The New Generation: 100 Years of Moeller contactors ... years of moeller... · Systematic...

Think future. Switch to green.

www.moeller.net

1904

19941984

1931

1999

1946

2004

1970

DIL contactors

PKZ motor-protec-tive circuit-breakers

MSC motor-starters

DS4 softstarters

Drives

Rapid Link

The complete range ofcontactors, efficient motor-starters and controlleddrives for the motor circuit.New simple to installsolutions based on clevercommunication.

– The New Generation:100 Years of Moeller contactors– Continuous Progress –

Technical EssayDipl.-Ing. Wolfgang Esser

For Sales and Support call KMparts.com (866) 595-9616

2

Overview of Contentsand Preface

Page

xStart, the new generation of motor-starters, 2again with application-orientated special features!

Contents and Preface Overview 2

Summary for readers in a hurry Brief description 3

A transparent system Scope of the system 4

Clever intersections Delineation between sizes 5

The added value lies in the width Sizes and widths 5

Not only electrical contacts Mechanical interfaces 7

How about some add-on features Auxiliary contacts 7

Powerful drives for every application Contactor drives 11

Connections made to measure Terminations 14

Small but very useful Accessories 15

Universal switching and protection using PKZM The PKZM system 15

Fuseless, means no problems with export The advantages of fuseless

motor-starters 16

Motor protection made to measure Motor-protective relays 18

Systematic connection = Kombi plug-in connection Kombi plug-in system 18

All in a row Busbar adapter 20

Efficient transport prevents losses Volume packaging 21

A look into the future Planned features to complete the system 21

Summary 22

Validity 23

Bibliography 23

, the New Generation ofMotor-Starters, again withapplication-orientated specialfeatures!

A contactor is no longer enough. These days, the expectationis for a motor-starter; suitable for world markets; a partner forthe bus and the electronic signal processing level; universallyapplicable, in the power distribution board or in the moderndecentralised control system; in North America as well as in the IEC world.

There is no doubt that motor-protective switching devicesare significant parts of motor-starters. Even today, in thenew generation, we still need contactor relays and motor-protective relays.

Two market segments need to be served: with increasingimportance on the one hand the superior fuseless range,and partly regionally configured, the solution with fuses.The steps that innovation takes however, must not be toogreat, even today. But the customer wish for exchangeableStandard-compliant devices still leaves enough room formodern differentiation. The foundation is laid for excitingonward developments. Contactors still come from Moellerand they are still called DIL, and motor-protective circuit-breakers are still called PKZM, what else.


3

Here is a short overview for people whodon’t have the time to read the wholearticle. Should the reader be particularlyinterested in certain items, then he canfind the paragraphs with detaileddescriptions from the index.

Motor-protective circuit-breakers,contactor relays, contactors and motor-protective relays are often combinedwithin switching installations. Moellertherefore puts these devices togetherin one product system suitable forworld markets. Optimised interfaces and significantlyreduced mounting and wiringeffort contribute to type-testedcombinations with enhancedsafety and reliability.As far as contators are concerned, allthe three-phase motor ratings arecovered by fewer device variants.The selection criterion for switchgearis the rated operational current,and this is now also included in theself-explanatory type reference.The new developments have broughtabout a considerable increase inperformance capability, as expressedin the Amps per mm of device width.A further reduction of power lossesnow allows a real increase in packingdensity to be implemented in theswitchgear cabinet. All the direct-

on-line starters up to 15 kW now havea width of only 45 mm. To put itsuccinctly: the customer gets moredevice and even higher quality for,in most cases, less money and withadditional application benefits.

The terminals up to 12 A and 16 Aoffered alternatively in screw ortension-spring technology,provide the majority of main currentconnections as box terminals, eachof which with two separate terminalchambers. Motor-protective circuit-breakersand contactors are offered with theoption of the new time-saving Kombiplug-in technology. This means oneplug-in action with visible isolatinggap instead of six times screwfastening.On reversing starter combinations, eventhe control wiring can be plugged in.The installation costs are loweredfurther through the mounting andwiring advantages offered by the newmounting rail and busbar adapter.In response to numerous customerrequests, motor-protective circuit-breakers for direct mounting onsimple machines are now againavailable with a pushbuttonactuated switching option. This is complemented by optimised

insulated enclosures and flush-mounting plates. In a dangeroussituation, the device can be simply‘knocked out’ using the Emergency-Stop button. This product system wasdeveloped in general in close contactwith customers in Germany and abroad.The new generation also includescontactor relays and motor-protective relays. These productshave not so far been fully replaced byothers since the electrical separation ofmechanical contacts continues to be animportant feature, and because motorprotection using relays represents acost-efficient solution. This allows theoption of implementing both the fusedand the more advantageous fuselessmotor-starters.

Moeller offers to the trade, panelbuilders and machine and installationequipment manufacturers a highlymodern and economical low-voltageswitchgear programme. This year inaddition, the new switchgear will becomplemented by the new xEnergyswitchgear cabinet system.In other words, a rounded, mutuallycomplementary range from a singlesource, for sophisticated customers inpower distribution and control systemsand for satisfied end-users.

Summary for People in a Hurry


4

7 9 12 18 25 32 40 50 65 80 95 115 150

DIL A

DIL A-XHI...

DIL M32-XHI...

ZB 12

ZB 32

ZB 65

ZB 150

DIL M150-XHI...

DIL M150-XHIA...

DIL M1000-XHI..-...

Direct-on-line and reversing starters, star-delta starters

Wiring aids, Kombi plug-in technology

Busbar mounting starters

Kombi plug-in technology *)

PKZM 4

PKZM 0

PKZM 01

System accessories for motor-protective circuit-breakers

NZM 2

Complementing the system with circuit-breakers

NZM 1

DIL M7

DIL M9

DIL M12

DIL M17

DIL M25

DIL M32

DIL M40

DIL M50

DIL M65

DIL M80

DIL M95

DILM115

DILM150

*) Kombi plug-in technology with PKZM0 up to 12 A

Product System

Switching and protecting againstshort circuit or overload

Starting and protecting motors by means of devicecombinations

Switching and protecting againstshort circuit or overload

Frequent switching of loads

Control and interlocking

Multiplication of contacts

Protecting againstoverloads

AC-3 rated currents in A

A Transparent System

The diagrams, Figures 1 and 23, showthe scope of the new system. It iscomplemented by the modern circuitbreakers, NZM1 and NZM2, that roundoff the motor-starter range at the highcurrent end of up to 150 A. But evenabove the new system described here,Moeller offers state-of-the-art andespecially powerful motor-starters.The introduction to the market of thesystem is to take place in stages. By the

autumn of 2004, the contactor relaysand contactors up to 65 A, togetherwith the motor-protective circuit-breakers and motor-protective relayswill be available. This first offeringwill be complemented by ready-for-connection motor-starters, eitherfor top-hat rail fixing or on busbaradapters.The motor-protective circuit-breakersare available with high degree ofprotection in insulated enclosures forseparate mounting and with flush-

mounting plates for mounting directlyon the machine. The contactors forrated currents above 65 A will beavailable in May 2005.

A new item in the range is the motor-protective circuit-breaker up to 16 A,with conventional pushbuttonactuation. Our customers havedemanded it. Pushing a button isobviously more popular than flickinga toggle or rocker.

Figure 1: System overview, scope of the new product system described


5

Clever intersections

The range described comprises motor-starters up to 150 A. Where should theintersections between sizes be? Whichfeatures must be the basic ones? Whereare the optimal interfaces to optionalfunctions? Where is there potential fordifferentiation? Experience, analysisand numerous conversations withcustomers in Germany and abroadprovided important decision-makingtools for the product management.Even before the designer draws the firstline, the system costs are establishedconceptionally for the entire life cycleof the system, virtually unalterably.

Clever management of variants canobviously play a decisive role ininfluencing the system costs alongthe entire value creation chain.The various customer benefits resultfrom significant reductions in:

The product costs,The number of basic data sets in thegoods management systems, The logistics costs, worldwide,

The material usage in the variousstorage facilities, The expenditure on obtainingapprovals, The cost of the many differenthandling processes during- Selection,- Engineering,- Ordering,- Delivery,- Goods inwards procedures- and order picking,Mounting and wiringAnd commissioning and servicing.

Costs can be lowered considerably forall the participants in the value creationchain with a favourable effect on theindividual component price, at themanufacturer’s end and onwards alongthe entire path via dealers, processorsof all kinds, right up to the end user.

The added value lies in the width

The space for switchgear installationsis often limited, the critical dimensionin most cases being the width of theswitchgear cabinet. Any reduction in

the width of the switchgear thereforebrings added benefits that can often becalculated precisely. Table 1 and Figure2 show the reduction in geometricalunits from 7 to 4 on the one hand, andthat the number of different unit widthsin the system up to 150A has decreasedfrom 5 to 3. At the same time, most ofthe current ratings have been increasedby the few Amps that make thedifference in practice. The new, smallestsize component, being a contactorrelay and contactor, represents a goodcompromise between minimaldimensions, high physical performancecapability and additional handlingbenefits. Table 2 shows, that in spite ofthe significant reduction in componentwidth, further user benefits wereachieved. Built-in auxiliary contacts incontactors from the most frequentlydemanded rating range, up to 15 kW,do more than just increase thecommercial benefit by the value of theauxiliary contact.This auxiliary contact,now being generally available, does notrequire its own enclosure, neither doesit represent another item in the partslist. What is more, the customer does

Table 1: Variant management as illustrated by the example of the new unit sizes and widths. The streamlining of the range from 7 to 4 component sizes(to 57%) and from 5 to 3 component widths (to 60%) has beneficial effects along the entire value creation chain. The current rating increase from 25 A to 32 A (28 %) enables motors up to 15 kW to be switched and protected at an economical component width of only 45 mm. In other words, approximately90% of all three-phase motors can be controlled by 45 mm of motor-starter width.* The DIL E contactors are retained in the range for special applications

AC-3 Previous Mounting widths of contactor relays and contactors New AC-3 Current in A range range Current in A

At 400 V Type 45 mm 60 mm 70 mm 100 mm 120 mm 45 mm 55 mm 90 mm Type At 400 V

142 DIL 4AM 7 4 DIL M150 150

104 DIL 4M 7 4 DIL M115 115

85 DIL 3AM 6 4 DIL M90 95

72 DIL 3M 6 4 DIL M80 80

58 DIL 2AM 5 3 DIL M65 65

43 DIL 2M 5 3 DIL M50 50

36 DIL 1AM 4 3 DIL M40 40

30 DIL 1M 4 2 DIL M32 32

22,5 DIL 0AM 3 2 DIL M25 25

15,5 DIL 0M 3 2 DIL M17 18

12 DIL 00AM 2 1 DIL M12 12

8,8 DIL 00M 2 1 DIL M9 9

8,8 DIL EM * 1

6,6 DIL EEM * 1 1 DIL M7 7

- DIL R 2 1 DIL A -

- DIL ER * 1


6

DIL M80 / DIL M95 / DIL M115 / DIL M150

DIL M40 / DIL M50 / DIL M65



DIL 4M115 / DIL 4AM145

DIL 3M80 / DIL 3AM85

DIL 2(A)M

DIL 1(A)M

DIL 0(A)M

DIL 00(A)M

Figure 2: Reduction in the number of sizevariants and reduction of mounting widthsabove 25 A. DIL E contactors remain in the rangefor special applications.

Table 2: Not only was the critical mountingwidth significantly reduced, but at the sametime, the coil connections on all the contactorswere made more accessible. All the contactorsin the most popular range, up to 15 kW, arenow equipped with one auxiliary contact asstandard. The table allows a comparison of thecurrents that can now, or could be previously,controlled by component widths correspondingto the new dimensions.

Figure 3: The component widths of the newcontactors (within the red lines) were reducedand the controllable AC-3 currents additionallyincreased in part of the range. The orangedelineation shows the contactor range now tobe replaced.

0 10 20 30 40 45 50 55 60 70 80 90 100 110 120 mm

Size 1 Size 2 Size 3 Size 4 Sizes

7 / 9 / 12 18 / 25 / 32 40 / 50 / 65 80 / 95 / 115 / 150 A / 400 V

45 45 55 90 mm Width

45 45 45 60 70 100 120 mm Width

3 / 4 4 / 5.5 7.5 / 11 15 / 18.5 20 / 30 37 / 45 55 / 75 kW / 400 VPr

evio

usl

yN

ew

Additional benefits from the new component widths

Type Width Benefits in addition to the reduction in width Reduction in width relative to the previous width at the current rating

DIL M32 45 mm - 25 % In all contactors up to 15 kW / 400 V On all contactors, coil connections located at the front 1 auxiliary contact built into a mounting width of 45 mm instead of behind the main current connections

DIL M40 55 mm - 9 %DIL M50 55 mm - 21 %DIL M65 55 mm - 21 %DIL M80 90 mm - 10 %DIL M95 90 mm - 10 %DIL M115 90 mm - 25 %DIL M150 90 mm - 25 %

kW400 V

75

55

45

37

30

20

18.5

15

11

7.5

5.5

4


7

not need to fit it. It can function as 1Make contact or 1 Break contact asrequired.In the past, the auxiliary contact wasoften lacking. It is very useful though.In many applications now, the basedevice with its shallow mountingdepth is sufficient. This is very beneficialparticularly where it is individuallyhoused in ever smaller machineenclosures or in the extremely compactwithdrawable distribution units (MCC).The new DIL MP20, has a fourth maincontact fitted in place of the auxiliarycontact for AC-1 currents up to 20 A.The reduction in device width (Figure 3)and simultaneous increase inoperational current significantly raisesthe performance capability of the newcomponents, as shown in Figure 4 bythe controllable Amps per availablewidth.

Not only electrical contacts

A system is more than just the sum of itsindividual parts. The key to systematicflexibility lies in the well thought-outmechanical contact points between thecomponents of the system. These pointsof contact are the ones that generatethe costs. They require precision indimensional tolerances, in forces atwork, and must be as simple as possiblebut also safe to handle. The inter-sections represent the conceptualchallenge for the product manager, thedesigner, the toolmaker, the productionspecialist and the quality control

engineer. As far as Moeller is concerned,it is here that the potential for differen-tiation and customer benefit lies, also inthe new generation. Figure 5 shows themain mechanical contactor interfaces.The following paragraphs introducethe tasks and advantages of theseinterfaces. Some of the interfaces canbe used for several different links. Theyallow the flexibility that our customersexpect, to enable them to meet theirwidely differing tasks around the world.Every customer wants to see his ownrequirements met as precisely and

economically as possible. This systemopens up significantly more optionsfor solutions than did older systems.

How about some add-on features

Safety circuits have become much morecomplex. Also, everyone wants to bebetter informed. Equally, for a simplesequencing control, there is no needfor a complete switchgear installation.In other words, there are many reasonsfor using auxiliary contacts. The newauxiliary contacts have also becomemore universally applicable and there-fore offer more scope. The limits are setby international Standards and by theregulations governing the operatingmedia of big operators. Auxiliarycontact modules for contactor relaysrequire different terminal markingsfrom those for contactors. But as faras construction and handling areconcerned, the modules for contactorrelays and for contactors are the same.Up to and inclusive of the DIL M32 (15kW), i.e. for all 45 mm wide contactors,the modules are of the same design,with 2 or 4 auxiliary contacts. Thereare variations in contact configurationfor different control tasks. Variouscombinations of Make and Breakcontacts and a number of specialmodules such as the DIL A-XHIV11 or

Performance capability: switchable A / mm available width

Available width in a small 45 mm 55 mm 90 mmenclosure:

Current: previously 22.5 A 22.5 A 58 A

Current: Xstart 32 A 65 A 150 A

Enhancement: + 42% + 188% + 158%

Figure 5: Location of the connection terminals and the mechanical interfaces for top-mounted andside-mounted auxiliary contacts on the 45 mm wide contactors up to 32 A. There are further interfacesto the contactor coil, and units up to 12 A have sockets for the Kombi plug-in technology. Thesesockets enable wiring-error free connections to be made quickly between the system components fordirect-on-line and reversing starters.

Contactor relay, Contactor up to 32 AContactor up to 12 A

1 Main current terminals (top and bottom)2 Auxiliary contact connection (top and bottom)3 Coil connection (top and bottom)4 Interface for the top-mounted auxiliary contact module5 Plug-in contact for the contactor coil (top and bottom)

6 Interface for the mechanical interlock between two contactors

7 Plug-in contacts to the connection terminals up to 12 A (top and bottom)

Figure 4: By reducing the component width and simultaneously increasing the current ratings, wehave significantly raised the contactor performance capability.

2 31

5

6

7

7

4

1 2 3 5

6


8

-XHI(C)(V)11-SI

-XHI(C)11-SA

+ + ++

+

DILM150 – XHI(A)...

DILM40-150

-XHI(C)(V)11-SI

-XHI(C)11-SA

+ + ++

+

DILM150 – XHI(A)...

DILM40-150

DIL A-XHIV22 are available, as can beseen from Table 3. An auxiliary contactbuilt into the base unit (up to 32 A), aswell as the two- or four-pole auxiliarycontact modules, enable economicalways of adapting to the requirement forauxiliary contacts without a great dealof fitting work. Contactor relay auxiliarycontact modules can also be used forcontactors up to 32 A. Such combina-tions, however, do not conform to theStandard terminal markings, and aretherefore less to be recommended.The regulations governing operating

media in certain large firms must benoted. These are intended to preventmistakes between make and breakcontacts when exchanging devices. These concerns demand the preferredcontact configuration every time, i.e.version E to the Standards DIN EN 50011[1, 2] and 50 012 [3] (Figure 6).The Moeller Main Catalogue assists inselecting Standard-compliant devices.Large concerns also limit the diversityof admissible and theoretically possiblecombinations of auxiliary contacts byimposing their own in-house standards.

With contactors, a distinction must bemade between the types up to 32 A,which have a built-in auxiliary contact(Figure 7) and the larger contactorswithout integral auxiliary contact.The choice for contactors > 32 A isbetween top-mounted auxiliary contactmodules for the narrow style starter,and the side-mounted auxiliary contactmodules for the flat style of motor-starter (Figure 8). No one in fact usesthese larger contactors without auxiliarycontact modules. To work out whetheror not you need them would come more

Admissible auxiliary contact configurations

For narrow style For flat styleType Basic Top-mounted Side-mounted Total number

1x right and 1x left of auxiliary 2-pole 4-pole 2-pole 2-pole contacts

Inside Outside

DIL A –XHI..DIL A 4 - - - - 4

4 1 - - - 64 - 1 - - 8

DIL M32-XHI..DIL A –XHI..

DIL M7... M32 1 - - - - 11 1 - - - 31 - 1 - - 51 1 *) - - 3 *)1 - 1 *) - - 5 *)

DIL M150-XHI.. DIL M1000-XHI..-..DIL M150-XHIA..

DIL M40... M65 - 1 - - - 2- - 1 - - 4- - - 2 - 4- 1 - 2 - 6

DIL M80... M150 - 1 - - - 2- - 1 - - 4- 1 - 2 - 6 - - 1 2 - 8- - - 2 2 8

*) Deviation from the Standard terminal marking

Table 3: The table shows the admissible auxiliary contact configurations on contactor relays and contactors. Where auxiliary contact modules forcontactor relays (light blue) are used for contactors (light green), the terminal markings in some cases deviate from the Standard. Additional auxiliarycontact modules for contactors are preferably to be combined with base units that have an auxiliary make contact built-in.


9

expensive than the auxiliary contactmodule itself. By the way, the side-mounted auxiliary contact modules, in asingle version, can be used right up to thevery large contactors (DIL M1000, DILH2000) up to 2000 A. Now you simplyand securely snap them on. Figures 9 to11 show the different auxiliary contactconfigurations achievable on contactorsand their terminal markings. And all theauxiliary contact modules described areavailable either with screw terminals orwith spring-loaded terminals at the sameprice. Both types of connection have theirfaithful following and it is difficult topersuade customers of the benefits ofthe other termination. Manufacturers,logistics operators, wholesalers andprobably also end users meanwhiledream in vain of a single solution.

Figure 6: Table 1 of DIN EN 50 011 [1]recommends the use of ‘contactor relays withcode letter E’. With two-tier contactor relays(base unit + top-mounted auxiliary contactmodule), a contactor with 4 make contacts (DIL A-40) must be used as base unit in order to achieve terminal markings to version E.

Figure 7: Where contactors have a built-inauxiliary contact, this contact should be a makecontact according to the Standard. The terminalmarkings of the additional auxiliary contactmodule begin with the decade 2. Break contactsin the base unit and auxiliary contact modulesof contactor relays can be used, however theydo not conform to the preferred equipment toStandard.

Figure 8: On the larger contactors it is possible to chose between slim or flat style contactors byselecting top-mounted or side-mounted auxiliary contact modules. Even the combination of bothstyles is admissible. Three variants of contact markings result as shown in Figures 9 to 11.

Top-mounted auxiliary contact module for contactors < DIL M32,with built-in auxiliary contact

Not to Standard !

Auxiliary contact modules for DIL A contactor relays

For version E to Standard

DIN EN 50 011, 4 make

contacts are always required

in the base unit!


10

1

2

3

Please note data in the Main Catalogue regarding maximum admissible number of contacts!

Figure 9: Variant 1, use of top-mountedauxiliary contact modules:The auxiliary contact module terminalmarkings begin with decade 1. Terminalmarkings beginning with decade 5 arepossible, but do not conform to Standard.

Figure 10: Variant 2, use of side-mountedauxiliary contact modules:The auxiliary contact module terminal markingsbegin with decade 1. Internal or externalauxiliary contact modules can be used,depending on the physical contactor size.

Figure 11: Variant 3, use of side-mountedand top-mounted auxiliary contact modules:The terminal markings of side-mountedauxiliary contact modules begin with decade 1.Internal or external auxiliary contact modulescan be used, depending on the physicalcontactor size. The contact markings oftop-mounted auxiliary contact modulesbegin with decade 5.

Top-mounted auxiliary contact modules for contactorswithout built-in auxiliary contact modules, e.g. DIL M40 – M150

Side-mounted - auxiliary contact modules for contactorswithout built-in auxiliary contact modules, e.g. DIL M40 – M150

Mixed auxiliary contact module configuration for contactors DIL M40 – M150

DIL M150-XHI..orDIL M150-XHIA..

e.g. DIL M65, no auxiliary contacts

e.g. DIL M80, no auxiliary contacts

Not to Standard!


11

Powerful drives for every application

The application spectrum of thecontactors described is extremely wide.The various actuating voltages,frequencies and the multitude ofapplications (AC and DC required)througout the world, necessitate analternating current and a direct current

magnet system in each case, to ensurethe reliable movement of the contactapparatus (Table 4). The new magnetsystems are the heart of the contactors.Careful dimensioning of the magnetsystems has a critical influence onmechanical and electrical contactlifespan, reliable contact operation,maximum admissible contact

configuration, admissible mountingpositions, voltage tolerance range,compatibility with electronics and thepower consumption account for thecontactor as well as the entire switchinginstallation.Thanks to the compre-hensive engineering know-howavailable in the company, the magnetsystems of this contactor generation

Table 4: The Table shows the main differences between conventional AC and DC drives and the new electronically assisted DC drives.

Principal differences between AC and DC drives

Feature Conventional AC drive Conventional DC driveModern electronically assisted DC drive from Moeller

Coil currentDetermined by:frequency, resistive and inductivecoil impedance

Determined by:resistive coil impedance

Determined by:changeover to reduced sealing voltage, (approx. 0.1 x Un), thereby extremely reduced sealing consumption

very small heat rise

no interval required betweenthe contactors

Power consumption

Pull-in power significantly higherthan sealing power, switch-Oninductivity is much lower than inthe On position, due to relativelylarge gap between the pole surfaces

Pull-in = Sealing power

Sealing power extremely low, pull-in power approximately of the same magnitude as with conventional DC drive

Drive force proportionalto the square over the coil current

Force alternates between 0 andFmax with a frequency of 2 x f(i) Proportional to the rise in current Proportional to the rise in current

Short-circuit rings necessary toensure that the force is > 0 at a travel of = 0 mm

Force is always > 0,since the current is always > 0

Force is always > 0,since the current is always > 0

Current controlled from pull-in tosealing by altering the inductivity(gap between pole surfaces)

Constant current due toconstant resistance

Quasi time-controlled changeoverbetween a pull-in and a sealing circuit

Construction of drive Simple More complex and larger than AC drive

Dimensions of AC and DC drive identical

Iron core Sheet metal Solid Sheet metal

Generation of noise Hum is possible in sealing operation No hum No hum

Add-on functions Optional, external suppressor circuit

Mostly external suppressor circuit

Generally built-in suppressor cir-cuit (function as bridge regulatorand rapid de-energization)

Prevents damaging voltagepeaks upon switch-Off

Protection against polarity reversalby diode (device does not switchOn!)

Protects the electronics in theevent of wrong connection


12

were again significantly improved intechnical terms. At the same time,the economic benefit of the productsystem was increased. Building on yearsof experience with contactors for highand highest ratings, the new contactorsizes above 12 A were fitted withDC drives the power of which iselectronically matched to the switchingstatus as required (Figure 12). Thistechnology prevents any power surplusthat would reduce the service life dueto contact bounce. At Moeller, thishas become the proven top-classtechnology. This new solution being forthe first time also used in the smallerratings range, offers the followingimportant benefits to the user:

The contactors with DC drives andthose with AC drives are nowphysically identical (Figure 13)This means a considerable reductionin the volume of the contactors andoffers the option of integratingauxiliary contacts into the base units. It enables the same slim mounting

widths as with the protective circuit-breakersThe drive consumption and the ratio

of switched rating to requiredauxiliary power has been significantlyimprovedThe heat rise is clearly reduced since- the DC sealing consumption for thecontactor drives with rated currentsbetween > 12 to 65 A or up to 30kW uniformly amounts to no morethan 0.5 Watt and

- for all the contactor drives between65 to 150 A rated current or up to75 kW uniformly amounts to nomore than 1.5 Watt (Figure 14),

- this means that even the DCcontactors can now be mounteddirectly adjacent to each other,

The switching dynamics stay the sameirrespective of the voltage range coilsand the wide voltage tolerance rangefrom 0.7 – 1.2 x Ue,

Figure 12: Printed circuit board for theelectronic optimisation of drive consumptionfor the new DC contactor drives up to 150 A.

Figure 14: The electronic changeover has achieved quite considerable reductions in pull-in and sealingpowers of DC contactors, which in turn has lead to the described technical and economic benefits.

Figure 13: The new AC and DC contactors compared to the previous contactor generation.The reduction of the dimensions and at the same time, the considerable lowering of driveconsumptions represent an important contribution to much more compact control systems.

Contactor coil consumptionDC operated contactors

Representation using logarithms

New DC contactor Previous DC contactor

New AC contactor Previous AC contactor

AC-3 duty / 400 V [kW]Pull-in previously Sealing previouslyPull-in new Sealing new

4 5.5 7.5 11 15 18.5 22 30 37 45 55 75

Pull-

in a

nd

sea

ling

co

nsu

mp

tio

n

[W]


13

....

Since all DC drives have built-insuppressor circuits and protectionagainst polarity reversal, theassociated handling costs areeliminated, ordering errors do nothappen and devices are not damagedby reversed polarity.Where suppressor circuits arenecessary for AC contactors, they caneasily be plug-fitted.The drive voltage tolerance of the DCoperated contactors (interface coils) isfar beyond that specified by theStandard, and ensures excellentcompatibility with electronics and theprotection against under- and over-voltages relevant in practicalengineering.Above 12 A of rated current, the DCvoltage range coils help reduce thenumber of variants, because in eachcase the wide voltage tolerancesextend the range both at the top andat the bottom (Figure 15).The voltage range coils also have adefined and constant closingthreshold voltage that providesconstant pull-in dynamics.DC operated contactors up to 32 Acan be connected directly to manyelectronics systems cost-efficientlyand in a space-saving manner withoutthe need for coupling relays. The verylarge contactors up to the DIL H2000offer this benefit too by the way.The latest American marketrequirements of the semiconductorindustry (SEMI F47 [4]) can becomplied with extremely cost-efficiently and in a space-savingmanner, since the bridging of voltage

dips without the need for additionalcomponents as demanded in thisdirective, is achieved.Wiring work and voltage testing arefacilitated by the uniformly front-accessible coil connections, either asscrew terminals or as spring-loadedterminals.

Figure 16 shows that the pull-in andsealing consumption of most sizes of AC operated contactors has also beensignificantly reduced (note represen-tation based on logarithms)

It is above all the pull-in consumption ofthe larger contactors that determinesthe size of the control transformers inswitching installations. Where aninstallation contains many small andonly a few large contactors, the controltransformers are dimensioned

Figure 16: In some of the AC operated contactors with new drives, the pull-in consumption wasclearly reduced

Figure 15: Illustration of the voltage tolerance of DC drives with voltage range coils in comparisonwith the specifications of Standard IEC / EN 60 947-4-1. The heightened under- and overvoltageprotection (shown for example with control voltage 200 to 240 V DC) represents an importantcontribution to the operational reliability and fail safety of electrical switching installations that arecombined with electronic control systems.

Rated contactor coil voltage

140 V

70 %

Plus

170 V

85 %

Standard

200 V

100 %

240 V

100 %

264 V

110 %

Standard

288 V

120 %

Plus

Contactor coil consumptionAC operated contactors

Representation using logarithms

Electronic support

AC-3 duty / 400 V [kW]Pull-in previously Sealing previouslyPull-in new Sealing new

4 5.5 7.5 11 15 18.5 22 30 37 45 55 75

Pull-

in a

nd

sea

ling

co

nsu

mp

tio

n

[VA

]


14

according to the continuous rating.Where large contactors are in themajority, the transformer is selectedaccording to its short-time rating,although the sealing consumption of allsimultaneously closed contactors mustnot exceed its continuous rating [5].

Since AC and DC contactors are alsoused together, the fact that they areof identical physical size is of greatadvantage for the design engineer.The reduction in mounting depth of DCoperated contactors by approximately25 mm, is particularly advantageouswhen it comes to building them intosmall and non-standard enclosures.The reductions in width and matchingof width to that of protective circuit-breakers, enables the layout withinswitching cabinets to be optimised.Motor-starters up to 15 kW now fit onto 45 mm wide busbar adapters. Thisis important since the useful width ofbusbar systems within every switchingcabinet is limited.

Due to the simultaneous reductionin component width and in driveconsumption, a compact control systemnow becomes a reality. The cost ofsealing consumption can now belowered in many cases due to fans beingunnecessary and due to the smallerpower supply units. In a MODANdrawer-type distribution section with20 starters, for example, the sealingconsumption of the contactor coils canbe reduced from 300 W to 15 W.

This saves approximately ¤ 200 annuallyin power cost per section, as well asmaking a contribution to environmentalprotection. Equally, there are resultingcost savings on control transformersand switched-mode power supply units.

Our new interface drives representparticularly worthwhile solutions toproblems with interfacing to electroniccontrols and sensors. The outputvoltage of electronics systems canfluctuate greatly due to the potentiallylarge voltage drops at semiconductorend stages. The voltage limits forelectronic control systems are definedin Standard IEC 61 131-2 [6]. Anothercritical factor at these interfaces isthat the contactor coils must have thesmallest possible sealing consumption,which then reduces the voltage drop viathe semiconductor. The reduced heatloss favours the temperatur-sensitiveelectronics components.

The built-in suppressor circuit inDC contactors protects relays andsemiconductor elements againstdamage from voltage peaks as canoccur when inductive elements, i.e.contactor coils are switched Off. Suppressor circuits for AC contactorsare selected only in cases where theapplication requires them, and they caneasily be plugged in retrospectively atthe front. To equip AC contactors withsuppressor circuits across the board,would not be technically sensible oreconomically acceptable in every case.

The extensive voltage tolerances ofthe DC drives are of benefit also inapplications where large voltage dropsare due to long cables. DC operatedcontactors are generally to be preferredwhere long cables are involved, sincethey prevent a delay in de-energizationof the contactor drives. Where ACvoltages are used with long cables, thecable capacities may lead to delayed de-energization. In the worst-case scenario,an AC operated contactor at the end ofseveral hundred metres of cable may notdrop out at all. The voltage tolerancesare also beneficial where DC voltageis obtained from batteries, becauseconsiderable voltage excess is involvedin the charging of batteries.

Connections made to measure

Every switchgear client first looks at thetermination technology. Our solutionallows wiring errors to be prevented,terminal heating to be excluded and,last not least, money to be saved dueto shorter wiring times. Figure 17shows a view of the terminations andthe direction of incoming cables. Thereis no screw in the way of the cable inthe box terminal connection chamber.Box terminals having two separatechambers ensure the necessaryconnecting force over their entirelifespan, to cope even with cablesdiffering from one another by several

Figure 17: Optimum terminations. Having proved their worth with circuit-breakers, large motor-protective circuit-breakers and contactors for years, they are now also a feature with the smallerratings: separate terminal chambers for two cables per connection in sturdy box terminals. The sametermination technology for contactors up to 400 A.

Contactor relay, Contactor up to 12 A Contactor up to 32 A

5

4

1st cable

2nd cable

1 2 3 4 5

On contactors: 1 ... 3 = main current terminals4 = auxiliary contact connection5 = coil connection

On contactor relays: 1 ... 4 = auxiliary contact connections5 = coil connection

Figure 18: The coil connections now are locatedat the contactor front. They are therefore nolonger obstructed by the often immovable maincurrent wiring, making wiring and voltagetesting easier and less time-consuming. Theterminals for the built-in auxiliary contactmodule are located at the second level.


15

cross-sections sizes. This reliableconnection technology is now availablethroughout on all contactors up to400 A, large motor-protective circuit-breakers and on many circuit-breakers.Since in switching installations it isnormally the main current wiring withoften large and inflexible cross-sectionsthat is wired first, the frontal coilconnections (Figure 18) play animportant role in the rationality ofwiring and the ease of testing it. Asdescribed, an alternative solution isavailable for all auxiliary connectionsand for the main current connectionsup to 12 A in the screwless spring-loaded terminals that, of course,also offer two separate apertures for2 cables each. But this is not all we offer.We devote an entire paragraph lateron to the additional terminals for ournew Kombi plug-in technology.

Small but very useful

For a control task, sometimes one needsmore than one contactor. For reversingand star-delta combinations severalcontactors are combined. The smallDILM(32)150-XVB links mechanicallyconnect them into a single unit. Thisassembly work can be carried out andprewired outside the switching cabinet.Ideally, the new plug-fit wiring bridgesfrom the Kombi plug-in technology canbe used, or such combinations can beobtained ready for connection directlyfrom Moeller. Small, but effective also,is the mechanical interlock that securelyprevents two contactors within acombination from ever closingsimultaneously, be it through anelectrical fault or due to mechanicalshock. The mechanical interlock nowconsists merely of a small sphere thatis inserted between the two contactors (> 12 A) using a ball dispenser. Thenthe contactors are assembled using themechanical links described. This verysimple solution does away with theneed to leave space between thecontactors. It saves 15 mm in width,which is particularly valuable whenusing reversing starters on busbaradapters. There is no need for an extrawide adapter to achieve the increasedfunctional reliability. After all, this cost-efficient solution saves 16 % of preciouswidth with 45 mm wide contactors. On contactors up to 12 A, an anchor-

shaped plastic part is used at the sameinterface point, also without additionalspace requirement. Parallel switchingbridges for AC-1 applications enablethe current carrying capacity of thecontactors to be increased by a factorof 2.5 to 3 for switching single-phaseloads, at minimal expense. Simple arealso the time-saving star-point bridges.

Universal switching and protectionusing PKZM

The PKZM motor-protective circuit-breakers are among the most versatileswitching and protective devices.They are complete motor-starters inthemselves. The PKZM motor-protec-tive circuit-breaker is the first choicefor many applications not requiringfrequent or remote switching. It combines the following universalfunctions in the smallest of spaces:

manual operational switching, occasional remote tripping, clear indication of the switch position, inherent short-circuit protection overwide ranges up to 150 kA (Table 5),application oriented inherent short-circuit protection at larger currentratings up to 50 kA at 400 V or groupprotection for several breakers, usable up to 690 V,

personnel protection through all-polede-energization and quick tripping, simultaneous short-circuit protectionfor cables and electrical equipment, overload protection for cables andelectrical equipment, for all current ratings up to 65 A, i.e.suitable for 90 % of all motors, optimised for motor protection ortransformer protection, suitable for switching and protectionalso of resistive loads through phase-failure sensitivity, suitable for the protection of EEx emotors, approval to the ATEX 100a [7]directive (for PKZM 0 and PKZM 4), short recovery time after faultremoval, suitable for world markets, with allthe necessary approvals andacceptances,Optionally- mounting and encapsulation withhigh degree of protection,

- protection by untervoltage tripsagainst automatic restart,

- use as main switch or Emergency-Stop switch in the main circuit,

- isolation of the Emergency-Stopcontrol circuit by early-make auxiliary contacts (Figure 19),

- versatile lockability,- multiple, differentiated status indication, even including a networkable solution,

- comprehensive accessories.

The PKZM from Moeller is synonymousin the market with the term motor-protective circuit-breaker.Nothing much needed to be improvedon it. It has proved its worth in itsmillions. But the old favourite is nowmaking its come-back since, for manyapplications, directly on simplemachines the pushbutton operation isergonomically the best (Figure 20). Inan emergency, it can be simply ‘knockedout’. Customers demand the pushactuation. They do not regard thetoggle or rocker actuation oncompetitor products as equivalent.In addition to the rotary operation,Moeller is therefore bringing back theclassical push actuation in the shape ofthe PKZM 01 for currents up to 16 A.Complete with mushroom button forEmergency-Stop actuation on simplemachines. Either open in the surfacemounting insulated enclosure with highdegree of protection, or with the

Figure 19: On circuit-breakers and motor-protective circuit-breakers, early-make auxiliarycontacts isolate the Emergency-Stop circuits ofthe undervoltage trips from the mains supply.This solution is to be selected where theEmergency-Stop circuit is spatially extensiveand, on occasion, external to the switchingcabinet. A circuit-breaker with undervoltage tripcan be switched On only provided voltage isflowing at the release. The auxiliary contacttherefore, must close before the main contacts.


16

proven flush mounting plate formounting directly in the machine orinstrument enclosure (Figure 21). Theopen-type circuit-breaker is padlockablein the Off position. Enclosed breakerscan be locked off using the padlockingfeature and several locks.

The circuit-breaker with rotary drive isthe correct internal solution for theswitching cabinet (Figure 22). For thisapplication, the rating increase to 32 Aon the PKZM 0 is the most interestinginnovation. In the protection of 15 kWmotors, the expansion of the settingbrings a clear reduction in volumetogether with a very favourable price.Motor-protective circuit-breakers areoften combined with contactors. Nowall the motor-starters up to 15 kW at

400 V fit onto 45 mm wide busbaradapters. In other words, all the motorsizes whose switchgear and controlgearis usually mounted side-by-side insidethe switching cabinet. But the reductionin width is also of great benefit for top-hat rail mounting where it results in aclear, space-saving switching cabinetlayout. In the electrical equipmentfor smaller current ratings, motor-protective circuit-breakers PKZM 0 andPKZM 01 are also used as main switchesto IEC / EN 60 204-1[8] or as Emergency-Stop switches in the main circuit. Theseapplications are increasing in numberdue to the modern trend towardsdecentralisation. Lockable door-coupling rotary handles are offeredin the specified colours together withdoor interlocks. Shaft extensions with

centring guides are available foradaptation to different enclosuredepths.

The PKZM 4 now protects motors upto 65 A.The corresponding contactors,DIL M65, with 55 mm width, measurethe same as the circuit-breakers, i.e. agood 20% less than before. The highlycompact NZM 1 and NZM 2 circuit-breakers protect the larger contactorsup to the DIL M150 and their electricalequipment. The NZM 1 setting rangefor motor protection covers up to100 A, and like the contactors, thecomponent is only 90 mm wide.

The new xStart range too, offers for allthe PKZ frame sizes the versatile andapproved accessories that ensure safeand rational control panel building(Figure 23). For most applications,auxiliary contact modules with differingcontact configurations are required forinterlocking or for signalling. The mainaccessories are:

Standard auxiliary contact modulesfor side mounting,Standard auxiliary contact modulesfor front mounting,Early-make auxiliary contact modulesfor remote-control Emergency-Stopcircuits, Trip-indicators for differential faultindication,Undervoltage or shunt release,Feeder terminal blocks for largercable cross-sections or for UL 508Type E and UL 508 Type F motor-starters for use in NorthAmerica [9],For rational panel building, there aretop-hat rail adapters available, andthe popular three-phase commoninglinks in many different versions forthe joint supply of several circuit-breakers.

Fuseless, means no problems with export

Fuseless motor-starters offer betterpersonnel protection and facilitatethe export of machines and electricalsystem equipment:

The increase in short-circuit breakingcapacity shown in Table 5, does awaywith the previous requirement inextensive applications for group

Figure 20: Ergonomics at the machine.The classical PKZM 01 motor-protective circuit-breaker makes a come-back due to customerdemand. Operators of simple machines wantthe pushbutton operation instead of the toggleor rocker.

Figure 21: Fitted into surface mounting enclosure, with or without mushroom-head for Emergency-Stop. Or PKZM 01 fitted with the flush mounting plate, directly into the machine enclosure.

Figure 22: Inside the switching cabinet, themotor-protective circuit-breaker with rotarydrive is most suitable. The PKZM 0 is nowavailable for currents up to 32 A. The smallmotor-protective circuit-breakers with rotarydrives are also available as PKZM 0-Ttransformer-protective switches with highershort-circuit tripping values. The PKZM 4 settingranges now cover up to 65 A.


17

22

21

28

27

1615

13

12

11

17

19

20

14

18

1724

26

2325

101

2 6 5 6

33

4

9

8

77 7

9

44

Excerpt from the SystemView without PKZM 4 and contactors up to 150 A. For the complete range, see the current Main Catalogue.Auxiliary and main current connections up to 12 A, either with screw terminals or spring-loaded terminals.

Contactors

1 Contactor up to 12 A


3 Suppressor circuit

4 Top-mounted auxiliary contact


6 Side-mounted auxiliary contact

7 Top-mounted auxiliary contact

Overload Relays

8 Overload relay up to 65 A

9 Overload relay up to 32 A

10 For Separate mounting

Motor-Protective Circuit-Breakers

11 Motor-protective Circuit-breaker

with rotary actuation

12 Motor-protective Circuit-Breaker

with pushbutton actuation

13 Current limiter module

14 Shunt- and undervoltage releases

15 Trip-indicating auxiliary contact

16 Side-mounted auxiliary contact

17 Front auxiliary contact

18 Early-make auxiliary contact

19 Door-coupling rotary handle

and extension shaft

20 Early-make auxiliary contact

21 Insulated flush mounting enclosure

22 Insulated surface mounting enclosure

with Emergency-Stop pushbutton

Starters

23 Electrical link

24 Mechanical link

25 Combination plug-in connector

26 Motor-starter with

combination plug-in technology

27 Busbar adapter

28 Top-hat rail adapter

Figure 23: This diagrammatic representation shows the main components of the xStart product system and how they fit together.


18

protection elements or CL-PKZM 0current limiters.Considering the multiplicity in theUSA and Canada of regionallydiffering fuse installations, it is oftendifficult for non-American machineand system builders to find out whatfusing system the end customerneeds, particularly as he and hislocation may not be known atthe time the project is planned. Irrespective of locally customaryfusing systems, fuseless startersremove the spare parts logisticsproblems. Switching installations becomemore compact. Since the fuse bases,particularly for North American fuses,are very large and take up muchspace in the control system, theirproportions compare unfavourablyto the increasingly smaller dimensionsof contactors and motor-protectiverelays.Fewer individual components needto be mounted and wired – a greatcost saving. In other words, the componentsdescribed enable the constructionto the latest directives, of compact,fuseless Ul 508Type E and Ul 508 Type F motor-starters [9] for the NorthAmerican market.These compact starters make itpossible to engineer and construct

‘world market switching cabinets’ toa uniform layout.

Motor protection made to measure

Despite the great benefits of fuselessinstallations, there are still applicationsfor fuses. Particularly, where highoperational voltages are involved andmore stringent demands for resistanceto welding, the use of fuses is in fact tobe recommended. When protectingmotors by means of fuses, there isalways the need for an additionalmotor-protective relay. Z motor-protective relays in approved version,and with ATEX 100a approval for theprotection of EEx e motors, are part ofthe xStart product system described.Due to the changes in contactordimensions and current ratings, therange of motor-protective relays too hasbeen adapted. The new ZB12 and ZB32for example, cover the entire ratingrange up to 32 A, with various settingranges. For every xStart contactor, thereare suitable motor-protective relaysavailable, with phase-failure sensitivity,for direct fitting or as separatecomponents. For close connection tothe contactor and straightforwardcommon wiring, the contactor terminal14 is repeated on the motor-protectiverelay. The coil connection of contactors

up to 12 A is also repeated for the samereason. The links between motor-protective relay and contactors plug in,and the components are mechanicallylatched with one another. Whetherwith or without fuses, using the EMT 6thermistor machine-protective relay,motor protection can be easilyupgraded to full motor protection [10].Motors in their basic form areincreasingly being fitted with integralthermistor sensors for directtemperature monitoring within themotor, and thus even better failureprevention.

Systematic connection = Kombi plug-in connection

Manual work represents a potentialweakness in a control system. It is alsohighly expensive. The time taken isdifficult to calculate and often thereare bottlenecks regarding qualifiedpersonnel. Where manual work is doneunder time pressure, errors creep ineasily. All these are reasons for seekingpractical compromise solutions betweenmanual fitting and automation. Thereare many repetitive actions involved incontrol system building. This is wherethe idea of the Kombi (combination)plug-in technology comes in: on each motor-starter, the connection must be

230 V 400 V 440 V 500 V 690 V

Iu Iq Icu Ics Fuse Iq Icu Ics Fuse Iq Icu Ics Fuse Iq Icu Ics Fuse Iq Icu Ics Fuse

A kA kA kA A kA kA kA A kA kA kA A kA kA kA A kA kA kA A

0.16 150 150 150 N 150 150 150 N 100 100 100 N 100 100 100 N 100 100 100 N

0.25 150 150 150 N 150 150 150 N 100 100 100 N 100 100 100 N 100 100 100 N

0.4 150 150 150 N 150 150 150 N 100 100 100 N 100 100 100 N 5 5 5 50

0.63 150 150 150 N 150 150 150 N 100 100 100 N 100 100 100 N 3 3 3 50

1 150 150 150 N 150 150 150 N 100 100 100 N 100 100 100 N 3 3 2 50

1.6 150 150 150 N 150 150 150 N 100 100 100 N 100 100 100 N 3 3 2 50

2.5 150 150 150 N 150 150 150 N 100 100 100 N 100 100 100 N 3 3 2 50

4 150 150 150 N 150 150 150 N 100 100 100 N 100 100 100 N 3 3 2 50

6.3 150 150 150 N 150 150 150 N 100 100 100 N 42 42 6 50 3 3 2 50

10 150 150 150 N 150 150 150 N 42 42 10 50 42 42 6 50 3 3 2 50

12 50 50 10 50 50 50 10 50 15 15 10 50 15 15 15 50 3 3 2 50

16 50 50 10 50 50 50 10 50 15 15 10 50 15 15 15 50 3 3 2 50

20 50 50 10 50 50 50 10 50 10 10 10 50 6 6 6 50 3 3 2 50

25 50 50 10 50 50 50 10 50 10 10 10 50 6 6 6 50 3 3 2 50

32 50 50 10 50 50 50 10 50 10 10 10 50 6 6 6 50 3 3 2 50

Table 5: The areas with green background denote the inherently short-circuit proof ranges of the PKZM 01 and PKZM 0 motor-protective circuit-breakers.The short-circuit rating was increased from 100 to 150 kA. No additional protective elements are required for the green areas. For the other ratings, groupprotection, circuit-breakers or the proven CL-PKZM 0 [13] current limiters can be used to increase the switching capacity.


19

made between motor-protectivecircuit-breaker and contactor.On reversing starters, the reversingwiring must be put in place. Wherethese links are made using wires, theregulations covering operating mediaspecify in many cases that both ends ofthe connection must be labelled, not tomention the ferrules. This is stupid work,on which expensive specialist personnelis wasted.

Up to 12 A, PKZM 0 motor-protectivecircuit-breakers with rotary actuation,and contactors in the xStart systemgenerally have additional oblong plugsockets on the front (Figure 24). 12 Aat 400 V equates roughly to 5.5 kW,a rating that is higher than that ofmost motors in today’s automationtechnology. On the contactors, even thebuilt-in auxiliary contact modules andcoil connections are equipped with theplug connections. Here for example,the reversing interlock in the controlcircuit is simply plugged in. High-qualityspringy plug-in lugs ensure reliableelectrical connection. The plugconnectors reliably cope with the entirecurrent and voltage spectrum, fromcontrol circuit connections in the mArange with low control voltages up tomotor currents of 12 A and voltagesup to 690 V. The plug-in technology

described was developed jointly withthe world market leader in electricalplug connectors. Figure 25 shows theKombi plug-in technology by theexample of a direct-on-line starter up to12 A. Mechanical plug modules connectmotor-protective circuit-breakers andcontactors to produce stable assembliesthat can be securely snap-fitted on tojust one top-hat rail. When the plugconnector is pulled out, there remainsa visible isolating gap. Further, mostinteresting components are in thedevelopment stage. The contactorapertures for the Kombi plugconnectors, as shown in Figure 26, arealso suitable for accepting reversing-or star-delta bridges. The Kombi plug-in technology opens up totally newspheres of application in the future. Itwill be possible for example, to simplyplug printed circuit boards, with directcontact to the main current terminalsand the contactor coil connections, onto contactors or reversing contactorcombinations (Figure 27)

The customer can equip these pcb’shimself with electronic componentsfor add-on functions such as delaycircuits, pulse circuits or his own specificnetworking functions (motto: printablecontactor combinations). Modularcomponents are fitted on to the

Figure 24: Connections for the Kombi plug-in technology on PKZM 0 motor-protective circuit-breakers with rotary actuation, for currents up to 12 A, as well as on DIL A contactor relays and DIL Mcontactors up to 12 A

Figure 25: Direct-on-line starter in Kombi plug-in technology with the advantages of secure fixingon just one carrier rail and positive and error-free connection between motor-protective circuit-breaker and contactor.

PKZM 0 motor-protective circuit-breaker with rotary actuation, up to 12 A

Additional front plug sockets for the Kombi plug-in technology

DIL A contactor relays, DIL M contactors up to 12 A


20

contactors (Figure 28), which also haveplug connections to the contactor coils.The enclosures can accept additionalfunction blocks. Presently in develop-ment are for example electronic timingrelays, thermistor evaluation or net-working circuits for various differentbus protocols. In addition, it will bepossible for feedback to be monitoredvia auxiliary contact modules, or tobuild in especially dust-proofed, highlyfail-safe auxiliary contacts for extra lowcurrents and voltages.

The system allows a flexible modularitywhile offering a dependable fixedmounting dimension.It reduces costs for fitting and testing,and it increases the serviceability ofinstallations by rapid exchange ofcomponents. The Kombi plug-intechnology, what is more, does not limitthe ways in which components havebeen customarily handled/ processed.By using the Kombi plug-in technology,you are not using special products,but standard products. The systeminterfaces on contactors and motor-protective circuit-breakers cost thesame. New costs only arise from usingthe plug connectors. But these costsare more than compensated for bythe systematic savings described.

All in a row

Busbars are needed in almost everyswitching cabinet for the distribution ofpower between incomers and outgoers.In the past, this need was usually metby using the space in the cabinet muchmore inefficiently than today. In thepast, busbars were often fitted withfuse outgoers, whereas today thespace needed for power distributionis simultaneously used for simplemechanical stopping and for contactingof motor-starters. Busbar adapterscontribute significantly to the rationalconstruction of switching cabinets. Thebusbar adapters can be convenientlyfitted with circuit-breakers andcontactors before being installed inthe switching cabinet. The almostcompletely prewired motor-startersare simply snap-fitted on to the busbar.A distance of 60 mm between busbarcentres is now widely established,the alternative being 40 mm betweenbusbar centres. Nowadays, more busbarsystems than are needed merely forpower distribution are frequentlyinstalled in a cabinet, and increasinglythese are vertical busbar systems.

Figure 26: Kombi plug-in technology with plug-in main current and control current connections forquick and error-free wiring, shown on a star-delta starter for example.

Figure 27: The Kombi plug-in technology enables pcb’s to be plugged on to switchgear to connectdirectly with the terminals. The user can design the layout of and equip the printed circuit board asrequired.

Parallel link Star-point bridge

Connector for electrical interlock in the control circuit

Reversing link (with bridge A2)


21

The greater busbar length is even moreeconomical to use, and is particularlypractical where many low-ratedindividual starters must be installed andwired. And, of course, the majority ofelectric motors have ratings below 4 kW.

The busbars can be used even moreefficiently since all direct-on-line startersup to 15 kW / 400 V fit on to 45 mmwide adapters. A 15 kW reversingstarter is mounted on a width of only 90 mm. The length of the switchgearcombination of motor-starters andcontactors approximately correspondsto the height of the busbar system.Adapters of double widthaccommodate the switchgear ofreversing starters and in additionoffer space for supplementary relays.

New busbar adapters (Figure 29) thatare optimally compatible with thebusbar systems and system accessoriesof busbar market leader, Wöhner,complement the xStart system. TheStandard ensures that busbar adaptersfor 60 mm between busbar centresfrom all the manufacturers fit ontosuch systems. The benefit for logisticsoperations is that busbar material isavailable the world over as Standard-compliant copper profile.

Prepared connectors are available forlinking circuit-breakers and contactors,or there is the new Kombi plug-intechnology. For a regular requirementof large volumes, Moeller can supplythe adapters ready fitted with theswitchgear for direct-on-line andreversing starters. Ready-for-connectionwiring of main current and controlcurrent connectors is also possible.The motor cable in such cases, is takendirectly up to the plug connector on the

busbar adapter. Such combinations arenot listed in the catalogue, but can bemade available if you speak to yourcontact at Moeller.

Efficient transport prevents losses

The manufacturers of volumemachinery or quantity applicationsoften require certain switchgear inlarge quantities to ensure processingcontinuity. Volume packaging offershandling benefits here, because thereis no need to open lots of individualpacks and then dispose of them. Pleasecontact Moeller if you are interestedin this type of despatch (this appliesto quantities of about 100 identicalproducts, but depends also on howmany devices fit into a transportcontainer).

A look into the future

The product system described is goingto be further developed into the future.A series of special capacitor contactorsfor group compensation is planned forexample. In the switching of capacitors,there are distinctly differingapplications:

individual power factorcompensation (PFC)group PFC with choke coilgroup PFC without choke coil

Figure 28: An enclosure that can be plugged on to the contactor and is mechanically linked with it,can accommodate standard circuits from the catalogue or customised circuits. These (e.g. electronictiming relays) then contact the coil connections directly and enable feedback signals from theswitchgear to be monitored if required.

Figure 29: Motor-starters on new busbar adapters are available for rational control panel anddistribution board building by rapid fitting.

External 24 V DC auxiliary voltage

Thermistor protection module based on Kombi plug-in technology

Motor with built-in thermistor sensor


22

These applications also make differingdemands on the contactors used. In PFCand PFC with choke coil, contactorsmust be able to control capacitorstarting currents that can amount to upto 30 times the capacitor rated current.PFC with choke coil are used innetworks in which, for example,frequency inverters provide for non-sinusoidal currents having a highharmonic content. The chokes limit theinrush current peaks to an acceptablelevel. In these two types ofcompensation, the contactors from thexStart system described are successfullyused for capacitor control. There is anincreasing trend towards PFC withchoke coil.

The requirements of contactors for theless inductive, PFC without choke coilare much more demanding. The loadcurrents of the capacitors here arenot merely drawn from the networkcomprising inductivities, e.g. fromtransformers and cables, but in additiondirectly and particularly non-inductivelyfrom the already charged capacitors of the special capacitor battery (Figure 30).

Within a few milliseconds, inrushcurrent peaks of 180 to 200 times thecapacitor current can arise here. Specialcapacitor contactors [11] are requiredfor this purpose. These capacitorcontactors have two circuits switched inparallel. One of these circuits is made upof early-make auxiliary contact modulesthat initiate a pre-loading of thecapacitors via low resistances orinductivities. The main contacts of thesame contactor close a few millisecondslater. They form the second circuitthat carries the continuous capacitorcurrent. Another improvement on theexisting solution lies in that the newgeneration of components ensuresthat the auxiliary contact module(first circuit) is no longer involved inthe de-energization of the capacitors.

This reliably prevents the thermaloverloading (possible in exceptionalcases) of the auxiliary contacts andcurrent limiting resistors. The new DIL Kseries of capacitor contactors will beavailable for all the various capacitorsizes.At present, there is a 4-pole contactor,DIL MP20, for a 4-pole continuous

thermal current of 20 A. Othercontactors for 32, 45, 63, 90 and 125 Aare to follow. These contactors are usedfor the electrical isolation of deviceswith power electronics, for switching ofvarious heating loads, filament lamplighting and other loads in utilizationcategory AC-1. Where only single-phaseswitching is required, several maincontacts can be switched in parallelusing the DIL M ..-XP1 parallel linksets to increase the current. By parallelconnection of three contacts of aDIL ..M, the admissible current rises byfactor 2.5, and with four contacts of aDIL ..MP in parallel, the current rises byfactor 3.

Summary

Having in the past four years renewedall the DIL M contactors in the upperrating range, the DS contactors andall the NZM and IZM circuit-breakers,Moeller now offers a new and versatileproduct system also in the lower ratingrange up to150 A. Where it is physicallypossible, uniform accessories are usedfor the whole range. The new productswere developed in close cooperationwith German and internationalcustomers from various differentbranches of trade and industry, underthe motto: From practical applicationfor practical application. A particularlyfavourable cost/benefit ratio in theresult of the development positively

influences the economics along thewhole value creation chain. This wasachieved also by trimming the numberof necessary components and by drasticreductions in volumes and heat losses.The range described will also makepossible further interesting additions tothe system in the next two years. Takentogether with the equally new RMQ-Titan command and signalling devices,the LS Titan position switches andthe market hit, the easy control relay,as well as the MFD inputting andvisualising devices, Moeller is offering tothe trade, switchgear system builders,and machine and system equipmentbuilders a state-of-the-art, as well aseconomical low-voltage switchgearprogramme.

This year, the switchgear will becomplemented by the new xEnergyswitching cabinet system. In otherwords, this is a rounded, range ofmutually compatible devices, fromone suppier, for the power distributionand control system market.

The handling/processing advantagesof the xStart system are dealt with indetail in article [14].

Figure 30: Various duties for switching and protective devices, cables and conductors, as well as forthe capacitors themselves, as a function of the type of compensation system.

Construction Current curve


23

Validity

This article represents the status ofdevelopment and internationaldirectives as at April 2004. Changes mayoccur. The most up-to-date statementsof fact are always to be found in thecurrent catalogues of the MoellerGmbH, Bonn. Here you will also finddetailed data regarding motor-startersfor various types of coordination andvoltages to IEC/EN 60 947-4-1 [12].Approvals and acceptances had beensought when this article went into print.

Literature:

*[1] DIN EN 50 005, “Industrial Low-Voltage Switchgear, TerminalMarkings and ConventionalNumbers, General Rules“

*[2] DIN EN 50 011, “Industrial Low-Voltage Switchgear, TerminalMarkings, Conventional Numbersand Code Letters for CertainContactor Relays“

*[3] DIN EN 50 012 “Industrial Low-Voltage Switchgear, TerminalMarkings and ConventionalNumbers for Auxiliary Contacts ofCertain Contactors“, 1978

[4] SEMI F47-0999„Provisional Specification forSemiconductor ProcessingEquipment SAG Immunity“

*[5] Wolfgang Esser“Control, Isolating and SafetyTransformers”, TI 39-013, Moeller GmbH, 1998

*[6] IEC / DIN EN 61 131-2, VDE 0411Part 500 “Programmable LogicControls, Part 2: Requirements forOperating Media and Testing”

*[7] ATEX 100a, Directive 94/9/EG, v. 23.3.94, for the harmonization oflegal prescriptions in member statesaffecting devices andprotective/safety systems for theregulated use in potentiallyexplosive areas, ABI. L 100 dated19.4.1994

*[8] DIN EN 60 204-1*VDE 0113 Part1,1998-11-00 DIN IEC 60204-1*VDE0113 Part1, Draft 2002-09-00“Safety of Machines – ElectricalEquipment of Machines – Part 1:General Rules“

[9] Wolfgang Esser,„Besondere Bedingungen für denEinsatz von Motorschutzschalternund Motorstartern in Nordame-rika“, VER1210+1280-928D,Moeller GmbH, Bonn, 2003

“Special consideration governingthe application of Manual MotorControllers and Motor Starters inNorth America", VER1210+1280-

928GB, Moeller GmbH, Bonn,2003, or in the Internet: deutsch:http://www.moeller.net/binary/ver_motorstarterna_de.pdf, English:http://www.moeller.net/binary/ver_motorstarterna_en.pdf

*[10] Wolfgang Esser, “Direct Montoring of TemperaturesProtects Speed-Regulated Drive Motors“ Maschinenmarkt, Würzburg, 103 (1997) 10

*[11] Dirk Meyer, “Switchgear forSystems with Reactive-PowerCompensation“, VER2100-934Moeller GmbH, 2003

*[12] IEC / EN 60 947-4-1 and DIN VDE0660-102 “Low-Voltage-Switchgear Part 4-1: Electro-mechanical contactors and motor-starters “

*[13]Wolfgang Esser, “The task of current-limitation onmotor-protective circuit-breakers“Maschinenmarkt, Würzburg, 103 (1997) 13

*[14] Wolfgang Esser,“Using xStart for efficient mounting and safe/secure wiring inmodern switching installations”,VER….Moeller GmbH, 2004

* Translation of the title


Think future. Switch to green.

Moeller addresses worldwide:www.moeller.net/addressE-Mail: [email protected]

© 2004 by Moeller GmbHSubject to alterationsVER2100-937GB MDS/DM 067/04 Printed in the Federal Republic of Germany (07/04)Article No.: 285552

Xtra Combinations

Xtra Combinations from Moeller offers a range of productsand services, enabling the best possible combination optionsfor switching, protection and control in power distributionand automation.

Using Xtra Combinations enables you to find more efficientsolutions for your tasks while optimising the economic viability of your machines and systems.

It provides:■ flexibility and simplicity■ great system availability■ the highest level of safety

All the products can be easily combined with one another mechanically, electrically and digitally, enabling you to arriveat flexible and stylish solutions tailored to your application –quickly, efficiently and cost-effectively. The products are proven and of such excellent quality thatthey ensure a high level of operational continuity, allowingyou to achieve optimum safety for your personnel, machinery,installations and buildings.

Thanks to our state-of-the-art logistics operation, our com-prehensive dealer network and our highly motivated servicepersonnel in 80 countries around the world, you can count on Moeller and our products every time. Challenge us! We are looking forward to it!


The New Generation: 100 Years of Moeller contactors ... years of moeller... · Systematic...

Documents

Transcript of The New Generation: 100 Years of Moeller contactors ... years of moeller... · Systematic...