Eaton Moeller ZEV Series Service manual

Moeller GmbH
Industrieautomation
Hein-Moeller-Straße 7–11
D-53115 Bonn
E-Mail: [e-mail]
Internet: www.moeller.net
© 2001 by Moeller GmbH
Subject to alteration
AWB2300-1433GB IM-D/IM-D/Ki 11/01
Printed in the Federal Republic of Germany (04/03)
Article No.: 267430
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Building Automation SystemsIndustrial Automation
Hardware and Engineering
11/01 AWB2300-1433GB
ZEV motor-protective system
Overload monitoring
of motors in EEx e areas
Rückenbreite entfällt

All brand and product names are trademarks or registered
trademarks of the owner concerned.
1st published 2001, edition date 11/01
© Moeller GmbH, 53105 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 festlegen! (1 Blatt = 0,106 mm)

I
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.
Moeller GmbH Safety instructions
Warning!
Dangerous electrical voltage!

11/01 AWB2300-1433GB
1
About this manual 3
Target group 3
Abbreviations and symbols 3
1 Motor-protective system ZEV 5
Preface 5
System overview 6
Unit description 8
– Current monitoring sensors 8
– Setting of the tripping CLASS 8
– Thermistor monitoring 10
– Thermistor protection 11
– Short-circuit monitoring of the thermistor circuit 12
–Phasefailure 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 and DIN rail 26
– Connecting cable 26
Contents

Contents
2
11/01 AWB2300-1433GB
4 Operating the devices 27
Settings 27
Setting up the menus 29
– Setting the operating current 29
– Setting the tripping CLASS 29
– Selecting the reset mode 29
– Setting the earth 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

3
11/01 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).
Target group This manual addresses skilled personnel who install,
commission and service the motor-protective systems.
Abbreviations and
symbols
The abbreviations and symbols used in this manual have the
following meaning:
Xindicates actions to be taken.
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 Testing Laboratory: Accredited
certification authority for devices operated in
EEx e areas.
PTC A PTC resistor is a temperature sensor with
positive temperature coefficient
h
hh
hDraws your attention to interesting tips and
supplementary information
Note
Warns of the risk of slight material damage.

About this manual
4
11/01 AWB2300-1433GB
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. Exceptions are the starting
pages of the chapters and empty pages at the end of a
chapter.
Warning!
Warns of the risk of heavy material damage and of fatal
injury or even death.

5
11/01 AWB2300-1433GB
1 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" type of protection
"e". These measures improve the degree of safety and
prevent impermissible high temperature 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 equipment and protective
systems intended for use in potentially explosive
atmospheres will be enforced as of 06.30.2003.
The motor-protective system ZEV is approved by the PTB
according the 94/9/EC (ATEX 100a) Directives.
h
hh
hNumber of the EU Certificate of Compliance:
PTB 01 ATEX 3233.


Motor-protective system ZEV
6
11/01 AWB2300-1433GB
System overview
Figure 1 : Basic electronic motor-protective relay unit ZEV
aPower supply
bFreely configurable auxiliary switches
cTerminals for connecting an external core-balance transformer
dTerminals for connecting a thermistor
eUp/Down adjusting buttons
fMode selector button
g1 NO + 1 NC contact for overload and thermistor tripping
hGrounding terminal
iReset/Test button
jDisplay
kTerminal for connecting a remote or automatic reset contact
ab
c
d
e
f
g
h
i
j
k

System overview
7
11/01 AWB2300-1433GB
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... for earth fault monitoring
Auxiliary external core-balance transformers SSW... are used
for earth fault monitoring (asection “Earth fault
monitoring”, Page 14).
ZEV-XSW-25
ZEV-XSW-65
ZEV-XSW-145
ZEV-XSW-820

Motor-protective system ZEV
8
11/01 AWB2300-1433GB
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.
Table 1: Current sensor operating ranges
Setting of the tripping CLASS
The system is suitable for standard and heavy startup
operation. 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
operational current Ie CLASS of the switchgear must be
reduced according to the CLASS setting on the ZEV. The
rated operational current Ie CLASS can be calculated based on
the reducing factors listed in Table 2 , Page 9.
Current sensor Current range I
III
A
ZEV-XSW-25 1 to 25
ZEV-XSW-65 3 to 65
ZEV-XSW-145 10 to 145
ZEV-XSW-820 40 to 820

Unit description
9
11/01 AWB2300-1433GB
Table 2: Settings for overload tripping
The contacts 95-96 and 97-98 are switched over in the event
of an overload tripping (afig. 6 on Page 16).
After overload tripping and before 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 I
IIIe CLASS =
5Ie
10 Ie
15 Ie x0.82
20 Ie x0.71
25 Ie x0.63
30 Ie x0.58
35 Ie x0.53
40 Ie x0.50
Warning!
The protected motor and the switchgear must be suitable
for the given startup conditions.
CLASS t
tt
trecovery
min
5 5
10 6
15 7
20 8
25 9
30 10
35 11
40 12

Motor-protective system ZEV
10
11/01 AWB2300-1433GB
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 (asection “Thermistor protection”, Page 11).
The contacts 95-96 and 97-98 change over when the
thermistor monitor trips the device (afig. 4 on Page 11).

Unit description
11
11/01 AWB2300-1433GB
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 RK F250 Oto the terminals T1-T2.
NAT = RTT = Rated Threshold Temperature
Figure 4 : Characteristics curve of temperature monitoring with
thermistor
aTripping
bReset
cThree temperature probes
dSix temperature probes
The ZEV trips at R= 3200 Og15 % 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 indication (afig. 7,
Page 18).
R [O]
5000
10000
2000
3680
1500
1000
900
800
700
600
500
ac
d
b
NAT
-10
-20 +10
+5
+20 +30
-30 K

Motor-protective system ZEV
12
11/01 AWB2300-1433GB
Short-circuit monitoring of the thermistor circuit
A current monitor can be installed in the thermistor circuit,
in order to monitor the current high limit and short-circuit as
shown in the following circuit diagram.
h
hh
hHazard 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 the
circuit.

Unit description
13
11/01 AWB2300-1433GB
Figure 5: Functional diagram of a current monitor
L1
L2
L3
N
96 06 08
98
95 05 07
A1 A2 PEC1 C2
T2
T1
<
>
M
3~
Reset
Fern-Reset
S1
S2 K1M
K1M
~=
97
µP
Mode
Class
Test
Reset
Up
Down
L1L2L3
%
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
hh
hThis circuit is suitable for full protection of motors
operated in "EEx e" areas.

Motor-protective system ZEV
14
11/01 AWB2300-1433GB
Phase failure
In the event of a phase failure, i.e. with an imbalance of
f50 %, 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
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
(afig. 30 on Page 31), the "earth fault" signal can also be
used to switch over one of the contacts 05-06 or 07-08
(afig. 7 on Page 18).
Core-balance
transformer
Opening
diameter
Fault current
mm A
SSW40-0,3 40 0.3
SSW40-0,5 40 0.5
SSW40-1 40 1
SSW65-0,5 65 0.5
SSW65-1 65 1
SSW120-0,5 120 0.5
SSW120-1 120 1
Caution!
An earth fault does not lead to a changeover of the
contacts 95-96 and 97-98.

15
11/01 AWB2300-1433GB
2 Configuration
Monitoring overload of
motors in the EEx e area
The "EEx e" degree of protection for motors is achieved by
means of special constructive measures. The motors are
assigned to temperature classes based on the maximum
permitted surface temperatures. The temperature rise time tE
and the ratio between the startup current and rated current
IA/INare calculated in addition and specified on the rating
plate of the motor.
The temperature rise time tErepresents the it takes the
temperature of the motor winding to rise from the final rated
operational temperature up to the limit temperature, at a
startup current 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 only
ensure proper monitoring of the motor current, but also
that the seized motor is switched off within the
temperature rise time tE. This means, that the protective
device must be rated in such a way, so as to ensure that
the tripping time tAfor the ratio IA/INof the EEx e motor is
not higher than its temperature rise time tE, according to
its characteristics curve, in order to safely switch off the
motor within that period (a following example).

Configuration
16
11/01 AWB2300-1433GB
Example: IA/IN= 6, tE= 18 s
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)
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 1610 100
35
30
25
20
15
10
CLASS 5
t
A
s
ms
 l
e
x l
e
c0102 II(2)G
Us

17
11/01 AWB2300-1433GB
3 Installation
Notes on installation The current mechanical and electrical installation instruction
manual AWA2300-1694 included with the units must be
observed.
h
hh
hThe basic ZEV units must be configured prior to initial
commissioning (afig. 22, Page 28).
Warning!
To ensure explosion protection, the ZEV 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. (afig. 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 interruption of the
control voltage. This is achieved by means of the latching
function of the power relay (afig. 7 , Page 18).