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03.06.2004
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Special Publication
Contactor and Motor Starter Generation:
Moeller Raises The Standard
Author: Dipl.-Ing.
Volker Busch
Innovations that
immediately stand
out: compared to
the previous product
series, the new generation of Moeller’s
contactors and
motor starters has
some striking features. An extremely
low power consumption or direct actuation from PLC outputs without the use
of coupling relays
are tangible and
noteworthy benefits.
Double box terminals, coil terminals
arranged on the
front and pluggable
function modules
benefit the practical
electrician above all.
Think future. Switch to green.
DRIVE SYSTEMS
TITLE STORY
Moeller's core area of
expertise is the source of
a comprehensive range
of switching and motor
protection solutions.
Having upgraded all higher
rated contactors (DIL M)
and circuit-breakers (NZM
and IZM) in recent years,
Moeller has now updated
its versatile contactors and
motor starters in the
strategically most important
range up to 150 A. With
innovations such as
electronically-controlled
DC drives and a clever
connection design, Moeller
has raised the standard
considerably higher for its
competitors.
Innovative features of the
Xstart contactor and motor
starter generation provide
unmistakable benefits in
mounting and operation
Contactor and Motor Starter Generation
Raising the standard
A contactor alone is far from sufficient
to be competitive in switching and protective applications. Motor starters that
are suitable for use worldwide are just
as necessary as the corresponding
motor-protective circuit-breakers, contactor relays and overload relay. The
market segments for both fuseless and
fused solutions need to be covered
equally, and this applies both to the IEC
and to the CSA/UL world. Customers do
not want development steps that are
too large, even though sufficient freedom should be ensured for innovative
product differentiation.
The new NZM1 circuit-breaker is an addition to the xStart system and rounds
off the selection of motor starters in the
current range up to 150 A. Contactor relays and contactors up to 65 A are available initially, together with motor-protective circuit-breakers and overload relays. Ready-to-connect motor starters,
either for top-hat rail mounting or for
busbar adapters, are added to the
range of components. A motor-protective circuit-breaker up to 16 A with conventional pushbutton actuation has
also been returned to the range. The
motor-protective circuit-breakers are
available in plastic enclosures for single
mounting and with mounting plates for
machine mounting.
Less width – more space –
more value
Space for control panels at machines is
often limited, and the width of the control panel is mostly a critical factor.
Moeller has therefore reduced its
number of variants from seven to four
frame sizes with three different widths
(45 mm up to 32 A, 55 mm up to 65 A
and 90 mm up to 150 A). The smallest
size for contactor relays and contactors
offers an ideal compromise between
minimum dimensions, outstanding
physical properties and additional
handling benefits.
The wide range of applications and suitability for worldwide use call for different operating voltages and frequencies,
as well as requiring both AC and DC
magnet systems for reliable contact operation. Thanks to Moeller's extensive
engineering know-how, new standards
could also be set with its magnet systems for this new contactor generation.
Based on the contactors in the current
range above 150 A; the new contactor
generation now features DC drives with
which the energy is electronically
adapted to the actual power required.
Volker, Busch, head of product marketing for
motor starters, Business Unit Motor Starters and
Drives, Moeller GmbH, Bonn
49th Year 2004, No. 3
DRIVE SYSTEMS
Low sealing power
eliminates the need for
coupling relays
This solution, which is now being used
in the lower rating range for the first
time, offers several customer benefits.
For example, contactors with DC and AC
operation have the same geometrical
design. This considerably reduces the
width of the contactors to the width of
a protective switch. Auxiliary contact
elements are furthermore already inte-
COMPACT
Motor protection and power switching is without doubt one of Moeller's core areas of expertise, and
has enjoyed a long tradition in the
company. This will now be continued with this new generation of contactors and motor starters. Although very little seems to have
changed on the outside, appearances can be deceptive: Standard
magnet systems with electronics
ensure very low power consumption, enabling direct switching via
PLC outputs without coupling relays, and offering greater safety in
the event of undervoltage. Double
box terminals, coil terminals arranged on the front and pluggable
function modules are further tangible benefits.
xStart Contactor and Motor Starter
Range
Electronics inside: The electronic magnet
systems ensure a wide voltage range and
low sealing power
49th Year 2004, No. 3
grated in the basic devices. The power
balance of the magnet systems and the
ratio of the switched effective power to
the required auxiliary power are considerably improved. For all contactor
magnet systems with a rated current
between 12 and 150 A or a rating of 75
kW the DC sealing power is only 0.5 –
1.5 Watts. All DC magnet systems are
also provided with an integrated suppressor. The voltage tolerance, for
example of 24 V drives for DC operated
contactors, is much greater than is
required by the standards and ensures
effective protection in the event of
undervoltage and overvoltage. Moreover, due to the low power consumption of DC operated contactors up to 32
A, they can be switched directly via the
outputs of the PLC, eliminating the
need for coupling relays which were
previously required. Another highlight
is the compliance of these contactors
with the latest US requirements from
the semiconductor industry (SEMI F47,
Semiconductor Equipment and Materials International), as the required bridging of voltage dips is even achieved
without the need for additional modules.
AC and DC contactors can also be used
in combination. The reduced mounting
depth of DC operated contactors brings
benefits when mounted in small and
special enclosures. Width reduction and
adaption to the width of the protective
switches now ensures an optimised
layout in the control panel. Motor
starters up to 15 kW can now be fitted
on 45 mm wide rail adapters.
Up to now, some contactor manufacturers offer a second series of so-called
Auxiliary contacts for control circuits are
already integrated
interface contactors in addition to their
standard series. These interface contactors can be switched directly from a PLC
due to their low pickup and sealing
power, thus eliminating the need for
coupling relays. As the new Xstart contactors up to 32 A can also be controlled
directly from a PLC, this second product
series is no longer necessary. This saves
costs both in logistics and stockkeeping.
A new magnet system for contactors
above 12 A has made this possible. The
new magnet system is now supported
electronically so that its power consumption is adapted to the power
required by the contacts. The power
requirement of the contacts is greater
on closing than when in a closed position. The power adjustment increases
the lifespan of the contacts at the same
time, since contact bounce caused by
the discharge of excess energy is considerably reduced.
Integrated
suppressor circuit
A further benefit of the new magnet
systems is the integrated suppressor circuit. This reduces the transient voltage
peaks of the drive coils to a level that is
not detrimental, so that an external
suppressor is no longer needed. Terminal design is a subject for everyone
involved with switchgear since manual
work is very time consuming and therefore very costly. Box terminals with two
separate chambers ensure the necessary
terminal force, even with different cross
sections. This reliable connection design
is used consistently with all contactors
up to 400 A, with the higher rated
Double box terminals ensure secure cable
fastening – even with different cross
sections
DRIVE SYSTEMS
motor-protective circuit-breakers and
with many other circuit-breaker types.
The screwless spring-loaded terminals
provided on the motor-protective circuit-breakers up 16 A have separate
openings for two conductors each.
Since the main current wiring on control panels is normally first implemented with thicker and rigid cross sections, the preferred coil terminals also
ensure more effective wiring.
PKZ is synonymous worldwide with the
motor-protective circuit-breaker, and in
the new xStart product system, Moeller
has reintroduced the popular pushbutton actuation for the PKZM01 (up to 16
A), in addition to the popular rotary
drive. The mounted mushroom head
pushbutton for emergency-stop actuation on simple machines has also been
reintroduced. PKZs can either be used in
an insulated surface mounting enclosure offering a high degree of protection, or mounted directly in the machine or equipment enclosure using a
mounting plate.
Devices with rotary drives are recommended for use in control panels.
Moeller has increased the current range
of the PKZM0 to 32 A. So that users can
easily combine the motor-protective circuit-breaker with contactors, all motor
starters up to 15 kW at 400 V come in a
standard 45 mm width, the ideal design
width for rail mounting and mounting
on busbar adapters.
The PKZM01 motor-protective
circuit-breaker as a small circuit-breaker
with pushbutton actuation for motor
on/off switching
PKZ motor-protective circuit-breakers
are increasingly being used with decentralised systems as main switches or as
main current emergency-stop switches.
Door coupling handles with door interlocks are also available for mounting in
control panels. Shaft extensions with a
centered guide simplify adaption to different control panel depths. The PKZM4
can now protect motors up to 65 A. The
associated DILM65 contactors now have
the same width as the switch, and the
contactor width has been reduced by 20
percent.
Combinations without
wiring thanks to plug-in
modules
xStart drastically reduces mounting and
wiring times by allowing standard com-
Holding capacity reduced with
DC contactors
100 %
The coil terminals (A1 and A2) arranged
next to the load contacts simplify wiring
ponents and motor starters to be combined without any tools – quickly and
without the possibility of installation
errors. On DOL starters, users simply
click components together instead of
fastening cables with six screws. On reversing starters, the time consuming
wiring of 23 terminal points such as
with paralleling or reversing links is no
longer necessary.
The modular xStart combination plug
connector offers the user an optional
neutral interface between the standard
PKZM0 motor-protective circuit-breakers and DILM contactors in the current
range up to 12 A – without any additional costs. This optional interface contacts the corresponding auxiliary and
main poles on the switches.
In a first step, electrical connector modules based on the combination plug
connector design are on offer. This
makes it possible, for example, to implement a DOL starter consisting of the
PKZM0 motor-protective circuit-breaker and the DILM contactor. A contact
module based on a combination plug
connector provides the electrical connection between the motor-protective
circuit-breaker and the contactor. The
switchgear and controlgear assembly
can be fitted on a mounting rail without the need for an adapter.
In the second step, Moeller will launch
function modules on the market that
will cover a number of applications such
as timer, thermistor protection and networking modules.
etc. (ku)
쏔
The reduced sealing power enables direct activation of the contactors without coupling
relays, and allows the use of small power supply units
49th Year 2004, No. 3
VER 1200+2100-936 GB Articel No. 285 282
Motor-protective circuitbreakers – for flexible
switching and protection