frequency (f1, f2, f3) through terminal 3 2 and 4 with internal control voltage Enable (START/STOP) and rotating field selection through terminal 1 n: Emergency-Stop circuit S1: Off S2: On Q11: Mains contactor Q1 R1: Line reactor K1: RFI filter Q1: Line protection PES: Cable screen PE connection S1 M1:Motor, 3-phase 400 V

FWD: Clockwise rotating field enable, reference frequency f S2 Q11 S FF1: Fixed frequency f1 FF2: Fixed frequency f2 FF1+FF2: Fixed frequency f3

Q11

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Wiring 3 h 400 V, 50/60 Hz f L1 fs = fmax L2 f3 L3 f2 PE f1 Q1 2 PE III FF1

Q11 FF2

W1V1U1 FWD

R1 PE

V2U2 W2

L1 L2 L3

K1 PE

L1 L2 L3 PE FF1 FF2 FWD L+ H T1 DC+ DC– U V W PE O L 4 3 1 P24 PES PES X1 R1 PES

PES PE

M M1 3 ~ e

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Version A: Motor in delta circuit Motor: P = 0.75 kW 1 h 230 V, 50/60 Hz Mains: 3/N/PE 400 V 50/60 Hz L N The 0.75 kW motor described PE below can be delta-connected to a 2 single-phase 230 V mains (version FAZ-1N-B16 F1 A) or star-connected to a 3-phase 400 V mains. Select the appropriate frequency DILM7 Q11 inverter for your mains voltage: +DILM12-XP1

• DF5-322 for 1 AC 230 V 1 • DF5-340 for 3 AC 400 V PE • Model-specific accessories for R1 EMC-complaint connection. DEX-LN1-009 2

L N

K1 PE DE5-LZ1-012-V2 L N PE

DF5-322-075 DV5-322-075 L+ T1 DC+ DC– U V W PE PES 230 / 400 V 4.0 / 2.3 A PES 0,75S1 kW cos ϕ 0.67 1410rpm 50 Hz X1 PES PES

U1 V1 W1 230 V M 4 A M1 3 ~ 0.75 kW W2 U2 V2 e

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Version B: Motor in star circuit 3 h 400 V, 50/60 Hz L1 L2 L3 PE Q1 2 PKM0-10

III

DILM7 Q11

U1 V1 W1

R1 PE DEX-LN3-004 U2 V2 W2

L1 L2 L3

K1 PE DE5-LZ3-007-V4 L1 L2 L3 PE

DF5-340-075 DV5-340-075 L+ W T1 DC+ DC– U V PE PES PES X1 PES PES

U1 V1 W1 400 V M 2.3 A M1 3 ~ 0.75 kW W2 U2 V2 e

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SP RP SN SN –10 V...+10 V V...+10 –10 O2 RJ 45

RS 422 RS 485

L V 0 2 OI mA 4...20

595-9616

O V 0...10 – V +10 + H

(866)

0...+10 V 0...+10 at

4...20 mA 4...20

FM AMI (PWM) V 10 TH PTC i KMParts.com + – P24 +24 V call

PLC CM1 FWD FW

K34K24K33 REV FF1

Delivery FF2 345 K2 K3

K23 AT

K11 RST 12 K1 e K12 K14 3 PEL3L2L1 PEWVU Immediate For M 3 ~ L+ BR* DC– DC+ Br Block DF6 diagram, R BR* DF6-320-11K, DF6-340-11K and DF6-340-15K only and DF6-340-15K DF6-340-11K BR* DF6-320-11K, 2-77 Moeller Wiring Manual 02/05 Electronic motor starters and drives Connection examples, DF6

Frequency inverter DF6-340-... Control section Example: Temperature regulation for ventillation system. When the room temperature rises, the fan speed must increase. The target temperature can 2 be set with potentiometer R11 (e.g. 20 °C)

S2 Q11

Q11

n: Emergency-Stop circuit S1: Off S2: On Q11: Mains contactor Q1: Line protection PES: Cable screen PE connection K1: RFI filter

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Wiring

3 h 400 V, 50/60 Hz 50 ˚C 100 % L1 L2 L3 20 ˚C 40 % PE 4 mA 10.4 mA 20 mA 2 Q1 PE III

Q11

L1 L2 L3

K1 PE

L1 L2 L3 PE

PID

L+ DC+ DC– U V W PE OI H O L FW P24

T1 PES PES PES X1 PES PE PES

4K7 M M1 M 4...20 mA 3 ~ R11 FWD e i B1

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SP RP SN SN –10 V...+10 V V...+10 –10 O2 RJ 45 RS 485 RS 422

2 L V 0

OI mA 4...20

O V 0...10

– V +10 + H

0...+10 V 0...+10

AM 4...20 mA 4...20

AMI 10 V (PWM) V 10

FM TH PTC i + – P24 +24 V

PLC CM1 FWD FW

CM2 P24 REV

FF1 78

IP FF2 6

+24 V

QTQ 2CH

FRS 13 14 15

RUN

JOG 345

FA1

AT 11 12 RST 12 TO K11 J51 RO K1 e K12 K14 3 PEL3L2L1 PEWVU M 3 ~ L+ BR* DC– DC+ Br R Block diagram, DV6 only and DV6-320-11K DV6-340-11K BR* DV6-340-075, For2-80 Immediate Delivery call KMParts.com at (866) 595-9616 Moeller Wiring Manual 02/05 Electronic motor starters and drives Connection examples, DV6 h M 3 2 595-9616 PWM u u' (866) i ACR V at – i + i' ASR n V KMParts.com FB e – o call + o ' + APR Delivery + G FFWG vector frequency inverterfrequency DV6 with vector encoder interface module DE6-IOM-ENC G V – v F FB V K Immediate + For REF K v ' Block diagram: speed control circuit, 2-81 Moeller Wiring Manual 02/05 Electronic motor starters and drives Connection examples, DV6

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

TI S1 R B T2

K11 S2 Q11 Q11 G1 K12

SPS K2 Enable K3

Q11 K2 M11

Example: Hoisting gear with speed regulation, control and monitoring through PLC Motor with thermistor (PTC resistor) n: Emergency-Stop circuit S1: Off S2: On Q1: Line protection Q11:Mains contactor K2: Control contactor enable RB: Braking resistor B1: Encoder, 3 channels PES:Cable screen PE connection M11:Holding brake

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2 P24 P24 FW REV FWD 3 38 n a 2 n 2 1 m 1 n Q.. Q.. Q.. Q.. Q.. I.. 13 I.. 12 b Encoder I.. 11 CM2 CM2 M11 B1 PES PES i EG5 EAPEAN EBP EBN EZP EZN CM1 DE6-IOM-ENC EP5 Th PE PE M1 W M 3 ~ V PE U III e L2 L3 DC– BR L1 L2 L3 L1 DC+ 400 V, 50/60 Hz V, 3 h 400 PES L+ K1 T1 Q11 Q1 PES 2 T1 T2 PE 1 DE4-BR1... B i L1 L2 L3 PE R Wiring For Immediate Delivery call KMParts.com at (866) 595-96162-83 Moeller Wiring Manual 02/05 Electronic motor starters and drives Connection examples, DV6

Installing encoder interface module DE6-IOM-ENC

2 1

2 4

M3 x 8 mm

0.4 – 0.6 Nm

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EG5

F 20 m EG5 1 2

3 15

Order ZB4-102-KS1 separately! M4 ZB4-102-KS1

TTL (RS 422) AAB BCC EP5 EG5 EAP EAN EBP EBN EZP EZN

–

+ M 5 V H 3 h

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Power and data bus: The power bus supplies the Rapid Link function g AS-Interface® flat cable modules with main and auxiliary power. Plug-in h Link for M12 connector cables tap-off points can be quickly and safely connected i Flexible busbar for 400 V h and 24 V at any point along the bus. The power bus can j Power feed for flexible busbar consist either of a flexible busbar (flat cable) or k Plug-in power link for flexible busbar standard round cables: l Round cable for 400 V h and 24 V • The flexible busbar RA-C1 is a 7-core flat cable 2 m Plug-in power link for round cable (cross-section 2.5 mm2 or 4 mm2) and has the Engineering following structure: 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® M White networks are quick and easy to implement. L+ Red AS-Interface® uses a geometrically coded, PE Green/yel- unscreened flat cable with a cross-section of 2 x N low 2 L3 Blue 1.5 mm . It is used to transmit both power as well L2 Black as all data traffic between PLC and I/O and – to L1 Brown some extent – supplies the connected devices Black with energy. The installation meets the usual requirements. Engineering is simplified by full flexibility in system • For the power bus you can also use layout and mounting. conventional round cables (cross-section When a link is connected to the flat cable, two 7 x 2.5 mm2 or 7 x 4mm2, outer core metal pins pierce through the cable’s jacket and diameter < 5 mm, flexible copper conductor to into the two cores to establish a contact with the IEC/EN 60228) with round cable feeders RA-C2. AS-Interface® cable. There is no need to cut and The cable can have an external diameter of strip cables, apply ferrules or connect individual 10 to 16 mm. cores.

6.5

a a

+ – 4 2 b

a Piercing pins b Flat cable, protected against polarity reversal

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Warning! AS-Interface®-/RA-IN-power supply must meet • Rapid Link must be operated only on the safe isolation requirements according to three-phase systems with earthed star point SELV. and separate N and PE conductors (TN-S The power sections are supplied through network). It must not be operated unearthed. disconnect control unit RA-DI (see illustration • All devices am connected to the power and data below) with: 2 2 bus must also meet the requirements for safe • Ie = 20 A/400 V at 2.5 mm 2 isolation according to IEC/EN 60947-1 Annex N • Ie = 20 to 25 A/400 V at 4 mm . or IEC/EN 60950. The 24 V DC power supply Round cables up to 6 mm2 can be used to feed unit must be earthed on the secondary side. The power to disconnect control unit RA-DI. 30 V DC PSU for the

3 AC 400 Vh, 24 V H 50/60 Hz F 2 RA-DI 6 mm Disconnect Control Unit RA-DI Q1 ⎧ ⎨ ⎩ 2.5 mm2 / 4 mm2 1.5 mm2 1.5 mm2 1.5 mm2 1.5 mm2 RA-MO RA-SP RA-MO RA-SP

Motor/Speed Control Units

1.5 mm2 1.5 mm2 1.5 mm2 1.5 mm2 PES PES PES PES M M M M 3h 3h e 3h e 3h e e

Disconnect control unit RA-DI protects the cable The combination of RA-DI and RA-MO fulfills the from overload and provides short-circuit requirements of IEC/EN 60947-4-1 as starter with protection for the cable as well as all connected type “1” coordination. That means that the RA-MO motor control units. 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.

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The affected RA-MO motor control unit must be • Observe the voltage drop in your specific replaced after a short-circuit! application. When you configure a power bus with a Instead of the disconnect control unit, you can use disconnect control unit, observe the following: a 3-pole miniature circuit-breaker In F 20 A and B • Even in the event of a 1-pole short-circuit at the or C characteristic. Here, you must observe the line end, the short-circuit current must exceed following: 150 A. • The let-through energy J in the event of a 2 • The total current of all running and short-circuit must not exceed 29800 A2s. simultaneously starting motors must not exceed • Therefore the short-circuit current Icc at the 110 A. mounting location must not exceed 10 kA a • The total load current (about 6 x mains characteristic curve. current) of all connected speed control units must not exceed 110 A.

2 5 i dt 10 2 [A s] 8 63 A FAZ-B 50 A FAZ-C 6 40 A 32 A 25 A 20 A 4 16 A 13 A 10 A

2 6 A 1.5 4 A

4 10 3 A 8

6 2 A

FAZ-...-B4HI 2

1.5

1 A 103 0.5 A 8

4 3

0.5 12345678911.5 015

Icc eff [kA]

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Motor control unit Motor control unit RA-MO allows the direct The unit is connected to AS-Interface® through bidirectional operation of three-phase motors. The an M12 plug with the following PIN assignment: rated current is adjustable from 0.3 to 6.6 A M12 plug PIN Function (0.09 to 3 kW). 2 Connections 1 ASi+ Motor control unit RA-MO is supplied ready for installation. The connection to the AS-Interface® 2 – data bus and the motor is described below. The 3 ASi– connection to the power bus is described in the earlier general section “Rapid Link system”. 4 –

External sensors are connected through an M12 socket. PIN Function

1 L+ 2 I 3 L– 400 V F 2.2 kW 4 I M On the RA-MO the motor feeder features a 3 h plastic-encapsulated socket. The length of the motor cable is limited to 10 m. The motor is connected through a halogen-free, 3 h 400 V PE 8 x 1.5 mm2, unscreened, DESINA-conformant 50/60 Hz motor supply cable with a length of 2 m 24 V H (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 contacts

146 PE 7 358

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M i 3h

SET-M3/... 2 1 1 U – – • – – – – 3 3 W – – 4 5 – – B1 (h/–) 5 6 – T1 – 6 4 – – B2 (h/+) 7 2 V – – 8 7 – T2 – PE PE PE – –

Motor connection without thermistor Motor connection with thermistor

: : 58173PE 58173PE

67123 67123* *

T1 T2 UVWPE T1 T2 UVWPE e e M 3 h M i 3 h

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.

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Note: Connecting a 400 V AC brake with rapid braking: The two connections illustrated below apply only for motor control unit RA-MO. 46 173PE Connecting a 400 V AC brake:

: 173PE 2 54 123*

B2B1 PEWVU 123 * e

PE M e 3 h

M 3 h 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.

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Speed Control Unit RA-SP Speed control unit RA-SP is used for electronic The unit is connected to AS-Interface® through variable speed control of three-phase motors. an M12 plug with the following PIN assignment: Note: M12 plug PIN Function Unlike the other Rapid Link system devices, the RA-SP speed control unit’s enclosure is fitted with 1 ASi+ 2 a heat sink and requires an EMC-conformant mounting and connection. 2 – Connections 3 ASi– Speed control unit RA-SP is supplied ready for connection. The connection to the AS-Interface® 4 – data bus and the motor is described below. The connection to the power bus is described in the On the RA-SP the motor feeder features a earlier general section “Rapid Link system”. 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 400 V length of 2 m, (SET-M4/2-HF) or 5 m, (SET-M4/5-HF). M 3 h 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.

3 h 400 V PE 50/60 Hz 146 PE 7 358

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RA-SP2-... 341-... 341(230)-... M i 2 3h Servo cable 400 V AC 230 V AC SET-M4/... 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 – – –

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5817 3PE 5817 3PE

PES PES

PES PES F 10 m 2

T1 T2 UVWPE T1 T2 UVWPE e e M 3 h M 3 h i i

U1 V1 W1 U1 V1 W1 230 / 400 V 3.2 / 1.9 A 400 / 690 V 1.9 / 1.1 A 0.75S1 kW cos ϕ 0.79 0.75S1 kW cos ϕ 0.79 W2 U2 V2 W2 U2 V2 1430rpm 50 Hz 1430rpm 50 Hz

5817 3PE 46 5817 3PE

PES PES

T1 T2 U V W PE B1 B2 T1 T2 UVWPE e e M 3 h M i 3 h

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

For controlling braking motors, their Note: manufacturers provide braking rectifiers, which When using speed control unit RA-SP, do not are fitted in the motor terminal strip. connect the braking rectifier directly to the motor terminals (U/V/W)!

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Page RMQ 3-2 Signal towers SL 3-8 Position switches LS-Titan®, AT 3-10 Inductive proximity switches LSI 3-17 Optical proximity switches LSO 3-19 3 Capacitive proximity switches LSC 3-20 Electronic position switches LSE-Titan® 3-22 Analog electronic position switches 3-23 New combinations for your solutions 3-25

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Commands and signals are the fundamental • Emergency-Stop buttons with lighting option functions for controlling machines and processes. for active safety, The required control signals are produced either • Contacts switch differing potentials, manually by control circuit devices or mechanically • For use also in safety-related circuits using by position switches. The respective application positive operation and positively opening governs the degree of protection, the shape and contacts, colour. • Complying with industry Standard Advanced technology has been used consistently IEC/EN60947. in the development of the new control circuit 3 devices RMQ-Titan®. The use of LED elements and 1) Cage Clamp is a registered trade mark of Messrs. laser inscription throughout offer maximum WAGO Kontakttechnik GmbH, Minden. reliability, efficiency and flexibility. In detail, this means: RMQ16 • 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 buttons with pull- and turn-to-release function,

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RMQ-Titan® System Overview

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RMQ-Titan® Four-way pushbutton Selector switch actuators Moeller has added more operator elements to its The selector switch actuators have four positions. highly successful range of control circuit devices The actuator is available as rotary head or RMQ-Titan. They are modular in construction. thumb-grip as required. One contact element is Contact elements from the RMQ-Titan range are assigned to each On and each Off position. used. The front rings and front frames are of the familiar RMQ-Titan format and colour. 3 Four-way pushbutton The four-way pushbuttons enable users to control machines and systems in four directions of movement, with each direction of movement being assigned one contact element. The actuator Labels has four individual button plates. They can be Moeller offers labels in various versions for all the specifically selected for various applications and operator elements. Versions available are: can be laser-inscribed to suit the customer's •Blank, requirements. • With direction arrows, • With inscription 0–1–0–2–0–3–0–4.

In addition, customized inscriptions are possible. The software Labeleditor enables customized inscriptions to be designed and these can be subsequently applied to the labels by laser, permanently and proof against wiping off.

Joystick The joystick has four precisely assigned positions. Each direction of movement is assigned one contact element. The joystick enables users to control machines and systems in four directions of movement.

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

21 10 13 01

14 22

13 21 20 13 23 11 02 11 21 3

14 24 14 22 12 22

30 13 23 33 21 13 21 33 12 13 21 31 03 11 21 31

14 24 34 14 22 34 14 22 32 12 22 32

Voltage versions with series elements

M22-XLED601) Ue FAC/DC Ue h/H 1x 60 V 12 – 30 V h/H 2x 90 V 3x 120 V 21 21 X121 X2 ...... 7x 240 V M22-XLED60/ M22-(C)LED(C)-... F M22-XLED220 M22-XLED220 Ue 1 x 220 VDC 1) For increasing the voltage AC/DC.

Ue h M22-XLED230-T1) U F 85 – 264 V h, e x 50 – 60 Hz 1 400 V~ 2x 500 V~

1 2 X121 X2 1) AC– for increasing the voltage 50/60 Hz. M22-XLED230-T M22-(C)LED(C)230-...

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Circuit for light test

The test button is used to check operation of the M22-XLED-T for Ue = 12 to 240 V AC/DC (also indicator lights independently of the respective for light test with signal towers SL) control state. Decoupling elements prevent voltage feedback. M22-(C)K(C)10 13 13 13 3 a 3 14 14 14 4 21

21 M22-XLED-T 1 1 1

2 M22-XLED60/ 2 M22-XLED60/ 2 M22-XLED60/ 12 – 240 V h / H 12 – 240 1 M22-XLED220 1 M22-XLED220 1 M22-XLED220

2 2 2 X1 X1 X1

X2 X2 X2 M22-(C)LED(C)-... 1)

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

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

M22-(C)K(C)10 L1 13 13 13 3 1 M22-(C)K(C)01 a 14 14 14 4 2 3

2 1

2 1 M22-XLED230-T X1 X1 X1 85 – 264 V h /50 – 60 Hz 85 – 264

X2 X2 X2 M22-(C)LED(C)230-... 2) N a Test button 1) For elements 85 to 264 V.

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Signal Towers SL – everything under visual control at all times Signal towers SL indicate machine states using Product features visible and acoustic signals. Mounted on control • Continuous light, flashing light, strobe light and panels or on machines, they can be reliably acoustic indicator can be combined as required. recognized as continuous light, flashing light, • Free programmability permits the actuation of strobe light or acoustic indicator even from a five addresses. distance, and dealt with as necessary. • Simple assembly without tools by bayonet fitting. 3 • 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.

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Programmability

3 1

4 3 0 ־ 5 5 5 BA15d F 7 W

4 ־ 4

3 ־ 3

2 ־ 2

1 ־ 1

0 5 4 3 2 1

فN 1...5 Ue = 24 – 230 Vh/H

Five signal lines from a terminal strip in the basic Thus, for example, a red strobe light and in module run through each module. The module is parallel with it an acoustic indicator can indicate addressed via a wire link (jumper) on each printed and announce the dangerous status of a machine. circuit board. Five different addresses can also be Insert both jumpers into the same position on the allocated several times. pcb – and it's done! (a section “Circuit for light test”, page 3-6.)

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LS, LSM, AT0, ATR AT4 AT4/.../ZB Standards • IEC 60947, • IEC 60947, • IEC 60947, EN 60947, EN 60947, EN 60947, VDE 0660 VDE 0660 VDE 0660 a EN 50047 a EN 50041 a EN 50041 • Dimensions • Dimensions • Dimensions • Fixing dimensions • Fixing dimensions • Fixing dimensions 3 • Switching points • Switching points • Switching points • Minimum IP65 • IP65 • IP65 Suitable • Also for use in safety • Also for use in safety • Safety position applications circuits, by positive circuits, by positive switches for operation and operation and protection of positively opening positively opening personnel contacts contacts • With separate actuating element for protective guards • Positive operation and positively opening contacts • Approval by German Trade Association and SUVA (Swiss accident prevention authority)

Actuator • Plunger • Plunger • Coded actuating • Roller plunger • Roller head element • Roller lever (adjustable in 90° • Operating head: • Angled roller lever steps, can be – Adjustable in 90° • Adjustable roller operated vertically steps lever or horizontally) – Can be actuated • Actuating rod • Roller plunger from both sides • Spring rod actuator • Roller lever • Actuating element • Operating heads • Adjustable roller – Convertible for adjustable in 90° lever vertical and steps • Actuating rod horizontal fixing • Spring rod actuator • With triple coding • Operating heads adjustable in 90° steps

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AT0-...-ZB ATO-...ZBZ Standards • IEC 60947, • IEC 60947, EN 60947, EN 60947, VDE 0660 VDE 0660 • IP65 • IP65

Suitable • Safety position • Safety position applications switches for switches for protection of protection of personnel personnel • With separate • With separate actuating element actuating element for protective for protective guards guards • Positive operation • Positive operation and positively and positively opening contacts opening contacts • Approved by • Electromagnetic German Trade interlocking Association and • Approved by SUVA (Swiss German Trade Accident Insurance Association and Institue) SUVA (Swiss Accident Insurance Institue) Actuator • Coded actuating • Coded actuating element element • Operating head: • Operating head: – Adjustable in 90° – Adjustable in 90° steps steps – Can be actuated – Can be actuated from four sides from four sides and from above

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AT4/ZB, AT0-ZB safety position switches Moeller safety position switches have been Positive opening is an opening movement by specially designed for monitoring the position of which it is ensured that the main contacts of a protective guards such as doors, flaps, hoods and switch have attained the open position at the grilles. They meet the requirements of the German same time as the actuating element assumes the Trade Association for the testing of positively Off position. Moeller position switches all meet opening position switches for safety functions these requirements. (GS-ET-15). These reqquirements include: 3 “Position switches for safety functions must be Certification designed such that the function used for All Moeller safety position switches are certified protection cannot be changed or defeated by hand by the German employers liability insurance or by using simple tools.” Simple tools include: association or by the Technical Monitoring Service pliers, screwdrivers, pins, nails, wire, scissors, (TÜV), Rheinland, and the Swiss accident pocket knives, etc. prevention authority (SUVA). In addition to these requirements, AT0-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 )“.

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“Personnel protection” by monitoring the protective device AT0-ZB AT4/ZB • Door open • AT...-ZB STOP switches off the power • No danger 3

AT...ZB Closed Open a Personnel protection

Door opening a Enabling contact (21–22) opening positively Door open a Enabling contact safely open, even where attempts are made to tamper using basic tools Closing door a Triple-coded actuator 21 22 21 22 closes the enable contact

13 14 13 14

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“Enhanced personnel protection“ by monitoring and interlocking the protective device AT0-ZBZ • Stop command • Waiting time • Machine stops

STOP • Protective device on • No danger 3

AT0-...FT-ZBZ, spring-powered interlock (closed-circuit principle) abc a Interlocked b Released c Open

A1 A1 A1

US US A2 A2 A2 21 22 21 22 21 22 11 12 11 12 11 12

A Enhanced personnel protection with separate indication of the door position

1.Door closed a De-energized: even with 4.Door open a Both contacts blocked in the + interlocked mains failure or wire breakage: open position, even where door interlocked = safe condition attempts are made to tamper enable contact(21-22) closed using basic tools 2.Releasing of a Applies voltage to coil (A1, 5.Closing of door a Triple-coded actuator cancels door A2) e.g. via zero-speed monitor, blocking of the enabling contact. enabling contact (21-22) opens Door position contact (11-12) closes 3.Opening of door a Only possible once it is 6.Interlocking of a Disconnects coil voltage: released. Door position contact door 1. Actuator, interlocked (11-12) opens 2. Enabling contact closed a Enable only, when door interlocked

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“Process protection“

• Stop command STOP • Waiting time • Process sequence ended • Protective device on • Product satisfactory 3

AT0-...MT-ZBZ, magnet-powered interlock (open-circuit principle) a Interlocked abc b Released c Open

A1 A1 A1 US A2 A2 A2

21 22 21 22 21 22

11 12 11 12 11 12

a Process protection + personnel protection with separate indication of the door position

1.Door closed + a Energized: enables 4.Door open a Both contacts blocked interlocked immediate access in the in the open position, even event of mains failure and where attempts are made to wire breakage. Both tamper using basic tools contacts closed 2.Releasing of door a Disconnects power 5.Closing of door a Triple-coded actuator from coil (A1, A2) e.g. via cancels blocking of the zero-speed monitor, enabling contact. Door enabling contact (21-22) position contact (11-12) closes opens 3.Opening of door a Only possible once it is 6.Interlocking of door a Applies coil voltage: released. Door position 1. Actuator, interlocked contact (11-12) opens 2. Enabling contact closed a Enabling possible only with the door interlocked

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“Personnel protection“ by monitoring of the protective device

ATR-... /TKG ATR-.../TS

STOP

3 • Hinged protective cover open • ATR/T... switches off the power • No danger

ATR-.../TKG, ATR-.../TS

Closed Open aPersonnel protection

Opening of hinged a Enabling contact (21–22) protective cover opening positively

Hinged protective cover a Enabling contact safely open open, even where attempts are made to tamper using basic tools

Closing of hinged a Closes enabling contact protective cover (21–22)

21 22 21 22

13 14 13 14

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The inductive proximity switch operates on the • Resistant to vibration, principle of the attenuated LC oscillator: when • Any required mounting position metal enters the response range of the proximity • LED display indicates the switching or output switch, power is withdrawn from the system. The status and simplifies adjustment during metal part causes an energy loss, which is caused installation, by the formation of eddy currents. The eddy • Operational temperature range –25 to +70 °C current losses are related to the size and nature of • Oscillating load: cycle time 5 minutes, the metal part. amplitude 1 mm in the frequency range 10 to The change in the oscillation amplitude of the 55 Hz, oscillator results in a current change, which is • Comply with IEC 60947-5-2, 3 evaluated in the downstream electronics and is • Have a steady-state output which remains converted into a defined switching signal. A activated as long as the unit is being attenuated steady-state signal is available at the output of the • Bounce-free switching behaviour in the unit, for the duration of the attenuation. microsecondsrange (10–6 s). ብ ቢባቤ Switching distance S The switching distance is the distance at which a metal part approaching the active surface effects ቦ a signal change at the output. The switching distance depends on: a Oscillator • Direction of approach b Rectifier • Parameter c Amplifier • Material of the metal part d Output The following correction factors must be used for e Power supply different materials:

Steel (St 37) 1.00 x Sn Properties of inductive proximity switches x The following details apply to all inductive Brass 0.35 – 0.50 Sn proximity switches: Copper 0.25 – 0.45 x Sn • Protective insulation to IEC 346/VDE 0100 or x IEC 536, Aluminium 0.35 – 0.50 Sn • Degree of protection IP67, High-grade steel 0.60 – 1.00 x S • High operating frequency or switching n frequency, Sn = Rated switching distance • Maintenance and wear-free (long service life),

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AC operating mode AC inductive proximity switches have two terminals. The load is connected in series with the L1 sensor. Sensor U Supply U Sensor

3 R Load

U, ILoad N

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

R Load

U, ILoad –

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Principle of operation The optoelectronic sensors in the switch operate The following correction factors apply to different using modulated infrared light. Visible light reflecting material characteristics. therefore cannot affect their operation. Infrared light can penetrate even severe dirt on the optics, Material Factor app. x and thus ensures reliable operation. Proximity Paper, white, matt, 1 Sd switch transmitters and receivers are matched to 200 g/m2 one another. The sensor receiver has an integral Metal, gloss 1.2 – 1.6 x Sd x bandpass filter to amplify primarily the Aluminium, black, anodized 1.1 – 1.8 Sd 3 transmitted frequency. All other frequencies are Polystyrene, white 1 x Sd attenuated. This gives the units good resistance to Cotton, white 0.6 x S extraneous light. Precision plastic optics ensure d x long range and long sensing distances. There are PVC, grey 0.5 Sd two types of optical proximity switch, Wood, untreated 0.4 x Sd distinguished by their function. Card, black, gloss 0.3 x Sd Card, black, matt 0.1 x Sd Reflected-light beam Sd = Switching range b Reflected-light barrier

a Object b Reflector a a Object a The unit transmits a pulsed infrared light beam, The reflected-light beam transmits infrared light to which is reflected by a triple reflector or mirror. The the object being scanned, which reflects this light interruption in the light beam causes the unit to in all directions. The portion of this light which switch. Light barriers identify objects irrespective of strikes the receiver ensures a switching signal is their surface, as long as they do not have a gloss produced, assuming adequate intensity. finish. The reflector size must be chosen such that Evaluation takes place of “Reflection“ and “No the object to be detected virtually completely reflection“. These states mean the same as interrupts the light beam. Reliable detection is presence or absence of an object in the sensing always achieved if the object is the same size as the range. The degree of reflection of the object reflector. The unit can also be set to detect surface to be monitored affects the operating transparent objects. range Sd.

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Principle of operation

The active area of a capacitive proximity switch Effects LSC is formed by two concentrically arranged metal electrodes. You can imagine these as the Capacitive proximity switches are activated both electrodes of a capacitor that are opened up. The by conductive as well as non-conductive objects. electrode surfaces of this capacitor are arranged in Metals achieve the greatest switching distances the feed-back branch of a high-frequency due to their high conductivity. Reduction factors oscillator circuit. This is adjusted such that it will for various metals, such as are necessary with 3 not oscillate when the surface is clear. When an inductive proximity switches, need not be taken object approaches the active surface of the into account. proximity switch, it enters the electric field in front Actuation by objects made of non-conductive of the electrode surfaces. This effects a rise in the materials (insulators): coupling capacitance between the plates and the When an insulator is brought between the oscillator begins to respond. The oscillation electrodes of a capacitor, the capacitance rises amplitude is monitored via an evaluation circuit relative to the dielectric constant e of the and converted into a switching command. insulator. The dielectric constant for all solid and liquid materials is greater than that for air. A+ Objects made of non-conductive materials affect the active surface of a capacitive proximity switch in the same way. The coupling capacitance is increased. Materials with a high dielectric constant achieve great switching distances. Note When scanninng organic materials (wood, grain, B– etc.) it must be noted that the attainable switching distance is greatly dependent on their water C content. (eWater = 80!) B d A a b c Influence of environmental conditions B As can be seen from the following diagram, the C e switching distance Sr is dependent on the dielectric constant er of the object to be a Oscillator monitored. b Evaluation circuit Metal objects produce the maximum switching c Amplifier distance (100 %). d Output With other materials, it is reduced relative to the e Power supply dielectric constant of the object to be monitored. A, B Main electrodes C Auxiliary electrode

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e e Material r r 80 Air, vacuum 1 Teflon 2 60 Wood 2 to 7 Paraffin 2.2 Kerosene 2.2 30 Oil of terpentine 2.2 3 Transformer oil 2.2 10 Paper 2.3 1 Polyethylene 2.3 10 20 40 60 80 100 Polypropylene 2.3 sr Cable insulation 2.5 [%] Soft rubber 2.5 Silicone rubber 2.8 The following table lists the dielectric constants er of some important materials. Due to the high Polyvinyl chloride 2.9 dielectric value of water, the fluctuations with Polystyrene 3 wood can be significant. Damp wood therefore is Celluloid 3 registered much more effectively by capacitive Perspex 3.2 proximity switches than dry wood. Araldite 3.6 Bakelite 3.6 Silica glass 3.7 Hard rubber 4 Oil-impregnated paper 4 Chipboard 4 Porcelain 4.4 Laminated paper 4.5 Quartz sand 4.5 Glass 5 Polyamide 5 Mica 6 Marble 8 Alcohol 25.8 Water 80

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Switching point adjustable and variable The switching point on electronic position switches LSE-Titan is adjustable and variable. Two adjust high-speed and bounce-free PNP switching outputs enable high switching frequencies. fasten The position switch is overload as well as conditionally short-circuit proof and has snap-action switching behaviour. This ensures a 3 defined and reproduceable switching point. The switching point lies in the range from 0.5 to 5.5 mm (supplied as = 3 mm). LED 1 s Adjustment to a new switching point is carried out adjust F as follows: fmax 2 N Move the plunger from the original to the new switch position. For this purpose, press the setting adjust button for 1 s. The LED now flashes with a high Bauart geprüft pulse frequency and the new switching point is Functional retentively set. TÜV Safety In redundant structures, position switches Rheinland LSE-Titan just like electromechanical position Type approved switches, achieve safety category 3 or 4 to EN 954-1, Safety of machinery. Contact travel diagram LSE-11 + Note Ue 0 0.5 5.5 6.1 This means that all the devices are also suitable Q1 for safety applications designed for personnel or electron. Q2 default=3.0 process protection. Q1 Q2 0V

LSE-02 +Ue 0 0.5 5.5 6.1 Q1 Q2 electron. default=3.0 Q1 Q2 0V

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Analog electronic position switches Two types are available: data. This means that the safe status can be • LSE-AI with current output, monitored and analysed at all times. The position • LSE-AU with voltage output. switch also has a self-test function. The outputs Q1 and Q2 are constantly scanned for overload, Analog, mechanically actuated position short circuit against 0 V and short circuit against switches directly linked with the world of +Ue. automation Contact travel diagram Analog position switches LSE-AI (4 to 20 mA) and LSE-AI 3 LSE-AU (0 to 10 V) represent another innovation I [mA] in electronic position switches. Using them, it is 20 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 4 S [%] analog fashion into voltage (0 to 10 V) or current 0 100 (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 LSE-AU and the results processed further. Simple rotational-speed dependent control U [V] systems of fan motors or smoke-venting blowers 10 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 S [%] have a diagnosis output for further processing of 0 100

Connection diagram

+24 V (–15 / +20 %)

LSE-AI +Ue F 200 mA diagnosis +Q2 4 – 20 mA analog +Q1 0 V A

< 400 O Q Ue

0 V

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+24 V (–15 / +20 %)

LSE-AU +Ue F 200 mA diagnosis +Q2 F 10 mA analog +Q1 0 V

3 V 0 V – 10 V Q Ue

0 V Circuit diagram Normal scenario LSE-AI LSE-AU Q1 4 – 20 mA 0 – 10 V Q Q Q2 Ue Ue LED

LED LED

t t

Fault scenario

LSE-AI LSE-AU Q1 0mA 0V Q2 0V 0V LED

LED LED

t t

Reset +Ue +Ue

t t > 1 s > 1 s

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RMQ-Titan® and LS-Titan®

a 3

LS-Titan

RMQ-Titan

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

Actuating devices RMQ-Titan® simply snap In addition, all the operating heads and the fitted adapter for accepting the RMQ-Titan actuators Another unique feature is the possibility to have a bayonet fitting that enables quick and combine control circuit devices from the secure fitting. Using the bayonet fitting, the heads RMQ-Titan range with the position switches can be attached in any of the four directions LS-Titan. Pushbuttons, selector switches or (4 x 90°). 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.

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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 4 Meter selector 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

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Use and mounting forms Moeller rotary switches and switch-disconnectors The following mounting forms are available: are used as: g Flush mounting, a Main switches, main switches used as h Centre mounting, Emergency-Stop devices, i Surface mounting, b ON-OFF switches, j Service distribution board mounting, c Safety switches, k Rear mounting. d Changeover switches, Refer to the latest issue of our Main Catalogue for e Reversing switches, star-delta switches, “Industrial Switchgear”. multi-speed switches, Other contact arrangements are listed in the K115 4 f Step switches, control switches, coding specialist catalog in addition to the switches listed switches, meter selector switches. in the Main Catalogue.

Basic P Iu Use as Mounting type type [KW] [A] a b c d e f g h i j k TM 3.0 10 – x – x – x k k – k – T0 6.5 20 x x – x x x + k k k + T3 13 32 x x – x x – + k k k + T5b 22 63 x x x x x – + – k – + T5 30 100 x – x x – – + – k – + T6 55 160 x – – x – – – – + – + T8 132 3151) x – – x – – – – + – + P1-25 13 25 x x x – – – + k + k + P1-32 15 32 x x x – – – + k + k + P3-63 37 63 x x x – – – + – + k + P3-100 50 100 x x x – – – + – + k + P5-125 45 125 x x – – – – + – – – + P5-160 55 160 x x – – – – + – – – + P5-250 90 250 x x – – – – + – – – + P5-315 110 315 x x – – – – + – – – + P = Max. motor rating; 400/415 V; AC-23 A Iu = Max. rated uninterrupted current 1) In enclosed version (surface mounting), max. 275 A. kDepending on the number of contact units, function and contact sequence. + Irrespective of the number of contact units, function and contact sequence.

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Circuit diagram example for maintenance T0(3)-3-15683 maintenance switch switches with a load shedding contact and (or) switch position indicator L1 Function L2 Load shedding: When L3 switching on, the main N current contacts close first, then the contactor is F1 F0 activated via the late-make N/O contact. When

95 switching off, the contactor 1 3 5 is first disconnected by 4 F2 Q11 opening of the early-break 2 4 6 96 contact, then the main 21 contacts isolate the motor F2 O supply. 22 Switch position 13 13 indication: The position of I Q11 the switch can be signalled 14 14 to the control panel or mimic diagram panel via additional NO and NC 135 7911 contacts. Q1

246 81012 UVW

A1 P1 P2 Q11 M A2 3

P1: On P2: Off Q11: Load shedding

T0(3)-3-15683 circuit diagram

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

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Changeover switches

T0-3-8212 L2L1 L3 T3-3-8212 01 2 1 T5B-3-8212 2 T5-3-8212 3 4 T6-3-8212 5 6 T8-3-8212 7 8 0 12 9 10 11 12 FS 684 4

Reversing switches

T0-3-8401 L2L1L3 T3-3-8401 102 1 T5B-3-8401 2 T5-3-8401 3 4 0 5 12 6 7 8 9 FS 684 10

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Star-delta switches T0-4-8410 L1 L2 L3 0YΔ T3-4-8410 1 Y 2 0 3 T5B-4-8410 4 T5-4-8410 5 6 FS 635 7 8 9 10 11 12 13 14 4 W2 U1 15 16 W1 U2

V1V2

Reversing star-delta switches T0-6-15877 L1L2L3 Y 0 Y T3-6-15877 1 1 2 0 SOND 28 ) 3 Y Y 4 5 6 7 FS 638 8 9 10 11 12 13 14 15 16 17 18 19 W2 U1 20 21 W1 U2 22 23 V1V2 24

1) Standard contactor interlock a section “Interlock Circuits”, page 4-11

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2 speeds, non-reversing

Tapped winding arrangement L1L2L3 T0-4-8440 0 1 2 1 T3-4-8440 2 T5B-4-8440 3 4 T5-4-8440 5 6 1 7 0 2 8 9 10 11 FS 644 12 13 1U 14 15 4 2W 2V 16

2U 1W 1V

ቢ a without links

2 separate windings T0-3-8451 L1L2L3 T3-3-8451 0 12 1 T5B-3-8451 2 3 T5-3-8451 4 5 1 0 2 6 7 8 9 10 FS 644 11 12

1U 2U

1W 1V 2W 2V

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2 speeds, reversing Tapped winding arrangement

T0-6-15866 L1L2 L3 T3-6-15866 20121 1 0 2 1 1 3 2 2 4 5 6 FS 629 7 8 9 T5B-7-15866 10 T5-7-15866 11 12 4 0 13 1 1 14 2 2 15 16 17 FS 441 18 19 1U 20 21 2W 2V 22 23 2U 24 1W 1V

2 separate windings, reversing L1L2L3 T0-5-8453 20121 1 T3-5-8453 2 3 0 4 1 1 5 2 2 6 7 8 FS 629 9 10 11 12 13 14 15 16 1U 2U 17 18 19 20 1W 1V 2W 2V

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3 speeds, non-reversing Tapped winding arrangement, single L1 L2 L3 winding for low speed 0 123 T0-6-8455 1 T3-6-8455 2 3 T5B-6-8455 4 5 T5-6-8455 6 7 1 2 8 0 3 9 10 11 12 FS 616 13 14 4 15 16 17 18 19 20 21 22 23 24

1U 1U 2W 2V

2U 1W 1V 1W 1V

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

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3 speeds, non-reversing Tapped winding arrangement, single L1 L2 L3 winding for high speed 0 123 T0-6-8459 1 T3-6-8459 2 3 4 1 2 5 0 3 6 7 8 9 FS 616 10 11 T5B-6-8459 12 13 4 T5-6-8459 14 15 2 1 3 16 0 17 18 19 20 FS 420 21 22 23 24

1U 1U 2W 2V

2U 1W 1V 1W 1V

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

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Interlock circuits between rotary switches and • Protection against automatic restarting after a contactors with overload relays provide neat and motor overload or power failure economical solutions for many switching drive • The facility for remote disconnection (e.g. tasks.The following points are common to all emergency-stop) can be provided by one or interlock circuits: more Off pushbuttons.

Without mains disconnection (SOND 27) With mains disconnection (SOND 28) Mains disconnection only by contactorprimarily Mains disconnection by contactor and switch for star-delta circuit

F0 Q11 Q11 F0 4 F2 F2 Q1 Q1 S0 S0 021 Control section 021 Control section SOND 27 SOND 28 Q11 Q11 Power section Power section without mains Q11 Q11 without mains disconnection disconnection

Circuit as required Circuit as required

M M 3~ 3~

Interlock with contactor (SOND 29) Interlock with contactor (SOND 30) Contactor can be energized only when switch is Contactor can be energized only when switch is in the Off position in an operating position

Q11 F0 Q11 F0 F2 F2 Q1 Q1 S0 S0 021 Control section 021 Control section S1 SOND 29 SOND 30 Q11 S1 Q11 Power section Power section Q11 Q11

Circuit as required Circuit as required

M M 3~ 3~

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Meter selector switches enable you to measure Numerous circuits are possible for the different currents, voltages and power in three-phase measurements, some of the most common ones systems with only one measuring device. being shown below.

Voltmeter selector switches T0-3-8007 T0-2-15922 3 x phase to phase 3 x phase to neutral without “0” 3 x phase to neutral with “0” position position

0 L2-L3 L1-L2 L1-N L1L2L3 N L1-L2 L3-L1 L1L2L3 L2-L3 L2-N L1-L2 L2-L3 L3-L1 L3-L1 L2-L3 L1-L2 0 L1-N L2-N L3-N L3-L1 L3-N 1 1 4 2 2 FS 1410759 3 FS 164854 3 4 4 5 5 6 6 7 7 8 V 8 9 10 11 V 12

Ammeter selector switches T0-5-15925 T3-5-15925 For direct measurement

0 L1L2 L3

L3 L1 L1L2L30 0 1 L2 2 3 FS 9440 4 5 6 7 8 9 10 A 11 12 13 14 15 16 17 18 L1L2L3

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Ammeter selector switches T0-3-8048 T3-3-8048 For measurement via transformers, complete rotation possible 0 L1 L3 L1 L2 L2 L3 0 L1L2L3 0 FS 9440 1 2 3 4 5 6 7 4 8 9 A 10 11 12

Wattmeter selector switches T0-5-8043 The Aron circuit will give a correct result for T3-5-8043 four-cable systems only when the sum of the Two-phase method (Aron circuit) for three-cable currents equals zero, i.e. only when the four-cable installations loaded as required. The sum of the system is balanced. two readings gives the total output.

0 L1 1 2 L2 L3

FS 953 W 120 1 2 3 11 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18

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1-pole disconnection, 3 steps T0-2-8316 T3-2-8316 T5B-2-8316

2 1 3 L1 L2 L3 0 0123 I II III 1 2 3 1 FS 420 4 5 I IIIII 6 2 7 4 8 3

T0-2-15114, complete rotation possible

1 011+22 0 0 1+2 1 2 2 3 4 FS 193840 5 6 7 8

q switched Q not switched

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.

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One step closed in each position, complete rotation possible T0-6-8239 1234511678910 12 T3-6-8239 1 2 3 4 5 3 2 6 1 7 4 12 8 5 1110 9 6 7 FS 301 8 9 10 11 12 13 14 15 4 16 17 18 19 20 21 22 23 24

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Stay-put switches On-Off stay-put switches 0 1 1-pole: T0-1-15401 1 2-pole: T0-1-15402 2 3 3-pole: T0-2-15403 4 5 0 6 1

FS 415 4 Changeover switches 1-pole: T0-1-15421 1-pole: T0-1-15431 2-pole: T0-2-15422 2-pole: T0-2-15432 3-pole: T0-3-15423 3-pole: T0-3-15433 0 0 HAND 0 AUTO 2 1 2 01 HAND AUTO 1 1 2 2 3 3 4 4 FS 429 5 FS 1401 5 6 6 7 7 8 8 9 9 10 10 11 11 12 12

On-Off stay-put switches (also usable as main switches, mains isolating device) 1-pole: T0-1-15521 2-pole: T0-2-15522 3-pole: T0-3-15523 With pulsed contact in the intermediate position ON 01

OFF 1 2 3 4 FS 908 5 6 7 8 9 10 11 12

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What does ATEX stand for? ATmosphéres EXplosibles = ATEX

Explosive atmospheres

Gas Dust

Two standards

For operators: 1999/92/EC For manufacturers: 94/9/EC 4 (binding from 06/2006) (binding from 06/2003)

Explosion risk assessment Device groups Gas, steam, Dust Ex risk Group Application field mist I Mining Zone 0 Zone 20 continuous, frequent, long, II everything apart from Zone 1 Zone 21 occasional mining Zone 2 Zone 22 normally not, but otherwise for a short period

Selection of devices and protective Selection of devices by device systems by categories groups Gas, steam, Dust Category Group Category Safety mist Zone 0, I M1 very high 1, 2 Zone 1, 2 Zone 20, 21, 22 1 I M2 high Zone 2 Zone 21, 22 1, 2 II 1 very high Zone 22 1, 2, 3 II 2 high II 3 normal

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ATEX approval for Moeller Moeller offers T rotary switches (from 32 to 100 A) • Changeover switches. and P switch-disconnectors (from 25 to 100 A) in accordance with the binding ATEX Directive The following ATEX switches are available: 94/6 EC (binding from 06/2006). The switches are provided with the equipment marking Ex II3D Current T rotary P range switches switch-discon- IP5X T90°C and are approved for the Ex zone 22 nectors in explosive dust atmospheres. Explosive dust atmospheres are present in: 25 A – P1-25/I2 • Mills, • Metal polishing workshops, 32 A T3-.../I2 P1-32/I2 4 • Woodworking facilities, • Cement industry, 63 A T5B-.../I4 P3-63/I4 • Aluminium industry, 100 A T5-.../I5 P3-100/I5 • Animal feed industry, • Grain storage and preparation, Note • Agriculture, Moeller ATEX switches have passed the EC •Pharmacy etc. prototype test for main, maintenance and repair switches for the current ranges from 25 to 100 A. The ATEX switches are used as: They are approved for explosive dust atmospheres • Main switches in accordance with category II 3D, with the test • Maintenance switches number: BVS 04E 106X. • Repair switches, For further information see installation • ON-OFF switches or, instructions AWA1150-2141.

General installation and application notes • Only suitable cable glands may be used for • Never open the device in dust explosive category 3D! atmospheres! • Use only temperature resistant cables (> 90°C)! • Observe the requirements of EN 50281-1-2! • The maximum surface temperature is 90°C! • It should be checked that the device is free of • Operation only permissible at an ambient dust prior to assembly! temperature between –20 and +40°C! •Do not open the device when energized! • Observe the technical data of the switch used!

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Page Contactor relays 5-2 Time and special purpose relays 5-8 Control relay easy, Multi Functions Display MFD-Titan® 5-12 Contactors DIL, Overload relays Z 5-58 Contactors DIL 5-60 Overload relays Z 5-64 Electronic Motor Protective relay ZEV 5-67 Thermistor Motor protection Device EMT6 5-74 5 Electronic Safety Relay ESR 5-77 Measurement and Monitoring Relay EMR4 5-78

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Contactor relays Contactor relays are often used in control and contact input and output. All Moeller contactor regulating functions. They are used in large relays have double-break contacts. quantities for the indirect control of motors, The German Trade Associations demand that, for valves, clutches and heating equipment. control systems of power-driven metalwork In addition to the simplicity which they offer in presses, the contacts of contactors must be project engineering, panel building, interlocked. Interlocking means that the contacts commissioning and maintenance, the high level of are mechanically connected to one another such safety which they afford is a major factor in their that break contacts and make contacts can never favour. be closed simultaneously. At the same time, it is Safety necessary to ensure that the contact gaps are at The contactor relay contacts themselves constitute least 0.5 mm over the entire life, even when a considerable safety feature. By design and defective (e.g. when a contact is welded). The 5 construction they ensure electrical isolation contactor relays DILER and DILA fulfil this between the actuating circuit and the operating requirement. circuit, in the de-energized state, between the

Moeller contactor relays

Moeller offers two ranges of contactor relays as a Modules having auxiliary functions modular system: Auxiliary contact modules having 2 or 4 contacts • Contactor relays DILER, The combination of normally open and normally • Contactor relays DILA. closed contacts is according to EN 50011. The and the modules are described on the following auxiliary contact modules of the contactors DILEM pages. 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 Modular system the add-on auxiliary contact module. 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.

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The system and the Standard European Standard EN 50011 “Terminal For 6 and 8 pole contactor relays, the “E” version markings, reference numbers and reference letters means that four make contacts must be arranged for certain contactor relays” has a direct bearing in the lower/rear contact level. If, for example, the on the use and application of the modular system. available auxiliary contact modules are used in the There are various types, which the Standard DILA-22 and DILA-3131, they result in contact differentiates between by means of reference combinations with reference letters X and Y. numbers and reference letters, depending on the number and position of the make and break Below are 3 examples of contactors with 4 contacts in the device, and their terminal normally open and 4 normally closed contacts markings. with different reference letters. Version E is to be Ideally devices with the reference letter E should preferred. be used. The basic devices DILA-40, DILA-31, DILA-22 as well as DILER-40, DILER-31 and 5 DILER-22 comply with the E version. . Example 1 Example 2 Example 3 DILA-XHI04 DILA-XHI13 DILA-XHI22

51 61 71 81 53 61 71 81 53 61 71 83

52 62 72 82 54 62 72 82 54 62 72 84

+ + + DILA-40 DILA-31 DILA-22

A1 1323 33 43 A1 13 21 33 43 A1 13 21 31 43

A2 14 24 34 44 A2 14 22 34 44 A2 14 22 32 44 q 44 E q 44 X q 44 Y DILA40/04 DILA31/13 DILA22/22

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Coil connections On the contactor relay DILA the coil connection A1 A1 is at the top and A2 at the bottom. As suppressor circuits the following are connected on the front : • RC suppressors A1 A2 • Varistor suppressors

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

DILER DILA 5 On the top positioned terminals A1–A2 of the contactor DILER the following accessories are connected to limit the relay coil switch off voltage peaks : • RC suppressors • Diode suppressors • Varistor suppressors

Suppressor circuits Electronic equipment is nowadays being Since interference-free disconnection is impossible increasingly used in combination with without an accessory, the coils may be connected conventional switching devices such as to a suppressor module, depending on the contactors. This equipment includes application. The advantages and disadvantages of programmable logic controllers (PLCs) timing the various suppressor circuits are explained in the relays and coupling modules, whose operation following table. 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.

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Circuit diagram Load current and Proof Addi- Induction voltage responses against tional voltage incorrect dropout limiting connec- delay defined tion also for AC

+ – Very long 1 V i I0 0 D t0 t 5 u U0 – t1 t2 0 U t

+ – Medium UZD i I D 0 0 t t ZD 0 u U0 – t t2 0 1 t U

Yes Short UVDR i I0 0 VDR t u U0 t t 0 1 2 t U

Yes Short – i I0 R 0 t0 t U C u 0 0 t T1

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Circuit diagram Damping Increased Remarks also rating below with ULIMIT circuitry.

+ – – Advan- Dimensioning uncritical. tages: Minimum possible induction voltage, Very D simple and reliable. 5 – Disadvan- Long drop-out delay tage:

+ – – Advan- Very short drop-out tages: delay. Dimensioning D uncritical. Simple construction ZD –

Disadvan- No damping below UZD tage: – – Advan- Dimensioning uncritical. tages: High energy absorption. Very simple construction VDR

Disadvan- No damping below UVDR tage: Yes Yes Advan- HF damping due to tages: stored energy. R Immediate de-energisation. Highly C suitable for AC.

Disadvan- Precise dimensioning tage: required

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Electronic timing relays are used in contactor • ETR2-44 control systems which require short reset times, Function 44 (flashing, two speeds; can be set high repetition accuracy, high switching to either pulse initiating or pause initiating) frequency, and a long component lifespan. Times • Multifunction relay DILET70, ETR 4-69/70 between 0.05 s and 100 h can be easily selected Function 11 (on-delayed) and set. Function 12 (off-delayed) The switching capacity of electronic timing relays Function 16 (on and off delayed) corresponds to the utilisation categories AC 15 Function 21(fleeting contact on energisation) and DC 13. Function 22 (fleeting contact on In terms of the actuating voltages there are with de-energisation) timing relays the following differences : Function 42 (flashing, pulse initiating) • Version A (DILET… and ETR4) Universal • Function 81 (pulse generating) devices: Function 82 (pulse shaping) DC 24 to 240 V ON, OFF 5 AC 24 to 240 V, 50/60 Hz • Multifunction relay ETR2-69 • Version W (DILET… and ETR4) Function 11 (on-delayed) AC devices: Function 12 (off-delayed) AC 346 to 440 V, 50/60 Hz Function 21 (fleeting contact on energisation) • ETR2… (as row mounting device to Function 22 (fleeting contact on DIN 43880) de-energisation) Universal device: Function 42 (flashing, pulse initiating) DC 24 to 48 V Function 43 (flashing, pause initiating) AC 24 to 240 V, 50/60 Hz Function 82 (pulse forming) • Star/delta timing relay ETR4-51 Function 51 (on delayed) The functions of each of the timing relays are as follows: With both DILET70 and ETR4-70 an external • DILET11, ETR4-11,ETR2-11 potentiometer can be connected. Upon Function 11 (on-delayed) connection, both timing relays automatically • ETR2-12 recognize that a potentiometer is fitted. Function 12 (off-delayed) • ETR2-21 The ETR4-70 has a special feature. Equiped with Function 21 (fleeting contact on energisation) two change-over contacts which can be converted • ETR2-42 to two timing contacts 15-18 and 25-28 (A2-X1 Function 42 (flashing, pulse initiating) 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.

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Function 11 Function 16 On-delayed On- and Off-delayed

A1-A2 A1-A2 Y1-Y2 15-18 B1 t 15-18 t t (25-28) The control voltage Us is applied via an actuating contact to the terminals A1 and A2. The control voltage Us is applied directly to the terminals A1 and A2. If the terminals Y1 and Y2 in After the set delay time the change-over contact the DILET70 are linked by a potential-free contact, of the output relay goes to the position 15-18 or in the case of of the ETR4-69/70 a potential is (25-28). applied to B1, after a set time t the changeover contact goes to the position 15-18 (25-28). 5 Function 12 If the connection Y1-Y2 is now interrupted, or B1 Off-delayed is separated from the potential, the changeover contact goes back to it´s original position 15-16 A1-A2 (25-26) after the same time t. Y1-Y2 B1 15-18 Function 21 t (25-28) Fleeting contact on energization

After the control voltage has been applied to the A1-A2 terminals A1 and A2, the changeover contact of the output relay remains in the original position 15-18 15-16 (25-26). If the terminals Y1 and Y2 in the t (25-28) DILET70 are linked by a potential-free make contact or, in the case of the ETR4-69/70 or After the voltage Us has been applied to A1 and ETR2-69, a potential is applied to B1, the A2, the changeover contact of the output relay changeover contact changes without delay to the goes to position 15-18 (25-28) and remains position 15-18 (25-28). actuated for as long as the set fleeting contact If the connection between the terminals Y1–Y2 is time. now interrupted, or B1 is separated from the A fleeting pulse (terminals 15-18, 25-28) of potential, once the set time has elapsed, the defined duration is therefore produced from a changeover contact returns to it´s original position two-wire control process (voltage on A1/A2) by 15-16 (25-26). this function.

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Function 82 Function 22 Pulse forming Fleeting contact on de-energization

A1-A2 A1-A2 Y1-Y2 B1 Y1-Y2 15-18 B1 t 15-18 (25-28) t (25-28) After the control voltage has been applied to A1 The control voltage Us is applied directly to A1 and and A2, the changeover contact of the output A2. If the terminals Y1 and Y2 of the DILET70, that relay remains in the rest position 15-16 (25-26). If have been shorted (DILET-70 potential-free) the terminals Y1 and Y2 in the DILET70 are linked before at a convienient time, are opened again (or by a potential-free contact, or in the case of the for ETR4-69/70 or ETR2-69 the contact B1 again 5 ETR4-69/70 or ETR2-69, a potential is applied to potential-free) the contact 15-18 (25-28) closes B1, the changeover contact changes without for the duration of the set time. delay to the position 15-18 (25-28). If Y1-Y2 is now opened again, or B1 is separated Function 42 from the potential, the changeover contact remains actuated until the set time has elapsed. If, Flashing, pulse initiated instead, Y1-Y2 remain closed or B1 is separated A1-A2 from the potential for longer, the output relay likewise changes back to its rest position after the 15-18 (25-28) set time. An output pulse of precisely defined tttt duration is thus produced in the pulse-forming function, irrespective of whether the input pulse After the voltage Us has been applied to A1 and via Y1-Y2 or B1 is shorter or longer than the set A2, the changeover contact of the output relay time. changes to position 15-18 (25-28) and remains actuated for as long as the set flashing time. The Function 81 subsequent pause duration corresponds to the Pulse generating with fixed pulse flashing time.

A1-A2 15-18 t 0.5 s (25-28)

The actuating voltage is applied to the 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 it´s original position 15-16 (25-26) after 0.5 s. This function is therefore a fleeting pulse with a time delay.

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Function 43 Function 51 Star-delta Flashing, pause initiated On-delayed

A1-A2 A1-A2

15-18 17-18 t t t t t 17-28 t tu LED When the control voltage U is connected to A1 After the voltage U has been applied to A1 and s s and A2 the instantaneous contact goes to position A2 the change-over contact of the output relay 17-18. After the set time duration the stays in position 15-16 for the set flashing time instantaneous contact opens and the timing and after the duration of this time goes to position contact 17-28 closes after a changeover time t of 15-18 (the cycle begins with a pause phase). u 50 ms. 5 Function 44 On-Off Function Flashing, two speeds A1-A2 A1-A2 15-18 A1-Y1 OFF ON OFF (25-28) 15-18 LED tt1 2 tt 1 2 tt1 2

Rel LED The On-Off function allows the operation of a A1-Y1 control system to be tested and is an aid, for example, for commissioning. The Off function 15-18 1 2 ttt 1 t 2 tt1 2 allows the output relay to be de-energized and it no longer reacts to the functional sequence. The Rel LED On function energizes the output relay. This function is dependent on the supply voltage being After the voltage U has been applied to A1 and s applied to the terminals A1/A2. The LED indicates A2 the changeover contact of the output relay the operational status. 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.

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Control relay easy

1 5

5 7

ESC

DEL ALT 12 8 ESC OK POWER COM-ERR

ADR

4 9

POW

BUS

4 10

ERR

4 NS

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1 Basic unit easy512 2 Basic unit, expandable easy719, easy721 3 Basic unit, expandable easy819, easy820, easy821, easy822 4 Multi Function Display MFD-Titan, expandable 5 Expansion unit easy618, easy620 6 Expansion unit easy202 7 Coupling unit easy200 for remote expansion of easy700, easy800 and MFD-Titan 8 Network module PROFIBUDS-DP; EASY204-DP 9 Network module AS-Interface; EASY205-ASI 10 Network module CANopen; EASY221-CO 11 Network module DeviceNet; EASY222-DN 5 12 Data plug EASY-LINK-DS

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1 2

5 4 6 4

5 DEL ALT

ESC OK

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1 Basic unit easy512 2 Basic unit, expandable easy719, easy721 3 Basic unit, expandable easy819, easy820, easy821, easy822 4 Multi Function Display MFD-Titan 5 Power supply/communication module MFD-CP4-800 6 Power supply/communication module MFD-CP4-500

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Programming instead of wiring Circuit diagramms are the basis of all “Remote” Display – Text display for electrotechnical applications. In practice electrical easy500, easy700, easy800 in IP65 devices are wired to each other. With the control relay easy it is simply by pushbutton or with easy to use easy-soft... by computer. Simple menu operation in many languages simplify the input. That saves time and therefore costs. easy and MFD-Titan are the professionals for the world market.

5 S1 K1 S4 S6

S5 Using Plug & Work the display MFD-80.. is connected via the supply and communication module MFD-CP4.. to the easy. The MFD-CP4.. K3 K3 has an integrated, 5 m long connection cable. Advantage: No software or driver is necessary for connection. The MFD-CP4.. offers real K1 K2 K3 Plug & Work. The input and output wiring is connected to the easy. The MFD-80.. is mounted into two 22.5 mm mounting holes. The IP65 display is backgound illuminated and easily readable. Individual labeling of the displays is possible.

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Control relay easy500 and easy700 MFD-Titan and easy800

easy500 and easy700 have the same functions. MFD…CP8… und easy800 have the same easy700 offers more inputs and outputs, is functions. MFD-80.. with IP65 they can be used in 5 expandable and can be connected to a standard harsher environments. In addition for expansion bus system. The series and parallel linking of and connection to standard bus systems 8 contacts and coils takes place in up to 128 current easy800 or MFD-Titan can be networked via paths. Three contacts and and a coil in series. The easyNet. The series and parallel linking of contacts display of 16 operating and report texts is via an and coils takes place in up to 256 current paths. internal or external display. Four contacts and a coil in series. The display of The main functions are: 32 operating and report texts is via an internal or • Multi-function timing relay external display. • Current impulse relay, Extra to the functions offered by easy700 the • Counter easy800 and the MFD-Titan offers: – forwards and backwards, • PID controller, – Fast counter, • Arithmetic modules, – Frequency counter, • Value scaling, – Operational time counter, • and much more. • Analog value comparator, • Week and year time switch, Individual labeling of the MFD-80 is possible. • Automatic summertime changeover, • Remanent actual values of markers, numbers and timing relays.

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Power supply connection

for AC devices for DC devices L + N —

> 1A L.1 > 1A +.1

LNN +...V 0 0

Basic unit Basic units EASY512-AB-… 24 V AC EASY512-DA-… 12 V DC EASY719-AB- 24 V AC EASY719-DA-… 12 V DC EASY512-AC-… 115/230 V AC EASY512-DC-… 24 V DC EASY719-AC-… 115/230 V AC EASY719-DC-… 24 V DC EASY811-AC-… 115/230 V AC ASY819-DC-… 24 V DC EASY82.-DC-… 24 V DC MFD-AC-CP8-… 115/230 V AC MFD-CP8-… 24 V DC Expansion devices Expansion devices EASY618-AC… 115/230 V AC EASY618-DC… 24 V DC EASY620-DC… 24 V DC

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Digital input connection of the AC devices

L.1 N

100 nF /275 V h

100 nF 1N4007 /275 V h 1 kO

1N 5

abcdef g h

a Input signal via relay contact e.g. DILER Note b Input signal via pushbutton RMQ Titan • Due to the input circuitry the drop-out time of c Input signal via position switch e.g. LS Titan the input is increased. d Conductor length 40 to 100 m for input • Length of input conductor without addtional without additional switching (e.g. easy700 I7, switching F40 m, with additional switching I8 already has addition switching, possible F100 m. conductor length 100 m) e Increasing the input current f Limiting the input current g Increasing the input current with EASY256-HCI h EASY256-HCI

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Digital input connection of the DC devices

+.1 –

p p

abcde

a Input signal via relay contact e.g. DILER Note b Input signal via pushbutton RMQ Titan • With conductor length consider also the c Input signal via position switch e.g. LS Titan volt-drop. d Proximity switch, three wire • Due to the high residual currents don´t use two e Proximity switch, four wire wire proximity switches.

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Analogue inputs Depending upon the device two or three 0 to 10 V • With short conductor lengths earth the screen inputs are available. on both sides and fully. With a conductor length The resolution is 10 Bit = 0 to 1023. of approx. 30 m the earthing on both sides can Valid: lead to circulating currents between the earthing points and interference of the I7 = IA01 analogue signals. In this case only earth the EASY512-AB/DA/DC… conductor on one side. I8 = IA02 • Don´t lay the signal conductor parallel to the EASY719/721-AB/DA/DC… power conductor. EASY819/820/821/822-DC… • Inductive loads that must be switched by easy I11 = IA03 MFD-R16, MFD-R17, should be connected to a seperate power MFD-T16, MFD-TA17 supply or a suppressor circuit should be used for I12 = IA04 motors and valves. Supplying loads such as motors, magnetic valves or contactors and easy 5 Caution! from the same power supply can by switching Analogue signals are more sensitive to lead to interference of the anologue input interferance than digital signals, therefore the signal. signal cables should be carefully routed and connected. Inappropriate connections can lead to unwanted switching conditions. • Use screened, twisted pair conductors, to stop interference of the analogue signals.

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Connection of power supply and analogue inputs for easy..AB device

L N

+12 V 0 V

5 F1 L01h N01 h

L N NI1 I7 I8

Note easy..AB devices that process analogue signals Be sure the common reference potential is earthed must be supplied via a transformer so that there is or monitored by an earth-fault monitoring device. a galvanic seperation from the mains supply. The Pay attention to the applicable reglations. neutral conductor and the reference potential of DC supplied analogue sensors must be galvanically connected.

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Analogue input connections to easy…DA/DC-… or MFD-R…/T…

+ – +.1

a 4...20 mA (0...20 mA)

+..V h -0 V Out O 5 0...10 V -35...55 ˚C 500 0 V -12 V

+...V 0 V 0 V

abcd

a Setpoint device via separate power supply and • Connect the 0 V of the or the MFD-Titan with potentiometer F1kO, e.g. 1 kO, 0.25 W the 0 V of the power supply of the analogue b Setpoint device with upstream resistance encoder. 1.3 kO, 0.25 W, potentiometer 1 kO, 0.25 W • sensor of 4(0) to 20 mA and a resistance of (value for 24 V DC) 500 O give the following approx. values: c Temperature monitoring via temperature –4mA Q 1.9 V, sensor and transducer –10mA Q 4.8 V, d Sensor 4 to 20 mA mit resistor 500 O –20mA Q 9.5 V. Note • Analogue input 0 to 10 V, Resolution 10 Bit, • Pay attention to the differing number and 0 to 1023. designation of the analogue inputs of each device type.

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Connection “fast counter”, “frequency generator”and “incremental encoder” for easy…DA/DC devices or MFD-R…/-T…

+ + – – +.1 +.1

p 5

ab c

a Fast counter, square wave signal via proximity c Square wave signal via incremental encoder switch, pulse pause relationship should be 1:1 24 V DC easy500/700 max. 1 kHz easy800DC… and MFD-R/T… max. 3 kHz easy800 max. 5 kHz Note MFD-R/T… max. 3 kHz Pay attention to the different number and b Square wave signal via frequency generator, designation of the inputs of the “fast counter”, pulse pause relationship should be 1:1 “frequency generator” and “incremental easy500/700 max. 1 kHz encoder” for each device type. easy800 max. 5 kHz MFD-R/T… max. 3 kHz

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Connection of relay outputs for easy and MFD-Titan

1 2 12 12 12 12

L.. L.. L.. L.. L.. 5

abcde

Protection operating potential L.. a Lamp, max. 1000 W at 230/240 V AC b Fluorescent tube, max. 10 x 28 W with electronic starter, 1 x 58 W with conventional starter at 230/240 V AC c AC motor d Valve e Coil F 8 A/B16 Possible AC voltage range: 24 to 250 V, 50/60 Hz z. B. L1, L2, L3 phase against neutral Possible DC voltage range: 12 to 300 V DC

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Connection from transistor outputs for easy and MFD-Titan

+ 24 V 0 V

5 f 2.5 A F 10.0 A

24 V DC

ab cd

a Contactor coil with zener diode as Note suppressor, 0.5 A bei 24 V DC When switching off inductive loads the following should be considered: b Valve with diode as suppressor, Suppressed inductances cause less interference in 0.5 A at 24 V DC the total electrical system. It is generally c Resistor, recommended to connect the suppressor as close 0.5 A at 24 V DC as possible to the inductance. When the inductances are not suppressed, then : d Indicator lamp 3 or 5 W at 24 V DC, several inductances must not be switched off at Output dependant upon device the same time, so that in the worst case the driver types and outputs block does not overheat. Should, in an emergency stop situation the +24 V DC supply be switched off by another contact and thereby more than one controlled output be switched off, the inductances must have a suppressor.

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Parallel switching Note The outputs may only be switched parallel within a group (Q1 to Q4 or Q5 to Q8, S1 to S4 or S5 to S8) ; e.g. Q1 and Q3 or Q5, Q7 and Q8. Parallel switched outputs must be similtaneously energised. when 4 outputs in parallel, max. 2 A at 24 V DC

when 4 outputs in parallel, max. 2 A at 24 V DC Inductance without suppression max. 16 mH

12 or 20 W at 24 V DC Output dependant upon device types 5 and outputs

0 V a

a Resistor

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Connection of analogue outputs for EASY820-DC-RC…, EASY822-DC-TC…, MFD-RA… and MFD-TA…

+ ñ +.1

0 V I A

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

a Servo valve control b Set value sekection for drive control Note • Analogue signals are more sensitive to interferance than digital signals, therefore the signal conductors should be carefully routed. Inappropriate connections can lead to unwanted switching conditions. • Analogue output 0 to 10 V, Resolution 10 Bit, 0-1023.

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Expansion of the input and output points for easy and MFD-Titan To expand the input and output points there are Networking via EASY-Net, up to 320 I/O various solutions : When expanding the inputs and outputs via Central expansion, to 40 I/O EASY-Net eight easy800 or MFD-Titan can be easy700, easy800 and MFD-Titan can be connected to each other. Every easy800 or expanded via easy202, easy618 or easy620. Here MFD-Titan can be extended with an expansion there are a maximum of 24 inputs and 16 outputs device. 1000 m Network length is possible. There available. An expansion of the basic device is are two types of operation: possible. • One master (position 1, device address 1) plus up to 7 further devices. The programme is in the Decentral expansion, to 40 I/O master. easy700, easy800 and MFD-Titan can be • One master (position 1, device address 1) plus expanded via the coupling module easy200-EASY up to 7 further “intelligent” or with easy618 or easy620. The expansion device “non-intellegent” devices. Every “intelligent” 5 can be operated up to 30 m from the basic device. device has a programme. There are a maximum of 24 inputs and 16 outputs available. An expansion of the basic device is possible.

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Central and decentral expansion for the basic devices easy700, easy800 and MFD-Titan

12 I 1 - I... R 1 - R... central expansion

Q 1 - Q... S 1 - S... easy700... easy618... easy800... easy620... easy202...

decentral expansion 12 E+ E- 5 I 1 - I... R 1 - R... F 30 m Q 1 - Q... S 1 - S... E+ E- easy700... easy618... easy800... easy200... easy620...

R 1 - R... central expansion MFD

S 1 - S... MFD-AC-CP8... easy618... MFD-CP8... easy620... easy202...

E+ E- decentral expansion R 1 - R... MFD F 30 m S 1 - S... E+ E- MFD-AC-CP8... easy618... MFD-CP8... easy200... easy620... EASY-LINK-DS

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EASY-NET, Network connection “through the device”

EASY-NET-R EASY-NET Geographic Device (124 O location, Example 1 Example 2 PIN 1 + 2) position1)

1 1 1 easy800

2 2 3 5

easy800 easy618 easy620

3 3 8

MFD-AC-CP8 easy618 MFD-CP8 easy200 easy620

8 8 2

easy800... easy202

EASY-LINK-DS 1) The geographic location/place 1 always has the device address 1.

• Addressing the devices: • The max. total length with EASY-NET is 1000 m. – Automatic addressing of device 1 or via • Should EASY-NET be interrupted or a device is not EASY-SOFT… by PC, geographic location = operational, the network isn´t active past the device, interrupted point. – Single addressing on the corresponding device or • 4 core cable unscreened, each two cores twisted. via EASY-SOFT… on each device, geographic Characteristic impedance of the cable must be location and device can be different. 120 O.

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EASY-NET, Network connection “T piece with spur cable”

EASY-NET-R EASY-NET Geographic Device (124 O location, Example 1 Example 2 PIN 1 + 2) position1)

1 1 1

easy800 F 0.3 m

5 2 2 3

easy800 easy618 easy620 F 0.3 m

3 3 8

MFD-AC-CP8 easy618 MFD-CP8 easy200 easy620 F 0.3 m

8 8 2

easy800... easy202

1) The geographic location/place 1 always has the EASY-LINK-DS device address 1.

• Addressing the devices: • Should EASY-NET be interrupted between the T – Single addressing on corresponding device or via piece and the device, or a device is not operational, EASY-SOFT… on every device. the network is still active to any further device. • The max. total length, including spur cables, with • 4 core cable unscreened, each two cores twisted. EASY-NET is 1000 m. Three cores are required. • The max. length of T pieces to easy800 or to Characteristic impedance of the cable must be MFD-Titan is 0,30 m. 120 O.

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Network connection Sockets RJ 45 and plug Configuration of the network cable for Connection layout of socket RJ 45 on easy and EASY-NET MFD-Titan. The network cable does not need to be screened. The characteristic impedance of the cable must be 1 120 O. 2 A1ECAN_H 3 A2ECAN_L 4 B 3 GND (Ground) 5 B4SEL_IN 6 7 Note 5 8 The minimal operation with easy-NET functions with the conductors ECAN_H, ECAN_L, GND. The Connection layout of plug RJ45 on easy and SEL_IN conductor is solely for automatic MFD-Titan. addressing. 1 Bus terminal resistor 2 A bus terminal resistor must be connected to the geographical first and last device in the network: 3 • Value of the bus terminal resistor 124 O, 4 • Connect to PIN 1 and PIN 2 of the RJ-45 plug, 5 a • Connection plug : EASY-NT-R. 6 7 Pre-finished conductors, RJ45 plug on both 8 ends Conductor length Part reference a Cable entry side [cm] 8 pole RJ 45, EASY-NT-RJ 45

Layout with EASY-NET 30 EASY-NT-30 PIN 1; ECAN_H; Data conductor; conductor pair A PIN 2; ECAN_L; Data conductor; conductor pair A 80 EASY-NT-80 PIN 3; GND; ground conductor; conductor pair B PIN 4; SEL_IN; Select conductor; conductor pair B 150 EASY-NT-150

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Freely useable conductors Calculation of conductor length when the 100 m 4 x 0.14 mm2; twisted in pairs: cross section is known EASY-NT-CAB For a known conductor cross section the RJ-45 plug: maximum conductor length is calculated. EASY-NT-RJ 45 lmax = Length of conductor in m Crimping tool for RJ-45 plug: EASY-RJ45-TOOL. S = Conductor cross section in mm2 r = specific resistance of copper, when Calculation of cross section when conductor cu nothing else given 0,018 Omm2/m length is known The minimum cross section is calculated for the know maximum use of the network. S x 12.4 l = Length of conductor in m lmax = 2 r Smin = minimum cross section in mm cu rcu = specific resistance of copper, when 5 nothing else given 0,018 Omm2/m

l x rcu Smin = 12.4

Note When the result of the calculation doesn´t give a normal cross section use the next highest normal cross section.

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Permissible network length for EASY-NET Conductor Transmission Conductor cross section, Bus conductor, length speed standardised minimum conductor EASY-NET total 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 5 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) Default setting

Note The chacteristic impedance of the conductor must be 120 O!

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Network connection with conductor cross Network connection with T piece and spur section > 0.14 mm2, AWG26 cable Network connect “through the device”. Network connection “T piece with spur cable” Example A, with terminals Example A, with terminals

1 1 2 IN 3 2 4 IN 3 1 a 2 4 3 c RJ 45 RJ 45 5 4 RJ 45 OUT OUT

easy800 easy800 MFD-Titan MFD-Titan a Recommendation F 0.3 m c F 0.3 m (3 core)

Example B, with interface element Example B, with interface element

2468 1357 IN 2468 1357 IN RJ 45 RJ45 2468 1357 b OUT RJ 45 d RJ 45 RJ 45 RJ 45 OUT

easy800 MFD-Titan easy800 MFD-Titan Recommendation F 0.3 m (EASY-NT-30) b d F 0.3 m (EASY-NT-30)

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Remote display in IP65

+ L.1 L L.1 – N

> 1A > 1A

+ 24 V 0 V LN 115/230 V 50/60 Hz 5

MFD-80...

MFD-...CP4... MFD-...CP4... F 5 m F 5 m MFD-CP4-500-CAB5 MFD-CP4-500-CAB5

easy500 easy800 easy700 easy800...x easy500...x easy700...x

On the “remote display” MFD-80… the easy No extra software or programming is necessary to indication display is shown. operate the “remote display”. The easy can also be operated with the MFD-80-B. The connection cable MFD-CP4-…-CAB5 can be shortened.

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COM-LINK connection MFD-80… MFD-…-CP8… + MFD..T../R.. easy800 MFD…CP8… + MFD..T../R..

POW-Side 5

The COM-LINK is a point to point connection serial The remote device can be a easy800 or a interface. Via this interface the status of the inputs MFD…CP8… and answers to the requests of the and outputs are read as well as marker areas read active devices. The remote device dosen´t and written. Twenty marker double words read or recognise the difference if the COM-LINK is active written are possible. Read and written are freely or a PC with EASY-SOFT-PRO uses the interface. selectable. This data can be used for the set values The devices of the COM-LINK can be centralised or or display functions. decentralised extended with easy expansion The devices of the COM-LINK have different devices. functions. The active device is always a The remote device can also be a device in the MFD…CP8… and controls the complete EASY-NET. interface.

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Field bus connection to the production process

easy204-DP easy221-C0 easy222-DN easy205-ASI 5

easy700, easy800

MFD…CP8…

network module can be connected with easy700, Further information can be found in the associated easy800 or MFD-Titan. The network module is manuals: intergrated as slave in the configuration. • AWB2528-1508 Expansion of the input and output points via easy500, easy700, control relay, EASY-NET is possible (a section “EASY-NET, • AWB 2528-1423 Network connection “through the device””, easy800, control relay, page 5-31 and a section “EASY-NET, Network • AWB2528-1480D connection “T piece with spur cable””, MFD-Titan, Multi Function Display. page 5-32).

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Contacts, coils, function modules, operand Operand Description easy500, easy700 easy800, MFD…CP8…

I Input basic device x x R Input expansion device 1) x x Q Output basic device x x S Output expansion device x x ID Diagnosis annuciator easy-NET – x M Marker x x N Marker x – 5 P P button x x : : x x RN Bit input easy-NET – x SN Bit output easy-NET – x A Analogue value comparitor x x AR Arithmetic – x BC Block comparison – x BT Block transfer – x BV Boolean function – x C Counting relay x x CF Frequency counters x2) x CH High speed counter x2) x CI Incremental value counter – x CP Comparitor – x DB Data module – x D Text output x x DC PID controller, – x FT PT1 Signal smoothing filter – x GT Draw value out of the easy-NET – x Ö H/HW (clock)/Week time clock x x Y/HY Summer/winter changeover clock x x LS Value scaling – x Z/MR Master reset x x

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Operand Description easy500, easy700 easy800, MFD…CP8…

NC Number transducer – x O/OT Hours run counter x x PT Place value in the easy-NET – x PW Pulse width modulation – x SC Sychronise clock via network – x ST Reference cycle time – x T Time-delay relay x x VC Value limiting – x MB Marker byte – x 5 MD Marker double word – x MW Marker word – x I; IA Analogue input x x QA Analogue output – x 1) With easy700, easy800 and MFD…CP8… 2) With easy500 and easy700 programmable as operation type.

Coil functions The switching behaviour of the relay coil is Not used outputs Q and S can also be used as determined by the selected coil function. The markers like M and N. specified function should for each relay coil only be used once in the wiring diagram.

Circuit diagram symbol easy display Coil function Example

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

Å Contactor function with ÅQ1, ÅD2, inverse result ÅS4

è Cyclical impulse at èQ3, èM4, negative edge èD8, èS7

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Circuit diagram symbol easy display Coil function Example

È Cyclical impulse at ÈQ4, ÈM5, positive edge ÈD7, ÈS3

ä Surge function äQ3, äM4, äD8, äS7

S Latch (set) SQ8, SM2, 5 SD3, SS4

R Reset (reset) RQ4, RM5, RD7, RS3

Parameter sets for times Example based on EASY-512… T1 Relay No. Depending up on the programme the following I1 Time 1 parameters can be set: I2 Time 2 • Switching function, # Switch state output: • Time range, # Normally open contact open, • Parameter display, â Normally open contact closed •Time 1 and ü Switching function •Time 2. S Time range + Parameter display T1üS+ 30.000 constant as value, e. g. 30 s i1 30.000 I7 Variable, e. g. Analoge value I7 T:00.000 clock time i2 i7 # T:00.000

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

Parameter Switching function

X Switching with On-delay

?X Switching with On-delay and random time range

â Switching with Off-delay

?â Switching with Off-delay and random time range 5 Xâ Switching with On-delay and Off-delay

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

ü Switching with single pulse

Ü Switching with flashing

Parameter Time range and set time Resolution

S 00.000 Seconds: 0.000 to 99,999 s easy500, easy700 10 ms easy800, MFD…CP8… 5 ms

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

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

Parameter set Displaying the parameter set via menu item “Parameter”

+ Can be accessed

- Cannot be accessed

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Basic circuits

The easy circuit configuration is input in ladder Permanent contact diagram. This section includes a few circuit examples which are intended to demonstrate the To keep a relay coil possibilities for your own circuit diagrams. permanently ------ÄQ1 energised wire the The values in the logic table have the following connection meanings for switching contacts: completely across 0 = Normally open contact open, normally all contact areas closed contact closed from the coil to the 1 = Normally open contact closed, normally left hand side. closed contact open For relay coils Qx” Logic table 0 = Coil not energized --- Q1 5 1 = Coil energized Note 1 1 The examples are shown as for easy500 and easy700. For easy800 and MFD…CP8… four contacts and one coils can be used in each path.

Negation Negation means that the contact opens, rather than closes when actuated (NOT circuit). In easy circuit example contact I1 i1------ÄQ1 changes with the ALT button normally closed and normally open contacts. Logic table I1 Q1

1 0 0 1

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Series circuit Parallel switching Q1” is actuated Q1 is controlled via via three normally I1-I2-I3-ÄQ1 a parallel circuit of I1u------ÄQ1 open contacts several normally connected in series i1-i2-i3-ÄQ2 open contacts (OR I2s (AND circuit). circuit). I3k Q2” is actuated A parallel circuit of via three normally normally closed closed contacts contacts controls connected in series Q2 (NOR circuit). i1u------ÄQ2 (NAND circuit). i2s In the easy circuit configuration, up to three normally open or normally closed contacts can be i3k connected in series in one line. Where more than 5 three normally open contacts have to be wired in series, use an auxiliary relay M. Logic table Logic table I1 I2 I3 Q1 Q2 I1 I2 I3 Q1 Q2 0000 1 0000 1 1001 1 1000 0 0101 1 0100 0 1101 1 1100 0 0011 1 0010 0 1011 1 1010 0 0111 1 0110 0 1111 0 1111 0

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Changeover circuit Logic table A changeover I1 I2 Contact Coil Q1 circuit is realised in I1-i2u---ÄQ1 Q1 easy with two series circuits that are i1-I2k 000 0 then combined in parallel (XOR). 100 0 XOR means 010 0 eXclusive OR circuit. Only when a contact is closed, is the coil 110 1 energized. 101 0 Logic table 011 1 I1 I2 Q1 5 111 1 000 The hold-on (self-maintaining) circuit is used to 101 switch machines on and off. The machine is 011 switched on at the input terminals via normally open contact S1 and is switched off via normally 110 closed contact S2. S2 opens the connection to the control voltage in order to switch off the machine. This ensures that Hold-on circuit the machine can be switched off even in the event A combination of S1 normally open contact of a wire breaking. I2 is always closed when not series and parallel on I1 actuated. contacts are wired S2 normally closed Alternatively a S1 normally open contact to a hold-on circuit. contact on I2 hold-on circuit with on I1 The hold-on wire break S2 normally closed contact (self-maintaining) I1uI2----ÄQ1 monitoring can on I2 function is achieved used with the set by the Q1 contact Q1k and reset coil I1------SQ1 being connected in functions. parallel to I1. When i2------RQ1 I1 is actuated and reopened, the current flows via contact Q1 until I2 is actuated.

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When I1 is switched, coil Q1 latches. I2 inverts the On-delayed timing relay normally closed signal from S2 and switches when The on-delay can be S1 normally open contact S2 is actuated and the machine must be switched used to override a on I1 off or when there is a broken wire. short impulse or Keep to the order that each coil is wired in the with a machine, to I1------TT1 easy circuit diagram: first wire the “S”-coil, and start a further then the“R”-coil. When I2 is actuated, the operation after a T1------ÄM1 machine will then be switched off even if I1 is time delay. switched on again.

Impulse changeover relay An impulse S1 normally open contact changeover relay is on I1 often used for 5 lighting control e.g. I1------äQ1 stairway lighting.

Logic table I1 Status of Q1 Q1

00 0 10 1 01 1 11 0

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Wiring of contacts and relays Fixed wiring Wired with easy

t t

S1 S1 S2 K1

K1 S2

K1 P1 5

Star-delta starting With easy it is possible to implement two star and delta contactors, and also the time delay star/delta circuits. The advantage of easy is that it between switching off the star contactor and is possible to select the changeover time between switching on the delta contactor.

. L

S2 Q11

Q12 Q11 K1

Q13 Q12

K1 Q11 Q12 Q13 N

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L N S1

S2 Q11

LN I1

Q1 Q2 1 221

Q11 Q12 Q13 N

Operation of the easy circuit configuration Start/stop the circuit T1: Changeover time star/delta (10 to 30 s) with the external I1u------TT1 T2: Waiting time between starcontactor off and pushbuttons S1and delta contactor on (30, 40, 50, 60 ms) S2. The mains dt1----ÄQ1 If your easy has an integral time switch, star/delta protection starts the dT1----TT2 starting can be combined with the time switch. In time relay in easy. this case, use easy to also switch the mains I1: Mains hT2----ÄQ2 contactor. protection switched on Q1: Star contactor ON Q2: Delta contactor ON

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Stairway lighting For a conventional circuit a minimum of five easy needs only four elements. With five elements are required. An impulse relay, two connections and the easy circuit the stairway timing relays, two auxiliary relays. lighting is operational.

S2 E1

E2 S3 E3 5 L N

K3 K1 Q12 Q12

Q11 K3 K2

K1 K2 K3 Q11 Q12 5 s 6 min

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

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S2 E1

E2 S3 E3

L N K1 5 L N I1

Q1 1 2

Button pressed briefly Light On or Off, the impulse changeover relay function is able to switch off continuous lighting where required. Light Off after 6 min. Switched off automatically. With continuous lighting this function is not active. Button pressed for longer than 5 s Continuous lighting

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The easy circuit configuration for the function Meaning of the contacts and relays used: below looks like this: I1: Pushbutton ON/OFF Q1: Output relay for lighting ON/OFF M1:Auxiliary relay used to block the “switch off I1------TT2 automatically after 6 minutes” when using T2------SM1 continuous lighting. T1: Cyclical impulse for switching Q1 ON/OFF, (ü , I1u------äQ1 impulse with value 00.00 s) T3k T2: Scan to determine how long the pushbutton was pressed. When pressed for longer than Q1-m1----TT3 5 s, it changes to continuous lighting. (X , On-delayed, value 5 s) q1------RM1 T3: Switch off after the light has been on for von 6 min. (X , on-delayed, value 6:00 min.) 5 T4: Switch off after 4 hours continuously on. (X , Expanded easy circuit configuration: after four On-delayed, value 4:00 h) hours, the continuous lighting is switched off.

I1------uTT1 hTT2 T2------SM1 T1u------äQ1 T3s T4k Q1um1----TT3 h------TT4 q1------RM1

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4 way shift register A shift register can be used for storing an item of Function: information – e.g. sorting of items into “good” or Pulse Value Storage position “bad” – two, three or four transport steps further on. 1 2 3 4 A shift pulse and the value (0” or 1”) to be shifted are required for the shift register. 111 0 0 0 Values which are no longer required are deleted via the reset input of the shift register. The values 200 1 0 0 in the shift register pass through the register in the 300 0 1 0 following order: 1st, 2nd, 3rd, 4th storage position. 411 0 0 1 Block diagram of the 4-way shift register 500 1 0 0 5 abc Reset = 1 0 0 0 0 d Allocate the value 0 with the information content bad. Should the shift register be accidently 1234 deleted, no bad parts will be reused. I1: Shift clock pulse (PULSE) I2: Information (good/bad) for shifting (VALUE) a Pulse I3: Delete contents of shift register (RESET) b Value M1:1. memory position c Reset M1:2. memory position d Storage position M1:3. memory position M1:4. memory position M7:Auxiliary relay one shot cycle pulse M8:One shot cycle pulse clock pulse

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I1um7----ÄM8 Generate shift tact h------ÄM7 M8uM3----SM4 4th memory position, set dm3----RM4 4th memory position, delete dM2----SM3 3rd memory position, set dm2----RM3 3rd memory position, delete 2nd memory position, set dM1----SM2 2nd memory position, delete dm1----RM2 1st memory position, set dI2----SM1 1st memory position, delete hi2----RM1 5 Delete all memory positions I3------uRM1 dRM2 dRM3 hRM4

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Display text and actual values , display and edit set values easy500 and easy700 can display 16, easy800 can display 32 freely editable texts. In these texts SWITCHING; actual values of function relays such as, timer relays, counters, hours run counters, anolog value CONTROL; comparitors, dates, times or analog values can be DISPLAY; displayed. Set values of timer relays, counters, hours run counters and analog value comparitors ALL EASY! can be altered during the display of the texts. Example of a text display: The text display has the following display characteristics: 5

RUN TIME M:S Line 1, 12 characters T1 :012:46 Line 2, 12 characters, one actual value or set value C1 :0355 ST Line 3, 12 characters, one actual value or set value PRODUCED Line 4, 12 characters

The text output unit D (D = Display,) functions in D2 to D16/D32 are displayed when activated. the circuit diagram like a normal marker M. When several displays are activated they are Should a text be attached to a marker this would shown one after the other every 4 secs. When a be shown at condition 1 of the coil in the easy set value is edited the corresponding display display. A precondition is that the easy is in RUN remains shown until the value transfer. mode and before the texts are displayed the status In one text several values, actual and set values, display is shown. from for example, function relays, analog input D1 is defined as alarm text and has therefore values or times and dates can be combined. The priority over other displays. set values can be edited: • easy500 and easy700, two values, • easy800, four values.

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Visualisation with MFD Titan The visualisation with MFD-Titan is by “screens”, • Pushbutton elements on which the display is shown. – Latching pushbuttons Example of a “screen”: – Pushbutton area • Text elements – Static text – Message text S1 S2 – Screen menu S3 – Ticker text – Rolling text • Value display elements – Date and time displays M 3 h – Number values – Timer relay value display 5 • Value input elements The following screen elements can be combined. – Value inputs • Graphic elements – Timer relay value inputs – Bit display – Date and time inputs – Bitmap – Weekly timer inputs – Bargraph – Yearly timer inputs

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Rated Max. AC-3 motor rating Conv. Part no. opera- therm. tional 220 V, 380 V 660 V, 1000 V current 230 V ,400 V 690 V current Ie Ith = Ie at 400 V AC-1 A kWKWkWkWA 6.6 1.5 3 3 – 22 DILEEM 8.8 2.2 4 4 – 22 DILEM 7 2.2 3 3.5 – 22 DILM7 9 2.5 4 4.5 – 22 DILM9 5 12 3.5 5.5 6.5 – 22 DILM12 17 5 7.5 11 – 40 DILM17 25 7.5 11 14 – 45 DILM25 32 10 15 17 – 45 DILM32 40 12.5 18.5 23 – 60 DILM40 50 15.5 22 30 – 70 DILM50 65 20 30 35 – 85 DILM65 80 25 37 63 – 130 DILM80 95 30 45 75 – 130 DILM95 115 37 55 105 – 190 DILM115 150 48 75 125 – 190 DILM150 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 1000 1000 DILM1000

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Auxiliary contact blocks Part no. For top For side mounting Motor Electronic mounting overload motor relay protection system ZEV

DILEEM 02DILEM – ZE-0,16 to 11DILEM ZE-9 DILEM 22DILEM DILM7 DILA-XHI(V) – ZB12-0,16 to … ZB12-12 DILM9 DILM32-XHI DILM12 … ZB32-0,16 to 5 ZB32-32 DILM17 DILM25 DILM32 DILM40 DILM150XHI( DILM1000-XHI(V) ZB65-10 to ZEV V)… … ZB65-65 + DILM50 ZEV-XSW-25 DILM65 ZEV-XSW-65 ZEV-XSW-145 DILM80 ZB150-35 to ZEV-XSW-820 ZB150-150 DILM95 DILM115 DILM150 DILM185 – DILM1000-XHI… Z5-70/FF250 to DILM225 Z5-250/FF250 DILM250 DILM300 ZW7-63 to ZW7-630 DILM400 DILM500 DILM580 DILM650 DILM750 – DILM820 DILM1000

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Accessories

Unit DILE(E)M DIL7 to DILM150 DILM185 DILM580 to to DILM1000 AC DC DILM500

Suppressor circuits – – integrated integrated integrated RC suppressors X X Varistor suppressors X X Star-point bridge X X X X – Parallel connector X X X to – 5 DILM185 Mechanical inter- X X X X X lock Sealable shroud X – – – – Cable terminals – – – X to DILM820 Individual coils – X1) X1) X X Electronic modules – – – X X Electronic modules – – – X X including coils Terminal cover – – – X X 1) from DILM17

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Contactors DILM These are designed and tested to IEC/EN 60 947. sections and have protection against incorrect For every motor rating between 3 kW and insertion to ensure safe connection. 560 kW there is a suitable contactor available. • Integrated auxiliary contact The contactors up to DILM32 have an Equipment features integrated auxiliary contact as normally open or normally closed contact. • Magnet system • Screw or spring terminals Due to the new electronic operation the DC The contactors DILE(E)M and DILA/DILM12, contactors from 17 to 65 A have a sealing including the corresponding auxiliary contacts, power of only 0.5 W. Even for 150 A is only up to 1000 A, are available with screw or spring 1.5 W necessary. terminals. • Accessible control voltage connections • Contactors with screwless terminals The coil connections are on the front of the They have spring terminals in the mains current contactor. They are not covered by the main circuit as well as for the coil terminals and 5 current wiring. auxiliary contacts. The shake proof and • Can be controlled directly from the PLC maintenance free spring terminals can The contactors DILA and DILM to 32 A can be terminate two conductors each of 0.75 to controlled directly from the PLC. 2.5 mm2 with or without ferrules. • Intergrated suppressor DC • Connection terminals With all DC contactors DILM a suppressor is Up to DILM65 the connection terminals for all integrated in the electronics. auxiliary contacts and coils as well as for main • Plug-in suppressors AC conductors can be tightened with a Pozidriv With all AC contactors DILM up to 150 A a screwdriver size 2. suppressor can be simply plugged in on the For contactors DILM80 to DILM150 Allen front when required. screws are used. • Control of the contactors DILM185 to • Mounting DILM1000 by three different methods: All contactors can be fitted on to a mounting – Conventionally via coil terminals A1-A2 plate with fixing screws. DILE(E)M and DILM up – Directly from a PLC via terminals A3-A4 to 65 A can also be snapped on to a 35 mm – by a low power contact via terminals top-hat rail to IEC/EN 60715. A10-A11. • Mechanical interlock • Conventional control of contactors DILM185-S With two connectors and a mechanical interlock to DILM500-S via coil terminals A1-A2. an interlocked contactor combination up to There are two coil versions (110 to 120 V 150 A can be achieved without extra space 50/60 Hz and 220 to 240 V 50/60 Hz) available. requirement. The mechanical interlock ensures • All contactors up to DIL150 are finger and that both connected contactors cannot be back-of-hand proof to IEC 536. Additional similtaneously be operated. Even with a terminal covers are available from DILM185 mechanical shock the contacts of both onwards. contactors cannot close similtaneously. • Double-frame terminal for contactors DILM7 to DILM150 With the new double frame-clamp the connection area is not limited by the screw. They give total security with varying cross

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In addition to individual contactors, complete Physical motor design results in that rated currents contactor combinations are also available from for the same rating sometimes differ widely. Moeller: Furthermore it determines the ratio of the • DIUL reversing contactors from 3 to transient peak current and the locked-rotor 75 kW/400 V current to the rated operational current (Ie). • SDAINL star-delta starters from 5.5 to 132 Switching electrical heating installations, lighting kW/400 V fittings, transformers and power factor correction installations, with their typical individual Application characteristics, increases the wide range of different uses for contactors. The three-phase motor dominates the electric The switching frequency can vary greatly in every motor sector. Apart from individual low-power application. The difference can be, for example, drives, which are often switched directly by hand, from less than one operation per day up to a most motors are controlled using contactors and thousand operations or more per hour. Quite contactor combinations. The power rating in 5 often, in the case of motors, a high switching kilowatts (kW) or the current rating in amperes (A) frequency coincides with inching and plugging is therefore the critical feature for correct duty. contactor selection. Contactors are actuated by hand 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 DILNM 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.

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Contactor DILP DILP contactors are used for problem-free order to switch the neutral pole as well in special switching of supply systems including the neutral applications. pole or for economical switching of resistive loads. In the area of 4 pole applications, there are In three-phase distribution systems, mainly 3 pole national differences concerning the Standards switchgear and protective devices are used. 4 pole situation, the customary distribution system and switchgear and protective devices are used in conventions that go beyond the Standards. Rating data max. rated operational current Ie AC-1 open conv. therm. current

40 °C 50 °C 70 °C Ith = Ie AC-1 Part no. 5 open

160 A 160 A 155 A 160 A DILP160/22 250 A 230 A 200 A 250 A DILP250/22 315 A 270 A 215 A 315 A DILP315/22 500 A 470 A 400 A 500 A DILP500/22 630 A 470 A 400 A 630 A DILP630/22 800 A 650 A 575 A 800 A DILP800/22

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Motor protection using Z thermal overload relays Overload relays are included in the group of Tripping occurs when the reference temperature is current-dependent protective devices. They reached. The tripping delay depends on the monitor the temperature of the motor winding magnitude of the current and preloading of the indirectly via the current flowing in the supply relay. Whatever the current, the relay must trip out cables, and offer proven and cost-efficient before the motor insulation is endangered, which protection from destruction as a result of: is why EN 60947 states maximum response times. • Non starting, To prevent nuisance tripping, minimum times are • Overload, also given for the limit current and locked-rotor • Phase-failure. current.

Overload relays operate by using the characteristic Phase-failure sensitivity changes of shape and state of the bimetal when Overload relays Z offer, due to their design, an 5 subjected to heating. When a specific temperature effective protection against phase failure. They is reached, they operate an auxiliary contact. The have phase failure sensitivity to IEC 947-4-1 and heating is caused by resistances through which therefore can also provide protection for EEx e the motor current flows. The equilibrium between motors (a following diagramms). the reference and actual value occurs at various temperatures depending on the magnitude of the current. ቤ S 97 95 97 95 97 95 ቢ 98 96 98 96 98 96

ባ

Normal operation (no fault) Three phase overload One phase drops out a Trip bridge b Differential bar c Differential travel

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When the bimetallic strips in the main current This differential movement is converted in the section of the relay deflect as a result of device by a step-up mechanism into a three-phase motor overloading, all three act on a supplementary tripping movement, and thus trip bar and a differential bar. A shared trip lever accelerates the tripping action. switches over the auxiliary contact when the limits are reached. The trip and differential bars lie Design note a section “Motor protection in against the bimetallic strips with uniform special applications”, page 8-7; pressure. If, in the event of phase failure for Further information to motor protection instance, one bimetallic strip does not deflect (or a section “All about Motors”, page 8-1. recover) as strongly as the other two, then the trip and differential bars will cover different distances.

Tripping characteristics The overload relays ZE, ZB12, ZB32 and the Z5 up These tripping characteristics are mean values of 5 to 150 A are, due to the German the scatter bands at an ambient temperature of Physical/Technical Bureau (PTB), suitable for 20 °C from cold. The tripping time is dependant protection of EEx e-motors to the upon the current. When units are warm, the ATEX-Guidelines 94/9 EG. In the relevant manual tripping delay of the overload relay drops to about all tripping characteristics are printed for all a quarter of the value shown. currents.

2h 2h 100 100 Z5 60 60 40 40 20 20 10 10 6 Minutes Minutes 6 4 4 2 2 1 1 40 40 3-phase 3-phase 20 20 10 10 6 6

Seconds 4 4 2-phase Seconds 2-phase 2 2 1 1 0.6 0.6 1 1.5 2 3 4 6 8 1015 20 1 1.5 2 3 4 6 8 1015 20 x Setting current x Setting current

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2 h 100 ZW7 60 40 20 10

Minutes 6 4 2 1 Maximum 40 20 10 Minimum 6 4 Seconds 5 2 1 0.6 1 1.5 2 3 4 6 8 10 15 20 x Setting current

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Method of operation and control Like overload relays operating on the bimetallic With direct measurement, the temperature in the strip principle, electronic motor-protective relays motor winding is detected by means of one or are current-dependent protective devices. more PTC thermistors. In the event of excessive The acquisition of the actual flowing motor temperature rise, the signal is passed to the current in the three external conductors of the tripping unit and the auxiliary contacts are motor connections is with motor protection actuated. A reset is not possible until the system ZEV with seperate push-through sensors or thermistors cool to less than the response a sensor belt. These are combined with an temperature. The built-in thermistor connection evaluation unit so that seperate arrangement of allows the relay to be used as complete motor the current sensor and the evaluation unit is protection. possible. In addition, the relay protects the motor against The current sensor is based on the Rogowski earth faults. Small currents flow out even in the principle from the measurement technology. . The event of minor damage to the motor winding 5 sensor belt has no iron core, unlike a current insulation. These earth faults currents are transformer, therefore it doesn´t become registered on an external summation current saturated and can measure a very wide current transformer which adds together the currents in range. the phases, evaluats them and reports earth-fault Due to this inductive current detection, the currents to the microprocessor in the relay. conductor cross-sections used in the load circuit By selecting one of the eight tripping classes have no influence on the tripping accuracy. With (CLASS) allows the motor to be protected to be electronic motor-protective relays, it is possible to adapted from normal to extended starting set higher current ranges than is possible with conditions. This allows the thermal reserves of the electromechanical thermal overload relays. In the motor to be used safely. ZEV System, the entire protected range from 1 to The motor-protective relay is supplied with an 820 A is covered using only an evaluator . auxiliary voltage. The evaluator has a The ZEV electronic motor-protective system carries multi-voltage version, which enables all voltages out motor protection both by means of indirect between 24 V and 240 V AC or DC to be applied temperature measurement via the current and as supply voltage. The devices have monostable also by means of direct temperature measurement behaviour; they trip out as soon as the supply in motors with thermistors. voltage fails. Indirectly, the motor is monitored for overload, phase failure and unbalanced current consumption.

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In addition to the usual normally closed contact Tripping in the event of a three-pole balanced (95-96) and the normally open contact (97-98) for overload at x-times the set current takes place overload relays the motor protection relay ZEV is within the time specified by the tripping class. The equipped with a programmable normally open tripping delay in comparison with the cold state is contact (07-08) and a programmable normally reduced as a function of the preloading of the closed contact (05-06). The above mentioned, motor. Very good tripping accuracy is achieved usual contacts react directly via thermistors or and the tripping delays are constant over the indirectly via the current, to the detected entire setting range. temperature rise of the motor, including If the motor current imbalance exceeds 50 %, the phase-failure sensitivity. relay trips after 2.5 s. The programmable contacts can be assigned to The accredition exists for overload protection of various signals, such as explosion proof motors of the explosion protection • Earth-fault, “increased safety” EEx e to guideline 94/9/EG as • Pre-warning at 105 % thermal overload, well as the report of the German 5 • separate indication of thermistor tripping Physical/Technical Bureaux (PTB report ) • internal device fault (EG-Prototype test certificate number PTB 01 The function assignment is menu-guided using a ATEX 3233). Further information can be found in display. The motor current is entered without tools the manual AWB2300-1433D “Motor protection using the keypad, and can be clearly verified on system ZEV, overload monitoring of motors in the display. EEx e areas”. In addition the display allows a differential diagnosis of tripping causes, and therefore a faster error handling is possible.

Electronic motor protection system ZEV

Evaluation device Push-through sensor Sensor belt 1 to 820 A 1 to 25 A 40 to 820 A 3 to 65 A 10 to 145 A

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Tripping characteristics Tripping characteristics for 3 phase loads These tripping characteristics show the 2h ZEV 3 pole relationship between the tripping time from cold 100 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 15 10 associated with it, the stated tripping delays are reduced to approx. 15 %. Minutes 5 CLASS 40 2 35 30 1 25 20 20 10 7 15 5 10 5 Seconds 3 CLASS 5 2 1 1 2 58643 7109 x Setting current

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

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Electronic motor protection sytem ZEV with earth-fault monitoring and thermistor monitored motor

L1 L2 L3 N PE f Z1 S1 e Z2 S2 Q11

Q11 C1 C2 A1 A2 PE 95 97 05 07

~ Reset = 5 a

L1 L2 L3 A d IµP b D % Class c

T1 < Mode Up M 3~ T2 Test Down > Reset

96 98 06 08 Q11

a Fault e Self hold-in of the contactor prevents an b Programmable contact 1 automatic re-start after the control voltage c Programmable contact 2 has failed and then returned (important for d Current sensor with A/D transducer EEx e applications, a AWB2300-1433D) f Remote reset

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Thermistor protection temperature sensors with a thermistor resistance F O F O With thermistor motor protection, to DIN 44081 of RK 250 or nine with a RK 100 can be and DIN 44082, up to six PTC thermistor connected to terminals T1-T2. R [ ] 12000

dc 4000 5 a 1650 b 750

T [ ˚ C] TNF TNF TNF TNF TNF –20˚ –5˚ +5˚ +15˚

TNF= Nominal response temperature input the contacts 95-96 and 97-98 switch over. a Tripping range IEC 60947-8 Additionally, the thermistor trip can be b Re-switch on range IEC 60947-8 programmed to different trip messages on c Tripping at 3200 Og15 % contacts 05-06 or 07-08. d Re-switch on at 1500 O +10 % With temperature monitoring with thermistors, no dangerous condition can occur should a sensor fail The ZEV switches off at R = 3200 Og15 % and as the device would directly switch off. switches on again at R =1500O +10 %. With switch off due to thermistor

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

L1 L2 L3 N PE a Z1 S1 Z2 S2 Q11 S3 Q11 C1 C2 A1 A2 PE 95 97 05 07

~ Reset = 5

L1 L2 L3 A IµP D % Class

T2 < Mode Up M 3~ T1 Test Down > Reset

96 98 06 08

IN1 IN2 IN3 11 Q11

K1 M

A1 A2 12 14

Short-circuit in the thermistor circuit can, when • Total PTC thermistor sensor resistance required, be detected by the additional use of a F 1500 O current monitor K1 (e. g. type EIL 230 V AC from • Programming ZEV: “Auto reset”, the company Cronzet or the similar type • Setting current monitor: 3U6352-1-1AL20 from the company Siemens). – Device to lowest current level, Basic data – Overload tripping, • Short-circuit current in the sensor circuit F – Store the tripping, 2.5 mA, • Confirmation of the short-circuit after clearing • max. cable length to sensor 250 m with pushbutton S3. (unscreened),

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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 1 the mounting instructions AWA2300-1694 or the 2 manual AWB2300-1433D. 3 Mounting ZEV and current sensor

1 Wrap the band around the current 5 conductors. 2 Engage the fixing pin. 3 Pull the fixing band tight and close with the velcro fastener. Attaching the sensor coils a following diagram. • Place the ZEV in the desired mounting position. • Click the ZEV on the current sensor. • Position motor conductors through the current sensor. Mounting on the current conductors Due to the fixing band the Rogowski sensor ZEV-XSW-820 is particularly easy to mount. And this saves the user time and money.

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EMT6 for PTC thermistors

L 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. A1 21 13 The EMT6-K(DB) and EMT6-DBK are fitted with a Power Tripped short-cicuit in sensor circuit monitor. Should the US resistance in the sensor circuit fall below 20 Ohm 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 5 A2 T1 T2 22 14 only after the fault has been rectified and the control voltage is present again. PTC Since all the units use the closed-circuit principle, N they also respond to a broken wire in the sensor circuit. The thermistor machine protection relays EMT6… L are accredited for protection of EEx e motors to ATEX-Guideline 94/9 EG by the German Physical/Technical Bureaux. For protection of EEx e motors the ATEX Guidelines require short-circuit monitoring in the sensor circuit. Because of their integrated short-circuit A1 21Y2Y1 13 monitoring the EMT6-K(DB) and EMT6-DBK are Power Tripped especially suitable for this application. US Reset +24 V

A2 T1 T2 22 14 PTC

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

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EMT6 as contact protection relay

3 400 V 50 Hz Application example L1 Control of a storage tank heater L2 L3 a Control circuit N b Heater Q11: Heater protection -Q1

I > I > I > L1 a

A1 1 3 5 -Q11 A2 246 5

UVW

b 400 V 50 Hz

Description of operation Switching on the heater Switching off the heater The heater can be switched on provided the main The heater protection Q11 stays in self maintain switch Q1 is switched on, the safety thermostat F4 until the main switch Q1 is switched off, the has not tripped and the condition T F Tmin is pushbutton S0 is pressed, the thermostat trips or satisfied. When S1 is actuated, the control voltage T = Tmax. is applied to the contactor relay K1, which When T = Tmax the changeover contact of the maintains itself via a make contact. The contact thermometer has the position I-III. The changeover contact of the contact thermometer sensor circuit of the EMT6 (K3) is low resistance, has the position I-II. The low resistance sensor the normally closed contact K3/21-22 open. The circuit of the EMT6 guarantees that Q11 is main protection Q11 drops out. actuated via K2 normally open contact 13-14; Q11 goes to self-maintain.

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Safety against broken wires

Security against wire break in the sensor circuit of when Tmax is exceeded it´s normally closed contact K3 (e.g. non-recognition of the limit value Tmax) is F4 switches off so that “switch off by guaranteed by the use of a safety thermostat that deenergisation” is carried out. 230 V 50 Hz 13 L1 14 -K1 4AF -F1

13 13 -S0 -K2 -Q11 14 14

-S1 -K1 5 -F4 a II III 21 -K3 22

A1 X1 T1 T2 A1 T2 T1 A1 A1 -K1 - H1 -K2 -K3 -Q11 A2 X2 EMT6 A2 EMT6 A2 A2 23 N 24

a Contact thermometer change over contact K1: Control voltage "On" I-II position at T F Tmin K2: switch on at T F Tmin I-III position at T F Tmax K3: switch off at Tmax S0: Off S1: Start F4: Safety thermostat

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Application

The electronic safety relay is used for monitoring Function safety relevant controls. The requirements for the electrical equiping of machines is defined in After switch on, in failure free operation the safety IEC/EN 60204. The machine operater must assess relevant circuit is controlled via the electronics and the risk on his machine to EN 954-1 and install the using a relay the switching circuit is switched on. controls to the necessary safety category 1, 2, 3 After switch off and in the case of a failure or 4. (earth-fault, short-circuit, wire break) the switching circuit is immediately (stop category 0) or delayed (Stop category 1) switched off and the Surface mounting motor isolated from the mains supply. The electronic safety relay consists of a mains unit, In redundant safety circuits a short-circuit is not the electronics and two redundant relays with dangerous, so that only by renewed switch on is forced contacts for the switching and indication the failure recognised and re-switch on is blocked. circuits. 5 Further information sources Mounting instructions • Evaluation device for two handed switching ESR4-NZ-21, AWA2131-1743 13 23 24 37 • Basic device for emergency and safety barrier A1 S33 S34 S35 apllications – ESR4-NV3-30, ESR4-NV30-30, AWA2131-1838 – ESR3-NO-31 (230V), AWA2131-1740 POWER – ESR4-NO-21, ESR4-NM-21, AWA2131-1741 – ESR4-NO-30, AWA2131-2150 K1 K3 K2 K4 – ESR4-NT30-30, AWA2131-1884

1 1.5 • Basis device for emergency applications .5 2 ESR4-NO-31, AWA2131-1742 .3 2.5 .15 3 • Emergency relay ESR4 -NV3-30 ESR4-NE-42, ESR4-VE3-42, AWA2131-1744

Safety manual , TB0-009D

S21 S22 S31 A2 Main catalogue Industrial Switchgear, Section 4 14 S11 S12 38 “monitoring relays”.

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General For the various applications measurement amd Selected bridging of short current peaks monitoring relays are necessary. With the new By using the selected time delay of between 0.05 EMR4 range Moeller covers a large number of and 30 s short current peaks can be bridged. requirements : • general use, current monitor EMR4-I Phase monitoring relay EMR4-W • 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 5 • increased safety by motor current principle , level relay EMR4-N • increase of the operational safety, insulation monitoring relay EMR4-R The phase monitoring relay EMR4-W monitors as well as the field rotation also the voltage height. Current monitoring relay EMR4-I That means protection against destruction or damage of single system parts. Here the minimum low voltage and also the maximum over voltage can be easily set, within a defined range, to the required voltage. Also a delayed on or a delayed off can be set. In the delayed on position short voltage breaks can be bridged. The delayed off position allows for a failure storage for the set time. The delay time can be set between 0.1 und 10 s. The current monitoring relay EMR4-I is suitable for The relay activates with the correct rotation and the monitoring of AC as well as DC current. Pumps voltage. After drop-out the device reactivates and drill machines can be monitored for low load when a the voltage exceeds a 5 % hysteresis. or overload. 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 for a direct feedback.

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Phase sequence relay EMR4-F500-2 Level monitoring relay EMR4-N

With the only 22.5 mm wide phase sequence The level monitoring relay EMR4-N is used mostly relay, portable motors, by which the direction of as dry running protection for pumps or for level rotation is important (e. g. pumps, saws, drills), regulation of liquids. It operates with sensors that can be monitored for correct rotation. That means measure conductivity. A sensor is required for the 5 space in the switchboard due to the narrow width maximum and also a sensor for the minimum and protection against damage due to the level. A third sensor is used for earth potential. monitoring of the rotating field. The 22.5 mm wide device EMR4-N100 is suitable With correctly rotating field the changeover for conductive liquids. It can be switched from contact switches the control voltage of the motor level regulation to dry running protection. The switching device. The EMR4-F500-2 covers the safety is increased as in both cases the motor total voltage range from 200 to 500 V AC. current principle is used.

Phase imbalance relay EMR4-A

The level monitoring relay EMR4-N500 has an increased sensitivity and is suitable for less The 22.5 mm wide phase imbalance relay is the conductive liquids. Due to an integrated rise and correct protection device against phase failure. fall delay of between 0.1 and 10 s moving liquids The motor is then protected against destruction. can also be monitored. That the phase failure is monitored on the basis of phase displacement can be recognised with a higher motor feedback and an overload of the motor can be prevented. The relay is able to protect motors with a rated voltage of Un = 380 V, 50 Hz.

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Insulation monitoring relay EMR4-R Further information sources Mounting 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 EN 60204 “Safety of machines” provides AWA2431-1863 increased operational safety by the monitoring of • Phase monitoring relay EMR4-W… the control voltage circuit for earth-fault using an 5 AWA2431-1863 insulation monitor. This is the main application for • Current monitoring relay EMR4-I… the EMR4-R. There are similar requirements in AWA2431-1862 medically used areas. An earth-fault is signalled via a changeover contact so that a fault can be Main catalogue Industrial Switchgear, Section 4 cleared without expensive down time. “monitoring relays”. The device has a selectable fault memory so that the fault must be acknowledged after it´s removal. By the use of a Test button the device can be checked for correct operation at any time. AC or DC control voltage There is a device for AC and also DC. Therefore the total control voltage range is covered. The DC device has a multi-voltage source. Therefore AC as well as DC is possible.

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Definition Motor-protective circuit-breakers are winding (overload protection) and an circuit-breakers used for switching, protection and electromagnetic release (short-circuit protection). isolation of circuits primarily associated with The following accessories can be fitted to motor loads. At the same time, they protect these motor-protective circuit-breakers: motors against destruction from locked-motor • Undervoltage release, starting, overload, short-circuit and phase-failure • Shunt release, in three-phase power supplies. They have a • Auxiliary contact, thermal release for protection of the motor • Trip-indicating auxiliary contact.

Moeller motor-protective circuit-breakers PKZM01 The major system modules are: The motor-protective circuit-breaker PKZM01 • Motor-protective circuit-breakers reintroduces the pushbutton actuation up to 16 A • Transformer-protective circuit-breakers which was very popular with customers. The • (High-capacity) contact modules mushroom actuator for Emergency-Stop operation 6 Description a section “The motor-protective on simple machines is also being reintroduced. circuit-breakers PKZM01, PKZM0 and PKZM4”, The PKZM01 is preferably installed in page 6-4. surface-mount or flush-mount enclosures. Many accessory parts from the PKZM0 can be used. PKZ2 Major system module: motor-protective PKZ2 for motor and distribution circuit protection circuit-breaker The PKZ2 is a modular and efficient system for protecting, switching, signalling and remote PKZM4 operation of motors and systems in low-voltage The PKZM4 system is a modular and efficient switchgear systems up to 40 A. system for switching and protecting motor loads up to 63 A. It is the “big brother” of the PKZM0 The major system modules are: and can be used with almost all PKZM0 accessory • Motor-protective circuit-breakers parts. • System-protective circuit-breakers Major system modules: motor-protective • (High-capacity) contact modules circuit-breakers Description a section “Motor and system PKZM0 protection”, page 6-16. The PKZM0 motor-protective circuit-breaker is a modular and efficient system for switching and protecting motor loads up to 32 A and transformers up to 25 A.

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PKZM01 PKZM0 PKZM4 PKZ2 circuit-breaker circuit-breaker circuit-breaker circuit-breaker

In surface mounting enclosure PKZM0 PKZ2 compact starter compact starter 6

MSC-D MSC-R direct-on-line starter reversing starter

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The motor-protective circuit-breakers PKZM01, PKZM0 and PKZM4 The PKZM01, PKZM0 and PKZM4 use bimetallic sensitivity of PKZM0 and PKZM4 allows for the releases which are delayed depending on the use in the protection of EEx e motors. An ATEX magnitude of the current to offer a proven, certificate has been awarded. The technical solution for motor protection. The motor-protective circuit-breakers are set to the releases are sensitive to phase failure and are rated motor current in order to protect the motors. temperature-compensated. The rated current with The following accessories complement the the PKZM0 up to 32 A is split into 15 ranges, for motor-protective circuit-breaker for the various the PKZM01 it is split into 12 ranges and for the secondary functions: PKZM4 up to 63 A into 7 ranges. The installation • Undervoltage release U, (motor) and the supply cable are reliably protected • Shunt release A, x by short-circuit releases, permanently set to 14 • Standard auxiliary contact NHI, Iu. The motor start is also guaranteed in every • Trip-indicating auxiliary contact AGM. operational situation. The single-phasing

The compact starter 6 It consists of the motor-protective circuit-breaker to be capable of immediate switch on even after a PKZM0 and the contact module SE00-...-PKZ0 short-circuit of up to 100 kA/400 V. which can be attached and features identical The compact starters and high-capacity compact contours. It has been developed for standard starters from the PKZ2 are available for motor applications such as switching and protection of a ratings of more than 4 kW/400 V (up to cooling water pump or a similar application, and 18.5 kW/400 V, or the combination of PKZM4 complies to the latest motor starter standards: with the proven contactor DIL. • IEC/EN 60 947-4-1 •&$§ •&$§ Whereas the motor-protective circuit-breaker PKZM0 guarantees the disconnection, short-circuit and overload protection tasks, the contact module (contactor) S(E)00-...-PKZ0 assumes the operational switching of the motor current. The compact starter can master a short-circuit current of 100 kA at 4 kW and 400 V. While the compact starter represents an economic solution for standard tasks, the high-capacity compact starter was developed specifically for switching and protection of motors in critical processes. This refers to motors whose failure would involve severe consequential costs. In order to guarantee the highest possible level of system availability, the high-capacity compact starter is comprised of the motor-protective circuit-breaker PKZM0 and the weld-free high-capacity contact module (contactor) S00-...-PKZ0. It is guaranteed

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Motor starter combinations The motor-starter combinations MSC are available The motor-starter combination MSC from 16 A up to 32 A. Motor starters up to 12 A consist of a consists of a motor-protective circuit-breaker motor-protective circuit-breaker PKZM0 and a PKZM0 and a contactor DILM. Both are fitted to a contactor DILM. Both are connected by a tool-less top-hat rail and mechanically and electrically mechanical connection element. Furthermore, a interconnected by a connector element. plug-in electrical connector is used to establish the The MSC is available as a direct-on-line starter connection with the main circuit wiring. The MSC-D and as a reversing starter MSC-R. motor-protective circuit-breaker PKZM0 and the contactor DILM up to 12 A feature the respective interfaces for this purpose.

Motor-protective circuit-breakers for starter combinations PKM0 for protection of resistive loads where no The PKM0 motor-protective circuit-breaker is a overloading is to be expected. protective switch for starter combinations or for These protective switches are also used in 6 use as a basic unit in a short-circuit protective motor-starter combinations with and without switch in the range 0.16 A to 32 A. The basic unit automatic reset, where an overload relay or a is without overload release, but equipped with thermistor overload relay is used as well. short-circuit release. This circuit-breaker is used

Transformer-protective circuit-breaker and current limiter PKZM0-T CL-PKZ0 The transformer-protective circuit-breaker is The current limiter module CL-PKZ0 is a designed for protecting transformer primaries. The short-circuit protective device specially developed short-circuit releases in the types from 0.16 A to for the PKZM0 and PKZM4 for 25 A are permanently set to 20 x Iu. The response non-intrinsically-safe areas. The CL module has ranges of the short-circuit releases are higher here the same base area and uses the same than with motor-protective circuit-breakers in termination's as the PKZM0. When they are order to cope with the even higher inrush currents mounted on a top-hat rail alongside one another, of idling transformers without tripping. The it is possible to connect them by means of overload release in the PKZM0-T is set to the rated B3...-PKZ0 three-phase commoning links. The current of the transformer primary. With the switching capacity of the series connected PKZM0 exception of the S00-...-PKZ0 high-capacity or PKZM4 + CL is 100 kA at 400 V. In a contact module, all the PKZM0 system accessories short-circuit the contacts of the motor-protective can be combined with the PKZM0-T. circuit-breaker and CL will open. While the current PKZM0-...-C limiter returns to the closed rest position, the The PKZM0 features a version with springloaded motor-protective circuit-breaker trips via the terminals. A version with springloaded terminals instantaneous release and produces a permanent on both sides, and a combined version which isolating gap. The system is ready to operate features springloaded terminals on the outgoer again, once any defect has been rectified. The side only can be chosen. The conductors can be current limiter can conduct an uninterrupted connected here without ferrules. The connections current of 63 A. The module may be used for are maintenance-free. individual or group protection. Any feed direction may be used. For Immediate Delivery call KMParts.com at (866) 595-96166-5 Moeller Wiring Manual 02/05 Motor-protective circuit-breaker PKZM01, PKZM0 and PKZM4

Individual and group protection using CL-PKZ0

Use the BK25/3-PKZ0 for terminals > 6/4 mm2 Iu = 63 A l> l> l> For grouped connection use B3...PKZ0 three-phase commoning links B3...PKZ0. Note utilization factors to IEC/EN 60 947.

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

6 Examples: PKZM0-16, PKZM0-16/20, PKZM0-20, PKZM0-25, PKZM4-16 PKZM4-16/20 PKZM4-20 PKZM4-25 or or or 4 x 16 A x 0.8 2 x (16 A + 20 A) 3 x 20 A x 0.8 3 x 25 A x 0.8 = 51.2 A x 0.8 = 57.6 A = 50 A = 60 A

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Auxiliary contacts and standard auxiliary contacts NHI for PKZM01, PKZM0 and PKZM4 They switch at the same time as the main against one another. They are available with contacts. They are used for remote indication of screw terminals or springloaded terminals. the operating state, and interlocking of switches Side mounted: 1.13 1.21 1.13 1.21 1.31 1.13 1.21 1.33

I >

1.14 1.22 1.14 1.22 1.32 1.14 1.22 1.34

Integrated: 1.53 1.61 1.53 6

1.54 1.62 1.54

Only for (high-performance) compact circuit-breakers PKZM0-.../S... 1.131.21 31 43 L

I >

T 1.14 1.22 32 44

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Trip-indicating auxiliary contact AGM for PKZM01, PKZM0 and PKZM4 These provide information about the reason for 4.13-4.14 or 4.21-4.22) two potential-free the PKZM0 having tripped. In the event of a contacts are actuated independently of one voltage/overload release (contact 4.43-4.44 or another. It is thus possible to indicate the 4.31-4.32) or short-circuit release (contact difference between short circuit and overload.

"+" "I >" "+" "I >" 4.43 4.13 4.31 4.21

I >

4.14 4.44 4.32 4.22 6

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Voltage releases

These operate according to the electromagnetic Shunt releases principle and act on the switch mechanism of the circuit-breaker. These switch the circuit-breaker off when they are connected to voltage. Shunt releases can be provided in interlock circuits or for remote releases Undervoltage release where voltage dips or interruptions are not to lead These switch the circuit-breaker off when no to unintentional switch off. voltage is present. They are used for safety tasks. C1 The undervoltage release U-PKZ0, which is connected to voltage via the early-make auxiliary contacts VHI20-PKZ0, 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 6 against wire breaks. C2 The VHI-PKZ0 can be used together with the PKZM4!

U <

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Motor-protective circuit-breakers PKZM01, PKZM0 and PKZM4 Manually operated motor-starter

L1 L2 L3

-Q1

I > I > I >

T1 T2 T3

Compact starter and high-capacity compact starter with maximum number of auxiliary contacts fitted 6 Compact starters consist of: Compact starter • PKZM0 motor-protective circuit-breaker and PKZM0-.../SE00-... + NHI2-11S-PKZ0 • Contact module (contactor) SE00-...-PKZ0

L1 L2 L3 L1 L2 L3 1.13 1.21 31 43

–Q1 -Q1

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

A1 13 21 A1 13 21

A2 14 22 A2 14 22

T1 T2 T3 T1 T2 T3 1.14 1.22 32 44

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High-capacity compact starter consisting High-capacity compact starters of: PKZM0-.../S00-... + NHI2-11S-PKZ0 • PKZM0 motor-protective circuit-breaker and • High-capacity contact module (contactor)

SE00-...-PKZ0 L1 L2 L3 1.13 1.21 31 43 L1 L2 L3 -Q1 -Q1

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

A1 13 21 A1 13 21 A2 14 22 A2 14 22 I>> I>> I>> I >> I >> I >> T1 T2 T3 1.14 1.22 32 44 6 T1 T2 T3

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Motor-protective circuit-breaker with auxiliary contact and trip-indicating auxiliary contact PKZM01(PKZM0-...)(PKZM4...) + NHI11-PKZ0 + AGM2-10-PKZ0

L1 L2 L3 1.13 1.21 -Q1

1.14 1.22 4.43 4.31 4.21 4.13

I > I > I >

4.44 4.32 4.22 4.14

T1 T2 T3

For differential fault indication 6 (Overload or short-circuit)

1.13 1.21 4.43 4.13 -Q1 -Q1 -Q1 -Q1 1.14 1.22 4.44 4.14

-X1 1 -X1 2 -X1 3 -X1 4

X1 X1 X1 X1

-E1 -E2 -E3 -E4 X2 X2 X2 X2

-X1 5 N

E1: circuit-breaker ON E3: general fault, overload release E2: circuit-breaker OFF E4: short-circuit release

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Remote switch off via shunt release High-capacity compact starter with auxiliary contact and shunt release PKZM0-.../S00-.. + A-PKZ0

L1 L2 L3 1.13 1.21 Q11: Contact module -Q1

C1 1.14 1.22

I > I > I >

A1 13 21 -Q11 A2 14 22 I>> I>> I>> T1 T2 T3

PE -X1 1 2 3 6

U1 V1 W1 M 3

-M1

L1 1.13 S1: Off -Q1 S2: On 1.14 S3: Circuit-breaker On

21 -S1 22 13 -S3 14

13 13 -S2 -K1 14 14 C1 -Q1 A1 -Q11 A2 N C2

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Direct switch-on, reversible (High-capacity) compact reversing starter PKZM0-.., 2 x (S)00-.../EZ-PKZ0 (with mechanical interlock MV-PKZ0 if required) L1 L2 L3

153 L1 L2 L3 -Q1 a

I > I > I >

T1 T2 T3 6 2 4 6

153 153 L1 L2 L3 L1 L2 L3 A1 13 21 A1 13 21 -Q11 -Q12 A2 14 22 A2 14 22 I>> I>> I>> I>> I>> I>> T1 T2 T3 T1 T2 T3 2 4 6 2 4 6

U1 V1 W1

M 3

-M1 a Fuseless

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For standard applications contact modules SE00-...-.PKZ0 may be used instead of high-capacity contact modules S00-...-PKZ0.

Q11 Q1 Q12 Q12 Q11 Q11 Q1 Q12 Q12 13 1.14 14 13 13 14 1.14 14 13 I 0 II 0

14 14 L1 -S11 L1 -S11 21 22 21 -Q11 -Q12 (Q11/1) 21 22 21 22 (Q11/1) 21 22 21 22 22 13 13 13 14 13 14 13 14 14 14 -F0 -F0 13 13 13 14 A B C A B C a -Q1 1.13 -Q1 1.13 1.14 1.14 22 22 21 21 -Q12 -Q11 0 0 22 21 21 22 21 22 21 22 -S11 II -S11 II 22 21 22 21 14 13 14 13 6 I I 13 14 14 14 13 14 14 14 -Q11 -Q12 -Q11 -Q12 13 13 13 13 22 22 22 22 -Q12 -Q11 -Q12 -Q11 21 21 21 21 A1 A1 A1 A1 -Q11 -Q12 -Q11 -Q12 A2 A2 A2 A2 N N

a With position switches remove the links

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Motor and system protection

The PKZ2 achieves its modularity by combining Special motor-protective trip block the motor or system-protective circuit-breaker ZMR-...-PKZ2 with various accessories. This results in numerous application options and adaptation to widely This trip block features an overload relay function differing requirements. which allows the following interesting application: In the event of an overload, the circuit-breaker The circuit-breaker does not trip. Instead, a normally closed contact The circuit-breakers PKZ2/ZM... consists of: (95-96) is actuated which switches off the • Basic unit and contactor in the control circuit (contactors up to • Plug-in trip block. 18.5 kW, AC-3). At the same time, a normally There is a choice of trip blocks: open contact (97-98) is actuated, which ensures • Motor-protective trip blocks (11 versions for the remote indication. The normally closed contact range from 0.6 to 40 A) and normally open contact are suitable for • System-protective trip blocks (5 versions for the carrying two different potentials. 6 range from 10 to 40 A) The trip block has a manual and an automatic All trip blocks are equipped with adjustable position: overload and short-circuit releases. • Automatic position: The normally closed Overload from ... to: contact and normally open contact

• Motor-protective trip-blocks: 8.5 to 14 x Ie automatically return to the original position • Trip block for distribution circuit protection: after the bimetallic strips have cooled down. 5to8.5x Ie The contact can be actuated again by actuation, for example, of a pushbutton. • Manual position: An acknowledgement locally, Standards at the unit, moves the contacts back to the The motor-protective circuit-breaker PKZ2 original position after tripping. complies with the IEC 947 and EN 60947 standards. The circuit-breaker has a switching capacity of 30 kA/400 V outside the Important note! inherently-safe range. It is auto-protected up to a For an EEx e application, the normally closed rated operational current of 16 A. In addition, the contact 95-96 must be used to shed the contact PKZ2 complies with the requirements stipulated in module or contactor, to achieve disconnection. IEC/EN 60 204 for disconnectors and main switches.

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(High-capacity) contact module (High-capacity) contact module for S-...-PKZ2 24 V DC control voltage A compact starter combination is produced by An actuating voltage of 24 V DC can be used with combining a contact module S-...-PKZ2 the contact module SE1A-G-PKZ2 (24 V DC) and (contactor) featuring the same contours with the the high-capacity contact module S-G-PKZ2 (24 V PKZ2: DC). It is necessary to take account of: • Switch + standard contact module • Pull-in capacity: 150 VA, SE1A-...-PKZ2. The contact module features the • Pull-in current: 6.3 A (16 to 22 ms), same functions and properties of a standard • Holding power: 2.7 W, contactor and can be used for operational • Holding current: 113 mA. switching of 1 x 106 AC-3 operations.

A1 13 A1 13 21

A2 14 +24 V A2 14 22 2 4 6 2 4 6 T1 T2 T3 T1 T2 T3 6 • Switch + S-PKZ2... high-capacity contact module. A high-capacity compact starter is Current limiter CL-PKZ2 obtained by using a motor-protective circuit-breaker (PKZ2/ZM...) as the switch, and A specially developed current-limiter module a combination circuit-breaker is produced by which can be attached and featuring the same using a circuit-breaker (PKZ2/ZM-...-8) as the contours is available to increase the switching switch. capacity of the circuit-breaker to 100 kA/400 V. In The high-capacity contact module increases the the event of a short-circuit the contacts of the switching capacity of the combination to PKZ2 and CL-PKZ2 will open. The PKZ2 trips via 100 kA/400 V, and is suitable for 1 x 106 AC-3 the magnetic release and remains in this position. operations. 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

A2 14 22 2 4 6 T1 T2 T3

I >> I >> I >>

2 4 6 T1 T2 T3

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The remote operator allows the PKZ2 to be Both remote operators must be supplied with the switched on and off remotely during operation. mains supply of 700 W/VA for 30 ms at the After tripping, it can be reset to 0 by the remote terminals 72–74 during the switching operation operator. (On/Off/Reset). Twelve voltage versions are The PKZ2 system has two remote operators: available per remote operator. These cover a wide • In the RE-PKZ2 – the electronic remote operator application range. The remote operators can for standard applications – both CONTROL and optionally be set for manual or automatic LINE are separate inputs, but with the same operation. reference potential. This allows actuation using • Manual position: remote switching on is reliably low current units, e.g. control circuit devices. electrically interlocked. • The electronic remote operator RS-PKZ2 can be • Automatic position: remote switching on is actuated directly, without any coupling possible. elements, from the semiconductor outputs of a An integrated normally open contact (33–34) PLC (24 V DC). when closed indicates the automatic position of Electrical isolation between the CONTROL and the remote operator. LINE allows it to take power for the switching 6 process from a separate power supply (e.g. 230 V 50 Hz).

Minimum command time for the remote operators RE-PKZ2 and RS-PKZ2

CONTROL ON I ON

0 f 15 t (ms)

CONTROL I OFF/RESET OFF/RESET

0 f 15 t (ms)

LINE f 300 I ON CONTROL Main contact 0 OFF F 30 F 30 t (ms)

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Remote operator RE-PKZ2 Off and Reset separate Off equals Reset

L 72 74

L(+) N(-) L(+) N(-)

72 74 72 74 LINE 33 LINE 33

I > CONTROL 34 CONTROL 34 A20 A40 B20 A20 A40 B20 I 0 I 0

T A20 A40 B20 ON OFF RESET ON OFF RESET

Remote operator RS-PKZ2 6 Off equals Reset

L 72 74 L(+) N(-) L(+) N(-)

72 74 72 74 LINE 33 LINE 33

CONTROL 34 CONTROL 34 I > A20 A30 A0 A20 A30 A0 – OFF/ I 0 OFF/ ON RESET RESET 24 V H ON 24 V h/H T A20 A30 A0 +

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Voltage releases

Undervoltage release U Undervoltage releases which switch off without Undervoltage releases trip the circuit-breaker in delay are suitable for Emergency-Stop circuits. the event of a power failure and prevent restarting The undervoltage release can be energized early when the power returns. Three versions are by an additional link (see circuit diagram). available: Undervoltage release with a 200 ms dropout • Non-delayed, delay. • With/without early-make auxiliary contact, • With 200 ms dropout delay. D1 2.13 D1 2.13 2.23

U < 6 U <

2.14D2 D2 2.14 2.24

Shunt release A

Shunt releases trip the circuit-breaker when a C1 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.

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Standard auxiliary contact NHI The NHI is available in 2 versions. NHI ... S for the starter combination, featuring the NHI for circuit-breakers, fitted and featuring the same contours, for indication of the position of the same contours, for indicating the position of the main contacts of the contactor and/or those of the main contacts of the switch. circuit-breaker.

1.13 1.21 1.21 1.43 1.21 43 1.13 1.21 1.13 1.311.13 31 NHI11

1.14 1.22

I > 1.13 1.21 1.31 1.43 I > or 13 21 PKZ 2(4)/ZM... NHI22 A1 6 A2 1.14 1.22 1.32 1.44 14 22

I >>

1.14 1.22 1.14 1.32 1.14 32 PKZ 2(4)/ZM.../S 1.441.22 1.22 44 NHI 11S NHI 22S NHI 2-11S

Trip-indicating auxiliary contact AGM The trip-indicating auxiliary contact is of particular importance. Two separate contact pairs signal that the circuit-breaker is in the tripped position. "+" "I >" One contact pair (normally open & normally 4.43 4.31 4.21 4.13 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 I > closed contact 4.21/4.22 are connected in series, then it is also possible to indicate overload tripping differentially. 4.44 4.32 4.22 4.14 PKZ 2(4)/ZM... AGM 2-11

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Motor-protective circuit-breaker consisting of:

• PKZ2 basic unit High-capacity compact starter, consisting • Plug-in trip block Z of:

L1 L2 L3 • Basic unit • Trip block -Q1 • High-capacity contact module fitted with same contour profile

L1 L2 L3 I I I -Q1

T1 T2 T3

I I I

6 Compact starter, consisting of: • Basic unit A1 13 21 • Trip block A2 14 22 • Contact module SE1A...-PKZ2, which can be I I I attached and has the same contours, for T1 T2 T3 operational switching

L1 L2 L3 Circuit-breaker with current limiter fitted –Q1

L1 L2 L3 -Q1

I > I > I >

A1 13 21 I I I

A2 14 22

T1 T2 T3

I I I T1 T2 T3

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On-off switching with remote operator Separate actuation of Off and Reset Circuit-breaker with remote operator, standard version. Example 1: PKZ2/ZM-.../RE(...)

L1 72 74 33

A20 A40 B20 34 N L1 L2 L3 -Q1 12 -X1

I > I > I > 6

72 74 T1 T2 T3 -Q1 A20 A40 B20 ቢ

3 4 5 6 -X1 -X1 -X1 7

13 13 13 33 -S11 -S01 -S21 -Q1 14 14 14 34

8 -X1 ብቤባ

a Separate actuation of OFF and Reset b Reset c OFF d ON Actuation by control circuit devices Auxiliary contact for signalling the (e.g. pushbuttons NHI, AGM, VS3, EK...SPS with manual/automatic position of the remote potential-free contacts). operator. Indicates the automatic position when closed.

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Joint actuation of Off and Reset Example 2: PKZ2/ZM-.../RS(...) Circuit-breaker with remote operator, standard version.

L1 72 74 33

A20 A40 B20 34 N L1 L2 L3

-Q2 9 10 -X1

I > I > I >

6 72 74 T1 T2 T3 -Q2 A20 A40 B20 ቢ

11 12 13 -X1 -X1 -X1 14

13 13 33 -S12 -S02 -Q2 14 14 34

15 -X1 ቤባ

a Off = Reset b Off/Reset c ON Actuation by control circuit devices Auxiliary contact for signalling the (e.g. pushbuttons NHI, AGM, VS3, EK...SPS with manual/automatic position of the remote potential-free contacts). operator. Indicates the automatic position when closed.

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Circuit-breaker with remote operator, 24 V DC version with electronic outputs For direct actuation by a programmable logic Example 3: PKZ2/ZM-.../RS(...) controller (PLC).

L1 72 74 33

A20 A40 B20 34

N L1 L2 L3 -Q3

1 2 -X2

I > I > I >

72 74

-Q3 T1 T2 T3 6

A20 A30 B20

3 4 -X2 -X2 5

33 24 V H 24 ON OFF/ -Q3 RESET 34

6 -X2

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

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Circuit-breaker with remote operator Actuation by control circuit devices. Example 4: PKZ2/ZM-.../RS(...)

L1 72 74 33

A20 A40 B20 34 N L1 L2 L3 -Q4

7 8 -X2 I > I > I >

72 74 6 -Q4 T1 T2 T3

A20 A30 A0

9 10 -X2 -X1 11 / ~ 13 13 33

-S22 -S23 24 V -Q1 14 14 34

12 -X2

S22: On S23: Off/Reset Actuation by control circuit devices via 24 V AC/DC. Auxiliary contact for signalling the manual/automatic position of the remote operator. Indicates the automatic position when closed.

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Indication by auxiliary contacts Circuit-breaker with auxiliary contact and Example: PKZ2/ZM-... + NHI11-PKZ2 + trip-indicating auxiliary contact. AGM2-11-PKZ2

L1 L2 L3 1.13 1.21 -Q1

1.14 1.22 4.43 4.31 4.21 4.13

I > I > I >

4.44 4.32 4.22 4.14

T1 T2 T3 For differential fault indication. L1 6

1.13 1.21 4.43 4.13 -Q1 -Q1 -Q1 -Q1 1.14 1.22 4.44 4.14

1 2 3 4 -X1 -X1 -X1 -X1

X1 X1 X1 X1

-E1 -E2 -E3 -E4 X2 X2 X2 X2

5 N -X1

E1: Circuit-breaker On E2: Circuit-breaker Off E3: General fault, Overload tripping E4: Short-circuit tripping

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Use of the undervoltage release in the Emergency-Stop circuit Motor-protective circuit-breaker with auxiliary Example: PKZ2/ZM... + NHI22-PKZ2 + contact and undervoltage release. UHI-PKZ2

L1 L2 L3 1.13 1.21 1.31 1.43 All poles of the Emergency-Stop circuit are isolated from the mains supply in the event of -Q1 a power failure.

D1 2.13 1.14 1.22 1.32 1.44

U > I > I > I >

D2 2.14

T1 T2 T3

1 2 3 PE -X1 6 U1 V1 W1

M 3

-M1 L1 S1: Emergency-Stop S2: Emergency-Stop 2.13 -Q1 2.14

21 -S1 22

21 D1 -S2 22 -Q1 U <

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Remote switch off via shunt release High-capacity compact starter with auxiliary contact and shunt release

Example: PKZ2/ZM-.../S-PKZ2 + A-PKZ2

L1 L2 L3 1.13 1.21 Q11: High-capacity contact module -Q1

C1 1.14 1.22

I > I > I >

A1 13 21 -Q11 A2 14 22 I>> I>> I>> T1 T2 T3

1 2 3 PE 6 -X1

U1 V1 W1

M 3

-M1

L1 S1: Off S2: On 1.13 S3: Circuit-breaker Off -Q1 1.14

21 -S1 22 13 -S3 14

-S2

C1 -Q1 A1 -Q11 A2 C2 N

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High-capacity compact starter with maximum number of auxiliary contacts fitted Example: PKZ2/ZM.../S-PKZ2 + NHI2-11S-PKZ2

L1 L2 L3 1.13 1.21 1.31 1.43 -Q1

I > I > I >

A1 -Q11 A2 I >> I >> I >> T1 T2 T3 1.14 1.22 1.3 1.4

1 2 3 PE -X1 6 U1 V1 W1

M 3

-M1

1.13 1.21 31 43 13 21 -Q1 -Q1 -Q1 -Q1 -K1 -K1 1.14 1.22 32 44 14 22

A1 A1 A1 A1 A1 A1 -K1 -K2 -K3 -K4 -K5 -K6 A2 A2 A2 A2 A2 A2 N

13 14 13 14 13 14 13 14 13 14 13 14 21 22 21 22 21 22 21 22 21 22 21 22 31 32 31 32 31 32 31 32 31 32 31 32 43 44 43 44 43 44 43 44 43 44 43 44

K1: Circuit-breaker On K4: Contact module On K2: Circuit-breaker Off K5: Contact module On K3: Contact module Off K6: Contact module Off

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Remotely actuated circuit-breaker with switch status indication Motor-protective circuit-breaker with remote Example: PKZ2/ZM.../RE + NHI11-PKZ2 + operator + auxiliary contact (1 NO, 1 NC) + trip AGM2-11-PKZ2 indicating auxiliary contact

72 74 33

A20 A40 B20 34 L1 L2 L3 1.13 1.21 -Q1

1.14 1.22 4.43 4.31 4.21 4.13

I > I > I >

4.44 4.32 4.22 4.14

T1 T2 T3 6 L1

1.13 1.21 4.43 4.13 -Q1 -Q1 -Q1 -Q1 1.14 1.22 4.44 4.14

13 13 13 -S5 -S2 -S1 14 14 14

21 72 74 -S2 -Q1 22 A20 A40 B20 A1 A1 A1 A1 -K1 -K2 -K3 -K4 N A2 A2 A2 A2

13 14 13 14 13 14 13 14 21 31 21 31 21 31 21 31 22 32 22 32 22 32 22 32 43 44 43 44 43 44 43 44

S1: On S2: Off S5: Reset Q1: Auxiliary contact, indication: manual-auto K1: Circuit-breaker On K2: Circuit-breaker Off K3: Overload indication K4: Short-circuit indication

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Circuit-breaker with current limiter in separate mounting Example: PKZ2/ZM... + NHI11-PKZ2 with CL/EZ-PKZ2

L1 L2 L3 1.13 1.21 L1 -Q1

1.14 1.22 1.13 1.21 -Q1 -Q1 I > I > I > 1.14 1.22

T1 T2 T3

L1 L2 L3 6 -Q2

I>> I>> I>> A1 A1 T1 T2 T3 -K1 -K2 A2 A2 1 2 3 PE -X1 N

U1 V1 W1 13 14 13 14 21 22 21 22 31 32 31 32 M 43 44 43 44 3 K1: Circuit-breaker On -M1 K2: Circuit-breaker Off Q2: Current limiter, separate mounting

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Special trip block ZMR-...-PKZ2 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.

L1 L2 L3 1.13 1.21 L1 -Q1

1.14 1.22 95 97

97 95 -Q1 -Q1 96 98 I > I > I > 98 96

T1 T2 T3 6

A1 13 21 -Q11 1.13 A2 14 22 -Q1 I>> I>> I>> 1.14 T1 T2 T3 4 -X1

X1 1 2 3 PE -X1

-E1 U1 V1 W1 A1 X2 -Q11 M 5 A2 -X1 3 N

-M1 Q11: Shutdown E1: Overload indication Q11: High-capacity contact module

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Page Overview 7-2 Overview, shunt releases 7-3 Undervoltage releases 7-4 Contact sequence of the auxiliary contacts 7-5 Internal circuit diagrams 7-7 Remote switch-off with voltage releases 7-9 Application of the undervoltage release 7-11 Shutdown of the undervoltage release 7-12 Indication of the switch position 7-13 Short-time delayed circuit-breakers – internal circuit diagrams 7-14 7 Mesh network circuit-breaker 7-15 Remote operation with motor operator 7-16 as a transformer switch 7-17 with residual-current release 7-18 IZM circuit-breaker 7-22

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NZM circuit-breakers These circuit-breakers protect electrical Circuit-breakers NZM and switch-disconnectors equipment against thermal overloading and in the are built and tested to the specifications in event of a short circuit. They cover the rated IEC/EN 60947. current range from 20 to 1600 A. They feature isolating characteristics. In Depending on the version, they have additional conjunction with a locking device, they are protective functions such as fault-current suitable for use as main switches to protection, earth-fault protection or the capability IEC/EN 60204. for energy management by recognition of load The electronic releases of frame sizes NZM2, peaks, and deliberate load shedding. NZM3 and NZM4 feature communication Circuit-breakers NZM are distinguished by their capabilities. compact shape and their current-limiting The current states of the circuit-breaker onsite can characteristics. be visualized via a Data Management Interface Switch-disconnectors without tripping units are (DMI) or via digital output signals. Additionally, available in the same sizes as the circuit-breakers the circuit-breakers can be connected to a and can be fitted with additional shunt or network, e.g. PROFIBUS-DP. undervoltage releases to suit on the versions concerned. 7 NZM1 NZM2 NZM3 NZM4

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IZM circuit-breakers Circuit-breakers IZM are built and tested to the specifications in IEC/EN 60947. These circuit-breakers protect electrical They feature isolating characteristics. In equipment in the rated current range from 630 to conjunction with a locking device, they are 6300 A. They have digital tripping electronics, suitable for use as main switches to which are available in four different versions. IEC/EN 60204. The tripping units offer extensive protection and The circuit-breakers in the IZM range are also signalling functions, extending from standard available as IN switch-disconnectors without short-circuit and overload protection to energy tripping units. management with data transmission. IZM1 IZM2 IZM3

Shunt releases A (Q1)

L1 An electromagnet which, when a voltage is (L+) applied, actuates a tripping mechanism. When de-energized, the system is in the rest position. A -S11 normally open contact actuates the system. If the C1 0 shunt release is rated for intermittent duty, the C2 intermittent operation must be ensured by Q1 positioning appropriate auxiliary contacts (usually HIN/S1) upstream of the circuit-breaker. -Q1 E1 C1 Shunt releases are used for remote tripping when -Q1 an interruption in the voltage is not intended to C2 lead to automatic disconnection. Tripping does N not occur in the event of wire breakage, loose (L-, L2) contacts or undervoltage.

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Undervoltage release U (Q1)

L1 An electromagnet which actuates a tripping (L+) mechanism upon interruption of the voltage. The system is in the rest position when energized. -S11 Actuation is produced by a normally closed D1 0 contact. Undervoltage releases are always D2 designed for uninterrupted operation. These are Q1 U< the ideal tripping elements for totally reliable interlocking tasks (e.g. Emergency-Stop). E1 -Q1 D1 Undervoltage releases trip the circuit-breaker -Q1 U< when the power fails in order, for example, to D2 prevent motors from restarting automatically. N They are also suitable for very reliable interlocking (L-, L2) 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. 7 Off-delayed undervoltage release UV (Q1)

L1 The off-delayed undervoltage release is a (L+) combination of a separate delay unit (UVU) and the respective release. This release is used to -S11 prevent brief interruptions in power leading to disconnection of the circuit-breaker. The delay D1 0 Q1 D2 time is adjustable between 0.06 and 16 s. U<

E1 -Q1 D1 -Q1 U< D2

N (L-, L2)

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Standard auxiliary contact HIN

I Used to provide command or signal outputs 1 from processes which are governed by the L1L2L3 position of the contacts. They can be used for HIN interlocking with other switches, and for the I remote indication of the switching state. 1 L1L2L3 • Standard auxiliary contacts behave like main switch contacts HIN • Switch position indication + I •Interlocking 1 • Disconnection of the shunt release L1L2L3

HIN

Trip-indicating auxiliary contact RHI, new designation: trip-indicating auxiliary contact HIA

I Used to provide command and signal output 1 relating to electrical tripping of the 7 L1L2L3 circuit-breaker (trip position +) as is required, HIA for example, for mesh network switches. No I pulse is produced when the switch is opened 1 or closed manually, or by a motor operator. L1L2L3 • Indication that the switch is in the tripped HIA position + I • Switch position indication only if tripping is caused by, for example, overcurrent, L1L2L3 short-circuit, test or voltage release. No HIA fleeting contact when switched on or off 0 r I manually or switched off with the motor (exception: manual switch off with motor Switch on operator NZM2, 3, 4). 0 R I Switch off + R I Trip Q contacts closed q contacts opened

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Early-make auxiliary contact HIV Used to provide command or signal outputs from NZM 1, 2, 3 I processes which are initiated before the closure or 1 opening of the main contact system. Because they L1L2L3 HIV close early, they can be used for interlocks with other switches. Furthermore, they allow a switch position I indication. 1 L1L2L3 The HIV has the same position in the tripped position of HIV the circuit-breaker and the off position of the circuit-breaker. Because of their early-make feature, they + I can be used for energizing the undervoltage release 1 a L1L2L3 ( section “Undervoltage releases”, page 7-4). HIV

NZM 4 I 0 r I 1 L1L2L3 Switched on 7 HIV 0 R I I Switch off 1 L1L2L3 + R I HIV Trip Q + I contacts closed 1 q contacts opened L1L2L3 HIV

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NZM1 Contact elements M22-K10 (K01) from the L1 L2 L3 RMQ-Titan range from Moeller are used 1.11 4.13 -Q1 1.13 4.11 3.13 3.23 for the auxiliary contacts. Two early-make auxiliary contacts (2 NO) are also available. Maximum component fitting:

I> I> I> NZM HIN HIA HIV 1 2 3 4 4.14 1.12 4.12 3.14 3.24 T1 T2 T3 1.14 HIN, 1 NO or 1 NC 1 2 3 3 HIA, 1 NO or 1 NC 1 1 1 2 HIV, 2 NO 1 1 1 1

7 NZM2 Details about the auxiliary L1 L2 L3 contacts: a section 1.23 1.21 1.11 4.13 3.13 3.23 -Q1 1.13 4.11 “Maximum component fitting:”, page 7-7

I> I> I> HIN HIA HIV 1.22 4.14 1.24 4.12 3.14 3.24 1.12 1.14 T1 T2 T3

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NZM3 Details about the L1 L2 L3 auxiliary contacts: 1.23 1.33 1.31 1.21 1.11 4.13 3.13 3.23 -Q1 1.13 4.11 a section “Maximum component fitting:”, page 7-7

I> I> I> HIN HIA HIV 1.24 1.22 1.32 4.14 1.34 4.12 3.14 3.24 1.12 1.14 T1 T2 T3

NZM4 Details about L1 L2 L3 the auxiliary 1.23 1.33 1.31 1.21 1.11 4.13 4.23 4.11 3.13 3.23 7 -Q1 1.13 4.21 contacts: a section “Maximum component fitting:”, I> I> I> page 7-7 HIN HIA HIV 1.24 1.22 1.32 4.14 4.24 1.34 4.12 3.14 3.24 4.22 1.12 1.14 T1 T2 T3

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Remote switch-off with undervoltage releases

L1 N L1 (L+) (L-, L2) (L+) -S. -S.

D1 D2 -Q1

D1 -Q1 U< D2

N (L-, L2)

Remote switch-off with shunt release

L1 N 7 L1 (L+) (L-, L2) (L+) -S. -S.

C1 1.13 C2 -Q1 HIN -Q1 1.14

1.13 C1 1.14 -Q1 C2

N (L-, L2)

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Main switch application in processing machines with Emergency-Stop function conform to the IEC/EN 60204-1 standard In the OFF position of the main switch all control elements and control cables which exit the -S. control panel are voltage free. The only live components are the control-voltage tap-offs with the control lines to the early-make auxiliary L1 L2 L3 N contact.

D1 HIV -Q1 D2 -Q1 U<

E1 -Q1 NZM 7

-S.

L1 L2 L3

D1 3.13 HIV 3.14 -Q1 D2 -Q1 U<

E1 -Q1 NZM

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Shut off of the undervoltage release

L1 N The early-make auxiliary contact HIV (Q1) can – (L+) (L-, L2) L1 as shown above – disconnect the undervoltage (L+) release from the control voltage when the circuit-breaker is in the Off position. If the undervoltage release is to be disconnected in 2 3.13 HIV poles, then a further normally open contact of Q1 D1 -Q1 must be connected between terminals D2 and N. D2 3.14 The early-make auxiliary contact HIV (Q1) will always apply voltage to the undervoltage release in time to permit closure. -Q1

D1 -Q1 U< 3.13 D2 3.14 N (L-, L2) 7

Starting interlock of the undervoltage release

L1 N Circuit-breakers with undervoltage release (L+) (L-, L2) L1 produce a positive Off position in conjunction (L+) with interlocking auxiliary contacts on the starter D1 (S5), ancillary devices on the motor (e.g. brush D2 -S5 lifting, S6) or on all switches in multi-motor 1.13 drives. -S6 -Q1 1.14 The circuit-breaker cannot be closed unless the 1.13 starter or switch is in the zero or Off position. 1.14 D1 -Q1 U< -S6 -S5 D2 N (L-, L2)

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Interlocking of several circuit-breakers using an undervoltage release

L1 N L1 (L+) (L-, L2) (L+)

1.21 1.21 -Q2 -Q1 1.22 1.22

D1 D1 D1 D1 -Q1 U< -Q2 U< D2 D2 D2 D2 1.21 1.21 -Q1 -Q2 N 1.22 1.22 (L-, L2)

When interlocking 3 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.

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On and Off indication using standard auxiliary contacts HIN (Q1)

L1 N (L+) (L-, L2)

-F0 L1 -F0 L1 -F0 (L+) (L+)

1.13 1.21 1.11 -Q1 1.14 1.22 1.14 1.12 1.21 -P2 1.22 X1 X2 -Q1 1.13 -P1 X1 X1 X1 X1 1.14 X1 X2 -P1 -P2 -P1 -P2 X2 X2 X2 X2 N N (L-, L+) (L-, L+) 7 P1: On P2: Off

Tripped indication using trip-indicating auxiliary contact HIA (Q1) Trip-indicating auxiliary contacts for mesh network switches

L1 N (L+) (L-, L2) -F0 L1 -F0 X1 (L+) -P1 4.13 X2 -Q1 4.13 4.14 4.14 X1 -Q1 -P1 X2 N (L-, L+)

P1: Tripped

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Time-discriminating network topology Short-time delayed circuit-breakers NZM2(3)(4)...-VE... NZM2(3)(4)/VE enable a time-discriminating Trip block VE network design with variable stagger times. Adjustable short-time delay: Where the prospective short-circuit currents are 0, 20, 60, 100, 200, 300, 500, 750, 1000 ms extremely high, additional installation protection is achieved by instantaneous releases, which respond without any delay. L1 L2 L3

-Q1

I> I>

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NZM1, NZM2, NZM3, NZM4 Circuit with capacitor unit and shunt release mesh network circuit-breaker can be undertaken 230 V, 50 Hz. independently of the circuit-breaker. The configuration of the capacitor unit which Connect the NZM-XCM to the power feed side! provides the energy for the shunt release of the

18 24

20 23

22 21

19 19 7 24 USt 24 24 V H 18 b 18

HIN-NZM... L1 20 NZM-XCM 23 L1 20 NZM-XCM 23 a 51 (C1) 230 V 53 (C2) HIN-NZM... 230 V 50/60 Hz 51 (C1) 50/60 Hz

53 (C2) 22 22 N 21 N 21

a Mesh network relay b Mesh network relay with low-capacity contacts

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Two-wire control Three-wire control Three-wire control with automatic return to the Off position after tripping

NZM2, 3, 4

L1 L1 L1 (L+) (L+) (L+)

0 I HIA P1 0 P1 0 P1

I I

70 71 72 70 71 72 70 71 72 NZM-XR NZM-XR NZM-XR 75 75 75 74 74 74 N N N (L-, L2) (L-, L2) (L-, L2) 7

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Faults upstream of the low-voltage sides. This interlocking with the high-voltage circuit-breaker, e.g. in the transformer itself, are circuit-breaker must always be provided when disconnected by suitable protective devices (e.g. a transformers are being operated in parallel. Buchholz relay) on the high-voltage side. The S7 If only one normally open contact is available as auxiliary contact of the high-voltage the auxiliary contact, an undervoltage release circuit-breaker trips out the NZM transformer must be used instead of the shunt release. At the switch on the low-voltage side in order to prevent same time, this provides protection against feedback to the high-voltage network. S7 thus undervoltage. isolates the transformer from the network on both

Circuit-breaker with shunt release Q1 Circuit-breaker with undervoltage release Q1 L1 N L1 (L+) (L-, L2) (L+) L1 N L1 (L+) (L-, L2) (L+) -S7 -S7 -S7 -S7 C1 C2 D1 Q1 D2 7 C1 Q1 -Q1 D1 C2 -Q1 U< D2 N (L-, L2) N (L-, L2)

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NZM2-4-XFI, XFI30 These circuit-breakers with integrated residual current protection offer: NL1L2L3 • Overload protection • Short-circuit protection 0 + I • Fault-current protection Q1 In addition to the protective functions, this circuit-breaker can perform the functions of a main switch with isolating characteristics. Like RCCB's built conform to VDE 0664, the residual NZM74-... current release recognises AC and DC fault currents. The residual-current release NZM74-... and NZM2-4-FI(30) are “pulse current sensitive”. The NZM2-4-FIA(30) is sensitive to AC and DC. In the event of a fault the circuit-breaker disconnects I I I I the fault circuitry. The residual-current protective switches for the NZM2-4 and NZM74 are built and tested to IEC/EN 60 947 and VDE 0664 Part 3. 7 The residual-current release requires no external auxiliary voltage for tripping. For the switch rated t I n v FIP current range 30–250 A at rated voltages 200–690 V (NZM2-4) and 380 – 690 V (NZM74), rated fault currents I = 0.1-0.5*-1-3 A and Dn ቢ delay times tV ˜ 60-150-300-450 ms can be set in steps. The XFI30 or FIP30 trips at a rated fault current of 30 mA. * 0.3 at NZM74 a Test button

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Residual-current relay PFR with ring-type transformer The area of application for the relay/transformer The fault current relay indicates when a fault combination ranges – depending on the standards current has exceeded the predefined fault current involved – from personnel protection to fire by using a changeover contact. The contact signal prevention to general protection of systems for can be processed further as a signal in 1 to 4-pole electrical power networks. programmable logic controllers or can initiate a There are three different relay types and seven trip via the undervoltage release of a different transformer types available. They cover circuit-breaker/switch-disconnector. The compact operating currents ranging from 1 to 1800 A. The ring-type transformer is placed without any three relay types are: particular space requirement at a suitable position • Rated fault current 30 mA, permanently set in the power chain. • 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.

230 V AC g 20 % 50/60 Hz L1 L2 L3 N 3 V A 7 N L 1S1 1S2

5678 > 3 m – 50 m LOAD

1234 NO C NC 50/60 Hz 250 V AC 6 A

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

N L1 L2 L3

-S.

6 A

5678

NZM.-XA... C2 7 C1

1234

1S1

1S2 PFR-W

LOAD

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

N L1 L2 L3

-S.

6 A

5678

NZM.-XU... D2 U < 7 D1

1234

1S1

1S2 PFR-W

LOAD

For Immediate Delivery call KMParts.com at (866) 595-96167-21 Moeller Wiring Manual 02/05 Circuit-breakers IZM circuit-breakers s s U U star point 1) e.g. or summation current convertor 1200 A/1 A 1) Convertor in Jumper with no N/L- L/L+ transformer 24 V external DC power supply if no external bussystem module IZM-XCOM-DP N-converter L/L+ L1 N Terminating resistor, L2 L3 595-9616

DPWrite Free Free Close Open IN Enable – + – + – + OUT XE XA,

XU (866) External

External 123 456689 Internal at 14 13 12 11 10 9 8 7 6 5 4 3 2 1 14 13 12 11 10 9 8 7 6 5 4 3 2 1 Terminal assignment plug of the control circuit Terminal X8 X7

7 Terminals a Internal KMParts.com call 0 V0 DC 24 V DC Signal state G-converter S1 G-converter S2 XFR remote reset Delivery first voltage release Internal system bus – XEE electrically “ON” Internal system bus + Internal system second voltage release XHIS signalling switch on XHIS signalling switch on IZM-XW(C) N-converter S2 IZM-XW(C) N-converter S1 Spring-operated stored energy stored Spring-operated Tripped signalling switch XHIA External voltage transformer L3 External voltage transformer L2 External voltage transformer L1 External voltage transformer star transformer voltage External Immediate For overload release Control circuit plugs X8, X7, X6, X5 are identical plugsX7, X6, X5 Control circuit X8, plug control circuit X8: optional only(Connections X8:1 to X8:8 a Electronic is located. with IZM...-U... andwith IZM...-D...) IZM...-U... X7: optional control circuit plug control circuit X7: optional Not available with communication function IZM- XCOM-DP. of position the At X7 a communications module

7-22 Moeller Wiring Manual 02/05 Circuit-breakers IZM circuit-breakers S S S s U U U U L/L+ N/L- L/L+ N/L- N/L- L/L+ N/L- L/L+ or jumper 595-9616 (866) at 14 13 12 11 10 9 8 7 6 5 4 3 2 1 14 13 12 11 10 9 8 7 6 5 4 3 2 1 X6 X5

7 M ab KMParts.com call b brown Motor operators Motor itch XHI: S1 “NO” itch XHI: S2 “NO” Delivery Closing release XE/A XE/A first shunt release a black-white, Only XUV “non-delayed trip” Emergency-stop Optional motor cut-off switch XMS XA1, XU, XUV second XU,voltage releaseXA1, XUV “Ready to close” auxiliary switch XHIB Standard auxiliary switch XHI: S1 “NC” Standard auxiliary switch XHI: S2 “NC” Standard auxiliary sw Standard auxiliary sw Immediate For Standard auxiliary contact XHI22: S4 “NC”, XHI31/XH40: S8 “NO” contactStandard auxiliary S4 “NC”, XHI31/XH40: XHI22: X6: standard control circuit plug circuit X6: standard control Standard auxiliary contact XHI11/XHI22/XHI31: S3 “NO”, XHI40: S7 contact XHI11/XHI22/XHI31: Standardauxiliary XHI40: S7 S3 “NC”, Standard auxiliary contact XHI11/XHI22/XHI31: XHI31/XHI40: S8 “NO” Standardauxiliary XHI22: S4 “NO”, contact X5: optional control circuit plug control circuit X5: optional

7-23 Moeller Wiring Manual 02/05 Circuit-breakers IZM circuit-breakers Control circuit isolator circuit Control Optional auxiliary switches XHI11(22)(31): S3, XHI22: S4 oder XHI40: S7, XHI40: S8 XHI40: S7, S4 oder XHI40: XHI22: S3, XHI11(22)(31): optionale Zusatz-Hilfsstromschalter

7 Standard auxiliary switches Standard XHI: S1, XHI: S2 XHI: S1, XHI: Standard-Hilfsstromschalter Terminals Klemmen Internal Intern Wire no. Wire Leitungsnummer Wire no. Wire Leitungsnummer Terminals Klemmen

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IZM circuit-breakers

Reset Trip XHIA XHIA Bell switch alarm Ausgelöst- Melde- schalter Signalling switch XUV XU

XA1

energized de-energized

XHIS1 Meldeschalter zweiter Spannungsauslöser XU oder XUV XA1, Signal 2nd voltage release XU or XUV energized XA1,

XHIS1 energized

XA de-energized 7 XHIS XHIS Meldeschalter Spannungsauslöser XA erster Signal 1st voltage release energized XHIF “Spring charged” signal Speicher- zustands- meldung XHIF XHIB

XHIB “Ready to close” signal Einschalt- bereitschafts- meldung

color color Klemmen Terminals Leitungsnummer no. Wire Intern Internal Leitungsnummer no. Wire Klemmen Terminals

For Immediate Delivery call KMParts.com at (866) 595-96167-25 Moeller Wiring Manual 02/05 Circuit-breakers IZM circuit-breakers XUV XU *) Emergency-stop or jumper *) Emergency-stop XA1 undervoltage release or undervoltage release with delay undervoltage release XU Unterspannungsauslöser oder XU Unterspannungsauslöser verzögert XUV Unterspannungsauslöser, XHIS1 Voltage release/electrical manual reset Voltage Option: 2nd shunt release or 2nd shunt release Option: Optional: XA1 zweiter Arbeitsstromauslöser XA1 zweiter Optional:

7 XHIS XA

XA Arbeitsstromauslöser erster 1 st shunt release color Intern Internal Wire no. Wire Leitungsnummer no. Wire Leitungsnummer Terminals Klemmen Terminals Klemmen

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For Immediate Delivery call KMParts.com at (866) 595-96167-27 Moeller Wiring Manual 02/05 Circuit-breakers IZM circuit-breakers XFR XFR remote reset coil reset XFR remote S 13 cut-off switch for coll reset remote XFR Fern-Rücksetzmagnet S13 Abstellschalter für Fern-Rücksetzung Motor operator, remote reset magnet reset remote Motor operator, XMS XM Motorantrieb XMS Motorabstellschalter Optional: 7 motor Charging motor cut-off switch XMS optional:

XM Motorantrieb Motor operator

color color Intern Internal Klemmen Terminals Leitungsnummer no. Wire Leitungsnummer no. Wire Klemmen Terminals

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1) Interner Systembus Internal system bus - 595-9616 (866) BSS-Modul BSS module Breaker Status Sensor Breaker at

7 Spannungswandler transformer Voltage Messmodul Metering module Metering module Messmodul KMParts.com - +

call

Internal system bus system Internal Interner Systembus Interner N-Wandler Delivery Protective circuits for overcurrent release with breaker status sensor and metering with breaker module release circuits for overcurrent Protective XZM... G-Wandler G sensor N sensor Elektronischer Überstromauslöser Overcurrent release Immediate For Auslösemagnet für Überstromauslösung magnet for Trip overcurrent release Internal Intern Terminals Klemmen

7-29 Moeller Wiring Manual 02/05 Circuit-breakers IZM circuit-breakers +

Interner Systembus Internal system bus - 595-9616 (866) at

7 Spannungswandler transformer Voltage Messmodul Metering module Messmodul Metering module KMParts.com Protective circuits for overcurrent release, metering module only release, for overcurrent circuits Protective - +

call

Internal system bus system Internal Interner Systembus Interner N-Wandler Delivery G sensor N sensor G-Wandler XZM... Elektronischer Überstromauslöser Overcurrent release Immediate For Auslösemagnet für Überstromauslösung magnet for Trip overcurrent release Intern Internal Klemmen Terminals

7-30 Moeller Wiring Manual 02/05 Circuit-breakers IZM circuit-breakers +

Interner Systembus Internal system bus - 595-9616 (866) Breaker Status Sensor Breaker Breaker Status Sensor Breaker BSS-Modul BSS module at

7 - KMParts.com +

Protective circuits for overcurrent release, breaker status sensor only breaker release, for overcurrent Protective circuits

call

Internal system bus system Internal Interner Systembus Interner N-Wandler Delivery XZM... G sensor N sensor G-Wandler Elektronischer Überstromauslöser Overcurrent release Immediate For Auslösemagnet für Überstromauslösung magnet for Trip overcurrent release Intern Internal Klemmen Terminals

7-31 Moeller Wiring Manual 02/05 Notes

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Page

Motor protection 8-3

Engineering notes 8-13

Circuit documentation 8-17

Power supply 8-19

Control current supply 8-22

Contactor markings 8-23

Direct-on-line start of three-phase motors 8-24

Direct-on-line start with motor-protective circuit-breaker PKZ2 8-32

Control circuit device for direct-on-line start 8-36 Star-delta starting of 8 three-phase motors 8-37

Star-delta starting with motor-protective circuit-breaker PKZ2 8-46

Control circuit devices for star-delta starting 8-49

Pole-changing motors 8-51

Motor windings 8-54

Multi-speed contactors 8-57

Multi speed switch for three-phase motors 8-59

Control circuit devices for multi-speed contactors UPDIUL 8-67

Multi speed switch for three-phase motors 8-72

Multi speed switch with motor-protective circuit-breaker PKZ2 8-87

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Page

Three-phase automatic stator starters 8-89

Three-phase automatic rotor starters 8-94

Switching of capacitors 8-98

Duplex pump control 8-102

Fully automatic pump control 8-104

Off position interlock of the loads 8-108

Fully automatic main transfer switch with automatic reset 8-109

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Overload relay with manual reset

They should always be used where continuous Back-up fuses and instantaneous contact devices (two-wire control) are releases concerned (e.g. pressure and position switches), to prevent automatic restarting. The They are needed to protect not only the motor, reset button can be fitted as an external but also the relay, against the effects of short feature in order to make it accessible to all circuits. Their maximum rating is shown clearly personnel. Moeller overload relays are always on every relay and must be adhered to without supplied with manual reset but can be fail. Higher ratings – chosen for instance converted to automatic reset by the user. according to the cable cross-section – would lead to the destruction of the motor and relay. Overload relays with automatic reset The following important questions and answers give a further guide to the behaviour They can be used only with pulsed contact of an installation with motor protection. devices (three-wire control) such as pushbuttons etc., because on these, the To what current must the overload relay cooling of the bimetal strips cannot lead to properly be set? automatic reconnection. To the rated motor current - no higher, no Special circuitry lower. A relay set to too low a figure will 8 prevent the full utilization of the motor; set too Special circuitry such as is found in star-delta high, it will not guarantee full overload starters, individually compensated motors, protection. If a correctly set relay trips too current transformer-operated relays etc. may frequently, then either the load on the motor require that the relay setting deviates from the should be reduced or the motor should be rated motor current. exchanged for a larger one.

Frequently recurring operating cycles When is it right for the overload relay to It makes motor protection difficult. The relay trip? should be set to higher than rated motor Only when the current consumption of the current in view of its shorter time constant. motor increases due to mechanical Motors which are rated for a high frequency of overloading of the motor, undervoltage or operation will stand this setting to a certain phase failure when the motor is under full load degree. Although this will not ensure complete or thereabout, or when the motor fails to start protection against overload, it will due to a stalled rotor. nevertheless provide adequate protection against non-starting.

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When does the overload relay fail to trip 3-pole overload relays should be so connected in good time although the motor is in the case of single-phase and DC motors so endangered? that all three poles of the overload relay carry With changes in the motor which do not cause the current, whether in single-pole or 2-pole an increase in current consumption: Effects of circuits. humidity, reduced cooling due to a reduction 1-pole 2-pole 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 An important characteristic feature of overload when the back-up fuse is rated too high. In relays conforming to IEC/EN 947-4-1 are the most cases, this will also endanger the tripping classes (10 A, 10, 20, 30). They contactor and motor. Therefore, always determine different tripping characteristics for adhere to the maximum fuse rating specified the various starting conditions of motors on every relay. (normal starting to heavy starting). 8

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

Type of Multiple of current setting Refer- overload ence relay ambient temper- A B C D ature t > 2 h t F 2 h Tripping Tripping Tripping Tripping starting class time in class time in from cold minutes seconds state of 10 A F 2 10 A relay 10 F 4 10 2 < T F 10 20 F 8 20 4 < T F 10 30 F 12 30 6 < T F 20 9 < T F 30 Non-ambient 1.0 1.2 1.5 7.2 + 40 °C temperature compensated thermal relays and magnetic relays 8 Ambient 1.05 1.2 1.5 7.2 + 20 °C temperature compensated thermal relays

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.

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Response limits of 3-pole thermal overload relays at 2-pole load Type of thermal overload Multiple of current setting Reference relay ambient tempera- A B ture t > 2 h, starting t F 2 h from cold state of relay Ambient temperature 3 poles 1.0 2 poles 1.32 + 20 °C compensated, without 1 pole 0 phase-failure sensitivity Non-ambient temperature 3 poles 1.0 2 poles 1.25 + 40 °C compensated, without 1 pole 0 phase-failure sensitivity Ambient temperature 2 poles 1.0 2 poles 1.15 + 20 °C compensated, with 1 pole 0.9 1 pole 0 8 phase-failure sensitivity

In the case of thermal overload relays with a The point of destruction is the point of current setting range, the response limits must intersection between the projected tripping apply equally to the highest and the lowest curves and the multiple of the current. setting of the associated current. Short-circuit rating of the main circuit Overload capacity With currents that exceed the breaking Overload relays and releases have heating capacity of the motor starter in relation to the coils which can be thermally destroyed by utilization category (EN 60947-1), it is overheating. The making and breaking permissible for the current flowing during the currents of the motor flow in thermal overload operating time of the protective device to relays which are used for motor protection. damage the motor starter. x These currents are between 6 and 12 Ie The permissible behaviour of starters under (rated operational current), depending on the short-circuit conditions is defined in the utilization category and the size of the motor. so-called types of co-ordination (1 and 2). It is The point of destruction depends on the frame common practice to state in the details of size and design and is usually approximately protective devices which type of co-ordination 12 to 20 x Ie. is ensured by them.

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Type “1” co-ordination The tripping characteristic of the overload In the event of a short circuit the starter must relay must not differ from the given tripping not endanger persons and installations. It does curve after a short circuit. not have to be fit for renewed operation without repair. Short-circuit withstand strength of the auxiliary contact Type “2” co-ordination In the event of a short circuit the starter must The manufacturer details the required not endanger persons and installations. It overcurrent protective device. The must be fit for renewed operation. There is a combination is subjected to three test risk of contact welding for which the disconnection's at 1000 A prospective current manufacturer must give maintenance with a power factor between 0.5 and 0.7 at instructions. rated operational voltage. Welding of the contacts may not occur (EN 60947-5-1).

Motor protection in special applications Heavy starting duty overload relay Z00. It is used principally for An adequate tripping delay is essential in medium and large motors. order to allow a motor to start up smoothly. In Up to two times rated current Ie, the the majority of cases, overload relays ZB, transformation ratio I1/I2 of the saturable core 8 motor-protective circuit-breakers PKZ(M) or current transformers is practically linear. circuit-breakers NZM can be used. The tripping Within this range it does not differ from the delays can be taken from the tripping normal overload relay, i.e. it provides normal characteristics in the Moeller Main Catalogue, overload protection during normal operation. Industrial Switchgear. However, within the transformer characteristic In the case of especially high-inertia motors, range (I > 2 x Ie) , the secondary current no whose run-up time exceeds the tripping delay longer increases proportionally to the primary of the above devices, it would be completely current. wrong to adjust an overload relay which This non-linear increase in the secondary tripped out before the run-up time expired, to current produces an extended tripping delay if a current level higher than the rated motor overcurrents greater than twice rated current current. This would, it is true, solve the starting occur, and hence permits longer starting problem, but the motor would no longer be times. adequately protected during normal operation. However, there are other solutions Adjusting the current transformer-oper- to the problem: ated relay ZW7 for lower motor ratings The setting ranges quoted in the Moeller Main Current transformer-operated relay ZW7 Catalogue, Industrial Switchgear apply when The ZW7 consists of three special saturable the incoming cable is looped once through the core current transformers, supplying an transformer relay.

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If the current transformer-operated overload current is then carried by the overload relay. relay ZW7 is required to provide protection to Provided it has been set correctly to the rated a motor of below 42 A rating (minimum value motor current, this will ensure full motor in the setting range of 42 A to 63 A), the protection during operation. Starting must be necessary range adjustment is achieved by monitored. looping the incomer several times through the The motor is a limiting factor with regard to aperture in the relay. The change in the rated the tripping delay of the current motor current quoted on the rating plate is transformer-operated relay and the bridging inversely proportional to the number of loops. period. One must ensure that the motor is able Example: to tolerate the high temperature generated by With the ZW7-63 relay, which has a setting direct starting, for the prescribed starting time. range from 42 A to 63 A, a motor rating of 21 Motor and starting procedure have to be A to 31.5 A can be accommodated by looping selected carefully when dealing with machines the leads twice through the relay. having a very large rotating mass, which are practically the only ones subject to this problem when direct starting is used. Bridging of motor protection during Depending on the operating conditions starting adequate protection of the motor winding may For small motors the bridging of the motor no longer be given by an overload relay. In that protection during starting is more economical. case it must be weighed up whether an 8 Because of the additional parallel contactor, electronic motor-protective relay ZEV or a the overload relay does not carry the full thermistor overload relay EMT 6 in conjunction current during starting. Only when the motor with an overload relay Z meets the has reached full speed is the bridging requirements. contactor switched off and the full motor

Star-delta starter (y D) Non-reversing Changeover time with overload relay in position A: < 15 s B: > 15 < 40 s C: > 40 s I Ie Ie e B

-Q11 -Q15 -Q13 -Q11 -Q15 -Q13 -Q11 -Q15 -Q13 A C

Setting of the overload relay 0.58 x Ie 1 x Ie 0.58 x Ie Full motor protection in Y Only partial motor protection Motor not protected in Y (star) position in y position (star) position

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Multi-speed switch 2 speeds One tapped winding 3 speeds 2 separate windings 1 x tapped winding + 1 winding

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

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

Heavy starting duty

Current transformer-operated Bridging of motor protection Bridging during starting using relay ZW7 during starting bridging relay 8

-Q11 -Q11 -Q12 -Q11 -Q12

For medium and large motors For small motors; no protection Automatic cut out during starting

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Individually compensated motor

xy Ie = Rated motor operational current [A] Iw = Ie []A Iw = Active cur.} Proportion of motor 2 2 Ib = Reactive cur. rated operational current [A] Ib = Ie – Iw[]A –6 Ic = Rated capacitor current [A] Ic = Ue 32πf C×××× 10 []A 3 Pc × 10 IEM = Setting current of overload relay [A] Ic = ------3 × U cos v = Motor power factor e

Ue = Rated operational voltage [V]

Pc = Rated capacitor output [kvar] C = Capacitance of capacitor [mF]

Capacitor connected to contactor terminals to motor terminals 8

-Q11 -Q11 PC IEM IEM PC

Setting IEM of overload relay

I = 1 × I 2 2 EM e IEM = Iw + ()Ib – Ic Capacitor does not relieve loading of cable Capacitor relieves loading of cable between between contactor and motor. contactor and motor; normal arrangement.

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Thermistor relay for machine protection relays Thermistor overload relays are used in • Rotor-critical conjunction with temperature-dependent Squirrel-cage motors whose rotor in the semiconductor resistors (thermistors) for event of stalling reaches the permissible monitoring the temperature of motors, temperature limit earlier than the stator transformers, heaters, gases, oils, bearings winding. The delayed temperature rise in the etc. stator can lead to a delayed tripping of the Depending on the application, thermistors thermistor overload relay. It is therefore have positive (PTC thermistors) or negative advisable to supplement the protection of (NTC thermistors) temperature coefficients. rotor-critical motors by a conventional With PTC thermistors the resistance at low overload relay. Three-phase motors above temperature is small. From a certain 15 kW are usually rotor-critical. temperature it rises steeply. On the other Overload protection for motors in accordance hand, NTC thermistors have a falling with IEC/EN 60204. These standards specify resistance-temperature characteristic, which that motors above 2 kW used for frequent does not exhibit the pronounced change starting and stopping should be adequately behaviour of the PTC thermistor characteristic. protected for this type of duty. This can be achieved by fitting temperature sensors. If the temperature sensor is not able to ensure Temperature monitoring of electric adequate protection with stalled rotors, an 8 motors overcurrent relay must also be provided. Thermistor overload relays EMT6 comply with Generally, where there is frequent starting and the characteristics for the combination of stopping of motors, intermittent operation and protective devices and PTC sensors to VDE excessive frequency of operation, the use of 0660 Part 303. They are therefore suitable for overload relays in conjunction with thermistor monitoring the temperature of series motors. overload relays is to be recommended. In order When designing motor protection, it is to avoid premature tripping out of the necessary to differentiate between overload relay in these operating conditions, it stator-critical and rotor-critical motors: is set higher than the predefined operational • Stator-critical current. The overload relay then assumes Motors whose stator winding reaches the stalling protection; the thermistor protection permissible temperature limit quicker than monitors the motor winding. the rotor. The PTC sensor fitted in the stator Thermistor overload relays can be used in winding ensures that the stator winding and conjunction with up to six PTC sensors to DIN rotor are adequately protected even with a 44081 for direct monitoring of temperatures in stalled rotor. EEx e motors compliant to the ATEX directive (94/9 EC). Copies of PTB certification are available on request.

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Protection of current and temperature-dependent motor-protective devices

Protection of the motor under Using Using Using the following conditions bimetal thermistor 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 + + + 8 Increased coolant temperature – + + Impaired cooling – + +

+ Full protection (+) Partial protection – No protection

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Three-phase automatic starters

I M d I Three-phase automatic stator resistance starters with starting resistors a Single or multi-step resistors are connected upstream of the

I' three-phase squirrel-cage motors to reduce the starting current and torque. M d With single-step starters, the starting current is b approximately three times the motor full-load current. With M' d multi-step starters, the resistors can be so designed that the 20 40 60 80 100 % n starting current is only 1.5 to 2 times the motor full-load current, with a very low level of starting torque.

I M d I Three-phase automatic stator resistance starters with starting transformers a This type of starting is preferable where the same starting torque is to be obtained as with the primary resistance starters but the starting current taken from the mains is to M I' d be further reduced. A reduced voltage Ua (approximately b 70 % of the rated operational voltage) is supplied to the M' d motor when starting via the starting transformer. Thus, the 20 40 60 80 100 % 8 n current taken from the mains is reduced to approximately half the direct starting current.

I M d Three-phase automatic rotor starters with starting resistors Resistors are connected in the rotor circuit of the motor to reduce the starting current of motors with slip-ring rotors. The current taken from the mains is thus reduced. In contrast to stator resistance starters, the torque of the motor is practically proportional to the current taken from the mains. The number of steps of the automatic starter is 20 40 60 80 100 % n determined by the maximum permissible starting current and by the type of the motor. I: line current Md:torque n:speed a Reduction of the line current b Reduction of the torque

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Important data and features of three-phase automatic starters

1) Style of starter Stator resistance starter (for squirrel-cage motors) Rotor starter (for slipring rotors)

2) Type of starter Star-delta With starting With starting trans- Rotor resistance switches resistors formers starter

3) Number of 1 only Normally 1 Normally 1 Selectable (no starting stages longer selectable when current or torque have been determined)

4) Voltage 0.58 x rated Selectable: Selectable: None reduction at the operational a x rated 0.6/0.7/0.75 x Ua motor voltage operational (transformer voltage tappings) (a < 1) e.g. 0.58 as with yd starter

5) Starting current 0.33 x inrush a x inrush Selectable (see 4) Selectable: from 0.5 taken from mains current at rated current at rated 0.36/0.49/0.56 x to about 2.5 x operational operational inrush current at rated current voltage voltage rated operational 8 voltage 5a) Starting As above As above Selectable (see 4) As above current at the 0.6/0.7/0.75 x Ie motor

6) Starting torque 0.33 x tightening a2 x tightening Selectable (see 4) Selectable (see 5) torque at rated torque at rated 0.36/0.49/0.56 x from 0.5 to pull-out operational operational volt- tightening torque at torque voltage age rated operational voltage

7) Current and Proportional Current reduction Proportional Current reduction torque reduction less than torque much greater than reduction torque reduction. From pull-out torque to rated speed almost proportional

8) Approximate 150–300 350–500 500–1500 500–1500 price (for similar data). DOL starting = 100 (with overload relay, enclosed)

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Switching of capacitors

DIL contactors for capacitors – individual switching

Individual compensation Group compensation

L1...3 L1...3

-F1 -F1

-Q11 -Q31 -Q11

M -C1 -C1 M M M 3 3 3 3 -M1 -M1 -M2 -M3 8

When capacitors are switched on, contactors A discharge circuit or discharge device must are heavily stressed by transient current peaks. reduce the residual voltage of the capacitor to When a single capacitor is switched on, less than 50 V within a minute of the capacitor currents up to 30 times the rated current can being switched off. 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.

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Contactor for capacitor DIL…K – Individual and group compensation

Group compensation

L1...3

-F1 -F2 -F3

-Q1 I > -Q11 -Q12 -Q13

-Q31 -Q32 a

M M M -C0 -C1 -C2 3 3 3 -M1 -M2 -M3 a Additional inductance with standard 8 contactor In the case of group compensation where If no special contactors are available, the capacitors are connected in parallel, it must be inrush currents can be damped by additional noted that the charging current is taken not inductance's. This is achieved either by longer only from the mains but also from the incoming leads to the capacitors or by capacitors connected in parallel. This produces inserting an air-cored coil with a minimum inrush current peaks which can exceed 150 inductance of approximately 6 mH times the rated current. A further reason for (5 windings, diameter of the coil these peak currents is the use of low-loss approximately 14 cm) between contactor and capacitors as well as the compact capacitor. The use of series resistors is another construction, with short connecting elements way of reducing high inrush currents. between contactor and capacitor. Use of reactors Where standard contactors are used, there is Frequently the capacitors in group danger of welding. Special contactors for compensation are provided with reactors to capacitors such as those available from avoid harmonics. The reactors also act to limit Moeller in the DILMK… range, which can the inrush current and normal contactor can be control inrush current peaks of up to 180 times used. the rated current, should be used here.

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General

Circuit documents serve to explain the Classification according to the type of function of circuits or electrical connections. representation They provide information for the construction, installation and maintenance of electrical Simplified or detailed installations. • Single-line or multi-line representation The supplier and the operator must agree on • Connected, semi-connected or separate the form in which the circuit documents are to representation be produced: paper, film, diskette, etc. They • Topographical representation must also agree on the language or languages In addition to this, there is the in which the documentation is to be produced. process-orientated representation with the In the case of machines, user information must function chart (see previous pages). be written in the official language of the Examples for drawing up circuit documents are country of use to comply with EN 292-2. given in IEC/EN 61082-1. The circuit documents are divided into two groups: Circuit diagrams Diagrams indicate the voltage-free or Classification according to the purpose current-free status of the electrical installation. Explanation of the mode of operation, the A distinction is drawn between: 8 connections or the physical position of the • Block diagram: simplified representation of components. These include: a circuit with its main parts, which shows • Explanatory circuit diagrams, how the electrical installation works and •Block diagrams, how it is subdivided. • Equivalent circuit diagrams, • Circuit diagram: detailed representation of a • Explanatory tables or diagrams, circuit with its individual components, which • Flow diagrams, tables shows how the electrical installation works. • Time flow diagrams, tables • Equivalent circuit diagram: special version of • Wiring diagrams, an explanatory circuit diagram for the analysis and calculation of circuit • Device wiring diagrams, characteristics. • Interconnection diagrams, • Terminal diagrams, • Assignment diagrams.

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L1, L2, L3 L1 L2 L3

Q1 135 13 Q 14

I > I > I > I > 246

135 135 Q11 Q12 Q11 Q12 246 246

UVW

M M 3 ~ 3 ~ Circuit diagram: 1-pole and 3-pole representation

8 Wiring diagrams Wiring diagrams show the conductive • Terminal diagram: representation of the connections between electrical components. connection points of an electrical They show the internal and/or external installation and the internal and external connections but, in general, do not give any conductive connections connected to them. information on the mode of operation. Instead • Assignment diagram (location diagram). of wiring diagrams, wiring tables can also be representation of the physical position of the used. electrical equipment, which does not have • Unit wiring diagram: representation of all to be to scale. the connections within the device or You will find notes on the marking of electrical combination of devices. equipment in the diagram as well as further • Interconnection diagram: representation of diagram details in the section “Specifications, the connections between the device or Formulae, Tables”. combination of devices within an installation.

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4-conductor system, TN-C-S

L11 a Protective earth conductor L21 Protective earth terminal in enclosure L31 (not totally insulated) N

ቢ PE

L1 L2 L3 N PEN

Overcurrent protective device is required in the supply for compliance to IEC/EN 60204-1 8 5-conductor system, TN-S supply system

L11 a Protective earth conductor L21 Protective earth terminal in enclosure L31 (not totally insulated) N

ቢ

L1 L2 L3 N PE

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

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3-conductor system, IT supply system

L11 L21 L31 N

L1 L2 L3 N

Overcurrent protective device is required in the supply for compliance to IEC/EN 60204-1 For all systems: use the N conductor only with the agreement of the user 8 L1 Separate primary and secondary L3 protection Earthed control circuit. In non-earthed control

1 3 5 circuit, remove link and provide insulation monitoring.

I I I 2 4 6

L01 L02

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L1 Combined primary and secondary L3 protection Earthed control circuit. In non-earthed control circuit, remove link and provide insulation 1 3 5 monitoring. Maximum ratio of U1/U2 = 1/1.73 I> I> I> Circuit not to be used with STI/STZ (safety and 2 4 6 isolating transformers).

L01 L02

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L1 Separate primary and L2 L3 secondary protection, with insulation monitoring on the L011 1 3 5 secondary side a Clear button I. I. I. b Test button 2 4 6 PE ab

0 L01

A1 15 S1 S2 E L15E

R < E

A1 A2 16 18 16 18 L A2 L02

DC power supply with L1 8 L2 three-phase bridge rectifier L3

1 3 5

I I I 2 4 6

Yy0

– +

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The contactors in contactor combinations mains contactor with anticlockwise rotation have, in accordance with EN 61346-2 for for high speed). equipment and function, the code letter Q, as The following table shows the marking used in well as numerical identification, which shows this Wiring Manual and in Moeller circuit the function of the component (e.g. Q22 = documentation. Type of Mains contactors Step contactors component Standard motor 2 speed/4 speed 3 speed One speed Low speed High speed For- Reve- For- Reve- For- Reve- Star Delta Starting Remarks ward rse ward rse ward rse stage Up Down Up Down Up Down Hoist Lower Hoist Lower Hoist Lower DIL (/Z) Q11 DIUL (/Z) Q11 Q12 SDAINL (/Z) Q11 Q13 Q15 SDAIUL (/Z) Q11 Q12 Q13 Q15 UPIL (/Z/Z) Q17 Q21 Q23 8 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 1-n Qn start- DAINL Q11 ing DDAINL Q11 stages DIL + discharge Q11 Q14 resistors DIGL + dis- Q11 charge resistors

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.

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Typical circuits with DIL contactors Fuseless without overload relay Fuses with overload relay Short-circuit protection1)and overload Short-circuit protection2) for contactor and protection by means of PKZM overload relay by means of fuses F1. motor-protective circuit-breaker or NZM Short-circuit protection3) for contactor by circuit-breaker means of fuses F1.

L1 L2 L3 L1 L2 L3 L1 L2 L3

1 3 5 13 -F1 -F1 14 -Q1 I > I > I > 1 3 5 2 4 6 -Q11 2 4 6

1 3 5 -F2 1 3 5 -Q11 97 95 -Q11 2 4 6 2 4 6 98 96

97 95 -F2 PE 8 2 4 6 98 96 UVW PE PE M UV W 3 UVW M -M1 M 3 3 -M1 -M1 1) Protective device in the supply line in accordance with Moeller Main Catalogue, Industrial Switchgear or AWA installation instructions 2) Fuse size in accordance with data on the rating plate of the overload relay 3) Fuse size in accordance with Moeller Main Catalogue, Industrial Switchgear (Technical data for contactors)

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Typical circuit with bridging of overload relay during starting

Without overload relay With overload relay

L1 L1 (Q11/1) (Q11/1) -F0 -F0

95 13 -Q1 -F2 96 14

21 21 0 0 22 22 -S11 -S11 13 13 I I 14 14

14 14 -Q11 -Q11 13 13 8 A1 A1 -Q11 -Q11 A2 A2 N N

F2 Q11 Q11 The short-circuit capacity of the contacts in the circuit has to be 96 14 13 0 I considered when selecting F0. Two-way pushbutton 21 21 22 22 14 13 13 14 A B

Control circuit device maintains itself after the button is enables via its I: ON own auxiliary contact Q11/14-13 and 0: OFF pushbutton 0 (three-wire control contact). For connection of further control circuit Contactor Q11 is de-energized, in the normal devices a section “Three-wire course of events, by actuation of pushbutton 0. In control”, page 8-36 the event of an overload, it is de-energized via Method of operation: Actuation of the normally closed contact 95-96 on the pushbutton I energizes the coil of contactor Q11. overload relay F2. The coil current is interrupted, The contactor switches on the motor and and contactor Q11 switches the motor off. For Immediate Delivery call KMParts.com at (866) 595-96168-25 Moeller Wiring Manual 02/05 All about Motors Direct-on-line start of three-phase motors

Application on drive motors with severe starting duty For connection when used with L1 L2 L3 motor-protective circuit-breakers PKZM... and circuit-breakers NZM(H)... -F1 a section “Fuses with overload relay”, page 8-28

1 3 5 1 3 5 -Q11 -Q14 2 4 6 2 4 6

97 95 -F2 2 4 6 9698

UVW PE

8 M 3

-M1

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L1 Q14: Bridging contactor (Q11/1) K1: Timing relay Q11: Mains contactor -F0

95 13 -F2 -Q1 96 14

21 0 22 -S11 13 14 44 14 I -Q14 -Q14 -Q11 14 13 43 13

22 F2 Q14 Q11 96 14 22 -Q11 0 I 21 -S11 21 21 22 22 16 13 13 14 -K1 14 15 A B A1 A1 A1 -Q14 -K1 -Q11 A2 A2 A2 N 8 Control circuit device I: ON 0: OFF For connection of further control circuit devices a section “Three-wire control”, page 8-36

Method of operation Actuation of pushbutton I energizes the motor has been switched off by pressing bridging contactor Q14 which then maintains pushbutton 0. The normally closed contact itself via Q14/13-14. At the same time, voltage Q11/22-21 prevents Q14 and K1 closing whilst is applied to the timing relay K1. The mains the motor is running. In the event of an contactor Q11 is closed by Q14/44-43 and overload, normally closed contact 95-96 on maintains itself via Q11/14-13. When the set the overload relay F2 effects de-energization. time - which corresponds to the starting time of the motor - has elapsed, the bridging contactor Q14 is disconnected by K1/16-15. K1 is likewise disconnected and, exactly as Q14, can only be energized again after the For Immediate Delivery call KMParts.com at (866) 595-96168-27 Moeller Wiring Manual 02/05 All about Motors Direct-on-line start of three-phase motors

Two directions of rotation, DIUL reversing contactor Fuseless without overload relay Fuses with overload relay Short-circuit protection and overload Short-circuit protection1) for contactor and protection by means of motor-protective overload relay by means of fuses F1. circuit-breaker PKZM or circuit-breaker NZM. Short-circuit protection1) for contactor by Fuse size in the supply line in accordance with means of fuses F1. Moeller Main Catalogue, Industrial Switchgear or AWA installation instructions.

L1L2L3 L1 L3L2 L1L2L3

1 3 5 13 -F1 -F1 14

-Q1 I > I > I > 2 4 6

1 3 5 1 3 5 1 3 5 1 3 5 1 3 5 1 3 5 -Q11 -Q12 -Q11 -Q12 -Q11 -Q12 2 4 6 2 4 6 2 4 6 2 4 6 2 4 6 2 4 6

97 95 -F2 -F2 2 4 6 98 96 8 U V W PE U V W PE U V W PE M M M 3 3 3

-M1 -M1 -M1 1) Fuse size in accordance with data on the rating plate of the overload relay F2

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Reversing after actuation of pushbutton 0 Reversing without actuation of pushbutton 0 L1 L1 (Q11/1) (Q11/1)

-F0 -F0

95 95 13 13 -Q1 -F2 -Q1 -F2 14 96 14 96

21 21 0 0 22 22

21 22 21 22 II I II I 22 21 22 21 -S11 -S11 14 13 14 13 I II I II 13 14 13 14 14 14 14 14 -Q11 -Q12 -Q11 -Q12 13 13 13 13 8 22 22 22 22 -Q12 -Q11 -Q12 -Q11 21 21 21 21 A1 A1 A1 A1 -Q11 -Q12 -Q11 -Q12 A2 A2 A2 A2 N N

Q11: Mains contactor, clockwise Q12: Mains contactor, anticlockwise

Q11 F2 Q12 Q12 Control circuit Q11 Q11 F2 Q12 Q12 13 96 14 13 device 14 13 96 13 14 I 0 II (three-way 0I II -S11 -S11 21 21 21 21 21

pushbutton) 21 22 22 22 22 22 I = Clockwise 22 13 13 14 13 14 14 13 14 13 13 14 A B C 0 = Stop 14 A B C II = Anticlock- wise

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Method of operation: Actuation of anticlockwise direction). Depending on the pushbutton I energizes the coil of contactor circuit, direction can be changed from Q11. It switches on the motor running clockwise to anticlockwise either after clockwise and maintains itself after button I is pressing pushbutton 0, or by directly pressing enabled via its own auxiliary contact the pushbutton for the reverse direction. In the Q11/14-13 and pushbutton 0 (three-wire event of an overload, normally closed contact control contact). The normally closed contact 95–96 of the overload relay F2 or normally Q11/22-21 electrically inhibits switch on of open contact 13–14 of the motor-protective contactor Q12. When pushbutton II is pressed, circuit-breaker or circuit-breaker will switch. contactor Q12 closes (the motor runs in the

Reversing and two speeds (reversing contactor)

Special circuit (tapped winding) for feed FORWARD: feed or high speed drives, etc. RETRACT: high speed only STOP: tapped winding

L1 L2 L3

8 -F1

1 3 5 1 3 5 1 3 5 -Q17 -Q22 -Q21 2 4 6 2 4 6 2 4 6

97 95 97 95 -F21 -F2 2 4 6 98 96 2 4 6 98 96

1U 2U 1V M 2V 3 1W 2W

1 3 5 -M1 -Q23 2 4 6

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L1 0: Stop (Q17/1) I = Low speed – -F0 FORWARD (Q17) II = High speed – 95 -F2/F21 FORWARD (Q21 + 96 Q23) 21 0 III = High speed – 22 FORWARD (Q22 + 22 13 Q23) III III 21 14

22 -S11 II 21 21 14 I I 13 22 13 14 14 II -Q21 -Q22 14 13 13

13 21 31 -Q17 -Q17 -Q17 14 22 32 31 22 22 32 8 -Q22 -Q22 -K1 -Q21 32 21 21 31 21 13 43 Q17: Feed forward -Q21 -K1 -K1 Q21: High speed forward 22 14 44 22 13 44 Q23: Star contactor -Q23 -Q23 -Q23 K1: Contactor relay 21 14 43 A1 A1 A1 A1 A1 Q22: Retract high speed -Q17 -Q21 -Q23 -K1 -Q22 A2 A2 A2 A2 A2 N Method of operation: Forward travel is High speed reverse is initiated by pushbutton initiated by pressing pushbutton I or II III: Contactor relay K1 picks up and energizes according to the speed required. Pushbutton I star contactor Q23 via K1/14-13. High-speed switches on the feed motion via Q17. Q17 contactor Q22 is energized via the normally maintains itself via its normally open contact open contacts, K1/43-44 and Q23/44-43, and 13-14. If the feed movement is to occur at high are maintained via Q22/14-13. The reverse speed star contactor Q23 is energized via action can only be stopped via pushbutton 0. pushbutton II which energizes the high speed Direct changeover/reversal is not possible. contactor Q21 via its normally open contact Q23/13-14. Both of the contactors are maintained via Q21/13-14. A direct switch over from feed to high-speed during the process is possible. For Immediate Delivery call KMParts.com at (866) 595-96168-31 Moeller Wiring Manual 02/05 All about Motors Direct-on-line start with motor-protective circuit-breaker PKZ2

Reversing

L1 L2 L3

-Q1

I > I > I >

T1 T2 T3

L1 L2 L3 L1 L2 L3 A1 13 21 A1 13 21 -Q11 -Q12 8 A2 14 22 A2 14 11 I>> I>> I>> I>> I>> I>> T1 T2 T3 T1 T2 T3

U V W

M 3

-M1 Instead of the high-capacity contact modules S-PKZ2, contact module SE1A…-PKZ2 can also be used provided a switching capacity of the circuit-breaker of 30 kA/400 V is sufficient.

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Q11 Q1 Q12 Q12 Q11 Q11 Q12 Q12 13 1.14 14 13 13 14 14 13 I 0 II I 0 II

-S11 21 21 21 21 21 L1 21 L1 -S11 22 22 22 22 22 (Q11/1) (Q11/1) 22 13 14 13 13 13 14 14 13 14 14 13 -F0 -F0 14 A B C A B C 1.13 1.13 -Q1 -Q1 1.14 1.14 21 21 0 0 22 22

21 22 21 22 -S11 II -S11 II 22 21 22 21

14 13 14 13 I I 13 14 13 14 14 14 14 14 -Q11 -Q12 -Q11 -Q12 13 13 13 13

22 22 22 22 8 -Q12 -Q11 -Q12 -Q11 21 21 21 21 A1 A1 A1 A1 -Q11 -Q12 -Q11 -Q12 A2 A2 A2 A2 N N a a

a Stop

S11 RMQ-Titan, M22-… 14 14 -Q11 -Q12 Q1 PKZ2/ZM-… 13 13 Q12 S/EZ-PKZ2 a Q11 S/EZ-PKZ2 22 22 -Q12 -Q11 F0 FAZ 21 21 a remove links with position switches

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Two speeds

L1 L2 L3

L1 L2 L3 1.13 1.21 L1 L2 L3 1.13 1.21 Instead of the -Q1 -Q2 high-capacity contact 1.14 1.22 1.14 1.22 modules S-PKZ2, contact module I > I > I > I > I > I > SE1A…-PKZ2 can also be used provided T1 T2 T3 A1 13 21 A1 13 21 a switching capacity -Q17 -Q21 A2 2214 A2 14 22 of the circuit-breaker I>> I>> I>> I>> I>> I>> of 30 kA/400 V is T1 T2 T3 T1 T2 T3 sufficient. 8

1U 2U 1V M 2V 1W 3 2W

-M1

1U 2U

1W 1V 2W 2V n < n >

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Version 1 Version 2 Q17 Q2 Q21 Q21 Q17 Q17 Q2 Q21 Q21 13 1.14 14 13 13 14 1.14 14 13 L1 0I II L1 I 0 II (Q17/1) (Q17/1) -S11 21 -S11 21 21 21 21 21 22 22 22 22 22 -F0 -F0 22 1.13 13 13 13 14 14 13

1.13 13 14 13 14 14 -Q1 -Q1 14 1.14 A B C 1.14 A B C 1.13 1.13 -Q2 -Q2 1.14 1.14 21 21 0 0 22 22

21 22 21 22 -S11 II -S11 II n> 22 21 n> 22 21 14 13 14 13 I I 13 14 13 14 n< 14 14 n< 14 14 -Q17 -Q21 -Q17 -Q21 13 13 13 13 22 22 22 22 8 -Q21 -Q17 -Q21 -Q17 21 21 21 21 A1 A1 A1 A1 -Q17 -Q21 -Q17 -Q21 A2 A2 A2 A2 N N Stop n< n> Stop n< n>

S11 RMQ-Titan, M22-… – Q1, Q2 PKZ2/ZM-…/S – Q21 S-PKZ2 n > Q17 S-PKZ2 n < S11 RMQ-Titan, M22-… –

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Typical example of circuits with contactor DILM…

Three-wire control

F2 Q11 Q11 Q11 F2 Q11 Q11 96 0I14 13 A2 96 14 13 0II 0 22 22 -S11 21

21 -S11 21 21 21 21 22 22 22 22 13 13 14 14 13 13 13 13 14 14 14 14 A B A B X1 X2 Illuminated pushbutton Two two-way pushbuttons Q11 Q11 F2 Q11 Q11 F2 F2 Q11 Q11 Q11 1 I 96 A2 14 13 14 13 96 14 13 96 0 1 0 I 0 Start Start 22 22 0 I 1

21 0 1 Start 21 1 1 14 13 14 13 2* S11 2* S11 3 3 A B C 4 4 8 Two-way pushbutton with T0-1-15511 spring-return T0-1-15366 spring-return indicator light switch with automatic return switch with automatic return to position 1 to position of rest

Two-wire control

Q11 Q11 F2 Q11 F2 F2 Q11 14 13 96 I ON 96 A1 0 A1 96 OFF

0 1 2 1 3 5 I 4 1 P > Q 2* S11 2 4 6 1 3 4 -S12

Changeover switch Pressure switch MCS Float switch SW T0-1-15521 with fleeting contact in the intermediate position

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Star-delta starters with overload relay

Arrangement in the motor line The star-delta starter with overload relay, including a thermally delayed overcurrent relay are situated in a standard circuit

1 3 5 configuration in the leads leading to the -Q11 motor terminals U1, V1, W1 or V2, W2, U2. 2 4 6 The overload relay is also operational in the star connection as it is in series with the motor 97 95 -F2 winding and the relay current flowing through 2 4 6 98 96 it = rated motor current x 0.58. a U1 V1 W1 The complete circuit diagram section “Automatic star-delta starters SDAINL”, page 8-39.

Arrangement in the mains supply line Instead of the arrangement in the motor line, -F1 the overload relay can be placed in the mains 8 supply line. The section shown here

97 95 indicates how the circuit differs from that on -F2 a section “Automatic star-delta starters 2 64 98 96 SDAINL”, page 8-39. For drives where the F2 relay trips out when the motor is starting in 1 3 5 the star circuit, the F2 relay rated for the -Q11 2 4 6 rated motor current can be switched in

U1 V1 W1 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.

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Configuration in the delta circuit Instead of the arrangement in the motor line or mains supply line, the overload relay can be

1 3 5 1 3 5 placed in the delta circuit. The section shown -Q15 -Q13 2 64 2 4 6 here indicates the modified circuit diagram a 97 95 from section “Automatic star-delta -F2 2 4 6 98 96 starters SDAINL”, page 8-39. When heavy, long-starting procedures are involved (e.g. for centrifuges) the F2 relay, rated for relay x V2 W2 U2 current = rated motor current 0.58, can also be connected in the connecting lines between the delta contactor Q15 and the star contactor Q13. In the star circuit no current then flows through the F2 relay. The motor is therefore not protected when starting. This circuit is always used when exceptionally heavy and long starting procedures are involved and when saturable core current transformer-operated relays react too quickly. 8

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Automatic star-delta starters SDAINL

L1 L2 L3 21 1 3 5 13 -Q1 14 22 B -F1 I > I > I > 2 4 6

1 3 5 1 3 5 1 3 5 -Q11 -Q15 -Q13 2 4 6 2 4 6 2 64

97 95 A -F2 2 4 6 98 96 8

U1 V2 V1 M W2 W1 3 U2

-M1

Arrangement and rating of protective devices

Position A Position B

F2 = 0.58 x Ie Q1 = Ie with F1 in position B ta F 15 s ta > 15 – 40 s Motor protection in y and d configuration Only partial motor protection in y configuration

Rating of switchgear Q13 = 0.33 x Ie Q11, Q15 = 0.58 x Ie

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Further notes on the configuration of the overload relay a section “Automatic star-delta starters SDAINL”, page 8-39.

Automatic star-delta starters SDAINL00AM to 4AM250 Pushbutton Two-wire control L1 L1 (Q11/1) (Q11/1)

-F0 -F0

HAND 95 13 95 -F2 -Q1 -F2 96 14 96 2 4 I 21 -S14 P > 0 2 MCS 1 22 -S14 Q -S11 1 13 14 SW 14 I -Q11 -Q11 14 13 13

44 14 14 14 14 17 44 -Q11 -Q13 -Q15 17 -Q11 -Q13 -Q15 43 13 13 -K1 -K1 8 18 28 43 13 13

22 22 -Q15 -Q13 F2 Q11 Q11 21 21 96 14 13 0I -S11 21 21 22 22 A1 A1 A1 A1 13 14 13 -Q11 -K1 -Q13 -Q15 14 A2 A2 A2 A2 A B N Q11: Mains contactor Two-way pushbutton K1: Timing relay approx. 10 s Control circuit Q13: Star contactor device Q15: Delta contactor I = ON 0 = OFF

For connection of further control circuit to star contactor Q13. Q13 closes and applies devices a section “Control circuit devices for voltage to mains contactor Q11 via normally star-delta starting”, page 8-49 open contact Q13/14–13. Method of operation Q11 and Q13 maintain themselves via the Pushbutton I energizes timing relay K1, the normally open contacts Q11/14–13 and normally open contact K1/17–18 Q11/44–43. Q11 applies voltage to motor M1 (instantaneous contact) which applies voltage in star connection.

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For connection of further control circuit devices a section “Control circuit devices for star-delta starting”, page 8-49 Method of operation Delta contactor Q15 closes and switches Pushbutton I energizes star contactor Q13, the motor M1 to full mains voltage. At the same normally open contact Q13/14–13 applies time, normally closed contact Q15/22–21 voltage to mains contactor Q11: Q11 closes interrupts the circuit of Q13, thus interlocking and applies mains voltage to motor M1 in star against renewed switching on while the motor connection. Q11 and Q13 maintain is running. themselves via normally open contact The motor cannot be started up again unless it Q11/14–13 and Q11 additionally via has previously been disconnected by Q11/44–43 and pushbutton 0. Timing relay pushbutton 0, or in the event of an overload, Q11 is energized at the same time as mains by the normally closed contact 95–96 of the contactor K1. When the set changeover time overload relay F2, or via the normally open has elapsed, K1 opens the circuit of Q13 via contact 13–14 of the motor-protective the changeover contact 15–16 and closes the circuit-breaker or circuit-breaker. circuit of Q15 via 15–18. Star contactor Q13 drops out. 8

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Automatic reversing star-delta starter SDAIUL Reversing

L1 L2 L3 1 3 5 13 21 -Q1 14 22 -F1 I > I > I > 264

1 3 5 1 3 5 1 3 5 1 3 5 -Q11 -Q12 -Q15 -Q13 2 4 6 2 4 6 2 4 6 2 4 6

97 95 -F2 2 4 6 98 96 8

W1 V2 V1 M W2 U1 3 U2

-M1

Rating of switchgear Standard version: relay current = motor rated Q11, Q12 = Ie current x 0.58

F2, Q15 = 0.58 x Ie For other arrangements of overload relay a section “Star-delta starters with overload Q13 = 0.33 x Ie relay”, page 8-37 The maximum motor output is limited by the upstream reversing contactor, and is lower than with automatic star-delta starters for only one direction of operation

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Reversing after actuation of pushbutton 0 L1 Three-way pushbutton (Q11/1) Control circuit devices I = Clockwise -F0 0 = Stop 95 13 II = Anticlockwise -F2 -Q1 96 14 Q11 F2 Q12 Q12 21 13 96 14 13 0 I 0 II 22 -S11 21 21 21 22 21 22 22 22 II I 22 21 13 14 14 13 13 -S11 14 14 II 13 A B C I 14 44 44 14 13 -Q11 -Q12 -Q12 14 -Q11 13 43 43 13 17 17 -K1 -K1 18 28 22 22 22 22 -Q12 -Q15 -Q13 -Q11 21 21 21 21 A1 A1 A1 A1 A1 -Q11 -K1 -Q13 -Q15 -Q12 8 A2 A2 A2 A2 A2 N

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Reversing without actuation of pushbutton 0 L1 Three-way pushbutton (Q11/1) Control circuit devices I = Clockwise -F0 0 = Stop 95 13 II = Anticlockwise -F2 -Q1 96 14 Q11 Q11 F2 Q12 Q12 21 13 14 96 14 13 0 I 0 II 22 -S11 21 21 21 22 21 22 22 22 II I 22 21 13 14 14 14 13 -S11 13 14 II 13 A B C I 14 44 44 14 14 13 -Q11 -Q12 -Q11 13 43 43 -Q12 13 17 17 -K1 -K1 18 28 22 22 22 22 -Q12 -Q15 -Q13 -Q11 21 21 21 21 A1 A1 A1 A1 A1 -Q11 -K1 -Q13 -Q15 -Q12 A2 A2 A2 A2 A2 N 8 For connection of further control circuit Delta contactor Q15 energizes and switches devices a section “Control circuit devices for motor M1 to the delta configuration, i.e. full star-delta starting”, page 8-49 mains voltage. At the same time, normally closed contact Q15/22–21 interrupts the Method of operation circuit of Q13, thus interlocking against Pushbutton I energizes contactor Q11 (e.g. renewed switching on while the motor is clockwise), pushbutton II energizes contactor running. Motor direction can be changed, Q12 (e.g. anticlockwise). The contactor first either after pressing pushbutton 0, or by direct energized applies voltage to the motor actuation of the reverse button, depending winding and maintains itself via its own upon the circuit. In the event of an overload, auxiliary contact 14–13 and pushbutton 0. The disconnection is effected by the normally normally open contact 44–43 fitted to each closed contact 95–96 of the overload relay F2. mains contactor energizes the star contactor Q13. Q13 energizes and switches on motor M1 in the star connection. At the same time, timing relay K1 starts. When the set changeover time has elapsed, K1/17–18 opens the circuit of Q13. Q13 drops out. K1/17–28 closes the circuit of delta contactor Q15.

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L1 L2 L3

L1 L2 L3 1.13 1.21 -Q1

1.14 1.22

U F 690 V I > I > I >

L1 L2 L3 A1 13 21 T1 T2 T3 Q13 A2 14 22 I>> I>> I>> T1 T2 T3

U F 500 V

L1 L2 L3 L1 L2 L3 135 A1 13 21 A1 13 21 -Q11 -Q15 -Q13 8 A2 14 22 A2 14 22 246 I>> I>> I>> I>> I>> I>> T1 T2 T3 T1 T2 T3

1U 2V 1V M 2W 1W 3 2U

-M1

With Icc > Icn short-circuit proof installation required.

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L1 (Q11/1)

-F0

1.13 -Q1 1.14 21 0 22

13 14 -S11I -Q11 14 13

44 14 -Q11 -Q13 -K1 43 13 15 A2 16 18

22 22 -Q15 -Q13 21 21 8 A1 A1 A1 A1 -K1 -Q11 -Q13 -Q15 A2 A2 A2 A2 N 10 s N Y

2 x RMQ-Titan, M22-… with indicator light M22-L…T0-1-8 rotary switch Q1 Q11 Q11 Q11 Q11 Q11 Q1 1.14 43 A214 44 44 14 1.14 0I 01 S11 1 21 22 2221 2 S11 3 13 14 1413 4 A B

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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 (y) + d protection F0 FAZ Setting l

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Three-phase reversing contactor DIUL reversing star-delta starter SDAIUL

F2 Q12 Q11 Q11 Q12 F2 Q11 Q12 Q12 96 III13 13 13 I A2 21 96 0 2114 II 13 -S11 -S11 21 21 21 22 22 22 21 21 22 22 14 14 14 13 13 13 14 14 13 13 B C D A B A E

Two-way pushbutton1)without Three-way pushbutton with indicator light. Reversing self-maintaining circuit (inching) for after actuation of pushbutton 0 use only with reversing contactors

0 0 Q12 F2 Q11 12 13 96 13 12 120 1 2 FS 4011 FS 684 3 4 Spring-return switch 1) Changeover switch1) 8 T0-1-8214, without Switch T0-1-8210 remains self-maintaining circuit in position 1 or 2 (inching) Automatic return to 0 only for reversing contactors

0 Q12 Q12 Q11F2 12

14 9613 13 START START START 01 2 START 1 FS 140660 2 3 4 Spring-return switch 5 6 T0-2-8177 with automatic 7 8 return to position 1 or 2

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

1) Overload relay always with manual reset

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The speed is determined by the number of be obtained by altering the number of poles. poles on induction motors. Several speeds can The usual types are: 2 speeds 1:2 1 reversible tapped winding 2 speeds 2 separate windings 3 speeds 1 reversible tapped winding 1:2, 1 separate winding 4 speeds 2 reversible tapped windings 1:2 2 speeds Tapped winding

The various tapped winding configurations The y/y y is preferred for better matching give differential output ratios for the two of the motor to machines in which the torque speeds increases by a quadratic factor (pumps, fans, rotary compressors). Moeller multi-speed Type of connection d/y yy/y y starters can be used for both types of Output ratio 1/1.5–1.8 0.3/1 connection. The d/y y configuration comes nearest to 2 speeds – separate windings satisfying the most usual requirement for In theory, motors with separate windings 8 constant torque. It has the additional allow any combination of speed and any advantage that, because nine terminals are output ratio. Both windings are arranged in y available, y/d starting can be used to connection and are completely independent of provide smooth starting or to reduce the one another. starting current for the low speed condition Preferred speed combinations are: (a section “Motor windings”, page 8-54). Motors with tapped 1500/3000 – 750/1500 500/1000 winding Motors with separate – 1000/1500 – – windings No. of poles 4/2 6/4 8/4 12/6 Code no. low/high 1/2 1/2 1/2 1/2

The code numbers are prefixed to the main notations to denote increasing speed. Example: 1U, 1V, 1W, 2U, 2V, 2W. Comparable to EN 60034-8.

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Motor circuit Circuit A Circuit B Circuit C Selection of low and high Selection of either speed from Selection of either speed from speed only from zero. No zero. Switching from low to zero. Switching back and return to low speed, only to high speed possible. Return forward between low and high zero. only to zero. speed (high braking torque). Return also to zero. High speed

Low speed

Off (zero) Switch-on and further switching Switch-off

3 speeds above the two tapped winding speeds. The The 1:2 speeds - tapped windings - are circuit must consider it (a page 8-82). supplemented by the speed of the separate Preferred speed combinations are: 8 winding. This speed can be below, between or Speeds 1000/1500/3000 750/1000/1500 750/1500/3000 = separate winding (in No. of 6/4/2 8/6/4 8/4/2 the circuit poles diagrams) Circuit X Y Z

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Motor circuit Circuit A Circuit B Circuit C Selection of any speed only from Selection of any speed from Selection of any speed from zero. Return only to zero. zero and from low speed. zero and from low speed. Return only to zero. Return to low speed (high braking torque) or to zero.

3rd speed

2nd speed

1st speed

Off (zero)

Switch-on and Switch-off further switching

4 speeds The 1:2 speeds - tapped windings - can follow in sequence or overlap, as the following 8 examples show: 1st winding 500/1000 2nd winding 1500/3000 = 500/1000/1500/3000 or 1st 500/1000 2nd winding 750/1500 = 500/750/1000/1500 winding

For motors having 3 or 4 speeds the non-connected winding has to be opened at certain pole ratios to avoid inductive circulating currents. This is achieved via additional motor terminals. A range of rotary switches is equipped with this connection (a section “Multi-Speed Switches”, page 4-7).

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Tapped winding Tapped winding 2 speeds 3 speeds Motor circuit Tapped winding Motor circuit X Motor circuit Y 2 speeds with yd starting at 2 windings, medium and 2 windings, low an 2 separate windings low speed high speed – tapped wind- speed – tapped win ing

Low speed d Low speed y Low speed Low speed y 22

1U 1U 1U 1U 2U 1U 2W1 2W 3W 3W 2W2 2U2 2W 2V 2U1 2V2 2V1 2U 2V 1W 1V 3U 3V 3U 3V 1W 1V 2W 2V 1W 1W 1V 1W 2U 1V

High speed yy High speed yy High speed Low speed d or 2 or 2

2U 2U 2U 1U 2U 2W2 1U

1W 1V 2U1 2W1 8 1W 1V 3W 3V 3W 3V 1W 2U2 2W 2V 1U 2W 2V2 2V1 1V 1U 2V 2W 2V 2W 3U 2V 1W 3U 1 a page 8-59 a page 8-59 a page 8-63 Low speed Medium speed Separate winding Separate winding High speed yy 1 1

2U1 1U 2U

1W 2W2 2U2 1V

1U 2V2 1W 1V 2W 2W1 2V1 a page 8-72 a page 8-81 a page 8-83

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Tapped winding 3 speeds Motor circuit Tapped winding Motor circuit X Motor circuit Y Motor circuit Z 2 speeds with yd starting at 2 windings, medium and 2 windings, low and high 2 windings, low and medium 2 separate windings low speed high speed – tapped speed – tapped winding speed – tapped winding winding

Low speed Low speed y 222

1U 1U 2U 1U 1U 2W1 3W 3W 2W 2W2 2U2 2U1 2V2 2V1 1W 1V 3U 3V 3U 3V 2U 2V V 2W 2V 1W 1V 1W 1V 1W 1V

High speed Low speed d or 2 or 2 or 2

2U 1U 1U 2U 2W2 1U

2U1 2W1 3W 3V 3W 3V 2W 2V 8 1W 2U2

2V2 2V1 1V 2W 2V 2W 3U 2V 1W 3U 1V 1W 2U 1V a page 8-63 Low speed Medium speed High speed Separate winding Separate winding Separate winding High speed yy 1 1 1

2U1 1U 2U 3U

1W 2W2 2U2 1V

1U 2V2 1W 1V 2W 2V 3W 3V 2W1 2V1 a page 8-72 a page 8-81 a page 8-83 a page 8-85

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Certain operating sequences for multi-speed these possibilities. Multi-speed contactor motors may be necessary, or undesirable, starters can achieve these circuits by depending on the nature of the drive. If, for interlocking with suitable control circuit example, the starting temperature rise is to be devices. reduced or high inertia loads are to be Fuse protection of the overload relay accelerated, it is advisable to switch to low When a common fuse is used in the supply speed first and then to high speed. line, it must not be larger than the back-up It may be necessary to prevent switching from fuses specified on the rating plate of either high to low speed in order to avoid overload relay, otherwise each relay must be oversynchronous braking. In other cases, it protected by its own back-up fuse, as shown in should be possible to switch each speed on the diagram. and off directly. The operating sequence and indexing facilities of rotary switches allow for

L1 L2 L3

-F11 -F1

135 135 -Q17 -Q21 246 246

97 95 97 95 -F21 -F2 24 6 98 96 246 98 96

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Fuseless arrangement Multi-speed motors can be protected against advantages of a fuseless circuit. Normally, the short circuits and overloads by fuse in the supply line protects the switches motor-protective circuit-breakers PKZ or from welding. circuit-breakers NZM, which provide all the

L1 L2 L3

1 35 13 1 35 13

14 14 -Q1 -Q2 I > I > I > I > I > I > 24 6 24 6

13 5 13 5 8 -Q17 -Q21 24 6 24 6

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Tapped winding, non-reversing, 2 speeds Multi-speed contactors UPIL Fuseless, without overload relay, with motor-protective circuit-breaker or circuit-breaker.

L1 L2 L3

1 35 13 1 35 13

14 14 -Q1 -Q2 I > I > I > I > I > I > 24 6

13 5 13 5 13 5 -Q21 -Q17 -Q23 8 24 6 24 6 24 6

2U 1U

2V M 1V 3 2W 1W

-M1 a section “Motor windings”, page 8-54 Synchronous speeds One multi-speed winding

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Motor terminals 1U, 1V, 1W 2U, 2V, 2W No. of poles 12 6 rpm 500 1000 No. of poles 8 4 rpm 750 1500 No. of poles 4 2 rpm 1500 3000 Contactors Q17 Q21, Q23

Rating of switchgear

Q2, Q17 = I1 (low speed)

Q1, Q21 = I2 (high speed)

Q23 = 0.5 x I2 8

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Circuit A (a page 8-53) 1 three-way pushbutton

L1 Q17 F21 Q21 Q21 (Q11/1) 13 96 14 13 II0 I -F0 -S11 21 21 21 22 22 22 13 14 13 13 14 13 14 -Q1 A B C 14 13 -Q2 14 Three-way pushbutton I: Low speed (Q17) 21 0: Stop 0 22 -S11 II: High speed 21 22 (Q21 + Q23) II I 22 21 Q17: Mains contactor, low speed 14 13 Q23: Star contactor I II 13 14 Q21: Mains contactor, high speed

14 14 -Q17 -Q21 8 13 13

21 21 -Q21 -Q17 22 22 22 14 -Q23 -Q23 21 13 A1 A1 A1 -Q17 -Q23 -Q21 A2 A2 A2 N

For connection of further control circuit Speed can be changed either after pressing devices a page 8-67, a page 8-68, pushbutton 0 (circuit A) or directly by pressing a page 8-69 the appropriate pushbutton (circuit C), depending upon the circuit. The motor can be Method of operation switched off either by pressing pushbutton 0, Pushbutton I energizes mains contactor Q17 or in the event of an overload, by normally (low speed). Q17 maintains itself via its open contact 13–14 of the motor-protective normally open contact 13 – 14. Pushbutton II circuit-breaker or circuit-breaker. 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.

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Circuit C (a page 8-53) 1 three-way pushbutton L1 Three-way pushbutton (Q11/1) I: Low speed (Q17) 0: Stop -F0 II: High speed (Q21 + Q23)

13 Q17 Q17 F21 Q21 Q21 -Q1 14 13 96 13 14 14 II0 I 13 -S11 21 -Q2 21 21 22 22 14 22 13 14 13 13 14 14 21 A B C 0 22 -S11 21 22 II I 22 21 14 13 I II 13 14

14 14 8 -Q17 -Q21 13 13

22 21 -Q21 -Q17 21 22 21 14 -Q23 -Q23 22 13 A1 A1 A1 -Q17 -Q23 -Q21 A2 A2 A2 N Q17: Mains contactor, low speed Q23: Star contactor Q21: Mains contactor, high speed

For connection of further control circuit devices a page 8-70

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2 separate windings, non-reversing, 2 speeds Multi-speed contactor UPDIUL, fuseless without overload relay L1 L2 L3

1 35 13 1 35 13

14 14 -Q1 -Q2 I > I > I > I > I > I > 24 6 24 6

13 5 13 5 -Q17 -Q21 24 6 24 6 8

1U 2U

1V M 2V 3 1W 2W

-M1

Rating of switchgear

Q1, Q17 = I1 (low speed)

Q2, Q21 = I2 (high speed)

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2 separate windings, non-reversing, 2 speeds Multi-speed contactor UPDIUL, with fuses and overload relay

L1 L2 L3

F1 135 135 Q17 Q21 246 97 95 246 97 95 F21 F2 246 98 96 246 98 96

1U 2U

1V M 2V 1W 3 2W

Fuse size in accordance with data on the rating plate of the overload relays F2 and F21. If overload relays F2 and F21 cannot be protected by a common fuse, then use circuit as in a page 8-57. a section “Motor windings”, page 8-54.

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Circuit A (a page 8-53) Circuit C (a page 8-53) 1 three-way pushbutton 1 three-way pushbutton

L1 L1 (Q17/1) FO -F0 95 13 FL1 Q1 F2 13 95 14 96 13 95 -Q1 -F2 14 96 Q2 F21 95 96 13 14 -Q2 21 -F21 14 96 0 21 22 S11 0 21 22 22 II I -S11 21 22 22 21 14 13 II I I II 22 21 13 14 14 13 I II 13 14 14 14 Q17 Q21 14 14 13 13 -Q17 -Q21 22 22 13 13 Q21 Q17 22 22 8 21 21 -Q21 -Q17 21 21 A1 A1 Q17 Q21 A1 A1 A2 A2 -Q17 -Q21 N A2 A2 N

Q17: Mains contactor, low speed Q21: Mains contactor, high speed Q17 F21 Q21 Q21 Q17 Q17 F21 Q21 Q21 13 96 14 13 14 13 96 13 14 II0 I I 0 II -S11 21 21 21 22 22 22 21 21 -S11 21 22 22 22 13 14 13 13 14 14 13 13 14 14 13 A B C 14 A B C

Three-way pushbutton For connection of further control circuit I: Low speed (Q17) devices, see a page 8-71. 0: Stop II: High speed (Q21 + Q23)

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Method of operation Speed can be changed either after pressing Actuation of pushbutton I energizes the coil of pushbutton 0, or directly by pressing the contactor Q17. Q17 brings in the motor at low appropriate pushbutton, depending upon the speed, and after pushbutton I is released, circuit. The motor is switched off either by maintains itself via its auxiliary contact 13–14 pressing pushbutton 0, or in the event of an and pushbutton 0. overload, by normally closed contact 95–96 of overload relays F2 and F21.

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2 separate windings, non-reversing, 2 speeds Circuit A (a page 8-53) One three-way pushbutton with indicator lights

-F0

95 -F2/F21 96 21 0 22 21 22 II I 22 21 13 14 II I 14 13 14 14 -Q17 -Q21 13 13

22 22 A -Q21 -Q17 B 8 21 21

A1 A1 B -Q17 D -Q21 A2 A2 N

Q17 Q21 F21 Q17 Q21 Q21 Control circuit devices 13 A2 96 21 14 13 I = Low speed (Q17) I 021 II 0 = Stop

-S11 21 22 21 21

22 22 II = High speed (Q21) 13 13 13 14 14 14 A B C D E

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Circuit A (a page 8-53) 2 three-way pushbuttons

-F0 95 -F2/F21 96 21 0a 22 21 0b 22

21 22 Ib IIb 14 13 22 21 Ia IIa 13 13 13 14 IIb Ib 14 14 22 21 IIa Ia 21 22 14 14 -Q17 -Q21 8 13 13 22 22 A -Q21 -Q17 B 21 21

Q21 F21 Q17 Q21 Control circuit devices 13 96 13 14 Ia IIa0a Ib IIb0b I: Low speed (Q17) 0: Stop 21 21 -S11 -S11 21 21 21 21 22 22 22 22 22 22 II: High speed (Q21) 13 14 13 14 13 14 13 14 13 14 13 14 Remove existing links and rewire A B C A B C

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Circuit A (a page 8-53) T0-1-8210 changeover switch Always set overload relay to manual reset L1 Q21 F2 Q17 13 96 13

-F0 1 0 2 1 95 2 3 S12 -F2/F21 4 96

1 2 24 -S12 -S12 13 14 14 -Q17 -Q21 13 13 22 22 AB-Q21 -Q17 21 21 Circuit B (a page 8-53) 1 three-way pushbutton L1

-F0 8

95 -F2/F21 96 21 0 22 21 13 II II 22 14 14 14 14 I -Q17 -Q21 13 13 13 22 22 A -Q21 -Q17 B 21 21 A1 A1 -Q17 -Q21 A2 A2 N

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Circuit B (a page 8-53) 2 three-way pushbuttons

L1 -F0 95

-F2(1) 96 21 0a 22 21 0b 22 21 IIb 22 21 IIa 22 14 14 13 13 Ib 14 Ia 14 IIa IIb 13 13 -Q17 13 -Q21 13 14 14 22 22 A -Q21 -Q17 B 21 21

Control circuit device for circuit B

Q17 Q17 F21 Q21 Q21 14 13 96 13 14 8 Ia 0a IIa Ib 0b IIb

21 22 21 22 21 22 21 22 21 22 21 22

13 14 13 14 13 14 S11 13 14 13 14 13 14 S11 A B C A BC

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Circuit C (a page 8-53) 2 three-way pushbuttons

L1 -F0

95 -F2(1) 96 21 0a 22 21 0b 22 21 22 IIb 22 Ib 21 21 22 IIa Ia 22 21 14 14 14 14 13 13 Ib Ia -Q17 -Q21 IIa IIb 13 13 13 13 14 14 22 22 A -Q21 -Q17 B 21 21

Control circuit device for circuit C

Q17 Q21 F21 Q21 8 14 13 14 96 13 Ia 0a IIa Ib 0b IIb 21 -S11 21 21 -S11 21 21 21 22 22 22 22 22 22 13 13 14 14 13 13 14 13 13 14 14 14 A B C A B C

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Tapped winding, non-reversing, 2 speeds Multi-speed contactors UPSDAINL Fuseless Star-delta starting at low speed Without overload relay

L1 L2 L3

135 13 135 13

14 14 -Q1 -Q2 I > I > I > I > I > I > 2 4 6 246

135 135 -Q17 -Q21 246 246 8 1 3 5 1 3 5 -Q23 -Q19 2 4 6 2 4 6

1U 1V 1W PE 2U2 2U1 2V2 3 2V1 2W2 Y 2W1

-M1 Rating of switchgear Q1, Q17 = I1 (low speed) Q2, Q21 = I2 (high speed) Q19, Q23 = 0,5 x I2

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With fuses and overload relay

L1 L2 L3

-F1

135 135 -Q17 -Q21 246 246 97 95 97 95 -F2 -F21 246 246 98 96 98 96

1 3 5 1 3 5 -Q23 -Q19 2 4 6 2 4 6

1U 1V 1W PE 2U2 2U1 8 2V2 3 2V1 2W2 Y 2W1

-M1 Rating of switchgear F2, Q17 = I1 (low speed) F21, Q21 = I2 (high speed) Q19, Q23 = 0,5 x I2 F1 = I2 Overload relays F2 and F21 are not used on multi-speed contactors without motor protection. If F2 and F21 cannot be protected by a common fuse, then use circuit on a page 8-57. a section “Motor windings”, page 8-54.

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L1 Circuit (Q17/1) Low speed selected -F0 only from zero, high speed only via low 13 95 speed without -Q1 14 96 95 actuation of the Stop 13 -Q2 -F21 button. 14 96 -S11 21 Three-way 0 22 pushbutton 13 I: Low speed I 14 (Q17, Q19) 0: Stop 13 43 13 15 13 -Q17 -Q17 -Q23 -K3 -Q19 II: High speed 14 44 14 16 14 (Q21, Q19, 21 32 21 13 Q23) II -Q19 II 31 22 -Q23 22 14 43 -Q21 22 22 14 44 -Q21 -Q19 -Q21 22 8 21 21 13 -Q17 21 A1 A1 A1 A1 A1 -Q17 -K3 -Q23 -Q19 -Q21 A2 A2 A2 A2 A2 N Q17: Mains contactor, low Q19: Delta contactor Q17 Q17 F21 Q17 Q21 Q19 speed Q21: Mains contactor, 43 13 96 14 22 44 14 K3: Timing relay high speed I 0 II Q23: Star contactor -S11 21 21 21 22 22 22 Method of operation 13 14 13 14 13 14 Actuation of pushbutton I energizes the coil of A B C star contactor Q23, and its normally open contact 13–14 energizes the coil of contactor Q17. The motor runs in star at low speed. The The motor runs in delta at low speed. contactors are maintained via auxiliary contact Actuation of pushbutton II de-energizes the Q17/13–14. At the same time, timing relay K3 coil of Q17 and via Q17/22–21 energizes the cuts in. When the set time has elapsed, coil of Q21. This state is maintained by K3/15–16 opens the circuit of Q23. Q23 drops Q21/43–44: The coil of star contactor Q23 is out, the coil of delta contactor Q19 is re-energized by normally open contact energized and maintains itself via Q19/13–14. Q21/14–13. The motor runs at high speed. The timing relay is de-energized via normally Pushbutton 0 (= Stop) effects disconnection. closed contact Q19/32–31. For8-74 Immediate Delivery call KMParts.com at (866) 595-9616 Moeller Wiring Manual 02/05 All about Motors Multi speed switch for three-phase motors

Tapped winding, reversing, 2 speeds (direction preselected)

Multi-speed contactors UPIUL Overload relays F2 and L1 L2 L3 F21 are not used on multi-speed contactors without motor protection. -F1

135 135 -Q11 -Q12 2 4 6 246

135 135 -Q17 -Q21 246 246 97 95 97 95 -F2 -F21 8 246 98 96 2 4 6 98 96

135 Rating of switchgear -Q23 246 Q11, Q12 = I2 (low and high speed) F2, Q17 = I1 (low speed) PE F1, Q21 = I2 Q23 = 0.5 x I2 (high speed) 1U 2U M 1V 2V 1W 3 2W

-M1

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L1 Five-way pushbutton (Q11/1) Circuit -F0 Change of direction 95 FORWARD–REVERSE -F2 96 after actuation of Stop 95 -F21 button, optionally 96 21 followed by

0 22 SLOW–FAST with no -S11 22 return to low speed. 21 I II 22 21

14 14 44 44 13 I 13 -Q11 -Q11 -Q12 43 -Q12 13 13 43 14 II 14 21 IV 22 22 III 21 14 14 13 14 III -Q17 IV -Q21 13 13 14 13

21 21 -Q17 -Q21 22 22 22 22 22 14 -Q11 8 -Q12 -Q23 -Q23 21 21 21 13 A1 A1 A1 A1 A1 -Q11 -Q17 -Q23 -Q21 -Q12 A2 A2 A2 A2 A2 N

Control circuit F21 Q11 Q12 Q12 Q17 Q11 Q17 Q17 96 13 13 14 13 43 14 21 device 0 I II III IV 0: Stop I: Forward (Q11)

-S11 21 21 21 21 21 22 22 22 22 22 II: Back (Q12) 14 13 13 13 13 13 14 14 14 14 III: Slow (Q17) A B C D E IV: Fast (Q21 + Q23)

Method of operation energizes high-speed contactors Q23 and Contactor Q11 is energized by pressing Q21. Auxiliary contact Q21/21–22 makes pushbutton I. Contactor Q11 selects the low-speed pushbutton III inoperative. direction, and maintains itself after release of Pushbutton 0 must be pressed before any pushbutton I via its auxiliary contact 14–13 change in speed or direction. 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 For8-76 Immediate Delivery call KMParts.com at (866) 595-9616 Moeller Wiring Manual 02/05 All about Motors Multi speed switch for three-phase motors

Tapped winding, reversing, 2 speeds (Direction and speed selected simultaneously) Multi-speed contactor UPIUL Fuseless without overload relay

L1 L2 L3

135 13 135 13

14 14 -Q1 -Q2 I> I> I> I> I> I> 246 246

135 135 135 135 -Q17 -Q18 -Q21 -Q22 246 2 4 6 246 246

1U 2U 1V M 2V 1W 3 2W

135 -M1 -Q23 246

Rating of switchgear

Q1, Q17, Q18 = I1 (low speed)

Q2, Q21, Q22 = I2

Q23 = 0.5 x I2 (high speed)

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Multi-speed contactor UPIUL With fuses and overload relay

L1 L2 L3

-F1

135 135 135 135 -Q17 -Q18 -Q21 -Q22 246 246 246 246

97 95 97 95 -F2 -F21 246 98 96 246 98 96

8 PE 1U 2U 1V M 2V 1W 3 2W

135 -Q23 246 -M1

Rating of switchgear Overload relays F2 and F21 are not used on multi-speed contactors without motor protec- F2, Q17, Q18 = I1 (low speed) tion

F21, Q21, Q22 = I2

Q23 = 0.5 x I2 (high speed)

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

L1 (Q17/1)

-F0

95 13 -Q1 -F2 14 96 13 95

-Q2 14 -F21 96

21 0 22

22 14 14 14 14 32 -Q23 -Q17 -Q18 -Q21 -Q22 -Q17 21 13 13 13 13 31 31 31 8 -Q22 -Q18 32 32 22 21 21 -Q21 21 -Q22 -K1 22 22 22 21 22 21 IV III II I 22 21 22 21 -S11 14 13 14 13 I II III IV 43 13 14 13 14 -K1 44 22 21 14 32 44 -Q18 -Q17 -Q23 14 -Q21 -Q23 21 22 13 -K1 31 43 13 A1 A1 A1 A1 A1 A1 -Q17 -Q18 -Q21 -Q23 -K1 -Q22 A2 A2 A2 A2 A2 A2 N Q17: Slow forward Q18: Slow back Q21: Fast forward Q23: Star contactor K1: Contactor relay Q22: Fast back

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F21 Q23 Q18 Q21 Q17 Q23 Q18 Q22 Five-way pushbutton 96 22 22 21 21 14 32 32 Control circuit device 0 I II III IV 0: Stop -S11 21 21 21 21

21 I: Slow forward (Q17) 22 22 22 22 22 II: Slow back (Q18) 13 13 13 13 13 14 14 14 14 14 A B C D E III: Fast forward (Q21 + Q23) IV: Fast back (Q22 + Q23)

Method of operation Desired speed and direction can be selected by actuation of the appropriate pushbutton. Contactors Q17, Q18, Q21 and Q23 maintain themselves by their contact 14–13 and can be de-energized only by actuation of pushbutton 0. Contactors Q21 and Q22 can maintain themselves only when Q23 has picked up and contact Q23/13/13–14 or 44–43 is closed. 8

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Tapped winding, medium and high speed, non reversing, 3 speeds, 2 windings Multi-speed contactor U3PIL Multi-speed contactor U3PIL with overload relay a page 8-83

L1 L2 L3

135 13 135 13 135 13

14 14 14 -Q1 -Q2 -Q3 I> I> I> I> I> I> I> I> I> 246 246 246

135 135 135 -Q17 -Q11 -Q21 246 2 4 6 246

1U 1V 1W PE 2U 3U 2V M 3V 2W 3 3W

135 -M1 -Q23 246

a section “Motor circuit X”, page 8-55 No. of 6 4 2 Synchronous speed poles Rpm 1000 1500 3000 Winding 1 2 2 Contactors Q11 Q17 Q21, Motor 1U, 1V, 2U, 2V, 3U, 3V, Q23 terminals 1W 2W 3W No. of 12 8 4 Rating of switchgear poles Q2, Q11 = I1 (low speed) Rpm 500 750 1500 Q1, Q17 = I2 (medium speed) No. of 8 4 2 poles Q3, Q21 = I3 (high speed) x Rpm 750 1500 3000 Q23 = 0.5 I3

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Circuit of motor winding: X Circuit A Circuit A Selection of any speed only from zero. L1 No return to low speed, only to zero. (Q17/1) F22 Q11 Q17 Q21 Q21 -F0 96 14 14 14 13 0 I II III -Q1 13 -Q2 21 21 21 21 22 22 22 -Q3 14 22 21 13 14 14 13 13 14 13 0 22 14 A B C D 22 14 III 21 III 13 -S11 22 14 II II 21 13 Circuit B 14 13 13 13 I -Q11 -Q17 -Q21 Selection of any speed from zero or from 13 14 14 14 low speed. Return only to zero. 22 22 32 -Q17 -Q11 -Q11 31 21 21 Q23 Q21 31 21 31 F22 Q11 Q11 Q17 Q17 -Q17 14 13 14 13 14 13 -Q21 32 -Q21 22 32 96 32 22 14 0 I II III -Q23 -Q23 -Q23 31 21 13 -S11 21 21 21 A1 A1 21 22

A1 22

A1 22 -Q11 -Q17 -Q23 -Q21 22 8 A2 A2 A2 A2 14 14 13 13 13 14 13 N 14 A B C D

Q11: Low speed winding 1 Four-way pushbutton Q17: Medium speed winding 2 0: Stop Q23: High speed winding 2 I: Low speed (Q11) Q21: High speed winding 2 II: Medium speed (Q17) III: High speed (Q21 + Q23)

Method of operation overload, normally open contact 13–14 of the Pushbutton I energizes mains contactor Q11 motor-protective circuit-breaker or (low speed), pushbutton II mains contactor circuit-breaker can also switch off. 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

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Tapped winding, low and high speed, non-reversing, 3 speeds, 2 windings Multi-speed contactor U3PIL Multi-speed contactor U3PIL without overload relay a page 8-81

L1 L2 L3

1 3 5 1 3 5 1 3 5 Q17 Q11 Q21 2 4 6 2 4 6 2 4 6

1 3 5 97 95 1 3 5 97 95 1 3 5 97 95 F2 F3 F4 2 4 6 98 96 2 4 6 98 96 2 4 6 98 96 8

2U 2V 2W

1U 3U 1V M 3V 1W 3 3W

1 3 5 M1 Q23 2 4 6

a section “Motor circuit Y”, page 8-55 Rpm 750 1000 1500 Synchronous speed Contactors Q17 Q11 Q21, Q23 Winding 2 1 2 Motor ter- 1U, 1V, 2U, 2V, 3U, 3V, Rating of switchgear minals 1W 2W 3W F2, Q17 = I1 (low speed) No. of 12 8 6 F3, Q11 = I (medium speed) poles 2 F4, Q21 = I3 (high speed) Rpm 500 750 1000 Q23 = 0.5 x I3 No. of 8 6 4 poles

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Circuit of motor winding: Y Circuit A Circuit A Selection of any speed only from zero. L1 No return to low speed, only to zero. F0 F22 Q17 Q11 Q21 Q21 96 14 14 14 13 0 I II III 95 F2 -S11 21 21 21 F3 21 22 22 22 F4 96 22 13 13 13 13 14 14 14 S0 21 14 0 A B C D 22 S3 22 14 III III 21 13 Circuit B S2 21 14 Selection of any speed from zero or II II 22 13 from low speed. Return only to zero. S1 14 13 13 13 Four-way pushbutton I Q17 Q11 Q21 13 14 14 14 0: Stop 22 22 32 I: Low speed (Q17) Q11 Q17 Q11 21 21 31 II: Medium speed (Q11) 31 21 31 Q21 Q21 Q17 III: High speed (Q21 + Q22) 32 22 32 32 22 14 8 Q23 Q23 Q23 31 21 13 F22 Q17 Q17 Q11 Q11 Q21 Q21 A1 A1 A1 A1 96 14 13 14 13 14 13 0 I III Q17 Q11 Q23 Q21 II A2 A2 A2 A2

-S11 21 21 21 21 22 22 22 N 22 Q17: Low speed winding 1 13 14 13 13 13 14 14 14 Q11: Medium speed winding 1 A B C D Q23: High speed winding 2 Q21: High speed winding 2

Method of operation Speed sequence from low to high is optional. Pushbutton I energizes mains contactor Q17 Switching in steps from high to medium or low (low speed), pushbutton II mains contactor speed is not possible. The motor is always Q11 (medium speed), pushbutton III star switched off by pressing pushbutton 0. In the contactor Q23 and via its normally open event of an overload, normally closed contact contact Q23/14–13 mains contactor Q21 (high 95–96 of overload relays F2, F21 and F22 can speed). All contactors maintain themselves by also switch off. their auxiliary contact 13–14.

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Tapped winding, low and medium speed, non-reversing, 3 speeds, 2 windings Multi-speed contactor U3PIL Multi-speed contactor U3PIL without overload relay a page 8-57

L1 L2 L3

1 3 5 1 3 5 1 3 5 Q17 Q11 Q21 2 4 6 2 4 6 2 4 6

1 3 5 97 95 1 3 5 97 95 1 3 5 97 95 F2 F3 F4 2 4 6 98 96 2 4 6 98 96 2 4 6 98 96 8

2U 2V 2W

1U 3U 1V M 3V 1W 3 3W

1 3 5 M1 Q23 2 4 6

a section “Motor circuit Z”, page 8-55 Rpm 750 1500 3000

Synchronous speed Contactors Q17 Q21, Q11 Q23 Winding 2 2 1 Rating of switchgear Motor 1U, 1V, 2U, 2V, 3U, 3V, terminals 1W 2W 3W F2, Q17 = I1 (low speed)

No. of poles 12 6 4 F4, Q21 = I2 (medium speed)

Rpm 500 1000 1500 F3, Q11 = I3 (high speed) Q23 = 0.5 x I No. of poles 12 6 2 3

Rpm 500 1000 3000

No. of poles 8 4 2

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Circuit of motor winding: Z Circuit A Circuit A Selection of any speed from zero. No return to low speed, only to zero. L1 F22 Q11 Q17 Q21 Q21 (Q17/1) 96 14 14 14 13 0 I II III -F0 -S11 21 21 21 21 22 22 22 22 -F2 95 13 14 13 14 13 13 14 -F21 14 -F22 96 A B C D 21 0 22 22 14 Circuit B III III 21 13 Selection of any speed from zero or from low -S11 22 14 II II speed. Return only to zero. 21 13 F22 Q11 Q11 Q17 Q17 Q23 Q23 14 13 13 13 96 14 13 14 13 14 13 I -Q17 -Q21 -Q11 0 I II III 13 14 14 14 22 32 22 -S11 21 21 21 21 22 22 22 -Q11 21 -Q11 31 -Q17 21 22 21 31 31 14 13 14 14 13 13 13 14 -Q21 22 -Q17 32 -Q21 32 22 32 A B CD 8 14 -Q23 21 -Q23 13 -Q23 31 A1 A1 A1 A1 -Q17 -Q23 -Q21 -Q11 A2 A2 A2 A2 N Q17: Low speed winding 1 Four-way pushbutton Q23: Medium speed winding 2 0: Stop Q21: Medium speed winding 2 I: Low speed (Q17) Q11: High speed winding 1 II: Medium speed (Q21 + Q23) III: High speed (Q11) Method of operation Speed sequence from low to high is optional. Pushbutton I energizes mains contactor Q17 Switching in steps from high to medium or low (low speed), pushbutton II mains contactor speed is not possible. The motor is always Q23 and via its normally open contact switched off by pressing pushbutton 0. In the Q23/14–13 mains contactor Q21 (high speed / event of an overload, normally closed contact medium speed), pushbutton III mains 95–96 of overload relays F2, F21 and F22 can contactor Q11. All contactors maintain also switch off. themselves by their auxiliary contact 13–14.

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L1 L2 L3 U F 690 V

L1 L2 L3 A1 13 21 -Q23 A2 14 22 I>> I>> I>> T1 T2 T3

L1 L2 L3 1.13 1.21 L1 L2 L3 1.13 1.21 -Q1 -Q2

1.14 1.22 1.14 1.22

I> I> I> I> I> I> U F500 V

A1 13 21 A1 13 21 1 3 5 -Q21 -Q17 -Q23 A2 14 22 A2 14 22 2 4 6 I>> I>> I>> I>> I>> I>> T1 T2 T3 T1 T2 T3

2U 1U 2V M 1V 2W 3 h 1W

-M1

No. of poles 12 6 Rpm 500 1000 No. of poles 8 4 Rpm 750 1500 No. of poles 4 2 Rpm 1500 3000

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Q17 Q2 Q21 Q21 Q17 Q17 Q2 Q21 Q21 13 1.14 14 13 13 14 1.14 14 13 L1 I 0 II L1 I 0 II (Q17/1) (Q17/1) -S11 -S11 21 21 21 21 21 21 22 22 22 22 22 -F0 -F0 22 1.13 1.13 13 14 13 13 14 14 14 14 13 14 13 -Q1 13 -Q1 1.14 A B C 1.14 A B C 1.13 1.13 -Q2 -Q2 1.14 1.14 21 21 0 0 22 22

21 22 21 22 -S11 II -S11 II 22 21 22 21 n > n > 14 13 14 13 I I 14 n < 13 14 n < 13 14 14 14 14 -Q21 -Q17 -Q21 -Q17 13 13 13 13

22 22 22 22 8 -Q21 -Q17 -Q21 -Q17 21 21 21 21 22 22 14 14 -Q23 -Q23 -Q23 -Q23 21 13 21 13 A1 A1 A1 A1 A1 A1 -Q17 -Q23 -Q21 -Q17 -Q23 -Q21 A2 A2 A2 A2 A2 A2 N N Stop n < n > Stop n < n >

Circuit Aa page 8-53 Circuit Ca page 8-53

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

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

L1 L2 L3

1 2 3 13 -F1 14

-Q1 I> I> I> 2 4 6

1 3 5 1 3 5 1 3 5 -Q11 -Q17 -Q16 2 4 6 2 4 6 264

X-R2 U1 -R1 U2 Y V1 V2 Z W1 W2

97 95 2 4 6 -F2 98 96 8

PE UVW

M 3

-M1 Use F2 when using F1 instead of Q1. Rating of switchgear:

Starting voltage = 0.6 x Ue Starting current = 0.6 x motor full-load current Starting torque = 0.36 x motor full-load current

Q1, Q11 = Ie

Q16, Q17 = 0.6 x Ie

Starting voltage = 0.6 x Ue

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

L1 (-Q11) -F0

95 13 -F2 -Q1 96 14 21 0 22 -S11 I 13 14

22 32 14 -Q11 -Q11 31 21 -Q11 13 14

-Q16 13 14 15 15 -Q17 13 -K1 -K2 18 18 8 A1 A1 A1 A1 A1 -Q16 -K1 -Q17 -K2 -Q11 A2 A2 A2 A2 A2 N

Q16: Step contactor K2: Timing relay K1: Timing relay Q11: Mains contactor Q17: Step contactor

Two-wire control L1 Always set overload relay to (Q11/1) manual reset -F0

13 -Q1 14 -S12

22 32 -Q11 -Q11 21 31

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Three-wire Two-wire F2 Q11 Q11 F2 Q11 Q11 control 96 32 21 control 96 22 32 0 I Two-way pushbutton -S11 21 21 -S12 22 I = ON 22 13 13 14 0 = OFF 14 A B

Method of operation de-energized by normally closed contacts Pushbutton I energizes step contactor Q16 and Q11/22–21 and Q11/32–31. The motor is timing relay K1. Q16/14–13 – maintain switched off either after actuation of themselves via Q11, Q11/32–31 and pushbutton 0, or in the event of an overload, pushbutton 0. The motor is connected to the by normally closed contact 95–96 of the supply with rotor resistors R1 + R2. When the overload relay F2 or normally open contact set starting time has elapsed, normally open 13–14 of the motor-protective circuit-breaker contact K1/15–18 energizes Q17. Step or circuit-breaker. contactor Q17 bypasses starting stage R1. At Step contactor Q17, resistor R2 and timing the same time, normally open contact relay K1 are omitted in single-stage starting Q17/14–13 energizes K2. When the set circuits. Timing relay K2 is connected directly 8 starting time has elapsed, K2/15–18 energizes to Q16/13 and resistor R2 is connected by mains contactor Q11, which bypasses the means of its terminals U1, V1 and W1 to second starting stage R2, and the motor runs Q11/2, 4, 6. at rated speed. Q11 maintains itself via Q11/14–13. Q16, Q17, K1 and K2 are

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

L1 L2 L3

1 3 5 13 Q1 F1 14

I > I > I > 2 4 6

1 3 5 1 3 5 Q11 K1 2 4 6 2 4 6 1U1 1V1 1W1

2W1 2V1 8 2U1

97 95 V2 2 4 6 U2 a W2 98 96 1 3 5 Q13 2 4 6

UVW

M 3

M1 Use F2 when using F1 instead of Q1. Rating of switchgear

Starting voltage = 0.7 x Ue (typical value) Tightening = 0.49 x motor full-load torque current

Starting current = 0.49 x motor full-load Q1, Q11 = Ie current

IA/Ie = 6 Q16 = 0.6 x Ie

tA = 10 s Q13 = 0.25 x Ie S/h = 30

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L1 Two-wire control Always set overload relay to manual reset F0 (automatic reset)

13 95 L1 Q1 F2 (Q11/1) 14 96 21 -F0 0 22 S11 95 13 13 -F2 I K1 96 14 14

55 67 -S12 K1 K1 68 56 67 55 22 22 14 -K1 -K1 Q13 Q13 Q11 68 96 13 21 21 A1 A1 A1 A1 Q16: Step contactor Q16 K1 Q11 Q13 K1: Timing relay A2 A2 A2 A2 N Q11: Mains contactor Q13: Star contactor 8

Three-wire control F2 K1 K1 Two-wire F2 K1 I: ON 96 13 14 control 96 55 0: OFF 0 I -S11 21 21 22 22 -S12 13 13 14 14 A B

Method of operation The motor cannot start up again unless Actuation of pushbutton I simultaneously previously switched off by actuation of energizes star contactor Q13, timing relay K1 pushbutton 0, or in the event of an overload, and, via normally open contact Q13/13–14, by normally closed contact 95–96 of the step contactor K16, and are maintained via overload relay F2. With two-wire control, K1/13–14. When K1 has elapsed, normally overload relay F2 must always be set to closed contact K1/55–56 de-energizes star manual reset. If the motor has been switched contactor Q13 and – via normally open off by F2, the motor cannot start up again contact Q13/13–14 – Q16 de-energizes: The unless the manual reset is released. starting transformer is disconnected, and the motor runs at rated speed. For Immediate Delivery call KMParts.com at (866) 595-96168-93 For Immediate Delivery call KMParts.com at (866) 595-9616 Moeller Wiring Manual 02/05 All about Motors Three-phase automatic rotor starters

2-stage, rotor 2-phase

L1 L2 L3

1 3 5 13 -F1 14

-Q1 I> I> I> 2 4 6

1 3 5 1 3 5 1 3 5 -Q11 -Q12 -Q14 2 4 6 2 4 6 2 4 6

97 95 -F2 2 4 6 98 96 8

U V W PE

K -R2 -R1 M L U2 U1 3 M XY V2 V1 -M1 Use F2 when using F1 instead of Q1. Rating of switchgear

Starting current = 0.5–2.5 x Ie Starting torque = 0.5 to pull-out torque

Q1, Q11 = Ie

Step contactors = 0.35 x Irotor

Final step contactors = 0.58 x Irotor

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

95 13 Q1 F2 14 96

21 0 22 S11 44 13 14 Q11 I Q11 14 13 43

32 14 15 14 Q13 Q13 U3 Q12 31 13 18 13 15 14 15 K1 Q14 K2 18 13 18 A1 A1 A1 A1 A1 A1 A1 Q11 K1 Q14 K2 Q12 Q13 U3 A2 A2 A2 A2 A2 A2 A2 8 N

Q11: Mains contactor Q12: Step contactor K1: Timing relay Q13: Final step contactor Q14: Step contactor K3: Timing relay K2: Timing relay

Two-way push- F2 Q11 Q11 For connection of further control circuit button 96 14 13 devices: a section “Control circuit devices I: ON 0 I for star-delta starting”, page 8-49 0: OFF -S11 21 21 22 22 13 13 14 14 A B

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Method of operation The motor is switched off either by pushbutton Pushbutton I energizes mains contactor Q11: 0, or in the event of an overload, by normally normally open contact Q11/14–13 transfers closed contact 95–96 of the overload relay F2 the voltage, Q11/44–43 energizes timing relay or normally open contact 13–14 of the K1. The motor is connected to the supply with motor-protective circuit-breaker or rotor resistors R1 + R2 + R3 in series. When circuit-breaker. the set starting time has elapsed, normally Step contactors Q13 and/or Q12 with their open contact K1/15–18 energizes Q14. Step resistors R3, R2 and timing relays K3, K2 are contactor Q14 short-circuits starting stage R1 omitted in single-stage or two-stage starting and via Q14/14–13 energizes timing relay K2. circuits. The rotor is then connected to the When the set starting time has elapsed, resistance terminals U, V, W2 or U, V, W1. The K2/15–18 energizes step contactor Q12, references for step contactors and timing which short-circuits starting stage R2 and via relays in the wiring diagrams are then changed Q12/14–13 energizes timing relay K3. When from Q13, Q12, to Q12, Q11 or to Q13, Q11 as the set starting time has elapsed, K3/15–18 appropriate. energizes final step contactor Q13, which is When there are more than three stages, the maintained via Q13/14–13. Step contactors additional step contactors, timing relays and Q14 and Q13 as well as timing relays K1, K2 resistors have appropriate increasing and K3 are de-energized via Q13. Final step designations. contactor Q13 short-circuits the rotor slip 8 rings: the motor operates with rated speed.

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Contactors for capacitors DIL

Individual circuit without Individual circuit with quick-discharge resistors quick-discharge resistors

L1 L2 L3 L1 L2 L3

-F1 -F1

1 3 5 1 3 5 -Q11 -Q11 2 4 6 2 4 6

21 31 -Q11 -Q11 22 32

8 -R1 -R1 -R1 -R1 -C1 -C1

-R1 R1 discharge resistors fitted in R1 discharge resistors fitted to contactor capacitor

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L1 L1 Q11 Q11 (Q11/1) 0I14 13 -F0 21 21 22 22 21 13 13 14 0 14 22 A B -S11 13 Two-way pushbutton I 14 For connection of further control circuit devices: a section “Control circuit devices for star-delta starting”, page 8-49 14 -Q11 13

A1 -Q11 A2 N

Two-wire control Q11 8 In the case of actuation by means of power L1 A1 factor correction relay, check that this has sufficient power to actuate the contactor coil. -S12 Interpose a contactor relay if necessary.

Method of operation Pushbutton I energizes contactor Q11. Q11 energizes and maintains itself via its own auxiliary contact 14–13 and pushbutton 0. Capacitor C1 is now energized. Discharge resistors R1 are not operative 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.

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Capacitor contactor combination Capacitor contactor with pilot contactor and with and without discharge resistors and with series resistors. Individual and parallel circuit series resistors.

L1 L2 L3

-F1

21 A1 21 13 1 3 5 31 43 A1 13 1 3 5 31 43 -Q14 -Q11 A2 22 14 2 4 6 32 44 A2 22 14 2 4 6 32 44

8 -R1 -R2 -R1

-C1

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

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L1 L1 (Q11/1) (Q11/1)

-F0 -F0 T0 (3)-1-15431

21 1 0 2 0 1 22 2 3 -S11 4 13 21 I 14 0 14 -Q11 22 13 -S12 -S12 13 I 14 14 14 -Q11 -Q14 13 13

14 A1 A1 -Q14 -Q14 -Q11 13 A2 A2 A1 A1 N -Q11 -Q14 A2 A2 N 8 Q11: Mains contactor Q14: Pilot contactor Actuation by two-way pushbutton S11 Actuation by selector switch S13, two-wire control S12 (power factor correction relay) and two-way pushbutton S11

Method of operation Discharge resistors R1 are not operative when Actuation by two-way pushbutton S11: Q11 and Q14 are energized. Pushbutton 0 Pushbutton I energizes pilot contactor Q14. effects de-energization. Normally closed Q14 switches capacitor C1 in with bridged contacts Q11/21–22 and 31–32 then switch series resistors R2. Normally open contact discharge resistors R1 to capacitor C1. 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.

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Fully automatic control for two pumps Starting sequence of pumps 1 and 2 can be P1 Auto = Pump 1 constant load, selected by control switch S12 Pump 2 peak load P2 Auto = Pump 2 constant load, Control circuit wiring with two float switches Pump 1 peak load for basic and peak loads (operation is also P1 + P2 = Direct operation independent of possible with two pressure switches) float switches (or pressure switches)

L1 L2 L3 a

a -Q1 b 0 I > I > I > c F7: 0 F8 Q 0 -F11 -F21 F7 F7: I F8 F8: 0 d F8: I -Q11 -Q12 F7 Q 8 I -F12 -F22

e I

U V W

g -M1 M f U V W 3 f h -M2 M 3

a Cable with float, counterweight, pulleys f Centrifugal or reciprocating pump and clamps g Pump 1 b Storage tank h Pump 2 c Inlet i Suction pipe with filter d Pressure pipe j Well e Outlet

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Duplex pump control

P 1, P 2 P 1, P

P 2 P Auto

P 1 P Auto 0 595-9616 T0(3)-4-15833 T0(3)-4-15833 1 2 3 5 6 7 L 8 9 4 11 13 12 10 (866) 13 14 -S12 at -Q11 Q12: Pump 2 mains contactor In position P1 + P2, both pumps are in operation, independent of the float switches (Caution! Tank may possibly overflow). On the version of duplex pump control with automatic load sharing S12 (T0(3)-4-15915), has a further position: the sequence of operations is automatically reversed after each cycle. 13 14 -Q12 13 14 8 KMParts.com -S21 2 1 call Q -F8 13 14 Q11: Pump 1 mains contactor the range of F7 (discharge is greater than intake), pump starts load). F8 2 (peak When deactivated. F8 is again, rises level water the continuesPump 2 running until F7 stopsboth pumps. The operating sequence of pumps1 and 2 can be determined using operatingmode selector switch S12: Position P1 auto or P2 auto. Delivery -S11 2 1 Q -F7 A1 A2 96 95 Immediate -F22 -Q12 For A1 A2 95 96 -F12 F0 EO -Q11 N F11 Method of operation The duplex pump control is designed for operation of two pump motors M1 and M2. Control is via float switches and F7 F8. Operating mode selector switch S12 in position P1 auto: The system operates as follows: or falls tank storage the in level water the When rises, F7 switches pump 1 on or off (basic load). If the water level drops below Float switch F7 closes before F8 8-103 Moeller Wiring Manual 02/05 All about Motors Fully automatic pump control

With pressure switch for air tank and domestic With 3-pole pressure switch MCSN (main water supply without water failure (run dry) circuit) safety device

L1 F1: Fuses (if required) L2 Q1: Motor-protective switch, manual L3 (z.B.PKZ) -F1 F7: Pressure switch MCSN, 3-pole M1: Pump motor a Air or pressure tank

-Q1 I > I > I > b Non-return valve Pressure pipe c d Centrifugal (or reciprocating) pump e Suction pipe with filter a P f Well -F7 d U VW b M 3 e c -M1 8 f

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With 3-pole float switch SW (main circuit) F1: Fuses (if required) a L1 Q1: Motor-protective switch, manual L2 L3 (z.B.PKZ) b F7: Float switch 3-pole (circuit: pump HW -F1 c full) 0 M1: Pump motor NW HW: Highest level -Q1 I > I > I > NW: Lowest value -F7 Q a Cable with float, counterweight, pulleys and clamps d U VW e b Storage tank M c Pressure pipe 3 I d Centrifugal (or reciprocating) pump f -M1 e Outlet f Suction pipe with filter g Well g 8

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With single-pole float switch SW (control circuit) F1: Fuses a L1 L2 0 Q11: Contactor or automatic L3 star-delta starter N b F2: Overload relay with automatic HW -F1 -F8 Q reset -Q11 135 F8: Float switch 1-pole (circuit: NW 246 S1 pump full) c 95 0 H A S1: Changeover switch -F2 96 I MANUAL-OFF-AUTO F9: Float switch 1-pole (circuit: d U VW pump full) e M M1: Pump motor 3 -M1 f a Cable with float, counterweight, I pulleys and clamps Q b Storage tank g-F9 c Pressure pipe 0 h d Centrifugal (or reciprocating) pump 8 e Outlet f Suction pipe with filter g Water-failure monitoring by means of a float switch h Well

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Solution using NZM circuit-breakers Off position interlock for control switches (S3) and undervoltage release. Cannot be used (Hamburg circuit) with auxiliary contact VHI with motor operator.

-Q1 -S3 I > I > I > -R1 -R2

51 52

U <

8 -Q2 I > I > I > -Q3 I > I > I > -Q4 I > I > I >

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Off position interlock for control or master (S3), NHI (S1) and undervoltage release. switches by means of auxiliary contacts VHI Cannot be used with motor operator. a Emergency-Stop b Off position interlock contacts on the control or master switches -Q1 -S1 V 10 b -S3 11 95 I > I > I > 10 11 b 96 a 10 11 b 51 U < 52

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Changeover device to DIN VDE 0108 – Power systems and safety power supply in buildings for public gatherings:

Automatic resetting, the phase-monitor is set Pick-up voltage Uon = 0.95 x Un to: Drop-out voltage Ub = 0.85 x Uon

L1 abL1.1 L2 L2.1 L3 L3.1 N N

-Q1 I > I > I > -Q1.1 I > I > I > 6 6 5 5 4 4 3 3 2 2 1 1

-Q11 -Q12 -F01 -F02

21 13 8 -K2 11 R S T -K2 14 22 22 22 11 R -K1 -Q12 S -Q11 21 21 12 14 T

12 14 A1 -Q12 A2 A1 A1 -Q11 -K2 A2 A2

a Main supply c To load b Auxiliary supply

Method of operation Q11 energizes and switches the mains supply Main switch Q1 is closed first, followed by on the loads. Contactor Q12 is also interlocked main switch Q1.1 (auxiliary supply). against main supply contactor Q11 via Phase monitor K1 is energized via the main normally closed contact Q11/22–21. supply and immediately energizes contactor relay K2. Normally closed contact K2/21–22 blocks the circuit of Contactor Q12 (auxiliary supply) and normally open contact K2/13–14 closes the circuit of contactor Q11. Contactor For8-110 Immediate Delivery call KMParts.com at (866) 595-9616 Moeller Wiring Manual 02/05 Specifications, Formulae, Tables

Page Marking of electrical equipment 9-2 Circuit symbols, European – North America 9-14 Circuit diagram example to North American specifications 9-27 Approval authorities worldwide 9-28 Test authorities and approval stamps 9-32 Protective measures 9-34 Overcurrent protection of cables and conductors 9-43 Electrical equipment of machines 9-51 Measures for risk reduction 9-56 Measures for risk avoidance 9-57 Degrees of protection for electrical equipment 9-58 North American classifications for control switches 9-68 9 Utilisation categories for contactors 9-70 Utilisation categories for switch-disconnectors 9-74 Rated motor currents 9-77 Conductors 9-81 Formulae 9-90 International unit system 9-94

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General Extracts from the DIN Standards with VDE The marking appears in a suitable position as Classification are quoted with the permission of close as possible to the circuit symbol. The the DIN (Deutsches Institut für Normung e.V.) and marking forms the link between the equipment in the VDE (Verband der Elektrotechnik Elektronik the installations and the various circuit documents Informationstechnik e.V.) It is imperative for the (wiring diagrams, parts lists, circuit diagrams, use of the standards that the issue with the latest instructions). For simpler maintenance, the date is used. These are available from complete marking or part of it, can be affixed on VDE-VERLAG GMBH, Bismarckstr. 33, 10625 or near to the equipment. Berlin and Beuth Verlag GmbH, Burggrafenstr. 6, 10787 Berlin. Selected equipment with a comparison of the Moeller used code letters old – new a Table, Marking to DIN EN 61346-2:2000-12 Page 9-3. (IEC 61346-2:2000) Moeller has decided, with a transitional period, to use the above mentioned standards. Deviation from the, up to now, normal marking determines now in the first place the function of the electrical equipment in the respective circuit of the code letter. The outcome is that there is a lot of freedom in the selection of the code letters. Example for a resistance • Normal current limiter: R 9 • Heater resistor: E • Measurement resistor: B As well as that, Moeller specific decisions have been made with regard to the interpretation of the standard that sometimes deviate from the standard. • 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.

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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 monitor B F Fuses (fine, HH, signal fuse ) F G Frequency inverters T G Generators G G Soft starter T G UPS G H Lamps E H Optical and acoustic indicators P 9 H Signal lamps P K Relays K K Contactor relays K K Semiconductor contactor T K Contactor Q K Time-delay relay K L Reactor coil R N Buffer amplifier, inverting amplifier T Q Switch disconnector Q Q Circuit-breaker for protection Q Q Motor-protective circuit-breaker Q

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Code letter old Example for electrical equipment Code letter new

Q Star-delta switches Q Q Disconnect switch Q R Variable resistor R R Measurement resistor B R Heating resistor E S Control circuit devices S S Push-button S S Position switch B T Potential transformer T T Current transformer T T Transformers T U Frequency converter T V Diodes R 9 V Rectifier T V Transistors K Z EMC filter K Z Suppressors and arc quenching devices F

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Component marking in the USA and Canada to NEMA ICS 1-2001, ICS 1.1-1984, ICS 1.3-1986 In order to differentiate between devices with Example: similar functions, 3 figures and/or letters can be The relay which introduces the first jog function is added to the marking. When using two or more of marked with “1 JCR”. That means here: these markings, the function marking is usually 1 = numerical specification put first. J = jog function of the equipment CR = control relay (contactor relay) – type of equipment

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Component or function code letters to NEMA ICS 1-2001, ICS 1.1-1984, ICS 1.3-1986 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 9 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

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Code letter Device or Function

OC Overcurrent OL Overload P Plugging, potentiometer PFM Power factor meter PB Pushbutton PS Pressure switch REC Rectifier R or RES Resistor, resistance REV Reverse RH Rheostat SS Selector switch SCR Silicon controlled rectifier SV Solenoid valve SC Squirrel cage S Starting contactor SU Suppressor 9 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

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As an alternative to device designation with code simplify harmonization with international letter to NEMA ICS 1-2001, ICS 1.1-1984, standards. The code letters used here are, in part, ICS 1.3-1986 the designation to class designation similar to those of IEC 61346-1 (1996-03). is permissible. Class designation marking should

Class designation code letter to NEMA ICS 19-2002