Moeller XStart User manual

11/01 AWB2700-1426GB
Hardware and Engineering
XStart
SystemsIndustrial AutomationBuilding Automation
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All brand and product names are trademarks or registered
trademarks of the owner concerned.
1st edition 11/2001
© Moeller GmbH, Bonn
Author: Ronald Dietrich
Editor: Ronald Dietrich
Translator: Scriptor GmbH
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
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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 (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 do 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 uncontrolled
operation or 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.
Moeller GmbH Safety instructions
Warning!
Dangerous electrical voltage!
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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.).
• According to their degree of protection
frequency inverters may feature during
operation live, bright metal, or possibly
moving, rotating parts or hot surfaces.
• The impermissible removal of the
necessary covers, improper installation or
incorrect operation of motor or frequency
inverter may cause the failure of the device
and may lead to serious injury or damage.
• The relevant national regulations apply to
all work carried on live frequency inverters.
• The electrical installation must be carried
out in accordance with the relevant
regulations (e. g. with regard to cable cross
sections, fuses, PE).
• All work relating to transport, installation,
commissioning and maintenance must
only be carried out by qualified personnel.
(IEC 60364 and HD 384 and national work
safety regulations).
• Installations fitted with frequency inverters
must be provided with additional
monitoring and protective devices in
accordance with the relevant safety
regulations etc. Modifications to the
frequency inverters using the operating
software are permitted.
• All shrouds and doors must be kept closed
during operation.
• In order to reduce hazards to persons or
equipment, the user must include in the
machine design measures that restrict the
consequences of a malfunction or failure of
the drive (increased motor speed or sudden
standstill of motor). These measures
include:
– Other independent devices for
monitoring safety-related variables
(speed, travel, end positions etc.).
– Electrical or non-electrical system
related measures (interlocks or
mechanical interlocks).
– Live parts or cable connections of the
frequency inverter must not be touched
after it has been disconnected from the
power supply due to the charge in
capacitors. Appropriate warning signs
must be provided.
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11/01 AWB2700-1426GB
Contents
1
About this Manual 5
Introduction 5
Prescribed Use 6
Notes Concerning Project Engineering /
Installation of this Product 6
Explanation of the Symbols Used 7
1 Introduction to XStart 9
Chapter Overview 9
The Basic Concept 10
The XStart Components 12
– Direct starter 13
– Reversing starter 14
– Base module 15
– Accessories for distribution of power 16
2 Technical Data 17
Chapter Overview 17
Introduction 18
Dimensions 21
General Technical Data 24
Diagnostic Messages of the Performance Module 26
Module Parameters 28
Direct Starter Without AGM Auxiliary Contacts 30
Direct Starter With AGM Auxiliary Contacts 33
Reversing starter without AGM auxiliary contacts 36
Reversing starter with AGM auxiliary contacts 39
3 Mounting / Dismounting 43
Chapter Overview 43
Mechanical Mounting 44
– General Mounting Regulations 44
– Mounting XStart Base Modules 47
– Plugging the Performance Modules 48
–Coding 50
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Contents
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Maximum Number of Modules 51
Dismounting 52
– Dismounting XStart Modules 52
– Dismounting Performance Modules 53
– Dismounting Base Modules 56
4 Electrical Installation 57
Chapter Overview 57
General Notes 58
Potential Relationships 58
Electromagnetic Compatibility 59
– Ensuring Electromagnetic Compatibility 60
– Grounding of Inactive Metal Components 60
Wiring 62
– Wiring an XStart Module 62
– Wiring Several XStart Modules 63
5 Connection to PROFIBUS-DP 65
Chapter Overview 65
General Notes on PROFIBUS-DP 66
Electronic Device Data Sheets (GSD Files) 66
Parameterization for XStart 68
Diagnostic Messages for XStart 69
Process Data 70
Maximum Number of Modules 71
Connection to a Moeller PLC PS4-341-MM1
with LE4-504-BS1 72
– Reading-in the GSD file 72
– Configuring the XI/ON Station with XStart 73
– Example of Diagnostics with a Moeller PLC
PS4-341-MM1 74
Connection to a Siemens S7-300 PLC 76
– Reading-in the GSD File 76
– Configuring the XI/ON Station with XStart 77
– Setting the Parameters for XStart Modules 78
– Diagnostics Based on Example of a Siemens
S7-400 PLC 78
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Contents
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Appendix 81
Glossary 81
Abbreviations 85
Ordering Information and Accessories 86
– XStart 86
– Accessories 88
Index 89
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5
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About this Manual
Introduction This manual contains detailed information about mounting /
dismounting as well as electrical installation of motor star-
ters from the XStart series. It is valid only in conjunction with
the manual „XI/ON PROFIBUS-DP", AWB2700-1394GB.
As well as describing the mechanical and electrical features
of XStart, this manual also describes its connection to
PROFIBUS-DP via a XI/ON station.
This manual has been specially conceived for personnel with
the necessary qualifications.
Please refer to the manual „XI/ON PROFIBUS-DP"
AWB2700-1394GB for further information concerning
XI/ON, PROFIBUS-DP as well as mounting and other infor-
mation.
hAll descriptions, safety and warning notes as well as all
other advices contained in the XI/ON Manual
AWB2700-1394GB remain valid unless otherwise
specified.
Please read this chapter carefully. Safety aspects should
not be left to chance when dealing with electrical
equipment.
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Zu diesem Handbuch
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Prescribed Use
Appropriate transport, storage deployment and mounting as
well as careful operating and thorough maintenance
guarantee trouble-free and safe operation of these devices.
Notes Concerning Project
Engineering / Installation
of this Product
The devices described in this manual must be used only in
applications prescribed in this manual or in the respective
technical descriptions, and only in connection with
components and devices from third party manufacturers
that have been certified.
It is imperative that all respective safety measures and
accident protection guidelines be adhered to.
In accordance with DIN VDE 0105-100 only qualified
electricians or personnel that have received electrotech-
nical instructions are permitted to carry out the electrical
installation and commissioning of XStart.
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Explanation of the Symbols
Used
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Explanation of the
Symbols Used
This sign can be found next to all warning notes that indi-
cate a safety hazard. This can relate to probable danger to
personnel or damage to the system (hardware and
software).
This sign means for the operator: work with extreme
caution.
This sign can be found next to all warning notes that
indicate a potential safety hazard. This can relate to
possible danger to personnel or damage to the system
(hardware and / or software).
hThis sign can be found next to all general notes that supply
important information about one or more operating steps.
These specific notes are intended to make operation easier
and avoid unnecessary work due to incorrect handling.
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1
1 Introduction to XStart
Chapter Overview This chapter describes the basic features of XStart and
contains an overview of the XStart components.
The Basic Concept 10
The XStart Components 12
– Direct starter 13
– Reversing starter 14
– Base module 15
– Accessories for distribution of power 16
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Introduction to XStart
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The Basic Concept XStart is the modular, bus compatible version of the proven
motor starters from Moeller. It connects motors with the
world of XI/ON; thereby adding system flexibility to the
available plant.
XStart presently offers motor starters in 4 versions:
• Direct starters with AGM auxiliary contacts
(trip-indicating)
• Direct starters without AGM auxiliary contacts
• Reversing starters with AGM auxiliary contacts
• Reversing starters without AGM auxiliary contacts
The XStart modules are made up of a base module and a
performance module. This performance module contains the
successful motor-protective circuit-breaker PKZM0 as well as
one or two contactors. They enable a bus connection with
assigned motor ratings up to 2.2 kW with a rated operati-
onal voltage of 400 V AC.
The connection to XI/ON is made via the internal XI/ON
module bus; just simply connect the XStart module to the
right side of the XI/ON station.
Xstart can be used with the following XI/ON gateways:
• XN-GW-PBDP-1.5MB XI/ON gateway PROFIBUS-DP
with 1.5 Mbaud; tension clamp
connection
• XN-GW-PBDP-1.5MB-S XI/ON gateway PROFIBUS-DP
with 1.5 Mbaud; screw
connection
• XN-GW-PBDP-12MB XI/ON gateway PROFIBUS-DP
with 12 Mbaud
XStart can not be operated in conjunction with the
PROFIBUS-DP 1.5 Mbaud standard XI/ON gateway:
XN-GW-PBDP-1.5MB-STD.
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The Basic Concept
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1
Figure 1: Example of a XI/ON station with XStart
aXI/ON gateway for PROFIBUS-DP
bPower distribution module
cXI/ON I/O modules
dXStart direct starter module
eXStart reversing starter module
Flexibility
You can adapt XStart to exactly match your plant.
XStart can be added to any point on your XI/ON station,
which enables you to divide your station into plant areas of
applications to suit your needs.
The motor can be switched off on the spot via the rotary
handle.
hThe connection to the fieldbus is made via the XI/ON
gateway, as is described in the manual "XI/ON PROFIBUS-
DP", AWB2700-1394GB.
1
2
33
45 4
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Introduction to XStart
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Easy to operate
All XStart modules are made up of a base module and a
performance module.
To mount, simply press the complete module on to the two
top-hat rails. The base module can be mounted first, and the
performance module added later.
No tools are required to mount or dismount either the perfor-
mance modules or the base modules.
The performance modules can be mounted or dismounted
without interrupting the power supply or output wiring. This
means that the system carries on operating, even when you
are required to exchange performance modules.
Separate release within the plant is not necessary.
The performance modules can be dismounted without inter-
rupting the power supply. Leading contacts ensure that the
motor is automatically turned off.
The XStart Components
hDetailed descriptions and technical data of the individual
XStart components is contained in chapter 2 of this
manual. The Appendix contains ordering information with
all XStart components and accessories as well as other
useful information.
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The XStart Components
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1
Direct starter
The direct starter is composed of a PKZM0 motor starter and
a DILEM contactor to turn the motor on and off.
It is used to both control and monitor the connected motor
as well as to route the main and auxiliary power.
The performance module can be pulled for commissioning or
maintenance purposes without having to interfere with the
wiring.
Direct starters are available without AGM auxiliary contacts
(trip-indicating) or with AGM auxiliary contacts.
Figure 2: Direct start without AGM auxiliary contact,
with base module
hPlease observe that the direct starter with AGM auxiliary
contact requires double the mounting space.
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Introduction to XStart
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Reversing starter
The reversing starter is composed of a PKZM0 motor starter
and two DILEM contactor one for the right-handed and one
for the left-handed rotation of the motor.
It is used to both control and monitor the connected motor
as well as to route the main and auxiliary power.
The performance module can be pulled for commissioning or
maintenance purposes without having to interfere with the
wiring.
Reversing starters are available without AGM auxiliary
contacts (trip-indicating) or with AGM auxiliary contacts.
Figure 3: Reversing starter with base module
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The XStart Components
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1
Base module
The base module is used for fixing the performance module
to the top-hat rails. It contains the electronics, which
monitor and the correct functioning of the performance
module generate error or diagnostic messages when neces-
sary.
The base module provides the connection to the XI/ON
gateway and the XI/ON modules via the internal XI/ON
module bus.
The coding of the performance module is contained in the
electronics of the base module, so that false plugging is
diagnosed. A false performance module cannot be activated.
The base modules are available in the following versions:
• For direct starters without AGM auxiliary contacts
• For direct starter with AGM auxiliary contacts and for
reversing starters
Figure 4: Base module for direct starters without
AGM auxiliary contact (side view)
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Introduction to XStart
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Accessories for distribution of power
To reduce wiring costs, accessories are available for distribu-
tion of power.
Should it be planned to mount several XStart modules next
to one another, the power can be supplied via a power
supply terminal. This power distributor is available for opera-
ting currents up to a maximum of 63 A.
Figure 5: Three-phase commoning link for maximum
4 XStart modules
Figure 6: Power supply terminal for power distribution.
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