SIEMENS Tea UE Control Panels Compliant with IEC Standards and European Directives IEC ssiemens.com/panelbuildingSIEMENS Industrial Controls Control Panels compliant with IEC Standards and European Directives Reference Manual 10/2017 ‘ASE38284819002A/RS-ABIO02 Preface Introduction 1 Scope of this documentation Markings and symbols for Organizations and standards 3 market access 4 Control engineering - definition of terms and 5 fundamental principles 6 Electrical equipment. Devices In the control panel and the machine data and tools environment Use of IE2 and IE3 motors 8 Engineering support with A European directives and CE marking for Industrial and B machine control panelsControl engineering - definition of terms and 5 fundamental principles Important basic terms relating to switchgear manufacture and control engineering are briefly explained and illustrated by examples in this chapter. You can find further definitions in German, English and French in the online dictionary of the DKE (International Electrotechnical Vocabulary): DKE-IEV (https://www2,dke.de/de/Online-Service/DKE- IEV/Seitenv/IEV-Woerterbuch.aspx) Detailed explanations can be found in the documentation for the relevant products or in the relevant product standards or the application standards, e.g. IEC EN 60204-1 or lec 61439-4 Control Panels compliant with IEC Standards and European Directives Reference Manual, 10/2017, ASE38284819002ARS-ABIO02 45Control engineering - definition of terms and fundamental principles 5.1 Safely rules 5.1 Safety rules A\l electrically skilled persons and electrically instructed persons shall be familiar with the five safety rules applicable to work on electrical installations. These rules shall always be ‘observed 5 safety rules Definition according to DIN VDE 0105-100 / EN 50110-1: ‘All work on electrical installations shall be carried out by electrically skilled persons, or by persons who have received instruction in working on electrical installations, or under the ‘supervision of one of the aforementioned. An installation or a section of an installation shall be released by the person charged with supervising the work afer all five safety rules have been followed. Adherence with the specified rule sequence is essential 1. Disconnect completely 2. Secure against re-connection 3. Verify absence of operating voltage 4, |. Carry out earthing and short-circuiting (exceptions may be made under certain circumstances) 5. Provide protection against adjacent live parts (exceptions may be made under certain circumstances) Skilled person (electrically) Definition according to DIN EN 60204~1: “Person with relevant education, knowledge and experience to enable him or her to analyze risks and to avoid hazards which electricity could create.” (Electrically) Instructed person Definition according to DIN EN 60204-1: “Person adequately advised by an electrically skilled person to enable him or her to avoid dangers which electricity may create.” Control Panels compliant with IEC Standards and European Directives 46 Reference Manual, 10/2017, ASE38284819002ARS-ABIO02Control engineering - definition of terms and fundamental principles 5.2 Types of grounding system 5.2 Types of grounding system TNS system directly grounded neutral N = low-resistance return conductor to transformer neutral point S = separate conductors for PE and N Advantage: System conforms with EMC guidelines Disadvantage; 5 conductors INC system era = directly grounded neutral »w-impedance return conductor to transformer neutral point ‘combined” conductor for PE and N = PEN ‘Advantage: Only 4 conductors Disadvantage: Susceptible to electromagnetic interference because harmonics are discharged via the PEN which means that loads with N conductor are additionally stressed by harmonics. INC-S system ‘With this system, a combined N and PE (PEN) conductor exits from the transformer, but at some point, the PEN conductor is split up into separate PE and N lines. PEN is nonetheless the correct description for this PE because the neutral can be separated out of the combined conductor at any time. Once the neutral has been separated out of the combined conductor, it cannot be connected to the PEN again, ie. it must be a “spur line"! Ia neutral conductor that had already been split rom the PEN were reconnected to it, it ‘would constitute a parallel connection with an incalculable impedance and thus also an incalculable short-circuit load. Furthermore, it can result in undesirable stray ("vagrant") 4 r + & . + 8 i t tt Ben { PEN Pe Lo ttth okey i225 << ne TT, paren + twc-s Electrical system 9 —_____» Figure 5-1 TN-C-S system Control Panels compliant with IEC Standards and European Directives Reference Manual, 10/2017, ASE38284819002ARS-ABIO02 47Control engineering - definition of terms and fundamental principles 5.2 Types of grounding system IT system TT system 48 ransformer neutral point isolated or with high-impedance ground connection T= Terra = each item of equipment has separate low-impedance ground connection ‘Advantage: First fault = conductive connection from phase to enclosure does not cause disconnection, Disadvantage; An additional monitoring system for detecting the first fault shall be installed. Used, for example, in situations in which high availability of electrical installations is, essential, e.g. in hospital operating theaters, potentially explosive atmospheres. Figure §-2 IT system T= Terra = directly grounded neutral T = Terra = each item of equipment has separate low-impedance ground connection The PE connection is provided by a local ground electrode. When the transformer is located a long way from the equipment, the large number of series and parallel equivalent resistances of the ground produce a relatively low grounding resistance which means that this system has similar characteristics to a TN system, ‘Advantage: Only 3 conductors are required Disadvantage; An effective system only when transformer is located a long way from ‘consumers. Used in low-voltage networks in areas in which the substation is located at a large distance from consumers, i. in rural localities. Used in medium-voltage networks in conjunction with (overhead) power lines. u B Figure 5-3 TT system (N conductor as required) Control Panels compliant with IEC Standards and European Directives Reference Manual, 10/2017, ASE38284819002ARS-ABIO02Control engineering - definition of terms and fundamental principles 5.3 Rated. Rated... 5.3 Rated, Whenever a term begins with or contains the word "rated...", it means that the circuit or the component concerned is designed to permanently withstand this value (see IEC 60204-1), Rated current Rated voltage Rated power Rated cross-sectional area Rated diversity factor ROF Rated short-time withstand current lew Control Panels compliant with IEC Standards and European Directives Reference Manual, 10/2017, ASE38284819002ARS-ABIO02 49Control engineering - definition of terms and fundamental principles ‘54 Current. 5.4 Current.. Overcurrent Current which exceeds the rated value. For conductors and cables, the rated value is their current-carrying capacity. The rated value for switchgear is the relevant rated current (Isied orb). Overload (of a circuit) ‘Time/current relationship in a circuit which is in excess of the rated full load when the circuit is not under a fault condition. (Source: IEC 60204-1) ‘Overload should not be used as a synonym for overcurrent, Short-cirouit current Overcurrent resulting from a short circuit due to a fault or an incorrect connection in an electric circuit. (Source: IEV 441-11-07) In this case, the magnitude of the current is significantly higher than the rated value. Circuit under a fault condition; low-impedance connection between phase and PE / N Earth fault current (US: Ground faut current) Current flowing to earth due to an insulation fault. (Source: IEV 442-01-23) Earth leakage current Current flowing from the live parts of the installation to earth, in the absence of an insulation fault. (Source: IEV 442-01-24) Control Panels compliant with IEC Standards and European Directives 50 Reference Manual, 10/2017, ASE38284819002ARS-ABIO02Control engineering - definition of terms and fundamental principles Cut-off current (let-through current) 5:4 Current. Maximum instantaneous value of current attained during the breaking operation of a switching device or a fuse. NOTE: This concept is of particular importance when the switching device or the fuse operates in such a manner that the prospective peak current of the circuit is not reached. (Source: IEV 441-17-12) I the prospective peak current of the circuit is not reached, the term “current limiting” is applied. In this case, the cut-off current io corresponds to the cut-off current actually attained This is specified as a peak value. oe io: Cut-off current (let-through current) ip: Peak short-circuit current tt: Melting time tu: Are quenching time Us: Are volage Source: Siemens AG, Handbook Switching, Protection and Distribution in Low-Voltage Networks, ‘Ath Edition 1997 Figure 5-4 Oscillagram of a short-circuit disconnection by a fuse Control Panels compliant with IEC Standards and European Directives Reference Manual, 10/2017, ASE38284819002ARS-ABIO02 51Control engineering - definition of terms and fundamental principles 5.5 Degree of protection of enclosures 55 Degree of protection of enclosures International Protection ‘The abbreviation IP stands for /nternational Protection, but in English-speaking countries IP is also derived from “Ingress Protection". IEC 60529 provides a detailed description of the degrees of protection provided by ‘enclosures. The letters IP are followed by 2 characteristic numerals, e.g. IPS4: ‘The first numeral defines the strength of the enclosure against the ingress of solid foreign objects (dust, contact by human body). © The second numeral defines the strength of the enclosure against the ingress of water. The following two letters are optional: ‘The first letter defines the degree of protection against access to hazardous parts, ‘* The second letter defines test methods (access of test probes). According to IEC 60529, additional letters are used in the following cases: ‘© When the actual protection against access to hazardous parts is higher than indicated by the first numeral. ‘* When only the protection against access to hazardous parts is specified and the first numeral is replaced by an X. Intemational Protection {st eharactrste numeral (19, oFX) 2nd characteristic numeral (009, oF) Loto (optional, (A. 8D) Lata (optional, (H, MLS, W) Figure 5-5 Degree of protection provided by enclosures: International Protection Control Panels compliant with IEC Standards and European Directives 52 Reference Manual, 10/2017, ASE38284819002ARS-ABIO02Control engineering - definition of terms and fundamental principles Examples 5.5 Degree of protection of enclosures IP54 '* 5 = dust-protected, Ingress of dust is not totally prevented, but dust shall not penetrate in ‘a quantity to interfere with satisfactory operation of the apparatus or to impair safety. ‘* 4= protected against splashing water. Water splashed against the enclosure from any direction shall have no harmful effects. This means that water may enter the enclosure, but it shall not cause any damage or safely hazards, (PX Protection against ingress of solid foreign objects and/or water is not required. The additional letter indicates, however, that access to hazardous pars is protected for incidental contact with fingers. This is generally referred to as “finger-safe Verification Enclosures shall be tested in specially equipped laboratories to verify that they comply with the requirements for a particular degree of protection. Recommendation Enclosures that have already been tested in accordance with IEC 60529, (e.g. 8MF, ‘ALPHA 3200, SIVACON) should be used Minimum degree of protection IEC 60204-1 -+ P22 IEC 61439-4 - IP2X the front of an open switchgear and controlgear assembly, + IPXXB Installation of command and signaling devices In the door of a control panel, e.g. with IP54, In order to maintain the degree of protection of the panel, the two numerals in the degree of protection of the equipment shall be equal to or higher than the numerals of the panel. Examples’ * Panel IP54 and pushbutton IP44 ~ not possible because degree of protection of panel ‘would then only be IP44 ‘© Panel IP54 and pushbutton IP54 ~ OK, overall degree of protection IP54 ‘* Panel IP54 and pushbutton IP65 ~ OK, overall degree of protection P54 Control Panels compliant with IEC Standards and European Directives Reference Manual, 10/2017, ASE38284819002ARS-ABIO02 53Control engineering - definition of terms and fundamental principles 5.5 Degree of protection of enclosures Conditions for accessing control panels and switchgear and controlgear assembles 54 With key or tool ‘Access only for electrically skilled persons, persons instructed in working on electrical installations. Live parts which can be accessed, for example, during resetting or adjustment shall have at least IP2X (IPXXB), inside of door at least IP1X (IPXXA). Disconnection of live parts — The parts shall be disconnected before the enclosure can be opened. — It shall not be possible to open the door until the disconnecting device is open. = Itshall not be possible to close the disconnecting device unless the door is closed — All parts that remain live after the disconnecting device(s) has(have) been opened shall be protected against direct contact and labeled accordingly (at least IP2X / IPXxB). This can be achieved, for example, by use of a door-coupling rotary operating mechanism, Note Exception It shall be possible to make an exception for electrically skilled persons. For information, see Chapter Basic protection (Page 102). Without key, tool or disconnection — All live parts shall have at least IP2X (IP4X) or IPXXB (IPXXD), = Covers can only be removed using tools. — Ifitis possible to remove covers without using tools, the relevant live parts shall be disconnected automaticaly. Control Panels compliant with IEC Standards and European Directives Reference Manual, 10/2017, ASE38284819002ARS-ABIO025.6 Finger-safety Control engineering - definition of terms and fundamental principles 5.6 Touch protection for electrical equipment Touch protection for electrical equipment EN 50274 "Low-voltage switchgear and controlgear assemblies - Protection against electric shock — Protection against unintentional direct contact with hazardous live parts" contains precise specifications with respect o touch protection including, for example, dimension drawings for test fingers. ‘Switchgear and controlgear assemblies that require occasional handling shall have touch protection: ‘* The touch protection in the area around the operator controls shall be "finger-safe” ‘© The touch protection in the rest of the panel shall be "safe from touch by back of the hand" The touch protection measures are always tested on the horizontal (not from the side or at an angle from above) Standardized "test fingers" are used to test electrical equipment for finger-safety ‘The purpose of this test is to ensure that nobody can access live parts with their fingers under normal conditions. This cannot be guaranteed, however, for parts used that are smaller than the “test finger’ Finger-safety measures are usually implemented in the direct vicinity of operator controls. ‘Safety from touch by back of hand Wire safety ‘A standardized ball (diameter 50 mm) that is shaped lke the back of a hand is used to test electrical equipment for this kind of safety. ‘The purpose of this test is to ensure that nobody can access live parts with the back of their hand under normal conditions. This cannot be guaranteed, however, for parts that are smaller, e.g. that can be accessed with a finger. Safety measures to provide protection against access with the back of the hand are usually implemented adjacent to the finger-safe area or near parts which need to be exchanged (e.g. fuses). Wire safety is calculated in 2 stages: © Wires with a diameter of not less than 2.5 mm. © Wires with a diameter of not less than 1 mm Wires with a diameter of not less than 1 mm are normally used for easily accessible, horizontal covers because this can provide reliable protection against contact between live components and “normal” wires used in the construction of switchgear and controlgear assemblies or “arm jewelry" (bracelets). Control Panels compliant with IEC Standards and European Directives Reference Manual, 10/2017, ASE38284819002ARS-ABIO02 55Control engineering - definition of terms and fundamental principles 5.6 Touch protection for electrical equipment Example of the application of finger-safety Finger-safety measures shall be implemented 30 mm around the pushbutton and to a depth of 80 mm, Po seme art dangerous to touch Cover not remied I | Source: Siemens AG, Handbook Switching, Protection and Distribution in Low-Voltage Networks, 4th Edition 1997, Figure 5-6 Test finger (dimensions in mm) Control Panels compliant with IEC Standards and European Directives 56 Reference Manual, 10/2017, ASE38284819002ARS-ABIO02Control engineering - definition of terms and fundamental principles 5.6 Touch protection for electrical equipment Example of the application of safety from touch by back of hand The ball shall not make any contact with live parts. 2 sonm 48mm Figure 5-7 Parts dangerous to touch, dimensions in mm Control Panels compliant with IEC Standards and European Directives Reference Manual, 10/2017, ASE38284819002ARS-ABIO02 87Control engineering - definition of terms and fundamental principles 5:7 Degree of pollution 57 Degree of pollution The degree of pollution refers to the ambient conditions in which the switchgear or the contro! panel can operate. For devices and components in an enclosure, the degree of pollution refers to the ambient conditions inside the enclosure. The pollution degree is required in order to evaluate clearances and creepage distances. The higher the degree of pollution, the larger the clearances and creepage distances. ‘The degree of pollution always relates to the environment directly around the equipment. Degree of pollution The table describes the 4 degrees of pollution as defined by IEC 6064-1 and the areas to which they are usually assigned Degree of pollution 3 can be regarded as standard in industry, Table 5-1 Degree of pollution Degree of | Description Areas Minimum polltlon valies of width X of grooves 1 'No pollution or only dry, non- | Air-conditioned or clean, dry areas | 0.25 mm Conductive pollution occurs. The pollution has no influence. 2 Only non-conductive pollution | Residential, retail or commercial | 1.0 mm occurs except that occasionally a_| areas, precision mechanics temporary conductivity caused by | workshops, laboratories, test condensation is to be expected. _ | stations, rooms used for medical purposes 3 Conductive pollution occurs or | Industrial companies, commercial [1.5 mm dry, non-conductive pollution __ and agricultural operations, ‘occurs which becomes conductive | unheated storage areas, due to condensation which is to | workshops, boller rooms. be expected 4 Continuous conductivity occurs | Outdoor areas: 25mm due to conductive dust, ain or ther wet conditions. + Dimensions in accordance with IEC 61439-1, Annex F, Table F.1 58 Control Panels compliant with IEC Standards and European Directives Reference Manual, 10/2017, ASE38284819002ARS-ABIO02Control engineering - definition of terms and fundamental principles 5.8 Clearance ‘5.8 Clearance and creepage distance Clearance and creepage distance "Shortest distance in air between two conductive parts” (Source: IEV 426-04-12) Example Wl © Conductive parts @ Clearance between the two conductive parts Figure §-8 Clearance Creepage distance "Shortest distance along the surface of a solid insulating material between two conductive parts" (Source: IEV 151-15-50) Example © Conductive parts @® __Creepage distance between the two conductive parts Figure 5-9 Creepage distance ‘The width of the groove depends on the degree of pollution. Ifthe groove is narrower than the minimum width for the degree of pollution, itis regarded as non-existent, i.e. the dashed line is the distance. ‘© Ifthe groove is of the minimum required width or larger, the distance is measured along the contour including the groove, i.e. the thick line is the distance. Control Panels compliant with IEC Standards and European Directives Reference Manual, 10/2017, ASE38284819002ARS-ABIO02 59Control engineering - definition of terms and fundamental principles 5.9 Overvollage category 59 Overvoltage category “Numeral defining a transient overvoltage condition.” (Source: IEV 81-21-02) The overvoltage category depends on limiting (or controlling) the values of prospective transient overvoltages occurring in a circuit (or within an electrical system having different nominal voltages) and depending upon the means employed to influence the overvoltages. Translent and temporary overvoltage v Figure 5-10 Transient and temporary overvoltage Transient overvotages Transient overvoltages are characterized by their very short duration (normally in the milliseconds range), but very high magnitude (in the kilovolts range). Overvoltage category Ill is the most common category for industrial equipment. Ifa lower overvoltage category is required, this can be achieved by installing appropriate ‘components such as surge arresters or line filters that block, absorb or discharge the covervoltage energy to reduce the transient overvoltage down to the relevant category. ‘Temporary overvottages ‘Temporary overvoltages are characterized by their relatively long duration (in the seconds range), but relatively low magnitude (in the volts range). Nominal voltage and rated Impulse withstand voltage Table G in EN 61439-1 or IEC 61439-1 shows the correlation between the nominal voltage of the supply system and the rated impulse withstand voltage of the equipment. Control Panels compliant with IEC Standards and European Directives 60 Reference Manual, 10/2017, ASE38284819002ARS-ABIO02Control engineering - definition of terms and fundamental principles 5.10 Selectivity 5.10 Selectivity Selectivity ‘An installation with various levels of protective devices is said to operate "selectively" when a fault is cleared only by the protective device Installed Immediately upstream of the fault location. In each case, the fault is cleared within the specified clearance time in accordance with the application / type of grounding system. \ Vv All of the other circuits unaffected by the fault remain operational. Selectivity Current selectivity Current selectivity is achieved when the series-connected protective devices are selected and set in such a way that the fault is only ever cleared by the device located immediately Upstream of the fault (without time delay) Time selectivity Time selectivity is achieved when all upstream protective devices delay tripping unti the device immediately upstream of the fault trips Total selectivity Total selectivity is achieved when the maximum possible short-circuit current trips only the device located immediately upstream of the fault, but does not trip any of the other upstream devices. Partial selectivity, as of a specific current value Selectivity limit Control Panels comph Reference Manual, Partial selectivity is achieved when the upstream device trips at the same time as the device located upstream of the faull as soon as the fault current reaches a specific value. This value differs according to the device combination and shall be calculated separately for each configuration. The selectivity limit is a “specific” fault current value (see "Partial selectivity") which, when exceeded, causes upstream protective devices to trip simultaneously. lant with IEC Standards and European Directives 10/2017, ASES8284819002A/RS-ABIO02 61Control engineering - definition of terms and fundamental principles 5.11 Utiization categories 5.11 Utilization categories Utilization catego Table 5-2 Utiizat ry according to IEC 60947-2 ion category - suitability for selectivity Utitzation category ‘Sultabllty for selecthty A Circuit breakers not specifically Intended for selectivity under shortsckcult condkions with respect to other short-circuit protective devices in series on the load side, i. without an Intentional short-time delay provided for selectivity under short-circuit conditions and therefore without a short-time [withstand current rating according to 4.3.6.4. Circuit breakers specfically Intended for selectiMtly under short-circuit conditions with respect to other short-circuit protective devices in series on the load side, ie. with an intentional short-time dolay (which may be adjustable), provided for selectivity under short-circuit conditions. Such circuit breakers have a short-ime withstand current rating according to 4.3.6.3. NOTE. Selectivity is not necessarily ensured up to the ultimate short-circuit breaking capacity of the circuit breakers (for example in the case of operation of an instantaneous release), but atleast up to the values specified in Table 3. ‘Source: IEC 60947-2, Utilization categor 62 excerpt from Table 4: Utilization categories; highlighting by author ries for contactors Utilization categories for contactors according to IEC 60947-4-1 Alternating current — selection ‘ACs1 Non-inductive or slightly inductive loads, resistance furnaces (le = 1.5 x; In= 1.5 x) AC-2 Slip-ring motors: starting, switching off (Ie = 4 x; In= 4 x) AC-3 Squirre!-cage motors: starting, switching off during operation (Ie = 10 x; la = 8 x) AC-4 Squirrel-cage motors: starting, plugging, inching (le = 12 x; Ia = 10 x) Direct current — selection DC-1 Non-inductive or slightly inductive loads, resistance furnaces DC-3 Shunt motors: starting, plugging, inching, dynamic braking of motors DC-5 Series motors: starting, plugging, inching, dynamic braking of motors DC-6 Switching of incandescent lamps Control Panels compliant with IEC Standards and European Directives Reference Manual, 10/2017, ASE38284819002ARS-ABIO02Control engineering - definition of terms and fundamental principles 5.11 Utilization categories Utlization categorles for contactor relays Utilization categories for contactor relays according to IEC 60947-5-1 ‘Akemating current ‘AC-12 Control of resistive loads and inductive loads with isolation by optocouplers ‘AC-13 Control of solid-state loads with transformer isolation ‘AC-14 Control of small electromagnetic loads (< 72 VA) ‘AC-15 Control of electromagnetic loads (> 72 VA) DC current DC-12 Control of resistive loads and solid-state loads with isolation by optocouplers DC-13 Control of electromagnets DC-14 Control of electromagnetic loads having economy resistors in circuit Utilization categorles for switch disconnectors Utilization categories for switch disconnectors with and without fuses according to EN 60947-3, Table 5-3. Ultilzation categories for switch disconnectors, Nature of current |__Utiization categories ‘Typical applications Category | Category A B ‘ac-20a* [AC-208" | Connecting and disconnecting under no-load conditions ACA [AC-218 [+ Switching of rosistive loads including moderate overloads Alternating current AC-22A—|AC-223 | Switching of mixed resistive and inductive loads, including moderate overloads AC23-A —|AC23-8 —|« _ Switching of motor loads or other highly inductive loads De-20A" — [DC-208* | Connecting and disconnecting under no-load conditions De-21A — |[DC-21B | Switching of resistive loads including moderate overloads De-228 — |DC-228 | Switching of mixed resistive and inductive loads, including moderate overloads (e.g. shunt motors) Direct current Dc23-A — [DC23-B | « Switching of highly inductive loads (e.9. series motors) The use of these utlization categories is not permitted in the USA, Source: EN 60847-3 Switch disconnectors with and without fuses, Table 2: Utilization categories Category A = Frequent use; Category B = Occasional use Control Panels compliant with IEC Standards and European Directives Reference Manual, 10/2017, ASE38284819002ARS-ABIO02 63Control engineering - definition of terms and fundamental principles 5.12 Switch disconnectors and circuit breakers 5.12 Switch disconnectors and circuit breakers Non-automatlc alr circult breakers ‘Same type of construction as a circuit breaker. Cannot be set if equipped with short- circuit release, ‘Same equipment as a circuit breaker, ‘e.g. remote operating mechanism, auxiliary release, auxiliary switch, ‘Switch disconnector ‘Same type of construction as a circuit breaker, but without any protection functions. For this reason, a fuse / circuit breaker needs to be connected upstream, ‘Same equipment as a circuit breaker, ‘e.g. remate operating mechanism, auxiliary switch. Circuit breakers for starter assembly ‘Same type of construction as a circuit breaker, but only one (adjustable) short- Circuit protection function, for adaptation to the destruction characteristic of the overload relay. ‘The motor is protected against overload by the overload relay. ‘Advantage: Clear signaling concept: Starter switch ~ short circuit bistable relay » overload. 64 Control Panels compliant with IEC Standards and European Directives Reference Manual, 10/2017, ASE38284818002ARS-ABIO02Control engineering - definition of terms and fundamental principles 5.12 Switch disconnectors and circuit breakers Requirements of clrcult breakers for line protection ‘Must trip within two hours at 1,3 x load. (This tripping time is one hour for devices up to 63 A), Must not trip within two hours at 1.08 x load. Usual setting ranges: Adjustabilty of the overload release is not necessary in most cases. Response values of the short-circuit releases 5- 10° A selectivity evaluation makes sense for ‘applications involving power distribution boards. Requirements of circuit breakers for motor protection ‘Must trip within two hours at 1.2 x oad. (This tripping time is one hour for devices Up to 63 A). ‘Must not trip within two hours at 1.05 x load. Insensitvity to motor starting inrush ‘current normally about 20 ms. Option Phase fallure sensitivity to protect, explosion-proof motors Temperature compensation (20°C... +60 °C) Thermal memory (several starting attempts cause temperature rise in motor) “+ prompt restart conditionally possible, without thermal memory > long delay Adjustable trip class for adjusting breaker to motors starting behavior. Control Panels compliant with IEC Standards and European Directives Reference Manual, 10/2017, ASE38284819002A/RS-ABIOO2 65Control engineering - definition of terms and fundamental principles 5.13 Selection of the electrical characteristics of circult breakers 5.13 Selection of the electrical characteristics of circuit breakers Below you will find a selection of the electrical characteristics of circuit breakers with the definitions according to EN 60947. lon — Rated short-circuit making capacity (peak value) Maximum prospective peak current that the switching device can connect. low — Rated short-time withstand current (r.m.s.) Max. prospective short-circuit current that the switching device can conduct for a specific time period (© thermal short-circuit withstand rating); ¢.g. lev = 100 kA, 0.5 leu Rated ultimate short-circult breaking capacky (r.m.s) Test sequence III (Iv): O-t-CO The circuit breaker shall be capable of disconnecting this current twice without sustaining damage. Thereafter the circuit breaker shall no longer be operational and shall be replaced or repaired Ics — Rated service ultimate short-circuit breaking capacity (r.m.s.) Test sequence Il (Is): O-t-CO-t-CO The circuit breaker shall be capable of disconnecting this current three times without sustaining damage. Then, among other characteristics, the performance of the circuit breaker is tested, ie. the circuit breaker shall afterwards be capable of conducting and also ‘switching the operational current (at least once). lec — Rated conditional short-clrcult current “The value of prospective short-circuit current, declared by the ASSEMBLY manufacturer that can be withstood for the total operating time (clearing time) of the short-circuit protective device (SCPD) under specified conditions NOTE The short-circuit protective device may form an integral part of the ASSEMBLY or may be a separate unit." (Source: IEC 61439-1) le — Cut-off current (let-through current) "Maximum instantaneous value of current attained during the breaking operation of a switching device or a fuse. NOTE This concept is of particular importance when the switching device or the fuse ‘operates in such a manner that the prospective peak current of the circuit is not reached.” (Source: IEC 60050-441:2007, 41-17-12) Control Panels compliant with IEC Standards and European Directives 66 Reference Manual, 10/2017, ASE38284819002ARS-ABIO02Control engineering - definition of terms and fundamental principles 5.14 Trip classes 5.14 Trip classes The trip classes according to IEC 60947-4-1 are intended to protect motors against inadmissible temperature rise in supply systems not affected by harmonics. They define the time intervals within which the protection equipment (overload release of a circuit breaker or overload relay) shall trip from the cold state in the case of a symmetrical, three-phase load. These protective devices shall trip the response thresholds in Section 8.2.1.5 of the standard, which represent a multiple value of the current setting. The response threshold is 7.2 times the current setting The trip classes in Table 2 of the standard apply in relation to the load connected to the motor and tolerance band E for electronic overload releases if stated by the manufacturer. The class, e.g. CLASS 10, defines a starting behavior of the motor including a load between 4 and max. 10 seconds. A protection device with CLASS 10 therefore allows a starting behavior of the motor including load torque for a maximum of 10 seconds. Table S-4 Trip classes of overload relays Trip class ‘Tripping time 7 ‘Tripping time To under the condition specified In 8.2.1.5.1, | under the condition spectied hn 8.2.1.5.1, Table 3 Cokmn D* ‘Table 3 Column D for tighter tolerances. s (tolerance band &}* 5 OS< hs 3 100 KW. 1 ‘Source: IEC 61439-2, Table 101: Values of assumed loading Control Panels compliant with IEC Standards and European Directives Reference Manual, 10/2017, ASE38284819002ARS-ABIO02 75Control engineering - definition of terms and fundamental principles 5.19 Motor duly types 5.19 Motor duty types Information about the duty types of motors under defined conditions. ‘The most common duty types are described below. Continuous duty $1 76 Table 5-8 Duty type 1: Continuous duty p Source: IEC 6034-1 This is operation at a constant load, e.g at rated power, maintained for sufficient time to allow the motor to reach thermal equilibrium. The system components shall be dimensioned in such a way that they can conduct the constant current for an unlimited time without the need for intervention and without their permissible temperature limits being exceeded. The appropriate abbreviation is $1 with an indication of the power rating, e.g. $1: 20 kW. Pload Py electrical losses © temperature max maximum temperature attained time Control Panels compliant with IEC Standards and European Directives Reference Manual, 10/2017, ASE38284819002ARS-ABIO02Control engineering - definition of terms and fundamental principles 5.19 Motor duly types Short-ime duty $2 Table 5-9 Duty type S2: Shorttime duty 1 Duty type S2 refers to operation at a constant load for a given time, less than that required to reach thermal ‘equilibrium, followed by a time de- energized and at rest of sufficient duration to re-establish machine temperatures within 2K of the coolant temperature, Pload Py electrical losses © temperature ©nax maximum temperature attained Mh time i ‘Ate operation time at constant load ‘Source: IEC 60034-1 Control Panels compliant with IEC Standards and European Directives Reference Manual, 10/2017, ASE38284819002ARS-ABIO02 7Control engineering - definition of terms and fundamental principles 5.19 Motor duly types Intermittent perfodlc duty $3 Table 5-10 Duty type S3: Intermittent periodic duty without starting - This refers to a sequence of identical z duty cycles, each including a time of ‘operation at constant load and a time de- Jain | energized and at rest. In this duty, the cycle is such that the starting current does not significantly affect the temperature rise Intermittent periodic duty implies that thermal equilibrium is not reached during the time on load Cyclic duration factor designation Includes time on load (P), time of one load cycle (7e) and power or current, €.9, ‘$3: 15 mlv/60 min, 20 KW, or the cyclic duration factor Ate/ Te, Cyclic duration factor as percentage / time of one load cycle: ©. g. $3: 20%, 60 min, 20 KW. Pload Py electrical losses © temperature max maximum temperature attained Hime Te time of one load cyclo Ate operation time at constant load Ate time do-energized and at rest Gydlic duration factor = Afo/Te Source: IEC 6034-1 In accordance with EN 60034-1 (VDE 0530), the cycle time for motors in intermittent duty is, 10 minutes unless otherwise agreed. This time of one load cycle shall be regarded in practice as the upper limit, Control Panels compliant with IEC Standards and European Directives 78 Reference Manual, 10/2017, ASE38284819002ARS-ABIO02Control engineering - definition of terms and fundamental principles 5.19 Motor duly types Perlodle duty In periodic duty with very short times de-energized and at rest, the thermally effective current may occasionally exceed the effective load current of the motor. This is generally the case if the period of operation and time de-energized and at rest of the motor are relatively short because the starting currents then affect the temperature rise. Annex E (Figure E6) of IEC 61439-1 contains the following method of calculating this thermal equivalent. 4 Starting time at t Run time at 6 Interval ime at h+h+6 =cycle time Figure 5-15 Calculation of average heating effect. Control Panels compliant with IEC Standards and European Directives Reference Manual, 10/2017, ASE38284819002ARS-ABIO02 79Control engineering - definition of terms and fundamental principles 5.19 Motor duly types Control Panels compliant with IEC Standards and European Directives 80 Reference Manual, 10/2017, ASE38284819002ARS-ABIO02Electrical equipment 6 6.1 Interface agreements between customer and manufacturer ‘The user and supplier shall come to an agreement about technical requirements before work commences on configuring and planning the electrical equipment. ‘Whether, for example, a control panel is dimensioned for a prospective short-circuit current of 10 kA of 50 KA, or whether it will be connected to a TN or an IT supply system, will have a significant impact on its design. The intended site of installation is also a crucial factor and will determine the degree of protection required for the panel. Harsh operating conditions (in factory workshops, for example) demand a higher degree of protection than would be needed in a clean electrical equipment room. Recommendation: A detailed agreement about all interfaces should be worked out in advance! (Only when an agreement has been reached is it possible for the supplier: © To draw up a quotation To plan the installation © To construct a standard-compliant installation ‘© To fulfil the customer's expectations and needs Both IEC 60204-1 (in Annex B) and IEC 61439-1 (in Annex C) contain specifications designed to facilitate the exchange of information in the form of questionnaires that are to be completed in advance by the customer. Control Panels compliant with IEC Standards and European Directives Reference Manual, 10/2017, ASE38284819002ARS-ABIO02 a1Electrical equipment 6.2 Incoming supply conductor termination and supply disconnecting device 62 Incoming supply conductor termination and supply disconnecting device 6.24 Incoming supply conductor termination Areas of responsiblity 82 The incoming supply conductor termination represents the power supply, ie. the supply of electrical power, for the machine Unless otherwise agreed between the user and the machine supplier, the area of responsibilty of the machine supplier begins at the point at which the machine is connected. to the incoming supply, In other words, at the infeed terminal of the supply disconnecting device or, if provided, at upstream connecting terminals. If a switch disconnector without fuses is used as a supply disconnecting device, the outgoing cables at the supply disconnecting device will not have any protection. In this case, the supplier shall specify that the operator uses suitable fuses upstream of the control panel. Responsibility Control pane! builder / original ‘equipment manufacturer (OEM) RResponsiity User Figure 6-1 Defining boundaries between areas of responsibilty of user and supplier In order to reduce the risks associated with electrical installations, Chapter 5.1 of IEC 60204-1 recommends the use of only one incoming supply conductor wherever this is practicable. Control Panels compliant with IEC Standards and European Directives Reference Manual, 10/2017, ASE38284818002ARS-ABIO02Electrical equipment 6.2 Incoming supply conductor termination and supply disconnecting device Electrical equipment of a machine Where another supply is necessary, e.g. for circuits that operate at a different voltage (contro! circuits, etc.), that supply should be derived, as far as is practicable, from devices that form part of the electrical equipment of the machine. Depending on the complexity of the machinery, there may also be a need for more than one incoming supply conductor, for example, for large, complex machinery (e.g. optional generator operation, UPS systems). As a general rule, however, the number of supply conductors should be kept to the absolute necessary minimum, Ifa neutral conductor is used, a separate insulated terminal labeled "N" shall be provided. Such a terminal can also be part of the supply disconnecting device. In this case, there shall be no connection between the neutral conductor and the protective bonding circuit inside the electrical equipment. Note Exception for TN-C and TN-C-S systems ‘Acconnection may be made between the neutral terminal and the PE terminal at the point of the connection of the electrical equipment to a TNC or TN-C-S supply system. Control Panels compliant with IEC Standards and European Directives Reference Manual, 10/2017, ASE38284819002ARS-ABIO02 83Electrical equipment 6.2 Incoming supply conductor termination and supply disconnecting device For types of grounding system (Page 47) in which an external protective conductor is routed to the machine, the protective conductor shall be connected to a terminal that is in the same terminal compartment as the associated line conductor terminals. The terminal for the ‘external protective conductor shall be marked with "PE" Trial auf ey Aa Figure 6-2 Separate terminals for neutral conductor and protective conductor Control Panels compliant with IEC Standards and European Directives 84 Reference Manual, 10/2017, ASE38284818002ARS-ABIO02Electrical equipment 6.2 Incoming supply conductor termination and supply disconnecting device Protective conductor Protective conductors made of copper require terminals dimensioned for a cross-sectional area specified in the table below. Table 6-1 Minimum cross-sectional area of copper protective conductors ‘Cross-sectional area ofthe conductor Minimum cross-sectional area of the ‘S(mm?) comesponding copper protective conductor (mm) S516 s 16< 5295 16 S335, S22 Source: IEC 60204-1, Table 1: Minimum cross-sectional area of copper protective conductors External protective conductors of a material other than copper may be used if they have a cross-sectional area of at least 16 mm?. Where a protective conductor of a material other than copper is used, the terminal size shall be selected to suit the cross-sectional area of the conductor and shall be suitable for the conductor material selected. You can find information about dimensioning aluminum protective conductors in the Chapter Protective bonding (Page 158) The terminal for the external protective grounding system or the external protective conductor shall be labeled with the letters PE, Figure 6-3 Example: Labeling of terminal for the extemal protective conductor Control Panels compliant with IEC Standards and European Directives Reference Manual, 10/2017, ASE36284819002A/RS-ABIOO2 85Electrical equipment 6.2 Incoming supply conductor termination and supply disconnecting device 6.22 Supply disconnecting (Isolating) device ‘Supply disconnecting (Isolating) device ‘The purpose of the supply disconnecting device is to disconnect (isolate) a machine from the incoming supply when required. With the exclusion of some excepted circuits, the electrical ‘equipment of the machine will be isolated from the supply when the supply disconnecting device is switched off. This may be necessary, for example, to allow maintenance work According to Chapter 5.3 of IEC 60204-1, supply disconnecting devices shall be provided for the following: * For each incoming source of supply to one or more machines * For each on-board power supply, e.g. for mobile machines Note ‘Two or more supply disconnecting devices Where two or more supply disconnecting devices are provided, protective interlocks to ‘ensure their correct operation shall also be provided in order to prevent risks to the safety of personnel, or damage to the machine or to the work in progress. Permissible types of supply disconnecting device According to IEC 60204-1, itis permissible to use the following types of supply disconnecting device: * According to IEC 60947-3: switch disconnector, with or without fuses, for utilization category AC-23B or DC-23B * According to IEC 60947-6-2: Control and protective switching devices with isolating properties © According to IEC 60947-2: Circuit breakers suitable for isolation ‘© Any other switching devices that fulfil an IEC product standard, requirements placed on isolating devices and the appropriate utilization category andior the stress requirements. specified in the product standards. © Plugisocket combinations for a flexible cable supply Note For further information, see Chapter SIRIUS 3RAG compact starters (Page 247) Control Panels compliant with IEC Standards and European Directives 86 Reference Manual, 10/2017, ASE38284819002ARS-ABIO02Electrical equipment 6.2 Incoming supply conductor termination and supply disconnecting device ‘Supply disconnecting devices supplied by Slemens ‘Siemens offers a large portfolio of suitable supply disconnecting devices (Page 234). Switch disconnectors compliant with IEC 60947-3 Figure 6-4 Selection of Siemens switch disconnectors compliant with IEC 60947-3, Circuit breakers compliant with IEC 60947-2: Figure 6-5 Selection of Siemens circuit breakers compliant with IEC 60947-2 Rule It shall have a visible position indicator that clearly shows whether the supply disconnecting device is ON or OFF, The following conditions shall be fulfilled for this purpose: ‘© There shall only be one OFF position and one ON position. ‘© The OFF position is marked with °O" and the ON position with *", or there shall be a Visible contact gap. Control Panels compliant with IEC Standards and European Directives Reference Manual, 10/2017, ASE36284819002A/RS-ABIOO2 87Electrical equipment 6.2 Incoming supply conductor termination and supply disconnecting device Rule The supply disconnecting device shall be accessible from outside the enclosure so that the machine can be shut down to allow work (maintenance, repair, etc.) The supply disconnecting device shall meet the following requirements: ‘© It shall have an external operating means © It shall be provided with a means permitting it to be locked in the OFF (isolated) position (against reclosure) © It shall disconnect all live conductors of its power supply circuit Example ~ Figure 6-6 Examples of external operating means (handles) for supply disconnecting devices Note The neutral conductor need not be disconnected by the supply disconnecting device if not required by the rules of the country concerned. See also Chapter Protection against ‘overcurrent (Page 119), If the supply disconnecting device is also required to fulfil an emergency stop function or an ‘emergency switching off function, the externally accessible operating means shall be red against a yellow background. Breaking capacity 88 It shall have a breaking capacity sufficient to interrupt the current of the largest motor when stalled together with the sum of all other loads, Not all connected loads need to be taken into account, It is sufficient to only consider the maximum number of loads that can be operated at the same time. Note Limitation of motor currents, Where motors are supplied by converters or similar solid-state switching devices, you should take the possible limitation of motor currents into account. Control Panels compliant with IEC Standards and European Directives Reference Manual, 10/2017, ASE38284819002ARS-ABIO02Electrical equipment 6.2 Incoming supply conductor termination and supply disconnecting device Example Breaking capacity of supply disconnecting device 2 current of largest motor when stalled + the sum of all other loads = 6 x 30A +20A + 15A=215A -------------1 30a 208 I l I,=15a, Figure 6-7 Example: Dimensioning of supply disconnecting device / main disconnect Note (Rated) breaking capactty + rated operational current The (rated) breaking capacity should not be confused with the rated operational current. With a circuit breaker, the (rated) breaking capacity is the maximum short-circuit current that can be disconnected. With a switch disconnector, a (rated) breaking capacity is also usually indicated on the data sheet, Control Panels compliant with IEC Standards and European Directives Reference Manual, 10/2017, ASE38284819002ARS-ABIO02 89Electrical equipment 6.2 Incoming supply conductor termination and supply disconnecting device Special requirements of plugs When a plug/socket combination is used as a supply disconnecting device, one of the following conditions shall be fulfilled: © It shall have an appropriate switching capability so that the plug can be removed from the socket under load. * It shall be interlocked with a switching device with an appropriate breaking capacity It shall have a breaking capacity sufficient to interrupt the current of the largest motor when stalled together with the sum of all other loads. The breaking capacity may be reduced by a rated diversity factor, if available. If the switching device is electrically actuated (e.g. a contactor), it shall have an appropriate Utilization category (Page 62). Where motors are supplied by converters or similar solid-state switching devices, the Possible limitation of motor currents should be taken into account. ‘Conditions for plug/socket combinattons; Plugisocket combinations shall also meet the following conditions: ‘* Plugisocket combinations shall be of such a design as to prevent unintentional contact, with live parts at any time, including during insertion or removal or the connectors. They shall have a degree of protection of at least IP2X or IPXXB. PELV circuits are excepted from this requirement ‘© Where socket combinations contain a contact for the protective bonding circuit, they shall have a first make last break protective bonding contact (grounding contact). ‘© Plugisocket combinations intended to be connected or disconnected during load conditions shall have sufficient load-breaking capacity. Where the plug/socket, combination is rated at 2 30 A, it shall be interlocked with a switching device so that the connection or disconnection is possible only when the switching device is in the OFF position, © Plug/socket combinations that are rated at > 16 A shall have a retaining means to prevent unintended or accidental disconnection. ‘© Where an unintended or accidental disconnection of plug/socket combinations can cause a hazardous situation, they shall be provided with a retaining means. ‘© Metallic housings of plug/socket combinations shall be connected to the protective bonding circuit © Plug/socket combinations that are not intended to be disconnected during load conditions shall have a retaining means to prevent unintended or accidental disconnection and shall be clearly marked that they are not intended to be disconnected under load. © Where more than one plug/socket combination is provided in the same electrical equipment, the associated combinations shall be clearly identifiable. It is recommend that mechanical coding be used to prevent incorrect insertion. Control Panels compliant with IEC Standards and European Directives 90 Reference Manual, 10/2017, ASE38284819002ARS-ABIO02Electrical equipment 6.2 Incoming supply conductor termination and supply disconnecting device * Plug/socket combinations used in control circuits shall fulfl the applicable requirements of IEC 61984. Exception: In plug/socket combinations in accordance with IEC 60309-1, only those contacts shall be used for control circuits which are intended for those purposes. This exception does not apply to control circuits using high-frequency signals superimposed on the power circuits. Note Exceptions to the requirements The requirements specified above do not apply to components or devices inside an enclosure, terminated by fixed plug/socket systems (no flexible cable), or components connected to a bus system by a plugisocket combination, Control Panels compliant with IEC Standards and European Directives Reference Manual, 10/2017, ASE38284819002ARS-ABIO02 1Electrical equipment 6.2 Incoming supply conductor termination and supply disconnecting device Operating means of the supply disconnecting device ‘The operating means of the supply disconnecting device shall be easily accessible and shall be external to the enclosure of the electrical equipment and located between 0.6 m and 1.9 m above the servicing level. Recommendation: An upper limit of 1.7 m. Exception: Circuit breakers with a motorized operating mechanism need not be provided with a handle outside the electrical equipment enclosure where other means (e.g. pushbuttons) are provided to open the supply disconnecting device outside the enclosure. on —— Ul oFF 60-190 em Figure 6-8 Installation height for operating means of the supply disconnecting device See also Types of grounding system (Page 47) Control Panels compliant with IEC Standards and European Directives 92 Reference Manual, 10/2017, ASE38284819002ARS-ABIO02