Moeller ZEV-XSW-145 Hardware And Engineering Download Page 3

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Before commencing the installation

• Disconnect the power supply of the device.

• Ensure relosing interlock that devices

cannot be accidentally restarted.

• Verify isolation from the supply.

• Connect to earth and short-circuit.

• Cover or fence off neighbouring live parts.

• Follow the installation instructions (AWA)

included with the device.

• Only suitably qualified personnel in

accordance with EN 50110-1/-2
(VDE 0105 Part 100) may work on this
device/system.

• Before installation and before touching

the device ensure that you are free of
electrostatic charge.

• The rated value of the mains voltage may

not fluctuate or deviate by more than the
tolerance specified, otherwise malfunction
and hazardous states are to be expected.

• Panel-mount devices may only be operated

when properly installed in the cubicle or
control cabinet.

eller

Gmb

Safety in

struc

tion

Warning!
Dangerous electrical voltage!

Summary of Contents for ZEV-XSW-145

Page 1: ...ler net Internet www moeller net 2001 by Moeller GmbH Subject to alteration AWB2300 1433GB Doku Doku Eb 10 06 Printed in the Federal Republic of Germany 10 06 Article No 267430 4 patpks nmvc v Rückentext Hardware and Engineering 10 06 AWB2300 1433GB A A A Think future Switch to green Think future Switch to green Rückenbreite bis 10 mm 1 Blatt 0 106 mm für XBS ...

Page 2: ...Bonn Author Klaus Grül Editor Heidrun Riege Translator Harold Schierbaum 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 written permission of Moeller GmbH Bonn Subject to alteration without notice Rückenbreite fe...

Page 3: ...ably qualified personnel in accordance with EN 50110 1 2 VDE 0105 Part 100 may work on this device system Before installation and before touching the device ensure that you are free of electrostatic charge The rated value of the mains voltage may not fluctuate or deviate by more than the tolerance specified otherwise malfunction and hazardous states are to be expected Panel mount devices may only ...

Page 4: ...II ...

Page 5: ... protection 11 Short circuit monitoring of the thermistor circuit 12 Phase failure 14 Earth fault monitoring 14 2 Configuration 15 Monitoring overload of motors in the EEx e area 15 Setup of the overcurrent protection system 15 Approvals 16 3 Installation 17 Notes on installation 17 Mounting the devices 19 ZEV and ZEV XSW 25 to 145 19 ZEV and ZEV XSW 820 21 Connections 25 Removing devices 26 ZEV a...

Page 6: ...h fault monitor 30 Assigning the free contacts 30 Display messages 31 Overload tripping 31 Thermistor tripping 31 Earth fault 31 Phase failure 32 Current imbalance 32 Device fault 32 Annex 33 Rating plates 33 Electronic motor protective relay ZEV 33 Current sensors ZEV XSW 33 ZEV tripping curves 35 3 phase tripping curve 35 2 phase tripping curve 37 Dimensions 38 ...

Page 7: ...eviations and symbols The abbreviations and symbols used in this manual have the following meaning X indicates actions to be taken Edition Page Description New Modification Omitted 10 06 33 Rating plates j CLASS Tripping class of a thermal overload circuit breaker EEx e Increased safety degree of protection RTT Rated threshold temperature PTB Physikalisch Technische Bundesanstalt German Federal Te...

Page 8: ...vide you with a good overview of this documentation Exceptions are the starting pages of the chapters and empty pages at the end of a chapter h Draws your attention to interesting tips and supplementary information Note Warns of the risk of slight material damage Warning Warns of the risk of heavy material damage and of fatal injury or even death ...

Page 9: ...mperature and development of sparking and arcing which is usually not found when motors are operated under normal conditions The motor protective devices used for this are operated outside of the EEx e area and must be certified by an accredited certification authority The guidelines on the application of Directive 94 9 EC ATEX 100a on the approximation of the laws of the Member States concerning ...

Page 10: ...uxiliary switches c Terminals for connecting an external core balance transformer d Terminals for connecting a thermistor e Up Down adjusting buttons f Mode selector button g 1 NO 1 NC contact for overload and thermistor tripping h Grounding terminal i Reset Test button j Display k Terminal for connecting a remote or automatic reset contact a b c d e f g h i j k ...

Page 11: ...nsors These are available in the following lengths 200 mm 400 mm 800 mm Figure 3 Supplementary external core balance transformer SSW for earth fault monitoring Auxiliary external core balance transformers SSW are used for earth fault monitoring a section Earth fault monitoring Page 14 ZEV XSW 25 ZEV XSW 65 ZEV XSW 145 ZEV XSW 820 ...

Page 12: ...peration The tripping characteristics are selected by means of the CLASS settings These are CLASS 5 for easy starting conditions CLASS 10 for standard starting conditions CLASS 15 to CLASS 40 for heavy to severe starting conditions The switchgear is designed for standard and overload operation of the CLASS 10 To avoid thermal overload of switchgear under severe starting conditions the rated operat...

Page 13: ...restarting the unit its recovery time as determined by the CLASS settings shown in Table 3 must be maintained Table 3 Recovery times after overload tripping CLASS Ie CLASS 5 Ie 10 Ie 15 Ie x 0 82 20 Ie x 0 71 25 Ie x 0 63 30 Ie x 0 58 35 Ie x 0 53 40 Ie x 0 50 Warning The protected motor and the switchgear must be suitable for the given startup conditions CLASS trecovery min 5 5 10 6 15 7 20 8 25 ...

Page 14: ...e for direct but also for indirect temperature monitoring by means of thermistors For this a thermistor is connected to input T1 T2 that is bridged by default a section Thermistor protection Page 11 The contacts 95 96 and 97 98 change over when the thermistor monitor trips the device a fig 4 on Page 11 ...

Page 15: ...toring with thermistor a Tripping b Reset c Three temperature probes d Six temperature probes The ZEV trips at R 3200 O g15 and resets at R 1500 O 10 The contacts 9596 and 9798 change over when the unit is tripped by the signal at the thermistor input The thermistor tripping circuit can also be assigned to switch over one of the contacts 05 06 or 07 08 in order to provide a distinguished tripping ...

Page 16: ...nd short circuit as shown in the following circuit diagram h Hazard due to sensor failure is also excluded when the temperature is being monitored by means of thermistors since this circuit switches off the unit instantaneously Warning Response of the thermistor monitoring unit must also directly shut down a motor that is controlled by means of an inverter Appropriate provisions must be made in th...

Page 17: ...95 05 07 A1 A2 PE C1 C2 T2 T1 M 3 Reset Fern Reset S1 S2 K1M K1M 97 I μP Mode Class Test Reset Up Down L1 L2 L3 79 0 20 PE K1 16 18 C B1 B2 B3 15 A1 A2 K1M K1 Caution The maximum short circuit current at the thermistor input is 2 5 mA h This circuit is suitable for full protection of motors operated in EEx e areas ...

Page 18: ...monitoring and with the option of monitoring earth faults via an auxiliary core balance transformers Table 4 Core balance transformers for earth fault monitoring In addition to the message shown on the display of the ZEV a fig 30 on Page 31 the earth fault signal can also be used to switch over one of the contacts 05 06 or 07 08 a fig 7 on Page 18 Core balance transformer Opening diameter Fault cu...

Page 19: ...nt of IA However since EEx e motors are not intrinsically safe explosion safety can only achieved by taking additional measures during installation and by selecting appropriate operating conditions PTB testing regulations e g by adding a correctly rated and set overload protection to the circuit Setup of the overcurrent protection system Warning The selected overload protection system must not onl...

Page 20: ... The motor protective system ZEV is compliant with IEC EN 60947 regulations for low voltage switchgear and EN and fulfils the requirements of the 94 9 EC ATEX 100a directives for the protection of motors operated in EEx e areas The system is approved by UL and CSA for the USA and Canada CLASS 40 10000 10000 100 10 18 100 1 0 1 1 6 10 100 35 30 25 20 15 10 CLASS 5 tA s ms le Nle c 0102 II 2 G U s ...

Page 21: ...EV may only be reset restarted either manually after the recovery time trecovery has expired or automatically via a control interlock circuit for the motor or electrically driven machine a fig 25 on Page 29 A manual reset may be carried out by skilled personnel either locally or in the control room Warning Particularly for EEx e applications an automatic restart must be safely prevented after an i...

Page 22: ...tart L1 L2 L3 N 96 06 08 98 95 05 07 A1 A2 PE C1 C2 T2 T1 M 3 Reset Fern Reset S1 S2 K1M K1M 97 I µP Mode Class Test Reset Up Down L1 L2 L3 79 0 20 PE K1M Warning The automatic restart of motors is coupled with the risk of injury and material damage The risk of an automatic restart is given in following setting in the Reset menu see also Fig 25 Page 29 AUT Reset ...

Page 23: ...ices ZEV and ZEV XSW 25 to 145 Figure 8 ZEV mounting position Figure 9 Mounting of the ZEV and current sensor X Place the ZEV into the required mounting position X Snap the ZEV onto the current sensor X Feed all motor phases through the current sensor 90 90 90 90 ...

Page 24: ...termined by the rated operational current of the motor IN a table 6 Figure 10 Loops of the motor feed cables Table 6 Number of loops IN rated operational current of the motor Ie current setting at the ZEV Current sensor Feedthrough O Conductor cross section mm mm2 AWG ZEV XSW 25 6 10 solid or multi wire 10 ZEV XSW 65 13 50 fine wire 1 ZEV XSW 145 21 150 fine wire 2 0 IN A 0 25 to 0 4 0 41 to 0 62 ...

Page 25: ...Figure 11 Connection the ZEV and current sensor with the cable X Connect the two units using a ZEV XVK patch cable ZEV XSW 820 strapped to a current busbar Figure 12 Opening the strap X Release the lock pin X Remove the lock pin X Release the strap 0 8 m 3 1 2 1 2 3 ...

Page 26: ... 13 Mounting the unit onto the busbar X Fold the strap around the busbar X Engage the lock pin X Fasten the strap Figure 14 Installation of the sensor cables X Install the sensor cable so that each one is wound around only one busbar 1 2 3 1 2 3 ...

Page 27: ... Removal of the strap X Release the lock pins X Remove the lock pins X Remove the strap Figure 16 Installation o the cable ties and wiring of the sensor cables X Wrap the cable tie around the current sensor and the busbar X Install the sensor cable so that each one is wound only around one busbar 1 2 1 2 3 1 2 3 ...

Page 28: ...e Figure 17 Mounting on power cable X Place the strap around the busbar X Engage the lock pin X Fasten the strap Figure 18 Installation of the sensor cables X Install the sensor cable so that each one is looped around one busbar only h Use additional cable ties at temperatures 50 C ...

Page 29: ...rap the current sensor to the power cable using the cable tie X Install the sensor cable so that each one loops only one power cable Connections Table 7 Conductor cross sections of the auxiliary cables mm2 mm2 AWG mm Nm 1 x 0 5 to 2 5 1 x 0 5 to 2 5 18 to 12 0 8 x 5 5 Z1 0 8 2 x 0 5 to 1 0 2 x 0 5 to 1 0 18 to 12 0 8 x 5 5 Z1 0 8 2 x 1 0 to 1 5 2 x 1 0 to 1 5 18 to 12 0 8 x 5 5 Z1 0 8 ...

Page 30: ...e 20 Removing the ZEV from the DIN rail X Push the ZEV down to release it X Pull the ZEV off the DIN rail Connecting cable Figure 21 Removing the ZEV XVK X Push a screwdriver into the cable socket X Move the screwdriver upwards X Remove the connecting cable 1 2 1 2 2 1 3 1 2 3 ...

Page 31: ...The MODE function key for selecting the various menus To acknowledge the entries made in the menus press the MODE button The UP DOWN button for selecting the desired values from the various menus The RESET TEST button to exit the menus without saving the values and to return to the previous menu The following Figure22 provides an overview of all possible settings at the basic unit ...

Page 32: ...est Reset Test Reset Test Mode Mode Mode Mode Reset Test Reset Test Reset Test Mode Mode Mode Reset Test Reset Test Reset Test Reset Test Mode Mode Mode Reset Test Reset Test Mode Mode Mode Reset Test Reset Test Reset Test Mode Mode Mode Reset Test Reset Test Reset Test Mode Mode Mode Operational current CLASS setting 5 to 40 Reset Manual Auto Earth fault monitor OFF EXT Assignment of the break co...

Page 33: ...igure 23 Operating current menu Setting the tripping CLASS X Use the UP DOWN buttons in to set the tripping class in steps of five Figure 24 CLASS menu Selecting the reset mode X Use the UP DOWN buttons to set either manual or automatic tripping of the ZEV Figure 25 Reset menu L1 L2 L3 A 1 0 L1 L2 L3 A 820 Up 5 Down 5 5 Class 10 Class 35 Class 40 Class MAN AUT Reset Reset ...

Page 34: ... Earth fault monitoring menu Assigning the free contacts The FC1 and FC2 contacts are available for connecting a remote message system a fig 27 X Use the UP DOWN buttons to select which message is to be output via the contacts FC1 or FC2 Figure 27 Free contacts menu a Earth fault tripping if not OFF b Overload pre warning c Thermistor tripping d Internal error EXT OFF a b c d FC 1 FC 1 FC 1 FC 1 i...

Page 35: ...1 Hz if an error has occurred Overload tripping Figure 28 Overload tripping message Thermistor tripping Figure 29 Thermistor tripping message Earth fault Figure 30 Earth fault message OFF 3 RDY Class L1 L2 L3 137 10 53 Reset Test Reset Test 1Hz 1Hz RDY Class L1 L2 L3 97 10 Reset Test R 1 6 kΩ R 3 1 kΩ OFF 1Hz 97 Class L1 L2 L3 97 10 Class L1 L2 L3 10 1Hz ...

Page 36: ...o connection to the current sensor ERR 2 EEPROM error ERR 3 Tripping device error OFF Class L1 L2 L2 L3 97 10 Reset Test 1Hz OFF 114 RDY 3 Class L1 L2 L3 10 97 Class L1 L2 L3 10 Class L1 L2 L3 10 L2 L3 L2 L3 53 F 0 8 1 min max Reset Test Reset Test 1Hz 1Hz 1Hz I I 97 ERR ERR ERR 97 97 Class L1 L2 L3 10 1 2 3 Warning Faulty devices ERR2 and ERR3 may not be opened for repairs and must be replaced on...

Page 37: ...8 Ie 1 5 A DC 13 Ue 24 V 95 96 97 98 Ie 1 A 05 06 07 08 Ie 1 A AUX CONT B300 R300 2 1N0 1NC TRIPPING CURRENT IS 125 OF SETTING WITH AUTOMATIC RESET AND 2 WIRE CONTROL MOTOR MAY RESTART AUTOMATICALLY FOR CLASS DESIGNATION AND TRIPPING CURRENT SEE INSTRUCTIONS PAGE 3 5 TIGHTENING TORQUE 0 8 1 2 Nm AUX AWG 18 14 75 C CU WIRE ONLY IEC 947 EN 60947 VDE 0660 0102 u A006653 II 2 G PTB 01 ATEX 3233 A00665...

Page 38: ... G PTB 01 ATEX 3233 A006653 340B 0102 s IEC 947 EN 60947 VDE 0660 Made in Germany ZEV XSW 145 10 145 A V 1 2 IND CONT EQ LISTED u Uimp 8000 V Ue 1000 V ZEV XSW 820 40 820 A V 1 2 Made in Germany II 2 G PTB 01 ATEX 3233 A006653 340B 0102 s IEC 947 EN 60947 VDE 0660 IND CONT EQ LISTED u ...

Page 39: ...ing curves 35 10 06 AWB2300 1433GB ZEV tripping curves 3 phase tripping curve Figure 39 ZEV tripping curve 3 phase 50 CLASS 5 15 10 tA min s 100 50 20 10 5 2 1 20 10 5 2 1 120 0 7 1 2 5 8 20 25 CLASS 40 30 35 le ...

Page 40: ...7 43 0 35 0 28 6 25 5 20 1 30 67 9 47 7 36 8 30 0 24 5 21 9 17 2 25 56 6 39 8 30 7 25 0 20 5 18 2 14 4 20 45 3 31 8 24 6 20 0 16 4 14 6 11 5 15 34 0 23 9 18 4 15 0 12 3 10 9 8 6 10 22 6 15 9 12 3 10 0 8 2 7 3 5 7 5 11 3 8 0 6 1 5 0 4 1 3 6 2 9 h In a 3 phase symmetrical tripping system the deviation of the tripping delay tA as of three times the tripping current tA is g20 ...

Page 41: ...ZEV tripping curves 37 10 06 AWB2300 1433GB 2 phase tripping curve Figure 40 Characteristics curve showing phase failure or imbalance 50 ...

Page 42: ...es to the tripping classes Dimensions Figure 41 Dimensions of the ZEV and ZEV XSW Table 10 Dimensions of the current sensors in mm CLASS tA s 3 4 5 6 7 2 8 10 40 2 5 2 5 2 5 2 5 2 5 2 5 2 5 35 20 25 20 15 10 5 29 a 93 b d ZEV XSW 25 65 145 a 24 49 68 b 93 93 93 d 6 13 21 ...

Page 43: ...ler net Internet www moeller net 2001 by Moeller GmbH Subject to alteration AWB2300 1433GB Doku Doku Eb 10 06 Printed in the Federal Republic of Germany 10 06 Article No 267430 4 patpks nmvc v Rückentext Hardware and Engineering 10 06 AWB2300 1433GB A A A Think future Switch to green Think future Switch to green Rückenbreite bis 10 mm 1 Blatt 0 106 mm für XBS ...

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