Moeller ZEV Series Hardware And Engineering
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Moeller ZEV Series Hardware And Engineering

Moeller ZEV Series Hardware And Engineering

Motor-protective system. overload monitoring of motors in eex e areas.
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ZEV motor-protective
system
Overload monitoring
of motors in
EEx e areas
Hardware and
Engineering
10/06 AWB2300-1433GB
A
T hink future. Switch to green.

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  • Page 1 ZEV motor-protective system Overload monitoring of motors in EEx e areas Hardware and Engineering 10/06 AWB2300-1433GB T hink future. Switch to green.
  • Page 2 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.
  • Page 3 Warning! Dangerous electrical voltage! Before commencing the installation • Disconnect the power supply of the device. • Before installation and before touching the device ensure that you are free of • Ensure relosing interlock that devices electrostatic charge. cannot be accidentally restarted. •...

  • Page 5: Table Of Contents

    10/06 AWB2300-1433GB Contents About this manual List of revisions Target group Abbreviations and symbols Motor-protective system ZEV Preface System overview Unit description – Current monitoring sensors – Setting of the tripping CLASS – Thermistor monitoring – Thermistor protection – Short-circuit monitoring of the thermistor circuit 12 –...
  • Page 6 10/06 AWB2300-1433GB Contents Setting up the menus – Setting the operating current – Setting the tripping CLASS – Selecting the reset mode – Setting the earth fault monitor – Assigning the free contacts Display messages – Overload tripping – Thermistor tripping –...

  • Page 7: About This Manual

    10/06 AWB2300-1433GB About this manual This manual applies to the motor-protective system ZEV. It describes the overload monitoring system for the protection of motors operating in potentially explosive atmospheres (EEx e areas). List of revisions Edition Page Description Modification Omitted 10/06 „Rating plates“...
  • Page 8 10/06 AWB2300-1433GB About this manual 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. The chapter title in the header on the left side and the title of the current topic on the right side provide you with a good overview of this documentation.

  • Page 9: Motor-Protective System Zev

    10/06 AWB2300-1433GB Motor-protective system ZEV Preface In addition to the degree of protection specified in the standards EN 60079-14 and VDE 0165 Part 1, further provisions have been made to ensure safety from ignition for motors operated in potentially explosive atmospheres. EN 50019 prescribes additional measures to be taken for the operation motors with "increased safety"...

  • Page 10: System Overview

    10/06 AWB2300-1433GB Motor-protective system ZEV System overview Figure 1 : Basic electronic motor-protective relay unit ZEV a Power supply b Freely configurable auxiliary 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...
  • Page 11 10/06 AWB2300-1433GB System overview ZEV-XSW-25 ZEV-XSW-820 ZEV-XSW-65 ZEV-XSW-145 Figure 2: Current sensors Always use patch cables of the type ZEV-XVK-... to connect current sensors. These are available in the following lengths • 200 mm, • 400 mm, • 800 mm, Figure 3: Supplementary external core-balance transformer SSW...

  • Page 12: Unit Description

    10/06 AWB2300-1433GB Motor-protective system ZEV Unit description Current monitoring sensors The ZEV series of electronic motor-protective relays belongs to the family of current-sensing protective devices, same as the motor-protective relays operating on a bimetallic release principle. The ZEV monitors the motor current by means of separate sensors, which cover the current range from 1 to 820 A.
  • Page 13 10/06 AWB2300-1433GB Unit description Table 2: Settings for overload tripping CLASS e CLASS x 0.82 x 0.71 x 0.63 x 0.58 x 0.53 x 0.50 Warning! The protected motor and the switchgear must be suitable for the given startup conditions. The contacts 95-96 and 97-98 are switched over in the event of an overload tripping (a fig.

  • Page 14: Thermistor Monitoring

    10/06 AWB2300-1433GB Motor-protective system ZEV Thermistor monitoring The ZEV is not only suitable 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.

  • Page 15: Thermistor Protection

    10/06 AWB2300-1433GB Unit description Thermistor protection Full motor protection can be achieved by connecting up to six DIN 44081 and DIN 44082 PTC temperature probes with a resistance of R F 250 O to the terminals T1-T2. 10000 R [O] 5000 3680 2000...

  • Page 16: Short-Circuit Monitoring Of The Thermistor Circuit

    10/06 AWB2300-1433GB Motor-protective system ZEV 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.
  • Page 17 10/06 AWB2300-1433GB Unit description Fern-Reset 05 07 C1 C2 A1 A2 Reset μP 79.0 Class Mode Down Test > Reset 06 08 B1 B2 B3 15 A1 A2 16 18 Figure 5: Functional diagram of a current monitor Caution! The maximum short-circuit current at the thermistor input is 2.5 mA.

  • Page 18: Phase Failure

    10/06 AWB2300-1433GB Motor-protective system ZEV Phase failure In the event of a phase failure, i.e. with an imbalance of f 50 %, the unit is tripped within a delay time of 2.5 seconds g20 %. Earth fault monitoring In addition to standard motor-protective functions, such as the protection from overload or phase failure and imbalance, the device is also equipped with a thermistor input for direct temperature monitoring and with the option of monitoring...

  • Page 19: Configuration

    10/06 AWB2300-1433GB Configuration Monitoring overload of The "EEx e" degree of protection for motors is achieved by motors in the EEx e area means of special constructive measures. The motors are assigned to temperature classes based on the maximum permitted surface temperatures. The temperature rise time t and the ratio between the startup current and rated current are calculated in addition and specified on the rating plate of the motor.

  • Page 20: Approvals

    10/06 AWB2300-1433GB Configuration Example: I = 6, t = 18 s 10000 10000 CLASS 40 CLASS 5 Figure 6: Tripping curve with 3-phase balanced load The motor is safely protected with the tripping classes CLASS 5, 10 and 15. Approvals 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)

  • Page 21: Installation

    10/06 AWB2300-1433GB Installation Notes on installation The current mechanical and electrical installation instruction manual AWA2300-1694 included with the units must be observed. The basic ZEV units must be configured prior to initial commissioning (a fig. 22, Page 28). Warning! To ensure explosion protection, the ZEV may only be reset/restarted either manually after the recovery time has expired, or automatically via a control recovery...
  • Page 22 10/06 AWB2300-1433GB Installation Fern-Reset 05 07 C1 C2 A1 A2 Reset µP Class Mode Down Test > Reset 06 08 Figure 7: The circuit prevents an automatic restart. The latching function of the K1M contactor relay prevents an automatic restart. Warning! The automatic restart of motors is coupled with the risk of injury and material damage.

  • Page 23: Mounting The Devices

    10/06 AWB2300-1433GB Mounting the devices Mounting the devices ZEV and ZEV-XSW-25 to 145 90° 90° 90° 90° Figure 8: ZEV mounting position Figure 9: Mounting of the ZEV and current sensor Place the ZEV into the required mounting position. Snap the ZEV onto the current sensor. Feed all motor phases through the current sensor.
  • Page 24 10/06 AWB2300-1433GB Installation The following conductor cross-sections can be used. Table 5: Maximum conductor cross-sections of the motor cables Current sensor Feedthrough Conductor cross-section ZEV-XSW-25 10 solid or multi-wire ZEV-XSW-65 50 fine-wire ZEV-XSW-145 150 fine-wire Mounting for low motor currents At the ZEV-XSW-25, the cables for motors operating with a current <...

  • Page 25: Zev And Zev-Xsw-820

    10/06 AWB2300-1433GB Mounting the devices ZEV and ZEV-XSW-820 0.8 m Figure 11: Connection the ZEV and current sensor with the cable Connect the two units using a ZEV-XVK-... patch cable. ZEV-XSW-820 strapped to a current busbar Figure 12: Opening the strap Release the lock pin.
  • Page 26 10/06 AWB2300-1433GB Installation Figure 13: Mounting the unit onto the busbar Fold the strap around the busbar. Engage the lock pin. Fasten the strap. Figure 14: Installation of the sensor cables Install the sensor cable so that each one is wound around only one busbar.
  • Page 27 10/06 AWB2300-1433GB Mounting the devices ZEV-XSW-820 strapped to a current busbar with cable ties Figure 15: Removal of the strap Release the lock pins. Remove the lock pins. Remove the strap. Figure 16: Installation o the cable ties and wiring of the sensor cables Wrap the cable tie around the current sensor and the busbar.
  • Page 28 10/06 AWB2300-1433GB Installation ZEV-XSW-820 strapped to a > 50 mm power cable Figure 17: Mounting on power cable Place the strap around the busbar. Engage the lock pin. Fasten the strap. Figure 18: Installation of the sensor cables Install the sensor cable so that each one is looped around one busbar only.

  • Page 29: Connections

    10/06 AWB2300-1433GB Mounting the devices ZEV-XSW-820 fastened on a F 50 mm power cable with cable ties Figure 19: Installation of the cable ties and wiring of the sensor cables Strap the current sensor to the power cable using the cable tie.

  • Page 30: Removing Devices

    10/06 AWB2300-1433GB Installation Removing devices ZEV and DIN rail Figure 20: Removing the ZEV from the DIN rail Push the ZEV down to release it. Pull the ZEV off the DIN rail. Connecting cable Figure 21: Removing the ZEV-XVK-... Push a screwdriver into the cable socket. Move the screwdriver upwards.

  • Page 31: Operating The Devices

    10/06 AWB2300-1433GB Operating the devices Settings The basic ZEV units must be configured prior to initial commissioning. The device provides three buttons for these operations: • The MODE function key for selecting the various menus. To acknowledge the entries made in the menus, press the MODE button.
  • Page 32 10/06 AWB2300-1433GB Operating the devices Class Mode Operational Mode Mode Reset/Test current 14.7 14.8 Mode Reset/Test Reset/Test CLASS setting Mode Mode Reset/Test (5 to 40) Class Class Mode Reset/Test Reset/Test Reset: Mode Mode Reset/Test Manual/Auto Reset Reset Mode Reset/Test Reset/Test Earth fault monitor Mode Mode...

  • Page 33: Setting Up The Menus

    10/06 AWB2300-1433GB Setting up the menus Setting up the menus Setting the operating current Use the UP/DOWN buttons to set the relevant operating current of the ZEV. Figure 23: Operating current menu Setting the tripping CLASS Use the UP/DOWN buttons in to set the tripping class in steps of five.

  • Page 34: Setting The Earth Fault Monitor

    10/06 AWB2300-1433GB Operating the devices Setting the earth fault monitor Use the UP/DOWN button to set up an auxiliary earth fault monitoring system with external core-balance transformer. Figure 26: Earth fault monitoring menu Assigning the free contacts The FC1 and FC2 contacts are available for connecting a remote message system (a fig.

  • Page 35: Display Messages

    10/06 AWB2300-1433GB Display messages Display messages The ZEV display shows the error messages described below. The indicator flashes at a frequency of 1 Hz if an error has occurred. Overload tripping Reset/Test Reset/Test Class Figure 28: Overload tripping message Thermistor tripping R >...

  • Page 36: Phase Failure

    10/06 AWB2300-1433GB Operating the devices Phase failure Reset/Test Class Figure 31: Phase failure message Current imbalance min : max F 0.8 : 1 Reset/Test Reset/Test Class Class Class Figure 32: Current imbalance message Device fault 97 97 Class Figure 33 : Device error messages ERR 1: Sensor error: There is no connection to the current sensor ERR 2: EEPROM error ERR 3: Tripping device error...

  • Page 37: Annex

    10/06 AWB2300-1433GB Annex Rating plates Electronic motor-protective relay ZEV A1, A2 : U = 24 ... 240V AC 50/60 Hz V 1.2 24 ... 240V DC Normal FC(Free contact) AC-15 220-240 V 95/96 + 97/98 I 05/06 + 07/08 I DC-13 24 V II(2)G...
  • Page 38 Annex ZEV – XSW – 145 10 – 145 A V 1.2 IND. CONT. 0102 340B EN 60947 LISTED II(2)G VDE 0660 A006653 PTB 01 ATEX 3233 Made in Germany Figure 37: ZEV-XSW-145 rating plate ZEV – XSW – 820 40 –...

  • Page 39: Zev Tripping Curves

    10/06 AWB2300-1433GB ZEV tripping curves ZEV tripping curves 3-phase tripping curve CLASS 40 CLASS 5 Figure 39: ZEV tripping curve, 3-phase...
  • Page 40 10/06 AWB2300-1433GB Annex Table 8: Assignment of the tripping delay to the tripping classes CLASS 90.5 63.6 49.1 40.0 32.7 29.2 23.0 79.2 55.7 43.0 35.0 28.6 25.5 20.1 67.9 47.7 36.8 30.0 24.5 21.9 17.2 56.6 39.8 30.7 25.0 20.5 18.2 14.4...

  • Page 41: 2-Phase Tripping Curve

    10/06 AWB2300-1433GB ZEV tripping curves 2-phase tripping curve Figure 40: Characteristics curve showing phase failure or imbalance > 50 %...

  • Page 42: Dimensions

    10/06 AWB2300-1433GB Annex Table 9: Assignment of tripping delay times to the tripping classes CLASS Dimensions Figure 41: Dimensions of the ZEV and ZEV-XSW Table 10: Dimensions of the current sensors in [mm] ZEV-XSW-...
  • Page 43 Industrieautomation Hein-Moeller-Straße 7–11 D-53115 Bonn E-Mail: info@moeller.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 * p a t p k s # n m v c - v *...

This manual is also suitable for:

Zev-xsw-25Zev-xsw-65Zev-xsw-820Zev-xsw-145

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