2-Component Combination Motor Controller Solutions . - Klockner Moeller
2-Component CombinationMotor Controller solutionsfor North AmericaM3 The complete range of contactors, efficient motor-startersand variable speed drives forthe motor circuit. New simple to install solutions basedon clever communication.Technical PaperDipl.-Ing. Wolfgang EsserContactors DILReliably and safely controlling,switching and managingpower. In industry, in buildingsand in machine construction.Innovative protection concepts.With built-in diagnostics andcommunication functions.Housed in modern switchboardsystems.Circuit-breakers NZMFor Moeller Electric Sales and Support call KMparts.com (866) 595-9616
2-Component Combination Motor Controllersolutions for North America– fuseless motor starters without separately mounted overload relay –Differing styles of motor startersEveryone would agree that motors areby far the most important pieces ofequipment in the machine tool andpanel building industry. This paper willdeal mainly with modern aspects ofswitching and protecting asynchronousor squirrel-cage motors, still the primaryworkhorses of the industry. There areessentially 2 traditional approachesinvolved in switching and protectingsuch motors. One uses fuses as theprimary overcurrent protective device.The other is fuseless, and relies onmotor protective switches or circuitbreakers as the core protective element.Both versions feature a separatelymounted overload relay as a means toprotect the motor against runningoverloads, and both are typicallycombined with motor switching and HPrated motor contactors to providelonger life and remote controloperational capabilities for the motorstarter. Fuseless solutions have theadvantage that they are inherentlyindependent of local fusing styles andconditions, which can vary greatly frommarket to market, and they also wouldpermit, in most cases, a relatively quickresetting of the circuit withoutexchange of components once thecause for the fault had been eliminated.An additional safety related consideration of significant importance wouldbe that the fuseless protective devicewould operate to open all 3 polessimultaneously in the event of a fault,whereas fuses operate independentlyand are thus more prone to allow singlephasing conditions to develop in acircuit.The combination of a motor protectivedevice, or a circuit breaker, and a motorswitching contactor also lends itselfwell to different levels of componentprotective co-ordination testing, such asbeen popularized for years in the IEC/EN 60 947 standard, and of late as wellin the recently introduced andcomparable North American UL 60 947industrial control standard.Co-ordination levels are indicators ofthe protection afforded to the circuitand a determination as to whether ornot, in the event of fault, welding andinoperability of the contactor arepermissible outcomes.In the IEC world, the choice between amotor protective switch or a circuitbreaker can often be made simplybased on the size and rated current ofthe motor. In North America, both typesof components fall under markedlydifferent product standards (UL 508resp. UL 489, or CSA-C22.2 No.14 resp.CSA-C22.2 No. 5-02), which ultimatelyalso impacts the application range ofboth components when they are usedas protective devices in branch circuits.Typically, the equipment would besubject to different constructionrequirements as well, such as the needfor circuit breakers to feature the largerelectrical clearances of distributionequipment. In the IEC world, thesituation is different, with manymanufacturers of motor protectiveswitches more apt to commonly refer totheir equipment as circuit breakers,making the line between both typesdecidedly more blurry. Motor protectiveswitches represent a particularlysignificant product grouping withinMoeller, both from a technical andmanufacturing volume point of view.Moeller actually prefers to use the moreprecise term „Motor Protective Switch“for their own devices, since they areoptimally designed for motorprotection and generally available inrelatively low current ranges, i.e. up toappr. 65A, to cover the large majority ofindustrial motors. These componentsare also phase failure sensitive per therequirements of IEC/EN 60 947, which isconsidered a premium feature formotor protection applications. Moelleris justifiably considered a pioneer in thefield of motor protective switch design,to the point where the PKZM brandreference in the electrical industry isoften used as an eponym or genericterm to refer to products from allmakes in this category.The IEC product standard pertaining toa molded case circuit breaker, IEC/EN 60 947 Part 2, does not contain anyspecific testing provisions for motorprotection. One needs to combinecertain test requirements from anadditional product standard, IEC/EN 60 947-4-1 for contactors, overloadrelays and motor starters, in order tolegitimize the device as a „MotorProtective Circuit Breaker“, or largemotor protective switch. A similarsituation exists in North America,whereby the applicable productstandards for molded case circuitbreakers and switches, i.e. UL 489 inthe US, and CSA-C22.2 No. 5-02 inCanada, also do not include any testingprovisions to specifically verify thecircuit breaker’s performance as amotor protective device. In order toestablish the circuit breaker as a motorprotective device, the breaker must firstbe listed under the UL 489 productstandard, and then pass additionalcalibration testing per the industrialcontrol standard, UL 508 [1]. In Canada,the same situation would apply, withadditional motor overload testingrequired per their equivalent standardfor industrial control equipment,CSA-C22.2 No.14. It can thus be saidthat, world-wide, a molded case circuitbreaker requires additional calibrationper the product standards forcontactors and motor starters in orderto verify its performance as a motoroverload protective switch.In the IEC world, as well as in NorthAmerica, one would typically add amotor switching contactor to a circuitbreaker in order to provide motors withthe added capability of remoteswitching, as well as a higher switchingfrequency and a longer electrical life forthe motor starter. In the IEC world,these motor starters would predominently consist of two components, i.e.a circuit breaker or motor protective2For Moeller Electric Sales and Support call KMparts.com (866) 595-9616
switch for motor overload and shortcircuit protection, and a motorcontactor for direct switching purposes.In North America, on the other hand,combination motor starters are stilloverwhelmingly made up of at leastthree power circuit components in themotor branch circuit.North American combinationmotor starters are mainly 3component assembliesWhereas it is common to find circuitbreakers additionally calibrated formotor overload protection in globalregions dominated by IEC standards, inNorth America circuit breakers are stillcommonly combined with separatelymounted overload relay protectivedevices conforming to UL 508 andCSA-C22.2 No.14 in motor startercircuits. Thus, the prevalent combination motor starter configuration inthe US and Canada consists of at leastthree power circuit components, anumber not unlike the combination offuses, contactor and motor overloadrelay still very commonly encountered inthe IEC world for motor circuits. In bothcases, the circuit breaker or fuse fulfillsthe role of branch circuit protectivedevice (BCPD) for the branch circuit. Atypical IEC motor protective device, e.g.a Moeller PKZM0, is referred to as amotor protective switch or manualmotor controller in North America.Manual motor controllers certified perUL 508 and CSA-C22.2 No.14 standardsare not suitable as branch circuitprotective devices (BCPD) per theelectrical codes. In a motor branchcircuit, they would require theadditional presence of a BCPD such as acircuit breaker or fuse [2]. They canfulfill the role of a BCPD for individualmotor branch circuits if they areadditionally evaluated as Type E selfprotected controllers, in which case theywould also require the provision of anadditional terminal block on theirUL 489 Inverse Time Circuit Breaker, with adjustable or,more commonly encountered, fixed overload responsetrips. (UL 508 Table 76.2,Construction Type C)incoming supply side to achieve thenecessary electrical clearances. In thatcapacity they can also be combined withconventional magnetic contactors forcertification as Type F combinationmotor controllers.Two common types of combinationstarters encountered in North Americainclude a circuit breaker as the overcurrent protective device along with amotor switching contactor and aseparately mounted overload relay. Thefirst, and most common, features anInstantaneous-Only Trip circuit breakeras the protective device and accounts forthe great majority of circuit breaker typecombination motor starters in the NorthAmerican industrial sector. The otherform of circuit breaker type combinationstarter would feature an inverse timecircuit breaker, most likely with a fixedoverload response setting (Figure 1).Circuit breakers with a fixed overloadresponse capability are very seldomUL 489 Motor Protective Circuit Breaker, withadjustable overload trip, with UL 508calibration, without separate overload relayI UL 489 InstantaneousTrip Circuit Breaker,without overload trips(UL 508 Table 76.2,Construction Type D)bNZM.-ME.-NAM3 M3 new!I I aM3 M3 cFigure 1: In North America, combination motor starters still predominently consist of at least 3 main power circuit components. Thenew motor protective circuit breaker Type NZM.2-ME.-NA allows for a 2 component combination motor starter solution consisting ofthe circuit breaker and a motor switching HP rated contactor.3For Moeller Electric Sales and Support call KMparts.com (866) 595-9616
have been tested and certified togetheras a motor starter assembly.The main disadvantages of a 3 component motor starter solution from an IECpoint of view, include an obviousgreater need for volume to house theassembly, as well as more elaboratemounting and wiring considerations. Inthe case of an inverse time breaker,there is the additional aspect that thebreaker and the motor overload relaywould now double the heat producedin the enclosed housing space throughnormal component power losses.The advantages of a 2component combination motorstarter solutionFIgure 2: Modern design 2 component combination motor starter solutions for the NorthAmerican market: UL 508 Type F – Combination Motor Starters, consisting of a PKZM0manual Type E self-protected combination motor controller combined with a DIL M motorswitching contactor. The pictured starters are mounted on busbar adapters directly fedfrom a busbar system. As a Type E device, the PKZM0 is also equipped with an incomingsupply terminal (circled in red) featuring the larger electrical distribution clearances.encountered in the IEC world, and aremostly found in Asia or in the residential market. The need for a circuitbreaker with fixed response settingswould more likely arise in non-motorload applications and would probablytend to feature larger currents and longcable lines, for which a closer match ofthe load ampacity to the breaker’s fixedsetting would be useful in keepingdown material costs, such as coppercontent. A circuit breaker with anadjustable overload or long timeresponse, on the other hand, wouldalways have to be connected to aconductor whose ampacity would beequal to, or greater than, the circuitbreaker’s maximum adjustable currentsetting, and could thus potentially leadto higher overall installation costs. Inthe IEC world, instantaneous-only tripcircuit breakers are occasionally usedfor motors with unusually long startingtimes, and combined with a separatelyprovided electronic motor overloadrelay on which various trip class settingscan be selected to better match theload. Instantaneous Trip-only circuitbreakers are certified in North Americaas Recognized Components only. Thistype of certification is by definitionrestrictive, and subject to additionalconditions of acceptability in order tomeet the requirements of the NorthAmerican electrical codes. In the case ofthese circuit breakers, this wouldprimarily involve the need to alwaysapply them with a dedicated motorcontactor and overload relay whichFigure 3: The motor protective circuitbreaker NZM2-ME-NA, listed per UL 489and certified per CSA-C22.2 No. 5-02, hasadditionally been evaluated per the motoroverload calibration requirements of UL508 and CSA-C22.2 No. 14. In additionto the adjustable overload and instantaneous short circuit trip adjustments, thedevice has a motor inrush trip class selection feature similar to the ones availablein premium design overload relays.Moeller offers 2 component combination motor starters in the form ofUL 508 listed Type F combinationcontrollers for current ranges up to52A. They are especially popular sincethey can also be mounted and wired inarrays on modern space saving busbaradpaters for control panel applications(Figure 2) [2, 3]. Moeller has introduceda new molded case circuit breaker, TypeNZM.2-ME.-NA, with a built-in motoroverload protective function (MotorProtective Circuit Breaker) for motorfull load currents in the range of45.200A. The circuit breaker is alsocertified and was developed at thesame time as the North Americanstandards and testing requirements forthis type of protective device werebeing formulated. The breaker is„UL-Listed“ and „CSA-Certified“. InMoeller’s line it’s a size 2 frame construction breaker, and it is equippedwith an electronic trip unit. These largerNZM.2-ME -NA „motor protectiveswitches“ also feature a much broader,and overlapping, adjustable settingrange (Figure 3). Only three separatedevices are required to cover the entire45A to 200A motor full load currentsetting range (Table 1). The currentvalues correspond to North Americanmotor HP ratings from 60 through150HP @ 460/480VAC. The instantaneous short circuit trips are adjustableand can be set in a broad rangebetween 2 . 14 x In in order toaccommodate typical motor inrushcurrents and prevent nuisance tripping.A special feature of this breaker is its4For Moeller Electric Sales and Support call KMparts.com (866) 595-9616
Motor Protective Circuit Breakers for North America (Inverse Time Circuit Breakers)Circuit Breakers with adjustable electronic trips for motor overload and short circuit protection.Listed to UL 489 und certified to CSA -C22.2 No. 5-02, also IEC rated and CE marked.Motor overload trip calibration per UL 508 and CSA C22.2 No.14Additional time delay setting, incremental between 2 and 20 seconds, to adjust for motor inrush at 6 x IrUL/CSA 100 % rated circuit breakersSetting RangeOverloadTrip*Instantaneousshort circuit tripProjectedMax. HPRatings460 V480 VHPBreaker with NormalInterrupting ratingTypeBreaker with HighInterrupting ratingTypeSCCRSCCR575 V 85 kA 240 V600 V 35 kA 480 V25 kA 600/347 VHPSuitable motorswitching contactorType150 kA 240 V100 kA 480 V50 kA 600/347 VIn Iu[A]Ir [A]Ii [A]Ii9045-909012602 . 14 x In 6075NZMN2-ME90-NANZMH2-ME90-NADILM80 DILM9514070-14014019602 . 14 x In 100125NZMN2-ME140-NANZMH2-ME140-NADILM115 DILM15020010020020028002 . 14 x In 150200NZMN2-ME200-NANZMH2-ME200-NADILM185 DILM225Ratings in the latest Moeller main catalog are binding!Table 1: Circuit breakers with adjustable overload and short circuit trips, and additional evaluation per the motor overload calibrationrequirements of the industrial control standards UL 508 and CSA-C22.2 No.14, are destined to become in North America the larger versions of popular motor protective switches. These breakers will be typically combined with remotely operable electro-magnetic motorswitching contactors for long life combiantion motor starter applications. The circuit breakers are also 100% rated, so that the fullrange of their adjustability can be utilized.100% rating. Conventional circuitbreakers in North America are normallyrated at 80%, which means that acircuit breaker serving a continuousload can only be operated up to 80% ofits current rating.100 % rated Circuit Breakers, on theother hand, can be set to up theirmaximum rating, which in the case ofthis motor protective circuit breakerwould correspond to the motor’s fullload current. Circuit breakers whichhave been certified for 100% rating inNorth America are all markedaccordingly, whereas standard 80%breakers do not have to carry a markingto this effect. These motor protectivecircuit breakers represent a significantimprovement in Moeller’s range ofmolded case circuit breakers for theNorth American market and constitutean important step in the effort toachieve world market rated assemblies,such as control panels for globalapplications, which would shareidentical layouts and bills of material.Per the North American electrical codes,circuit breakers are able to also fulfillthe function of motor controller.However, it is much more typical anduseful to combine them with motorswitching contactors in motor starterapplications in order to provide thestarter with both a remote operationalcapability and a much longer electricallifespan. The circuit breaker is bettersuited as the main disconnect andprotective device in these applications.Of course, motor reversing applicationscan also be easily accommodated withthe use of an additional contactor toconfigure a reversing combinationmotor starter assembly. Thus, theavailability of 2 component combinationmotor starters for motor rated currentsup to 200A easily covers the very largemajority of motors encountered intoday’s modern industrial environment.The motor protective breaker andcontactor combinations have beenlisted as „Combination Motor Starters“with two levels of Short Circuit CurrentRatings (SCCR) to provide a broader andmore flexible range of values forindustrial control panel applications.Motors with full load rated currentsextending beyond 200A are encountered much less frequently than smallmotors so that, relatively speaking, 3component combination motor starterscan still be applied for larger motorswithout too great of an additional costburden for the installation. The newmotor protective circuit breakers alsocarry IEC ratings and bear the importantCE mark for applications within theEuropean Union. They are thus equallysuitable as motor protective devices incountries subject to compliance with IECstandards. IEC compliant circuit breakersfor motor protection are, in fact,available for motor rated currents up to1400A.Acknowledgment:With grateful acknowledgment of thesupport from:Mr. Andre R. Fortin, BA Phys.Manager – Codes & StandardsInternational Corporate Advisor –Power ProductsMoeller Electric Corporation,Millbury, Massachusetts, USAandMr. Dieter Reiß, Dipl.-Ing. Approvals,Institute for International ProductSafety GmbH, Bonn5For Moeller Electric Sales and Support call KMparts.com (866) 595-9616
Bibliography:[1]„Schaltgeräte und Schaltanlagen für denWeltmarkt und für den Export nachNordamerika“VKF0211-563DArticle No. 110188„Components and Systems suitable forWorld Markets and Export to NorthAmerica“VKF0211-563GBArticle No. 110189Moeller GmbH, Bonn, 2007[2]Wolfgang Esser„Besondere Bedingungen für den Einsatzvon Motorschutzschaltern undMotorstartern in Nordamerika“VER1210 1280-928DArticle No. 267951„Special considerations governing theapplication of Manual Motor Controllersand Motor Starters in North America“VER1210 1280-928GBArticle No. 267952Moeller GmbH, Bonn, 2003[3]Wolfgang Esser„Sammelschienenadapter für die rationelleMotorstartermontage– jetzt auch für Nordamerika –“VER4300-960DArticle No. 110774„Busbar Component Adapters for modernindustrial control panels“VER4300-960GBArticle No. 110775Moeller GmbH, Bonn, 2007[4]Wolfgang Esser„Leistungsschalter für den Einsatz inNordamerika“VER1230-939DArticle No. 285780“Molded Case Circuit Breakers, forapplications in North America”VER1230-939ENArticle No. xxxxxMoeller GmbH, Bonn, 04/2008Moeller addresses worldwide:www.moeller.net/addressE-Mail: info@moeller.netInternet: www.moeller.netwww.eaton.comIssued by Moeller GmbHHein-Moeller-Str. 7-11D-53115 Bonn 2008 by Moeller GmbHSubject to alterationsVER1200 2100-967en ip 07/08Printed in Germany (07/08)Article No.: 118983Eaton’s electrical business is a global leader inelectrical control, power distribution, uninterruptible power supply and industrial automation products and services. Eaton’s globalelectrical brands, including Cutler-Hammer ,Powerware , Holec , MEM , Santak andMoeller , provide customer-driven PowerChain Management solutions to serve thepower system needs of the industrial, institutional, government, utility, commercial, residential, IT, mission critical and OEM marketsworldwide.Eaton Corporation is a diversified industrialmanufacturer with 2007 sales of 13.0 billion.Eaton is a global leader in electrical systemsand components for power quality, distribution and control; hydraulics components,systems and services for industrial and mobileequipment; hydraulics, fuel and pneumaticsystems for commercial and military aircraft;intelligent truck drivetrain systems for safetyand fuel economy; and automotive engineair management systems, powertrain solutions and specialty controls for performance,fuel economy and safety. Eaton has 79,000employees and sells products to customers inmore than 150 countries. For more information, visit www.eaton.com.For Moeller Electric Sales and Support call KMparts.com (866) 595-9616
specific testing provisions for motor protection. One needs to combine certain test requirements from an additional product standard, IEC/ EN 60 947-4-1 for contactors, overload relays and motor starters, in order to legitimize the device as a „Motor Protective Circuit Breaker", or large motor protective switch. A similar
SMC-50 series Smart Motor Controller (soft starter) by using its built-in EtherNet/IP interface. This instruction communicates with the motor controller to start, stop and jog the motor, monitor the status of the motor, detect motor failure to start or stop or motor controller faults, and display motor runtime information such as power,
Controller Firmware Comment CMMS-ST-. From Version 1.3.0.1.14 Standard motor controller for stepper motors CMMS-AS-. From Version 1.3.0.1.16 Standard motor controller for servo motors CMMD-AS-. From Version 1.4.0.3.2 Standard double motor controller for servo motors Table 1.1 Controller and firmware versions For older versions:
Simple High-Power Motor Controller 18v15 or 24v12 bottom view with dimensions. 1.3.18v25 and 24v23 Included Hardware Simple High-Power Motor Controller 18v25 or 24v23 with included hardware. Simple High-Power Motor Controller 18v25 or 24v23 with included hardware installed. Simple High-Power Motor Controller 18v25 or 24v23 with custom power and
A combination of a Bulletin 140M manual self protected combination motor controller and 100-C contactor can be listed as a Type E self-protected combination motor controller. In this case, both the 140M and 100-C must pass the additional 6000 electrical and 4000 mechanical operational test.
RR Donnelley Component R.R. Donnelley Printing Companies Component Haddon Component Banta Employees Component Banta Book Group Component Banta Danbury Component Banta Specialty Converting Component Moore Wallace Component (other than Cardinal Brands Benefit and Check Printers Benefit) Cardinal Brands Benefit of the Moore Wallace Component
starters would predominently consist of two components, i.e. a circuit breaker or motor protective switch for motor overload and short-circuit protection, and a motor contactor for direct switching purposes. In North America, on the other hand, combination motor starters are still overwhelmingly made up of at least
FRC battery and Victor 884 motor controller Free motor shaft & step input PWM neutral to max-10 0 10 20 30 40 50 60 70 80 90 100 110 120 130 . FRC battery and Victor 888 motor controller Free motor shaft & step input PWM neutral to max-10 0 10 20 30 40 50 60 70 80 90 100 110 120 130
4.1 Simulink Block of PID Controller 58 4.2 Detailed Simulink Block of the System 60 4.3 Output of DC Motor without PID Controller 60 4.4 Detail Simulink Block of the System with PID Controller 61 4.5 Output of DC Motor without PID Controller 62 4.6 Sim
