Moeller Rapid Link User guide

Switching and
Installation System
Rapid Link
User Manual
01/08 AWB2190-1430GB
A
We keep power under control.

All brand and product names are trademarks or registered
trademarks of the owner concerned.
1st published 2002, edition date 03/02
2nd edition 07/03
3rd edition 10/03
4th edition 02/04
5th edition 01/05
6th edition 01/08
See revision protocol in the “About this manual“ chapter
© Moeller GmbH, 53105 Bonn
Author: Jörg Randermann
Production: Thomas Kracht, Barbara Petrick
Translators: OneWord
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.

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 the device.
• Cover or enclose any adjacent live components.
• Follow the engineering instructions (AWA) for 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 an open circuit on the
signal side does not result in undefined states in the automation
devices.
• Ensure a reliable electrical isolation of the extra-low voltage of
the 24 V supply. Only use power supply units complying with
IEC 60364-4-41 or HD384.4.41 S2 (VDE 0100 Part 410).
• Deviations of the mains voltage from the rated value must
not exceed the tolerance limits given in the specifications, other-
wise this may cause malfunction and dangerous operation.
• Emergency-Stop devices 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 a
restart.
• Devices that are designed for mounting in housings or control
cabinets must only be operated and controlled after they have
been installed and with the housing closed. Desktop or portable
units must only be operated and controlled in enclosed housings.
• 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 injury or
material damage, external measures must be implemented to
ensure a safe operating state in the event of a fault or malfunc-
tion (for example, by means of separate limit switches, mechan-
ical interlocks etc.).
• Depending on their degree of protection, frequency inverters
may contain live bright metal parts, moving or rotating compo-
nents or hot surfaces during and immediately after operation.
• The impermissible removal of the required 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 accident prevention and safety regulations
apply to all work carried out 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).
• Transport, installation, commissioning and maintenance work
must only be carried out by qualified personnel (observe
IEC 60364, HD 384 and national work safety regulations).
• Installations containing frequency inverters must be provided
with additional monitoring and protective devices in accordance
with the applicable safety regulations. Modifications to the
frequency inverters using the operating software are permitted.
• All covers and doors must be kept closed during operation.
Moeller GmbH Safety instructions
Warning!
Dangerous electrical voltage!

• To reduce the hazards for people or equipment, the user must
include in the machine design measures that restrict the conse-
quences 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 vari-
ables (speed, travel, end positions etc.).
– Electrical or non-electrical system-wide measures (electrical or
mechanical interlocks).
– Never touch live parts or cable connections of the frequency
inverter after it has been disconnected from the power supply.
Due to the charge in the capacitors, these parts may still be
live after disconnection. Fit appropriate warning signs on the
frequency inverter.
• The decentralised power distribution systems must only be
utilised in accordance with the operating manual for their
intended use in technically perfect condition, taking into account
safety requirements and any possible hazards.
• Proper transport, storage, installation, careful operation and
maintenance must be ensured for the trouble-free and safe oper-
ation of the control system. Any faults that may impair safety
must be rectified immediately.
• If the decentralised power distribution systems are part of the
electrical equipment of a machine, they must be included by the
machine manufacturer in the conformity assessment procedure.
The IEC/EN 60204-1 standard must be observed.
• The safety requirements of the Machine Directive 89/392/EC
must be observed when engineering, installing and commis-
sioning the decentralised power distribution systems as part of
the power supply of machines and their control systems. The
national occupational safety regulations apply in the specific
application. Observe the relevant safety and accident prevention
regulations for the application, such as the Safety of Machinery
standards. All safety devices of the controlled machine must be
implemented so that they operate independently of the control
system. Emergency-Stop devices complying with IEC/EN 60204
must be effective in all operating modes of the system. The
power supplies of all the switching elements of the control
system must be disconnected in the event of an Emergency-Stop.
Uncontrolled and undefined startups must not occur, e.g.
– Startup after unlatching the Emergency-Stop devices and/or
– Startup of the control systems without the DP master or DP
slave responding.
• For stationary installations or systems without all-pole mains
switches, the building installation must be provided with a
mains switch or fuse.
• The rated voltage range set for load current power supplies and
power supply modules must comply with the local mains supply.
• With the 24 V power supply ensure that
– lightning protection measures are provided and/or
– the 24 V SELV voltage is provided with safe electrical isolation.
• 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.
• Transport, installation, commissioning and maintenance work
must only be carried out by qualified personnel (in accordance
with IEC 60364, HD 384 and national occupational safety regu-
lations).
• Before installation and before touching the device ensure
that you are free of electrostatic charge.
• Suitable safety hardware and software measures should be
implemented for the I/O interface so that an open circuit on the
signal side does not result in undefined states in the automation
devices.
• A suitable electrical tool should be used. The mains supply
connection should always be disconnected (remove mains plug
or open isolating switch) before opening the device. Fuses
should only be replaced with those specified in the technical
data.
• The highest permissible operating temperature of the decentral-
ised power supply systems is 50 °C. Cables must be protected
from impermissible temperatures by means of shielding or suffi-
cient clearance from the heat source.
• Cables should be laid in a cable duct in areas where there is a
risk of mechanical damage to cables or conductors, e.g. with
forklift trucks.

01/08 AWB2190-1430GB
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About this manual 7
Abbreviations and symbols 7
List of revisions 8
1 System Rapid Link 9
System overview 9
– Proper use 10
– Improper use 10
Engineering 10
– Data bus 10
–Powerbus 13
– Information to EMC 17
–Loads 17
– Addressing slaves
(with hand-held addressing unit PG2-105-AD2) 17
Installation of Rapid Link function modules 19
Mounting data bus 20
Installation of flexible busbar RA-C1-7x… 20
– Laying the flexible busbar 20
– Establishing connections 21
– Fitting feeder and junctions 21
– Removing 22
– End pieces and bushings 22
Installing the round cable junction 23
2 Head station RA-IN 25
Device overview 25
Key to part numbers 25
Proper use 25
Improper use 25
Functions overview 26
Engineering 26
–Design 26
– Extended diagnostics functions 26
– Information to EMC 26
Accessories 26
Installation 28
– Mounting position 28
– Mounting 28
– PROFIBUS-DP interface 28
– as-interface®29
– Connecting the power supply 29
Device operation 29
–Devicestartup 29
– Engineering mode 30
– Protected operation mode 30
– Addressing AS-Interface®slaves in engineering mode 30
– AS-Interface®slave addressing 30
– AS-Interface®deleting slave addresses 31
– Addressing AS-Interface®slaves with configuration
errors 31
– Setting the PROFIBUS-DP station address 31
– Station addresses 31
– First operation of the AS-Interface®circuit 31
Contents

Contents 01/08 AWB2190-1430GB
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Indicating elements 32
– Display and control unit 32
– Digital display 32
– Diagnose and status via LEDs 34
– Extended diagnostics of RA-IN 35
–PROFIBUS-DP 35
3 Incoming circuit-breaker RA-DI 37
Device overview 37
Key to part numbers 37
Proper use 37
– Functions overview RA-DI 38
Engineering 38
– Settings on the device 39
– Core insulation 39
– Safe isolation 39
– Accessories 39
– Information to EMC 39
Installation 40
– Mounting position 40
–Design 40
– Wiring and connections 41
– AS-Interface®connection 41
– Mounting 41
Device operation 42
– Switch on 42
Diagnose and status via LEDs 43
4 Motor starter RA-MO (to Version 2.x) 45
Device overview 45
Key to part numbers 45
Proper use 46
Engineering 47
– Functions overview RA-DIMO 47
– I/O assignment 48
– Sensor connection through M12 (RA-MO…4…) 48
– Actuator connection through M12 (RA-MO…4A…) 48
– Motor cable/motor plug 48
– Selection of short-circuit devices 48
– Cable routing 48
– Accessories 48
Installation 49
– Mounting position 49
– Mounting 49
– Connections 50
– Connecting the power supply 51
– AS-Interface®connection 51
– Connecting AS-Interface®and 24 V (RA-MO…/C…A) 51
– Connecting sensor and actuator 52
– Motor connection 52
Conversion of DOL starter RA-MO…DE… into a reversing
starter 54
– Conversion accessories 54
Device operation 55
– Functions through AS-Interface®55
– Commissioning the drive 55
– Safety-relevant power off 55

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– I/O fault messages, internal device faults 56
– Auto configuration for servicing 56
–Key-switches 56
– Reset 56
–Selectorswitch 56
Description of functions 57
–Phasereversal 57
– Quick stop and interlocked manual mode 57
– Monitoring of lower current limit 59
– Reading diagnostic status through
AS-Interface®parameter channel 59
– Set plug monitoring as part of Ready message 60
Setting the functions with DIP switches/jumpers 60
– Setting current values (pins 1 to 4) 62
– Configuration overview (pins 5 to 8) 62
– Activate phase reversal switch (pole 7) 63
– Configure external outputs (pole 5 – 6, 8) 63
– Monitoring of lower current limit 64
– Diagnostic status through AS-Interface®parameter
channel 64
Diagnose and status via LEDs 65
5 Motor starter RA-MO (from Version 3.0) 67
Device overview 67
Key to type references 67
Proper use 68
Engineering 68
– Functions overview RA-DIMO 68
– I/O assignment 69
– Sensor connection through M12 69
– Actuator connection through M12 (RA-MO…A…) 69
– Motor cable/motor plug 69
– Selection of short-circuit devices 69
– Cable routing 69
– Accessories 69
Installation 70
– Mounting position 70
– Mounting 70
– Connections 71
– Connecting the power supply 71
– Connecting AS-Interface®and 24 V (RA-MO…/C3A) 71
– Connecting sensor and actuator 72
– Motor connection 72
Device operation 74
– Functions through AS-Interface®74
– Commissioning the drive 74
– Safety-relevant power-off (RA-MO24V… only) 74
– I/O fault messages, internal device faults 75
– Auto configuration for servicing 75
–Key-switches 75
– Reset 75
–Selectorswitch 75
Description of functions 76
–Phasereversal 76
– Quick stop and interlocked manual mode 76
– Monitoring of lower current limit 78

Contents 01/08 AWB2190-1430GB
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– Reading diagnostic status through AS-Interface®
parameter channel 78
– Set plug monitoring as part of Ready message 79
Setting the functions with DIP switches/jumpers 79
– Setting current values (pins 1 to 4) 80
– Configuration overview (pins 5 to 8) 80
– Activate phase reversal switch (pole 7) 81
– Configure external outputs (pole 5 – 6, 8) 81
– Monitoring the lower current limit with RA-MO24V 81
– Diagnostic status through AS-Interface®parameter
channel 81
Diagnose and status via LEDs 82
6 Speed controller RA-SP 83
Device overview 83
Key to part numbers 84
Proper use 84
Features of the Speed Control Unit 85
Engineering 85
– Overview of functions, RA-SP 85
– Sensor connection through M12 86
– Accessories (optional) 86
– Selection criteria, RA-SP2… 87
– Selection criteria, RA-SPV… 88
–DesignRA-SP 89
Power supply 90
– Network configuration 90
– Mains voltage, mains frequency 90
– Interaction with p.f. correction equipment 90
– Protective devices and cable cross-sections 90
– Protection of persons and domestic animals with
residual-current protective devices 91
– Current peaks 91
– Mains choke 91
– EMC Guidelines 92
– Cable routing 92
– EMC correct mounting and installation 93
Installation 94
– Mounting position 94
– Mounting dimensions 95
– Mounting 95
– Connections 96
– Connecting the power supply 97
– AS-Interface®connection 98
– Connecting AS-Interface®and 24 V (RA-SP…/C…A) 98
– Connecting sensors (RA-SP2-34…) 98
– Motor connection 99
Device operation 103
– Functions through AS-Interface® 103
– Commissioning the drive 103
– Selector switch 106
– Key-switch 106
Description of functions 107
– Quick stop and interlocked manual mode with
RA-SP-HE… 107
– Quick stop with creep speed with RA-SP-HE… 108
Setting the functions with DIP switches (RA-SP-HE…) 109

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– Configuring signal management (pins 1 and 2) 109
– Configuring external inputs for RA-SP-HE…
(pins 3–6) 110
– Activate phase reversal switch (pole 7) 111
– Configuring stop behaviour of RA-SP-HE… (pole 8) 111
– Reading diagnostic status through AS-Interface®
parameter channel with RA-SP-HE… 111
Diagnose and status via LEDs 112
– Controlling the speed control unit 113
Diagnostics and troubleshooting 113
Auto configuration for servicing 114
Parameterization 114
RA-SP and keypad DEX-KEY-10 115
Description of parameters applicable to RA-SP 123
– F-00 transition frequency (F-BASE) 123
– F-01 End frequency (F-MAX) 123
– F-03 Automatic voltage regulation (AVR) 124
– F-04 Voltage/frequency characteristic and boost 125
– F-06, F-07 time ramps (ACC, DEC) 126
– F-11 Fixed frequencies (SPD) 128
– F-20 DC braking 129
– F-32 Frequency value signal FA2 130
– F-22 Mains failure duration (IPS) 131
– F-23 Electronic motor protection (E-THM) 132
Calibrating current indication and motor protection 133
– F-24 Current limit (OLOAD) 134
– F-25 Parameter protection (S-LOOK) 135
– F-26 Operating frequency range (LIMIT) 135
– F-34, F-35 Initialization of built-in digital
inputs/outputs (IN-TM, OUT-TM) 136
– F-36 Pulse frequency (CARRIER) 136
Copier function with DEX-KEY-10 136
– Copy and Read function example 137
Parameterization with DrivesSoft 138
– System requirements 138
– Parameterization 138
Appendix 143
Special technical data 143
– System Rapid Link 143
Dimensions 147
– System Rapid Link 147
– Head station RA-IN 150
– RA-DI incoming circuit-breaker 150
– Motor starter RA-MO (to Version 2.x) 150
– Motor starter RA-MO (from Version 3.0) 150
– Speed controller RA-SP 151
Optional accessories 152
– Lock shackle SET-M-LOCK 152
Index 153

01/08 AWB2190-1430GB
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01/08 AWB2190-1430GB
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About this manual
This manual contains a description of the Rapid Link system and
its various function modules. The first section is an introduction to
the overall system. It also contains descriptions that apply to all
function modules.
The subsequent sections provide special information needed to
configure, install and operate the Rapid Link function modules.
Read this manual carefully, before you install theRapid Link system
and start using it. We assume that you have a good knowledge of
engineering fundamentals and that you are familiar with electrical
systems and the applicable principles and are able to read,
interpret and apply the information contained in technical
drawings.
Abbreviations and symbols
The abbreviations and symbols used in this manual have the
following meanings:
XIndicates actions to be taken.
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. This does not apply to pages at
the start of a chapter and empty pages at the end of a chapter.
All dimensions are in millimetres, unless otherwise specified.
DESINA Decentralized, standardized installation technology
EMC Electromagnetic compatibility
ESD ElectroStatic Discharge
Fn No. Function number
LAS List of Active Slaves
LCS List of Corrupted Slaves
LDS List of detected Slaves
LOS List of Offline Slaves
LPS List of Configured Slaves
PELV Protective Extra Low Voltage
PES PE - Positive earth cable screen connection
PNU Parameter Number
FS Factory Setting
hDraws your attention to interesting tips and
supplementary information.
hAttention!
Warns of the risk of material damage.
iCaution!
Warns of the possibility of serious damage and slight
injury.
jWarning!
Indicates the risk of major damage to property, or serious
or fatal injury.

About this manual 01/08 AWB2190-1430GB
8
List of revisions
The following significant amendments have been introduced since previous issues:
Edition date Page Keyword new Amend-
ment
deleted
01/05 Chap. 1, 4 , 5 General revision because of new devices
01/08 – General revision
chapter 5 Motor starter RA-MO (from Version 3.0) j
earlier Chap. 6 Programmable function unit RA-LO j

01/08 AWB2190-1430GB
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1 System Rapid Link
Rapid Link is a modern automation system for material handling
systems. Because the Rapid Link modules can be simply fitted into
a power and data bus, it allows electrical drives to be installed and
taken into operation much more quickly than with conventional
methods. A time-saving installation is implemented with the aid of
a power and data bus in which the rapid link modules are
installed.
System overview
Figure 1: Overview Rapid Link
Function modules:
aInterface control unit A-IN
rInterface to the open field bus
bDisconnect control unit RA-DI
r Power infeed with lockable rotary handle;
rCircuit-breaker to protect from overload and short-circuits
cMotor control unit
rThree-phase electronic motor protection with additional use as direct-
on-line starter, expandable DOL starter or reversing starter
dSpeed control unit
rOperation of three-phase asynchronous motors with four fixed
speeds, two directions and soft starting
Power and data bus:
eAS interface®flat cable
fLink for M12 connector cables
gFlexible busbar for 400 V hand 24 V H(RA-C1…)
hPower feed for flexible busbar
iPlug-in power link for flexible busbar
jRound cable for 400 V h and 24 V H (RA-C2...)
kPlug-in link for round cable
a
bcd
e
g
f
h
ii
j
k
k

System Rapid Link 01/08 AWB2190-1430GB
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Proper use
Rapid Link is intended only for switching, protecting and controlling
three-phase motors in machines and installations. Any other or
additional use is considered improper use. The manufacturer or
supplier does not accept liability for damage caused by improper
use.
To ensure proper use of the decentralized power supply systems,
observe the instructions and guidelines for the mechanical and
electrical installation, commissioning and operation.
• Rapid Link must be operated only on 400V-three-phase systems
with earthed star point and separate N and PE conductors (TN-
S network). It must not be operated unearthed.
• All Rapid Link function modules fulfil the safe isolation
requirements of IEC/EN 60947-1, Annex N, between the AS-
Interface®voltage and the 24 V Hand 400 V h supplies as
well as to the thermistor circuit in RA-MO and RA-SP-.
• All devices am connected to the power and data bus must also
meet the requirements for safe isolation according to IEC/EN
60947-1 Annex N or IEC/EN 60950. The 24 V DC power supply
unit must be earthed on the secondary side. The 30 V DC PSU
for the AS-Interface®power supply (interface control unit head
station) must meet the safe isolation requirements according to
SELV.
• Emergency-Stop devices (according to IEC/EN 60204-1) must
be fitted and their function must not be impaired in any way.
• The plant must contain effective lightning protection measures
to prevent damage to electronic equipment.
Improper use
Engineering
The Rapid Link function modules are installed immediately
adjacent to the drives. They can be connected to the power and
data bus at any point without having to interrupt the bus.
Data bus
The AS-Interface®data bus is a system solution for networking
different modules. AS-Interface®networks are quick and easy to
implement.
Data cable
AS-Interface®uses a geometrically encoded, unscreened flat cable
with a cross-section of 2 x1.5 mm2. It is used to transmit both
power as well as all data traffic between PLC and I/O and – to some
extent – supplies the connected devices with energy. The
installation meets the usual requirements. Engineering is simplified
by full flexibility in system layout and mounting.
When a link is connected to the flat cable, two metal pins pierce
through the cable’s jacket and into the two cores to establish a
contact with the AS-Interface®cable. There is no need to cut and
strip cables, apply ferrules or connect individual cores.
Rapid Link function modules can be installed and removed any
number of times in various locations within the system. The
AS-Interface® flat cable is self-healing, dust-proof and protected
against spray water. The network can be laid out in a star, linear
or tree structure.
jWarning!
Risk of hazard from connected actuators (motors,
hydraulic units, etc.) through incorrect configuration,
installation, maintenance and operation of the complete
plant or machine, non-observation of the instructions in
this manual and handling by insufficiently qualified
personnel.
Figure 2: AS-Interface®-flat band conductor
aPiercing pins
bFlat cable, protected against polarity reversal
a a
b–
+
10
6.5
4
2

01/08 AWB2190-1430GB Engineering
11
Data Transfer
Data is transmitted modulated through the power supply, the
station’s transmitter injecting the data signals into the line in the
form of current changes. These current changes induce a voltage
in the data coupling coils, which is detected by all stations’
receivers along the AS-Interface®line.
The cycle time is determined by the number of stations along the
busbar run, regardless whether the stations can have 31 or 62
addresses (A/B slaves). For 31 stations the cycle time is about 5 ms
and for 62 stations about 10 ms. The cycle time is calculated as
follows: 150 s x (number of stations + 1)
Background information for PLC technicians about the
function principle of parameter transmission in RA-MO,
RA-SP and RA-IN
Parameters are transmitted according to the possibilities provided
by the A2S-i microcontroller. Parameter bits P1 to P4 (bank A) sent
by the controller are provided to the RA-MO electronics mc (bank
B) unchanged. The data returned to the master (bank C) is
generated through an AND gate.
For slaves with A-address, parameter bit on bank A is
automatically set to 1, and for slaves with B-address to 0 (for A- and
B-addresses, see section “Addressing slaves (with hand-held
addressing unit PG2-105-AD2)” on page 17.
When the PLC sends parameter bits P1 to P3 = 000 (A), only
parameter value 000 (C) is returned, regardless of the RA-MO
electronic’s status.
Reading out diagnostic status:
If the PLC sends the value 111 (A), the motor starter interprets this
as a request to return the diagnostic status. To allow correct
transfer of the diagnostic status (atable 2 on page 60), the PLC
must send only parameter value 111 until it receives the receive
data.
Parameter handling in RA-IN:
In the interface control unit RA-IN parameters are handled with
mailbox commands. With the command SET PP (set parameter
value) the PLC can permanently save a parameter value for each
slave in the EEPROM of the RA-IN. When it is switched on, the RA-
IN automatically sends these values to all slaves provided the
communication in the AS-i run is working). The parameter values
remain available even if the PLC fails.
With the command WRITE P (write parameter value) the PLC can
transfer a value other than the set parameter value to each AS-i
slave. This does not affect the parameter data written to the RA-
IN’s EEPROM with SET PP.
Figure 3: AS interface®network in star design
PROFIBUS-DP RA-IN PEX
RA-IN PEX
RA-IN PEX
30 V H
P4
Figure 4: Function principle of parameter transmission
hFor further information, see manual “Hardware and
Engineering of the AS-i/PROFIBUS Gateway”. You can
find the latest version of this manual under http://
www.moeller.net/support: Search term: AWB2700-
1409G)
&
P3
&
P4
&
P1
&
P2
P3
P4
P1
P2
P3
P4
P1
P2 mC
B
A
C

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Head station
The interface control unit RA-IN head station provides the
connection to the PROFIBUS-DP field bus and handles all
communication within the AS-Interface® run.
The user program receives its input information from the interface
control unit RA-IN. To the outside, the overall system acts like a
single connection cable. In the higher-level fieldbus the interface
control unit RA-IN is a station with its own address.
The interface control unit RA-IN contains a built-in power extender
(PEX) with a data link for up to 2.8 A at 30 V HAS-Interface®
voltage. The AS-Interface®power extender is current-limited (self-
resetting time-lag fuse, 3 A).
For the power supply of the interface control unit RA-IN, a standard
PSU with 30 V Hto AS-Interface®specifications (SELV, smoothing,
etc.) with or without data link is needed. Each PSU can supply
several interface control units RA-IN. Power supply cables can be
standard round cables with 3 x1.5 mm2or 3 x2.5 mm2. The
length of these cables are not included in the permissible 100 metres
length of the AS-Interface®busbar run.
Cable lengths and voltage drop
When defining the length of the AS-Interface®line, observe the
following:
• Te maximum expansion, including all spur lines and M12 plug
lines of the function modules (for each assembled 0.5 m long
cable with M12 plugs, calculate 0.9 m), is 100 m. The cable
between PSU and RA-IN is not included in these 100 m.
• Each slave must be supplied with at least 24 V H+10/–15 %.
• The interface control unit RA-IN must be supplied with at least
26 V H.
Calculate the current demand and voltage drop to ensure that all
sensors, actuators and the interface control unit RA-IN receive the
required voltage.
Length of AS-Interface®data cable:
The rule of thumb for the length of the AS-Interface®data cable
with 1.5 mm2 depending on the voltage of the interface control
unit RA-IN is:
• AS-Interface®voltage > 28 V: 80 m cable length
• AS-Interface®voltage > 26 V: 60 m cable length
Voltage at interface control unit RA-IN:
The voltage at the interface control unit RA-IN depends on:
• The length of the supply cable between PSU and RA-IN
• The cross-section of the supply cable between PSU and RA-IN
• the current consumption
Cable length between PSU and RA-IN:
The cable length between PSU and interface control unit RA-IN 8
is calculated from the voltage drop.
Voltage drop DU= Length l xcurrent I x2 [V]
Conductivity κx cross-section A
Length l = Voltage drop DU xconductivity κxcross-section A [m]
2x current I
Conductivity of copper: κ=57 m
Omm2
RA-…
U f26 V
Round
conductor
RA-IN
F2,5 mm2
RA-…
U f26 V f24 V
Power
supply
30 V H
Round
conductor
RA-IN
F2,5 mm2
RA-… RA-…
U f26 V
Round
conductor
RA-IN 1 m
F2,5 mm2
Figure 5: Design of a data bus

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Power bus
The power bus supplies the Rapid Link function modules with main
and auxiliary power. Plug-in tap-off points can be quickly and
safely connected at any point along the bus. The power bus can
consist either of a flexible busbar (flat cable) or standard round
cables:
Incoming supply 400 V AC
The power sections are supplied through disconnect control unit
RA-DI (see illustration below) with:
•IeF20 A/400 V at 2.5 mm2
•IeF25 A/400 V at 4 mm2.
Round cables up to 6 mm2can be used to feed power to
disconnect control unit RA-DI.
• The disconnect control unit RA-DI protects the cable from
overload.
• It also provides short-circuit protection for the cable and for all
connected motor control units RA-MO.
The combination of RA-DI and RA-MO fulfills the requirements of
IEC/EN 60947-4-1 as starter with type “1” coordination. That
means that the contactor’s contacts in the RA-MO are allowed to
weld in the event of a short-circuit in the motor terminal strip or
the motor supply cable. This arrangement also conforms to IEE
wiring regulations.
The affected RA-MO motor control unit must be replaced after a
short-circuit!
When you configure a power bus with a disconnect control unit,
observe the following:
• Even in the event of a single-pole short-circuit at the line end,
the short-circuit current must exceed 150 A (250 A). This value
is a main factor in determining the length of the power bus.
• The total current of all running and simultaneously starting
motors must not exceed 110 A (170 A).
• The incoming circuit-breaker RA-DI (or PKZ2-ZM25-8) can
switch on the following number of speed controllers RA-SP
without the short-circuit release being tripped by the RA-SP:
– 10 to 15 (20 to 25) RA-SP...075... or
– 5 to 8 (10 to 13) RA-SP...1K1... or
– 3 ti 5 ( 7 to 9) RA-SP…2K2…
jWarning!
• Rapid Link must be operated only on 400V-three-phase
systems with earthed star point and separate N and PE
conductors (TN-S network). It must not be operated
unearthed.
• All devices am connected to the power and data bus
must also meet the requirements for safe isolation
according to IEC/EN 60947-1 Annex N or IEC/
EN 60950. The24 V DC power supply unit must be
earthed on the secondary side. The 30 V DC PSU for
the AS-Interface®-/RA-IN-power supply must meet the
safe isolation requirements according to SELV.
Figure 6: Example arrangement, Rapid Link system with RA-DI, RA-MO and RA-SP
e
M
3h
1.5 mm2
2.5 mm2 / 4 mm2
3AC 400 Vh,
50/60 Hz 24 V H
RA-DI
Q1
M
3h
e
e
M
3h
1.5 mm21.5 mm2
RA-MO RA-SP RA-MO
M
3h
e
Motor Control Units RA-MO,
SpeedControl Units RA-SP
Disconnect
Control Unit RA-DI
F6 mm2
1.5 mm2
1.5 mm21.5 mm2
1.5 mm2
RA-SP
1.5 mm2
PES
PES
PES
PES
⎧ ⎨ ⎩
F20 A at 2,5 mm2
F25 A at 4 mm2
= 130 A – 210 A
hThe short-circuit release of the RA-DI is factory set top the
lowest setting of 130 A. The values in brackets in the list
below apply to the maximum setting of 210 A. The
configuration of the short-circuit release is described on
page 39.

System Rapid Link 01/08 AWB2190-1430GB
14
Depending on the length of the power bus and the arrangement
of the power links, the incoming circuit-breaker RA-DI can also
switch on a higher number of RA-SP units. In any case, the total
mains current of the RA-SP units must not exceed 25 A (or 20 A
at 2.5 mm2) in continuous operation. The mains currents
change proportionally to the currently flowing motor current.
• Observe the voltage drop in your specific application.
Instead of the disconnect control unit, you can use a 3-pole
miniature circuit-breaker InF20 A and B or C characteristic.
Here, you must observe the following:
• The let-through energy Jin the event of a short-circuit must
not exceed 29800 A2s.
• Therefore the short-circuit current Icc at the mounting location
must not exceed 10 kA (acharacteristic curve figure 7).
Incoming supply 24 V DC
Use all power supply devices in combination with safe isolation
and earth them on their secondary side.
• Switched-mode power supply units with foldback characteristic
limit the short-circuit capacity by reducing the voltage and
allowing the highest permissible voltage (depending on model
rating) to flow permanently until the fault has been rectified.
Once the fault has been rectified, the voltage builds up again
(automatic restarting). This type of power supply unit must not
supply a continuous short-circuit current higher than 16 A or –
if a flat cable RA-C1-7x2,5PVC is used – 6 A.
• Switched-mode power supply units with short-circuit
recognition, i.e. with disconnection and automatic restarting,
should disconnect a short-circuit current (e.g. 3 xIN) after no
more than 0.1 seconds. The rated current can be up to 16 A or
– if a flat cable RA-C1-7x2,5PVC is used – 6 A.
• If non-stabilized power supply units without short-circuit
protection are used, an additional short-circuit protection
device must be fitted. In the event of a short-circuit, the
disconnection should take place after no more than 0.1
seconds. Here miniature circuit-breakers with characteristic R in
the secondary circuit are recommended. With a short-circuit
release response current of 2 – 3 xIN, these are suitable for the
protection of semiconductor elements . The power supply unit
must have a corresponding short-circuit capacity. The fuse
specification fo the secondary circuit must not exceed 16 A or –
if a flat cable RA-C1-7x2,5PVC is used – 6 A.
Figure 7: Cable protection with FAZ-3-B20
2 A
1 A
0.5 A
10 A
13A
16 A
20 A
25 A
32 A
40 A
50 A
63A
4 A
3A
6 A
0.5 1.5 1512345678910
10
3
10
4
10
5
8
6
4
2
1.5
8
6
4
2
8
6
4
3
1.5
FAZ-B
FAZ-C
FAZ-...-B4HI
Zi2dt
[A2s]
Icc eff [kA]
20 A
29800 A2s
10 kA

01/08 AWB2190-1430GB Engineering
15
Flexible RA-C1 busbar
The flexible busbar RA-C1 is a 7-core flat cable (cross-section 2.5
mm2 or 4 mm2)and has the following structure:
The flexible busbar is supplied through a round cable with a cross-
section of up to 4 mm2 through distribution module RA-C1-VM-7.
The distribution module can supply up to three flat cable segments
through two-tier terminals with round cables. You can also supply
400 V and 24 V through two round cables (M25 and M20
knockout entries).
For connecting the Rapid Link function units RA…/C1, a
connection socket for power plugs is available:
These connection sockets are mounted on the flexible busbar. To
make the contacts, simply tighten the seven screws. When
assembled and connected, they have degree of protection IP65.
For secure termination and for IP65 protection, fit end-pieces to
the open cable ends.
Current carrying capacity of the flexible busbar:
Supplied through distributor module RA-C1-VM-7, the 7 x4 mm2
flat cable has a maximum rating of 25 A at 50 °C. If they are laid
in a cable duct, the 400 V strands are rated 25 A at 40 °C. The
consumers must form a balanced load. The highest permissible
current for the 24 V DC strands is also 25 A. The flexible busbar
junctions RA-C1-VP-PLF and RA-C1-PLF have a maximum current
rating of 16 A.
The maximum continuous current of the 7 x2.5 mm2-flat cable is
20 A at up to 40 °C ambient temperature and three live strands;
i.e. the 24 V DC strands carry a current of no more than 5 A.
The flat cable junction RA-C1-VP-SR must be used a feeder module
only in combination with the 7 x2,5 mm2flat cable and can be
loaded with up to 20 A.
Round cable junction RA-C2
For the power bus you can also use conventional round cables (cross-
section 7
x 2.5 mm
2
or 7 x 4 mm
2
, outer core diameter < 5 mm,
flexible copper conductor to DIN VDE 295, class 5) with round cable
feeders RA-C2. The cable can have an external diameter of 10 to 16
mm.
The cable strands are inserted in the seven terminals and contacted
with screws. The junction socket prewired and conforms with the
DESINA specification
.
In its assembled and connected state, it provides degree of
protection IP65.
At the free cable end, a blanking plug is fitted in the free sealing
insert.
Current carrying capacity of the round cable junction:
The current carrying capacity of round cables is indicated by the
manufacturer. The round cable junction can be loaded up to 25 A
at an ambient temperature of 50 °C.
Figure 8: RA-C1-7x... flat cable..
Figure 9: RA-C1-VM7 distribution module with RA-C1-DF
hAlternatively the RA-C1-7x4 can also be supplied through
the new terminal module RA-C1-AM-7:
• +40 °C: 3 x 23,5 A (400 V AC) + 2 x 10 A (24 V DC)
• +38 °C: 3 x 25 A (400 V AC) + 2 x 10 A (24 V DC)
Contacts are easily established with cage clamp terminals
for round cables and piercing screws for the flexible
busbar RA-C1-7x4.
Figure 10: Flexible busbar junction RA-C1-VP-PLF or RA-C1-PLF
M
L+
PE
N
L3
L2
L1
Figure 11: End piece RA-C1-END or RA-C1-END1
Figure 12: Round cable junction RA-C2-S1-4

System Rapid Link 01/08 AWB2190-1430GB
16
Cable length
When defining the length of the power bus line, observe the
following:
• In the event of a short-circuit in a single-pole at the end of the
power bus – for example in the motor’s terminal board of the
last consumer – the upstream safety device must trip. The
magnitude of the short-circuit depends on:
– Cable lengths
– Conductor cross-section
– Short-circuit current at the incoming point
• Level of application-specific voltage drop. This depends on:
– Cable lengths
– Conductor cross-section
– Current consumption of motors
Through calculation of the short-circuit current and voltage drop
according to the IEE Wiring Regulations, ensure that the protective
functions are fulfilled.
You can calculate the cable length of the power bus as follows:
The national and regional standards (for example VDE 0113, EN
60204) must be observed and the necessary approvals (for
example UL) at the site of installation must be fulfilled.
When the device is operated in a UL-approved system, use only
UL-approved fuses, fuse bases and cables.
L =
U0x1000 – Zv– ZStich
irm
zpower bus
L=
lengt
h
u0= 230 V (no-load voltage 1-ph.)
ir
m
= Tripping current of short-circuit release, e.g.
150 A for RA-DI
zv= e.g. 100 mO(series impedance of feeder)
ZStich = 35,50 mO/m (spur line 1,5 mm2)
zpower bus = 13,40 mO/m (power bus 4.0 mm2)
21,50 mO/m (power bus 2.5 mm2)
Figure 13: Demands placed on the RA-DI group protection device with
short-circuit
Precondition: The short-circuit current Ikmust be greater than the
tripping current of short-circuit release Irm.
Ikis dependent on the impedance or length of the power bus and the
spur line (for Rapid Link about 2 m incomer plus 2 m motor cable)
hYou can obtain a calculation and engineering tool from
Moeller GmbH.
hAttention!
When selecting the cable cross-section, take the voltage
drop under load conditions into account. The end user is
responsible for the observation of any other applicable
standards (for example IEC/EN 60204).
3AC 400 Vh, 50/60 Hz
RA-DI
Irm
Ik
Q1
L
M
3h
RA-MO
1.5 mm2
I >