Eaton Moeller Series User manual

Moeller® series
Manual
Contactor monitoring device
CMD(24VDC), CMDTD
10/12 MN04913001Z-EN
replaces 04/10 AWB2441-1595en

All brand and product names are trademarks or registered trademarks
of the owner concerned.
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Please call your local representative:
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or
Hotline of the After Sales Service:
[phone] (de, en)
[email protected]
Original Operating Instructions
The German-language edition of this document is the original operating
manual.
Translation of the original operating manual
All editions of this document other than those in German language are
translations of the original German manual.
1st published 2007, edition date 08/07
2nd edition 2010, edition date 04/10
3rd edition 2010, edition date 10/12
See revision protocol in the “About this manual“ chapter
© 2007 by Eaton Industries GmbH, 53105 Bonn
Production: Heidrun Riege, René Wiegand
Translation: Terence Osborn
All rights reserved, including those of the translation.
No part of this manual may be reproduced in any form (printed, photo-
copy, microfilm or any other process) or processed, duplicated or distri-
buted by means of electronic systems without written permission of
Eaton Industries GmbH, Bonn.
Subject to alteration without notice.

I
Before commencing the installation
• Disconnect the power supply of the device.
• Ensure that devices cannot be accidentally
restarted.
• Verify isolation from the supply.
• Earth and short circuit.
• Cover or enclose neighbouring units that
are live.
• Follow the engineering instructions
(IL/AWA) of the device concerned.
• 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 functional earth (FE) must be
connected to the protective earth (PE) or
to the potential equalisation. The system
installer is responsible for implementing
this connection.
• Connecting cables and signal lines should
be installed so that inductive or capacitive
interference does not impair the
automation functions.
• Install automation devices and related
operating elements in such a way that they
are well protected against unintentional
operation.
• Suitable safety hardware and software
measures should be implemented for the
I/O interface so that a line or wire breakage
on the signal side does not result in
undefined states in the automation
devices.
• Ensure a reliable electrical isolation of the
low voltage for the 24 volt supply. Only
use power supply units complying with
IEC 60364-4-41 (VDE 0100 Part 410) or
HD 384.4.41 S2.
• Deviations of the mains voltage from the
rated value must not exceed the tolerance
limits given in the specifications, otherwise
this may cause malfunction and dangerous
operation.
•Emergencystopdevices complying with
IEC/EN 60204-1 must be effective in all
operating modes of the automation
devices. Unlatching the emergency-stop
devices must not cause restart.
• Devices that are designed for mounting in
housings or control cabinets must only be
operated and controlled after they have
been installed with the housing closed.
Desktop or portable units must only be
operated and controlled in enclosed
housings.
Eaton Industries GmbH Safety instructions
Danger!
Dangerous electrical voltage!

II
• Measures should be taken to ensure the
proper restart of programs interrupted
after a voltage dip or failure. This should
not cause dangerous operating states even
for a short time. If necessary, emergency-
stop devices should be implemented.
• Wherever faults in the automation system
may cause damage to persons or property,
external measures must be implemented to
ensure a safe operating state in the event
of a fault or malfunction (for example, by
means of separate limit switches,
mechanical interlocks etc.).

1
10/12 MN04913001Z-EN
About this Manual 3
Target group 3
Writing conventions 3
Abbreviations and symbols 4
List of revisions 4
1 CMD contactor monitoring relays 5
Application of the CMD 5
System overview 6
Improper use 7
2 Engineering 9
Distinction from other regulations 9
Performance Level 9
Control system of category 3 9
Average diagnostic coverage DCavg 10
Mean time to dangerous failure MTTFd11
Approvals 14
Product standard 14
Electromagnetic compatibility (EMC) 14
3 Installation 15
Mounting 15
Connection 15
– Connection for DOL starters 16
– Connection for reversing starters 17
Wiring 18
4 Operating the device 19
Function messages 19
Test function 20
Content

Content
2
10/12 MN04913001Z-EN
Appendix 21
Nameplate 21
Technical Data 22
–General 22
–Contacts 23
– Magnet systems 23
Dimensions 23

3
10/12 MN04913001Z-EN
About this Manual
Target group This manual is aimed at specialist personnel involved in the
design, installation, commissioning and maintenance of
plant safety functions.
It describes the use of the CMD contactor monitoring device
in safety-related control systems.
Writing conventions Symbols used in this manual have the following meanings:
For greater clarity, the name of the current chapter is shown
in the header of the left-hand page and the name of the
current section in the header of the right-hand page. Pages
at the start of a chapter and empty pages at the end of a
chapter are exceptions.
iCaution!
Warning!
warns of the possibility of serious damage and slight
injury.
jDanger!
warns of the possibility of serious damage and slight injury
or death.
hDraws your attention to interesting tips and supplemen-
tary information.

About this Manual
4
10/12 MN04913001Z-EN
Abbreviations and
symbols
List of revisions
IFA Institute for Occupational Safety and Health (BGIA)
SIL Safety Integrated Level
PL Performance Level
CCF Common cause failure
DCavg Average diagnostic coverage
MTTFdMean time to dangerous failure
B10d Lifespan up to a dangerous failure
nop Mean number of annual switch operations
LED LED
Edition
date
page Subject New Modi-
fica-
tion
Omitt
ed
10/12 4, 6, 14 BGIA aIFA j
6, 7, 13 PKZ2 j
9 Engineering IEC/EN 60204-1 j
15 Installation j
04/10 17 Figure4 „Reversing starter“ j

5
10/12 MN04913001Z-EN
1 CMD contactor monitoring relays
Application of the CMD In the event of an emergency in safety-related electrical
control circuits, the hazardous plant section is shut down
from the main power supply by means of contactors
aEmergency stop (stopping in the event of an emergency)
in accordance with IEC/EN 60204-1.
For Category 3 control systems in compliance with EN/ISO
13849, the connection of two contactors in series is recom-
mended. This technique can be replaced using one contactor
and the CMD contactor monitoring device connected to the
backup circuit-breaker/motor-protective circuit-breaker in
the plant.
The contactors must be provided with an auxiliary NC
contact that operates as a mirror contact in accordance with
IEC/EN 60947-4-1 Annex F. The contactors also require an
additional auxiliary NO contact. The motor-protective circuit-
breakers/circuit-breakers are provided with an undervoltage
release.
In the event of a hazard the contactor is disconnected via an
upstream safety PLC or a safety relay by means of an enable
contact. The CMD compares the control voltage of the
contactor with the status of the main contacts. The status of
the main contacts is monitored via an auxiliary NC contact
that acts as a mirror contact in accordance with IEC/
EN 60947-4-1 Annex F.
If the contactor is welded, the status of the main contacts
does not correspond to the status of the control voltage. The
undervoltage release of the backup circuit-breaker is tripped
via an internal relay in the CMD. This disconnects the
outgoer. The undervoltage release prevents the welded
contactor from be switched on again.

CMD contactor monitoring
relays
6
10/12 MN04913001Z-EN
The CMD contactor monitoring device is approved by the IFA
in combination with Eaton contactors and circuit-breakers
(asection ”System overview”, Page 6). It is also provided
with a CE declaration of conformity and an EU type testing
certificate.
System overview
Figure 1: Contactor monitoring devices
The CMD contactor monitoring device requires a control
power supply.
CMD(24VDC), CMDTD: control voltage 24 V DC
The CMD relay can be combined with the following Eaton
contactors, motor-protective circuit-breakers and circuit-
breakers:
• Contactors/contact modules, fitted with an auxiliary NC
contact as mirror contact and an additional auxiliary NO
contact
Control voltage 24 V DC:
– DILM(C)7, DILM(C)9, DILM(C)12, DILM(C)15,
DILM(C)17, DILM(C)25, DILM(C)32, DILM(C)40,
DILM(C)50, DILM(C)65, DILM(C)72, DILM(C)80,
DILM(C)95, DILM(C)115, DILM(C)150, DILM(C)170
– DILEEM-G and DILEM-G
– DILM185A, DILM225A, DILM250, DILM300A,
DILM400, DILM500

Improper use
7
10/12 MN04913001Z-EN
• Motor-protective circuit-breakers, circuit-breakers and
switch-disconnectors, fitted with an undervoltage release
– NZM1, N1 + NZM1-XUVL
– NZM2, N2 + NZM2/3-XUV
– NZM3, N3 + NZM2/3-XUV
– NZM4, N4 + NZM4-XUV
Improper use The CMD contactor monitoring device has only been tested
and approved in combination with the Eaton contactors and
circuit-breakers that are listed in section “System overview”,
(apage 6).
hThe contactor must be provided with an auxiliary NC
contact that is designed as a mirror contact in accordance
with IEC/EN 60947-4-1 Annex F.
The auxiliary NO contact and auxiliary NC contact must be
interlocked opposing in accordance with IEC/EN 60947-5-
1 Annex L.
The contactor and the CMD are fed with the same control
voltage.
hThe CMD must therefore only be combined with these
devices.

8
10/12 MN04913001Z-EN

9
10/12 MN04913001Z-EN
2Engineering
Distinction from other
regulations
The safety-related part of the CMD contactor monitoring
device's control system has EN/ISO 13849-1 approval. The
CMD is used for safety-related applications in machine
control systems. It has not been assigned to a SIL category
as per IEC/EN 61508. The system must be set up as per
IEC/EN 60204-1.
Performance Level The CMD contactor monitoring device can be used to set up
control systems that meet the requirements of performance
level (PL) "d" as per
EN/ISO 13849-1. The control system's setup meets the
requirements of category “3“ as per EN/ISO 13849-1.
In order to reach a PL of “d“, a common-cause failure (CCF)
analysis must be performed for the control system.
The control system must meet the requirements of one of the
following two combinations of the average diagnostic
coverage (DCavg) and the mean time to dangerous failure
(MTTFd):
•DC
avg = low and MTTFd= medium to high,
or
•DC
avg = medium and MTTFd= medium.
Control system of
category 3
The CMD contactor monitoring device can be used in combi-
nation with DOL starters or reversing starters. The sche-
matics are shown in section “Connection” (apage 15).

Engineering
10
10/12 MN04913001Z-EN
Average diagnostic
coverage DCavg
Disconnection in the event of a hazardous situation is imple-
mented from two units that are included in the calculation as
parallel channels:
• Channel 1: contactor,
• Channel 2: series connection of the CMD and under-
voltage release of the motor-protective circuit-breaker/
circuit-breaker.
The mirror contacts used allows a DCavg = 99 % to be
applied to channel 1.
For channel 2 the DCavg for the CMD was calculated at DCavg
=90 %. The undervoltage release can be estimated a DCavg
= 60 % provided that regular inspections are carried out.
hTwo CMD relays are required in reversing starter circuits.
To attain category 3, faults were excluded by wiring inside
a control cabinet.
On disconnection via the undervoltage release, a time
delay of 100 ms G20 % can occur.
An enable circuit must be protected with a max. 2 A gG/
gL fuse to protect the internal relay contacts.
hThe function of the undervoltage release must be tested
manually at regular intervals.

Mean time to dangerous
failure MTTFd
11
10/12 MN04913001Z-EN
The generally recognized inspection frequency is a hundred
times more often than the MTTFd. The test interval can be
determined from:
Mean time to dangerous
failure MTTFd
The MTTFdtime for the components is based on
with
B10d: Lifespan up to a dangerous failure (aTables)
nop: Average number of annual switch operations
The MTTFd time for the CMD contactor monitoring device
was calculated at MTTFd= 125 years. This value is based on
a maximum operating frequency of 350, 400 operations/year
(1 operation per minute, 16 hours per day, 365 days a year).
The MTTFdtime of the contactors depends on the applica-
tion. The utilization category in accordance with IEC/
EN 60947-4-1 and the operating frequency are an important
factor here. Depending on the utilization category, the
following values can be applied to B10d, aTabelle 1:
TTest =MTTFd(formula 1)
100
hsection “Mean time to dangerous failure MTTFd”
(apage 11).
It is recommended that the test is carried out under no-
load conditions.
MTTFd=B10d (formula 2)
0.1 xnop

Engineering
12
10/12 MN04913001Z-EN
Table 1: B10d values for contactors
The MTTFdtime of the contactor is calculated according to
formula 2 with the mean annual number of switch opera-
tions depending on the application.
Contactor B10d value
Utilization category
AC-3
Utilization category
AC-4
Utilization category
AC-1
[Mill. switch opera-
tions]
[Mill. switch opera-
tions]
[Mill. switch opera-
tions]
DILM7 1.3 0.2 0.6
DILM9 1.3 0.2 0.6
DILM12 1.3 0.2 0.6
DILM15 0.75 0.2 0.6
DILM17 1.3 0.2 0.6
DILM25 1.3 0.2 0.6
DILM32 1.3 0.2 0.6
DILM40 1.3 0.2 0.6
DILM50 1.3 0.2 0.6
DILM65 1.3 0.2 0.6
DILM72 0.75 0.2 0.6
DILM80 1.3 0.2 0.6
DILM95 1.3 0.2 0.6
DILM115 1.3 0.2 0.6
DILM150 1.3 0.2 0.6
DILM170 0.75 0.2 0.6
DILM185 1.3 0.04 1.2
DILM225 1.3 0.04 0.6
DILM250 1.3 0.04 0.4
DILM300 1.3 0.04 1.7
DILM400 1.3 0.04 1.2
DILM500 1.3 0.04 0.3

Mean time to dangerous
failure MTTFd
13
10/12 MN04913001Z-EN
The MTTFdvalue of the undervoltage release depends on the
application. The following values can be estimated for B10d:
Table 2: B10d values for undervoltage release
At an assumed operating frequency of 3 operations per day
up to NZM2 and 1.33 operations per day for the NZM3 and
NZM4 the MTTFdvalue is:
Table 3: MTTFdvalues for undervoltage releases
Undervoltage release B10d value
[Switch operations]
NZM1 10000
NZM2 10000
NZM3 7500
NZM4 5000
Undervoltage
release
B10d value Operations nop MTTFd
[Switch opera-
tions]
per working
day
[O/year] [Years]
NZM1 10000 3 750 133
NZM2 10000 3 750 133
NZM3 7500 1.33 333 225
NZM4 5000 1.33 333 150
hAn annual inspection meets the requirements in accor-
dance with section “Average diagnostic coverage DCavg”
(apage 10).
For further calculation of the safety function see
EN/ISO 13849.

Engineering
14
10/12 MN04913001Z-EN
Approvals The CMD contactor monitoring device is approved by the IFA
in combination with Eaton contactors and circuit-breakers
(asection ”System overview”, Page 6).
A CE declaration of conformity and a prototype test certifica-
tion are also available.
The CMD has UL and CSA approval for the US and Canadian
markets.
Product standard The CMD contactor monitoring device meets the product
standard for Low-voltage switchgear and controlgear –
Part 5-1:
Control circuit devices and switching elements –
Electromechanical control circuit devices, DIN/EN 60947-5-1
(IEC 60947-5-1).
Electromagnetic compati-
bility (EMC)
No particular EMC measures are required for the CMD
contactor monitoring device.
The CMD complies with the following standards:
• DIN/EN 61000-6-2: EMC generic standard,
interference immunity for the industrial environment,
• DIN/EN 61000-6-4: EMC generic standard,
emitted interferences for the industrial environment.

15
10/12 MN04913001Z-EN
3 Installation
Mounting The CMD contactor monitoring device is mounted on a top-
hat rail. Any mounting position is possible.
Figure 2: Mounting positions for CMD
Connection The CMD relay can be used for DOL starters and for reversing
starters.
90°
90°
90°
90°
hThe electrical mounting space must at least meet the
requirements of IP54 protection.
During installation, a lateral clearance of at least 22.5 mm
must be kept from other devices.
hAll connected devices, such as pushbuttons, must have a
rated insulation voltage Uif300 V.

Installation
16
10/12 MN04913001Z-EN
Connection for DOL starters Figure 3: DOL starter aSwitching by safety relay or safety PLC bSignal contact to PLC evaluation
I> I> I>
U<
M
3˜
-Q1
-Q1
-K
-S1
-F1
-Q11
-X1
-M1
L1 L2 L31.13
21
22
1.14
-Q11
13
14
-Q11
33
34
-Q11
21
22
-F2
CMD
-Q1D1
D2
D2
A1
A2
L S21 S22 S13S14 S31S32
-Q11
A1
12
A2
T1
135
246
T2 T3
L1 L01 L01
L02 L02
L2
PE UVWPE PE
L3
L1
L2
L3
-S2 13
14
-S3
21
22
13
14
a
b
TEST
34
56
1314
21 22
33 34