1. L1L2L3CB L1L2L3T1T2T3M1 H3 H2 4X1 X2MH1 H4H1 H48Command and SignallingL1 SmartWire-DTL2L3-Q11X11 3 5I I I2 4 61 3 52 4 6U V WPEU V W PEPEM3 ~-M1-Q11.13 1.211.14 1.22 4.434.44 4.134.144.434.44-Q1 -Q181.131.14-Q11X0 X1 X2 X3 X4A1A2+ I >24 V0 VDCwww.wiringmanual.comMoeller seriesWiring Manual | 2011AutomationMotor ApplicationsPower Management

2. All brand and product names are trade marksor registered trademarks of the owner concernedUpdated edition 2011, publication date 06/11 2008 by Eaton Industries GmbH, 53105 BonnEditorial: Walter Heumann, Thomas Kracht, Barbara Petrick,Heidrun Riege, Ren WiegandAll the connections are designed according to our best expertiseand have been carefully tested. They serve as practical examples.Eaton Industries GmbH does not accept any liability for any errors.All rights reserved, also for the translation.No part of this Wiring Manual may be reproduced in any form(printed, photocopy, microfilm or any other process) or processed,duplicated or distributed by means of electronic systems withoutthe written permission of Eaton Industries GmbH, Bonn, Germany.Subject to alteration.Printed on paper made from cellulose bleached without the use ofchlorine or acid. 3. Eaton Wiring Manual 06/110-100Eaton Wiring ManualChapterEaton Wiring Manual 0Switching, control, visualization 1Electronic motor starters and drives 2Pilot devices 3Cam switches 4Contactors and relays 5Motor-protective circuit-breakers 6Circuit-breakers 7All about Motors 8Export to World Markets and North America 9Standards, formulae, tables 10Index 11 4. Eaton Wiring Manual 06/11Eaton Wiring Manual0 0 Page0-2Moeller is Eaton 0-3Eaton Stromversorgungsqualitt 0-4Eaton Medium Voltage Systems 0-6What's new in this edition? 0-7Competence and Experience from a SingleSource 0-8Support Portal 0-10Eaton Online Catalog 0-11After Sales Service 0-12Photovoltaics in residential buildings 0-14Eaton power distribution equipment 0-22 5. Eaton Wiring Manual 06/110-3Eaton Wiring Manual00Moeller is EatonMoeller is EatonMoellers strengths remain and Eaton isbuilding on them.Now that the integration of Moeller in the globalEaton Corporation has been completed, its not justthe Moeller name that is being preserved. Our rangeof services also benefits from the alliance. The Moellername will continue to exist as a product series desig-nation.Recognizing the values transferred to Eaton,MoellerSeries appears on former Moeller products,while the packaging features the Eaton logo.With our constantly growing range of services, wehelp you to meet the increasing demands of the marketevery day. We develop standards and remain true toour core competencies. You are holding a good exampleof this in your hands right now. With the latest ver-sionof the switching manual, we are proud to againprovide you with a fit companion to your daily work. 6. Eaton Wiring Manual 06/11Eaton Wiring Manual0-40 0Eaton power supply qualityGet to know Eatons products forpower supply qualityEaton TechnologiesEaton has been developing innovativetechnical solutions for protecting powersupplies since 1962 (first patent applica-tion).With new, advanced and patentedtechnologies, Eaton responds to custo-mersrapidly changing requirements.Nine power supply problemsat a glanceHow a UPS is part of the solutionEaton UPS systems offer protectionagainst all nine typical power supplyproblems described below. They meetthe requirements for assured powersupply quality, energy distribution andpower management for computer net-worksand data centers as well as fortelecommunications, healthcare andindustrial applications.Eaton product overviewEatons product range for protectingpower supply quality comprises anextensive selection of power manage-mentsolutions from a single source. Itincludes UPS systems, surge protectionequipment, power distribution units(ePDUs), remote monitoring, testingdevices, interconnect materials,housings, cabinets and services. Ourportfolio for power supply quality isdesigned to customers specific require-ments;comprehensive solutions areoffered for both new systems as well asPower supply problem1 Power supply failure2 Voltage dip3 Voltage surges4 Undervoltage(voltage drop)5 Overvoltage6 Electrical disturbancesignals7 Frequency deviations8 Spikes due to switchingoperations9 Harmonic distortion(harmonic waves)existing ones. With all its products,Eaton strives for continuous success inadvancing technical innovation in order 7. Eaton Wiring Manual Eaton power supply qualityEaton Wiring Manual 06/110-500Definition Cause Solutionto develop next-generation solutions.The products and services listed belowrepresent examples from our extensivesolutions range. To view the entire rangeor request a product catalog, please visitwww.eaton.com/powerquality.Total failure of supplynetworkCan occur from a number of events: lightningstrike, breaking of transmission lines, networkcongestion, accidents and natural disastersTemporary under-voltageTriggered by major power consumers beingswitched on, switching in the supply network,failure of grid facilities, lightning strike and powersupply systems unable to meet requirements.In addition to possible device failure, hardware canalso be damaged.Temporary voltagesurge of more than110 percent of thenominal valueCan be caused by lightning strike and temporarilyincrease mains voltage to over 6,000 volts.A voltage peak almost always causes data lossesor hardware damage.Reduced mains voltagefor a period of betweena few minutes to afew daysCan occur if the mains voltage is intentionallyreduced to reduce power during peak consumptionperiods or if the connected consumer load exceedsthe supply capacity.Increased mainsvoltage for a period ofbetween a few minutesand a few daysTriggered by strong load reduction, major powerconsumers being switched off and other switchingoperations in the network. Hardware can bedestroyed as a result.Disturbance signalswith higherfrequenciesThese can be triggered by electromagneticinterference (EMI) or radio frequency interference(RFI) from welding equipment, transmittingequipment, printers, thunderstorms etc.Instability of mainsfrequencyThese occur as a result of load variations, in partic-ularin smaller generator installations. Frequencydeviations can cause processes to fail, data losses,system breakdowns and damage to equipment.Temporary voltagedipsSpikes of this kind last a very short time, within thenanosecond range.Distortion of sinusoi-dalwaveform, usuallycaused by non-linearloadsSwitching mode power supplies, stepper motors,copiers and fax machines are examples of non-linearconsumer loads. They can cause communicationerrors, overheating and hardware damage.Single-phase UPS series 3Single-phase UPS series 5Single-phase and three-phase UPS series 9 8. Eaton Wiring Manual 06/11Eaton Wiring Manual0-60 0Eaton Medium Voltage SystemsMedium voltage systemsThe quality of Eatons medium voltagesystems is founded on over 100 years ofexperience.Vacuum TechnologyVacuum technology is at the heart ofEatons switching systems. Eaton hasover 30 years of experience in applyingvacuum technology in circuit-breakersand load-break switches. The use of thistechnology results in a maximally environ-mentally-friendly switchgear solution.Primary switchgearAs its name says, primary switchgear isthe first stage in transmitting electricalcurrent from the supply network to theend customer. The importance of thestrategic position of the substation andits switchgear within the system re-flectsthe fact that layout, constructionand operation must be designed formaximum availability and reliability. Forthis reason, Eatons portfolio includesthe MMS a compact stationaryswitchgear unit with single or doublebusbar and PowerXpert UX, aswitchgear unit with removable circuit-breakers,switches and contactors.Secondary switchgearEaton has developed universal, modularsecondary switchgear under the SVSand Xiria product series. It is suitable foruse in supply networks, business prem-ises,infrastructure projects, industrialapplications and for structures relatingto renewables such as wind farms andcombined heat and power plants. Thedesign of the SVS and Xiria is based on acombination of vacuum and epoxy resintechnology. There are a multitude ofdifferent types of switchgear suitablefor every kind of application. With itscompact dimensions and SF6 -free de-sign,SVS and Xiria are also the idealsolution for underground applications oninfrastructure projects.Ring main unitsElectrical energy has become an indis-pensableelement of modern society.A reliable and constant energy supply isincreasing in importance every day. Fromthe standpoint of energy companies andthe industry, this means that the powerdistribution network must cope withever increasing demand. It goes withoutsaying that safety and operationalreliability play a significant role.www.eaton.comwww.eaton.com/electrical 9. Eaton Wiring Manual 06/110-7Eaton Wiring Manual00What's new in this edition?Export to the world market and to North AmericaThe target markets of machine and systembuilders are international. Eaton knowsthese markets and is a competent partnerworldwide in all issues relating to theexport of switchgear and switchgearsystems. The special requirements on theexport of products to North America (USAand Canada) are taking on increasingimportance, see chapter 9.Photovoltaics in residential buildingsThe use of regenerative energy isbecoming increasingly important. Eaton isa competent PV supplier and thispublication describes the technicalbackground information and range ofcomponents required, seepage 0-14.The way to a safe machineeasySafety Fulfills the highest safetydemands.The safety of people and machines must betaken into account for the total lifecycle ofa machine/system. For personnelprotection safety components such asposition switches, light curtains, two-handcontrol switches or emergency switchingoff pushbuttons come into use. The safetyinformation is monitored and evaluated bythe new easySafety control relay whichcomplies with the highest safetyrequirements,Section The way to thesafe machine, page 1-29.Always up-to-dateWe make every effort to adapt and updateevery new edition of the Wiring Manualaccording to the ever increasingrequirements of the markets.The many example circuits in particular arecontinually being updated by ourspecialists to the best of their knowledgeand carefully tested. They serve aspractical examples. Eaton IndustriesGmbHdoes not accept any liability for any errors. 10. Eaton Wiring Manual 06/11Eaton Wiring ManualEdition 1958 Edition 19860-80 0Competence and Experience from a Single Sourcewww.wiringmanual.comThe Wiring Manual has been classic forover 50 years and is probably the mostpopular publication of the company.Worldwide distribution has given it newimpetus in recent years. The 2005 editionwas translated for the first time into ninelanguages: English, French, Italian, Spanish, Dutch, Russian, Czech, Romanian, SwedishIts contents are also available online atwww.wiringmanual.com.The online version combines the provenexpertise with the latest Internettechnology. For example, full text searchesare also possible.A special page with links to all the differentlanguage versions available is provided asa service to users from all over the world.www.eaton.com/moeller/support(Wiring Manual) 11. Eaton Wiring Manual 06/11Eaton Wiring Manual Competence and Experience from a Single Sourcewww.Eaton.com the Products of the Moeller series 000-9Eaton offers you a range of products andservices that can be optimally combinedwith one another. Visit our website on theInternet. You will find there everythingabout Eaton, such as: Up-to-date information about Eatonproducts, The addresses of the Eaton sales officesand representatives worldwide, Information about the Europeanactivities of Eaton, Publications in the press, specialistpress, References, Exhibition dates and events, Technical support in the Eaton SupportPortal.www.eaton.com/moeller/support The Support PortalYou can receive technical support for allEaton products just by a mouse click. Andtips und tricks, Frequently Asked Questions(FAQs), updates, software modules, PDFdownloads, demo programs and muchmore.You can also put your name down toreceive the Eaton Newsletters.Uncomplicated and quick way of findingthe information you need: PDF downloads, Internet-supportedbrowser catalogs, smartphone apps Catalogs Manuals and instructional leaflets Product information, such asbrochures, selection aids, technicalessays, declarations of conformity andof course Eaton Wiring Manual Software Downloads Demo versions Updates Software modules and user modules Selection aids Motor startersSection Selectionaids, page 8-3 12. Eaton Wiring Manual 06/11Eaton Wiring Manual0-100 0Support PortalYou can also find a link to the Eaton AfterSales Service via the Support Portal(Section After Sales Service,page 0-12).You can send your queries directly to theTechnical Support/pre-sales service bye-mail. Simply select the e-mail form thatmeets your requirements to the Eatonexperts. 13. Eaton Wiring Manual 06/110-11Eaton Wiring Manual00Eaton Online CatalogThe efficient way to detailed product informationFrom detailed product information right upto the enquiry for your products by email orfax from your Eaton product supplier. Allthis and more you can find in the EatonOnline Catalog.This gives you fast access to newinnovations as well as extensiveinformation on the current Eaton ranges. Industrial switchgear, Drives, Automation systems, drives, Power distribution systems.Create a comprehensive data sheet for aproduct and save it as a PDF document orprint it out.The Search tools Several search options are available toenable the right access for any productsearch. The product group tree structure enablessimple searching in just a few clicks ofthe mouse Selection tools provide logical filters inproduct groups containing severalproducts A powerful search function with aproposal list ensures above-averagesearch resultsA number of links to additional productinformation and all aspects of it enable youto ensure optimum use of the product: Application examples and project designnotes, Approvals Instructional leaflets, Manuals, Software etc.Choose Your Online Catalog on theInternet.http://ecat.moeller.net/?locale=en_ENThe Online Catalog on the Internet isupdated regularly. 14. Eaton Wiring Manual 06/11Eaton Wiring Manual0-120 0After Sales ServiceAs close as you wishService Specialists Gain the benefit of our Service personnel.Comprehensive expertise linked with longterm experience and modern equipmenthelp you find the solution to your tasks.Material characteristic Components, cards and spare parts of ourproduct range are available for your use.Logistics Personnel and material are furnishedaccording to your requirements,professionally and on time.HelplineHotline You will receive competent and quicktelephone assistance round the clock inthe event of unscheduled machine stopsand plant down-times, system faults anddevice break-downs.Help desk During business hours, you will receivesupport for commissioning, applicationqueries right through to fault analysis,which can also be carried out using remotediagnostics.Specialists are available in the areas ofautomation, drives, low-voltage powerdistribution or switchgear.Onsite ServiceTroubleshooting onsite Qualified technicians and specialists canvisit you in order to rectify faults quicklyand reliably.Mounting and commissioning support Contact us if you require fast andcompetent support in installing andcommissioning tasks.Conversions and expansions Whether with controllers, circuit-breakersor other components, we can bring yourmachines and plants up to the lateststate-of-the-art.Inspection and maintenance The legal requirements and regulationsdemand the regular testing of electricalequipment in order to ensure its propercondition. Further information is availablefrom our website.www.eaton.com/moeller/aftersalesThe After Sales Service therefore offersappropriate services for circuit-breakersand low-voltage distribution boards.We support you in the inspection andmaintenance of the circuit-breakers andlow-voltage distribution boards supplied byus, determine the condition of yoursystems and carry out the necessary work.If required, thermography or networkanalysis are also carried out with this work. 15. Eaton Wiring Manual After Sales ServiceEaton Wiring Manual 06/11Service seminars 00 Tailored service seminars that meet yourindividual requirements to train up yourpersonnel.Thermography Thermography gives us an efficient way ofanalysing your electrical systems andcontrols during operation.Network analysis Network analysis provides clearinformation about the specific state of yournetworks without the need for lengthy andexpensive fault retrieval.Bus monitoring Please enquire whether we can inspectthe communication networks of yoursystems with the latest technicalequipment.RepairsDirect exchange In the event of a fault, the direct exchangeservice for selective productsconsiderably reduces the downtime ofyour production plant.Repairs The repair of products in our ServiceCenter is an inexpensive alternative forfault rectification.Share parts/Replacement devices We reduce maintenance costs withselected spare parts and devices forcurrent/discontinued product lines.Online ServiceOnline troubleshooting We can provide special assistance if youwish to analyse and rectify faults onproducts. You can carry out interactivetroubleshooting via the Internet with directaccess to our Service-database.FAQ - Frequently Asked Questions There are some questions about ourproducts that our customers very oftenask. You can benefit from the answers. Youcan read the FAQ with the correspondinganswers on all aspects of automation.Downloads You're at the right place here if you requireupdates, software, documentation anddeclarations of conformity. Visit the EatonDownload Center to obtain all theinformation you require.ContactHotline for faults In the event of a fault contact your localrepresentativewww.eaton.com/moeller/aftersalesor the After Sales Service directly+49 (0) 180 522 3822, 24/7 (round the clock)Help desk Tel.: +49 (0) 228 602 3640(Mon. Fri. 08:00 16:00 CET).email AfterSalesEGBonn@eaton.comInternet www.eaton.com/moeller/aftersales0-13 16. Eaton Wiring Manual 06/11Eaton Wiring Manual0-140 0Photovoltaics in residential buildingsUsing solar energy safely Solutions from EatonSafe photovoltaic systemsPhotovoltaic systems use solar cells toconvert solar energy into electrical energy.If the system is connected to the grid, thegenerated electricity is fed directly into it.Unlike grid independent systems thecomplicated temporary storage ofelectricity is not required, however, thegenerated DC current has to be convertedto AC.Apart fromthe PV panels, a grid-connectedsystem consists of one or several invertersand switching devices, for operation,maintenance and protection in the event ofa fault such as: a DC string protective device, DC switch-disconnector DC surge protection PV inverter Residual current device (RCD), AC surge protection and xComfort system (optional).The PV panels are connected in series (asa string) in order to provide the requiredinput DC voltage for the inverter.Two or several strings are connected inparallel to increase the power of thesystem. For safety reasons, all electricalequipment must be isolated, protected andsecured with switching devices whichmust likewise be protected withenclosures. All these important protectivedevices can be sourced directly fromEaton.Safe isolation, switching and protecting. In order to feed the generated electricityinto the public grid or even to use it,inverters are required to convert the DCcurrent of the solar cells in the AC current.The frequency and voltage values areadjusted to the grid parameters at hand.Also here, Eaton offers reliable protectiveand grid isolation devices such as invertersfrom 1500 to 4000Wfor indoor use and from4000 to 4600Wfor outdoor applications.DC stringprotective deviceDC fuse switchdisconnectorDC switchdisconnectorDC surgeprotectionPV inverterResidual currentdeviceMeter readingPV incomer panel 17. Eaton Wiring Manual 06/11Eaton Wiring Manual Photovoltaics in residential buildingsConverting solar energy efficiently 000-15Grid-connected power inverters from 1500to 4600 W Each photovoltaic installation is asindividual as the requirements of its user.Eaton therefore offers a complete line ofsingle-phase power inverters from 1500 to4600 W: Suitable for moncrystalline andpolycrystalline PV generators. Maintenance free, highly reliable andvery easy to install. Integrated LCD display simplifiesoperation. Optimum efficiency with maximumpower point tracking (MPPT). Fan-free thanks to natural convectioncooling. High performance compared to size. Particularly quiet and low pollutionoperation. Standard RS232 ENS interface inaccordance with VDE0126-1-1/DK5940. Compact elegant modern design.Indoor use The ISG series with degree of protectionIP43 is designed for indoor installation.Outdoor use The ISG series with degree of protectionIP65 is designed for both indoor andoutdoor applications.Specifications All power inverters are designed forambient temperatures from -20 to +55 C.Optimum operation is achieved at ambientair temperatures between 0 and +40 C.The power of the sun used optimally The total output of a photovoltaic systemnot only depends on the total area of the PVpanels, their alignment and the inclinationangle of the modules.Components such as inverters play animportant part in the efficiency of thesystem. Eaton inverters ensure you havethe maximum output.Requirements, the DC isolation gapDC switch-disconnector The IEC 60364-7-712 standard stipulatesthe installation of a switch-disconnectorbetween the PV generator and the inverter.Eaton offers enclosed and openswitch-disconnectors for DC voltages up to1000V. In accordance with the regulationsof VDI 6012 they can be used as separateswitching points, so that a faulty invertercan be completely de-energized safely. Allswitch-disconnectors switch two polesand are therefore also suitable forungrounded systems. All switches are TVcertified. 18. Eaton Wiring Manual 06/11Eaton Wiring Manual Photovoltaics in residential buildings0-160 0Compact disconnectors for inverters Eaton offers both enclosed and openswitch-disconnectors in its range. Theopen P-SOL switch disconnectors aredesigned for mounting in customizedenclosures or inverters. They are mountedon 35-mm top-hat rails, and their terminalsenable a connection to all commonly usedcable types.Perfectly enclosed for outdoor installation Eaton's enclosed SOLswitch-disconnectors are ready to fit andare therefore very easy to install. Variantsfor 2, 3, 4 or 8 strings are available for themost common connector types such asMC4 or metric glands. The enclosure isprotected to IP65 and is suitable foroutdoor installation. The lockablemechanism ensures safety duringmaintenance work. A pressure-equalizingelement prevents the formation ofcondensation, preventing malfunctionscaused by flashovers.Fireman's switch small investment,massive protectionIn the event of a house fire, the fire brigadecan often only rescue persons or animalsor prevent the fire spreading toneighboring buildings. This is due to thevoltage of up to 1000 V generated by PVsystems, which is still present after theinverter has been isolated. Rescueservices are thus exposed to fatal riskswhen entering the building due to thepossibility of damaged DC cables. Eaton'sSOL30-SAFETY fireman's switch provides asolution here, and de-energizes the linefrom the solar modules to the inverter, thismaking safe any fire fighting activities.Although VDE 0100-7-712 stipulates the useof a DC isolator, it does not stipulate thelocation. The isolator is frequentlyintegrated in the inverter so that the cablebetween this and the house terminal issafe, whilst a DC voltage of up to 1000V isstill present in the solar modules and DCcables up to that point, with up to ~8A foreach string. 19. Eaton Wiring Manual 06/11Eaton Wiring Manual Photovoltaics in residential buildings0-1700Simple installation Fireman's switches are installed in directproximity to the PV modules and inserted inthe DC cable directly after the entry pointinto the building between the panels andthe power inverter. The PV modules aredisconnected automatically usingundervoltage releases in the fireman'sswitch, when the AC voltage of the buildingis isolated either by the fire brigade or thelocal utility company or on site via a PV-OFFswitch.DC-string protectionIf a PV installation has three or morestrings, a string protection device using DCfuses or DC string circuit-breakers isrecommended. These protect the PVpanels from leakage and feedbackcurrents that can occur on faulty strings,and prevent the feedback of good panels topanels with short-circuits. Compared tofuses, string circuit-breakers have theadvantage that they are immediatelyoperational again after the fault is rectifiedas well as having the ability to send tripindications via auxiliary contacts to thusavoid any losses in yield. A further featureof the DC string circuit-breaker is thevariable tripping range for short-circuitcurrents: it reacts already from 1.051.3times the residual current. Eaton offersboth fuse switch-disconnectors as well asstring circuit-breakers that can becombined easily with other components asrequired.Fuse switch-disconnectors withintegrated short-circuit protective device The task of the FCFDC10DISOL fuseswitch-disconnector for the ASFLC10-SOLcylindrical fuse cartridges for fuse sizes 10x 38 is to protect PV panels fromshort-circuit currents. A flash function canoptionally be used to indicate a blown fuse.String circuit-breakers The Eaton PKZ-SOL string circuit-breakersare the fuseless alternative for protectionagainst short-circuit currents. Its variabletripping range enables optional settings tothe actual short-circuit current of a string.A thermal release responds already at 1.05... 1.3 times the current, whilst the magneticrelease responds at 6 times the current.Non-enclosed string circuit-breakers aredesigned for installation in customizedgenerator terminal boxes. 20. Eaton Wiring Manual 06/11Eaton Wiring Manual Photovoltaics in residential buildings0 0 DC surge protectionSurge protective devices for PVapplications The Eaton SPPT2PA surge arrester isspecially developed for photovoltaicapplications and offers protection fromtransient overvoltages that can occurthrough the indirect effect of lightning.Eaton offers types for both grounded andnon-grounded systems in which the use ofa spark gap ensures galvanic isolation. Theunits can be supplied pre-wired as ready touse connection units.Increasing building safety and comfortAC switching devices for buildings, such asminiature circuit-breakers and residualcurrent devices offer maximum safety.Eaton products of the xPole series combineall functional, mounting and safetybenefits: intelligent design solutionsexclude the possibility of mounting faults.They even offer optimum safety for the enduser:Personnel protection in the form of residualcurrent devices and protection of theelectrical installation in the form ofovervoltage protection and MCBs. Theportfolio is rounded off with an extensiverange of intelligent switching devices suchas remote switches, restart devices andothers.0-18Digital residual current device FI With the development of digital technologya new level of precision was achieved thatenables the avoidance of nuisancetripping. This can occur for example withpermanent residual currents of electricaldevices or temporary faults caused bystorms. Here too, Eaton is also one stepahead:Eaton is the first company worldwide tooffer a digital residual current device. Thecontinuous status monitoring of theinstallation allows unwanted and annoyingdisconnections to be considerablyreduced, thus guaranteeing optimumsystem availability. Three LEDs use the"traffic light" principle to indicate when adifferential current has reached the 30%warning threshold. In this way,countermeasures can be taken in theinstallation before the situation getsworse.The installation user is thus provided withincreased safety with greaterconvenience.Combination switch The benefits of MCBs and RCDs combinedin a single device this is the Eatoncombination switch. It saves space, whilstensuring complete safety: reliable fire andpersonnel protection (30 mA) with enoughspace for flexible generous cabling.The surge current proof design preventsunwanted disconnection and selectivetypes enable the selective disconnectionof faulty system sections. 21. Eaton Wiring Manual 06/11Eaton Wiring Manual Photovoltaics in residential buildingsMiniature circuit-breakers Regardless of whether plug terminalWireless monitoring of PV installation00 connections or screw terminals areand simple energy managementrequired, Eaton has the right MCB forEnergy measuring sensor up to 16 A andresidential buildings and for industrialRoom Manager applications. Extensive accessories suchConvenient monitoring of electricityas auxiliary contacts, shunt releases,generation from your living room modernrestart devices and intelligent busbarhome automation makes this possible.solutions enable a host of applications andWith xComfort, Eaton is offering the Roomautomation solutions.Manager with integrated energymanagement software (Energy Manager)Distribution systems for a powerful solution.From the compact distribution board to theThe connection of the Eaton energy sensormeter cabinet and the data networkwith the inverter enables the electricalcabinet, Eaton offers a complete productenergy currently fed into the grid to beportfolio. All applications can thus bemeasured.covered for the infrastructure in residentialand non-residential buildings as well as inThis data is then transferred wirelessly tothe industrial sector.the Room-Manager which is installed inone of the living areas. Here, the user of theSurge protection system can view values such as energyLightning strikes and overvoltages not only(kWh), power (kW), voltage (V) and ampspose a risk for electrical installations but(A) on a display.also for their operators. Eaton offers anextensive range of surge protectivedevices. Attachable auxiliary contacts alsoenable the monitoring of device functions.0-19 22. Eaton Wiring Manual 06/11Eaton Wiring Manual Photovoltaics in residential buildings0-200 0 23. Eaton Wiring Manual 06/11Eaton Wiring Manual Photovoltaics in residential buildings0-2100Comfort, safety and energy management Wireless home automation enableslighting management, shade control,monitoring and danger warnings, as wellas energy saving control concepts forheating, cooling and ventilation.Eaton's xComfort and Energy Managerthus offer transparency, comfort andsafety combined: Consumption control Cost saving Reduction of CO2 emissionEU regulations stipulate that the actualenergy consumption must be clearly visibleto end consumers. The Eaton RoomManager covers this requirement bydisplaying and controlling the energyconsumption of specific electrical or gasdevices in the entire home.Entering the price per unit of measuremakes it is possible to calculate the costsfor a consumption cycle quickly andsimply, for example for a bath or a washingmachine cycle.More consumption and cost control isoffered by a function that reads the historyof the previous 24 hours right through to thelast 12 months from the archive and showsit as a value or a trend on the display. It isalso possible to output a warning messageas soon as a user-defined limit value isexceeded. All this makes Eaton's energymanagement software a useful tool foridentifying possible savings and reducingelectricity costs for private system users. 24. Eaton Wiring Manual 06/11Eaton Wiring Manual0-220 0Eaton power distribution equipmentxEnergy Safe energy distribution up to 5000 AThe modular system consists of perfectlyfitting function modules that are typetested to IEC/EN 61439 with Form 1 to Form4 internal partitioning, and which takeEuropean and local (DIN, VDE, CEI, NF,UNE) installation practice into account.xEnergy provides the panel builder with aflexibly combinable product range forpower distribution systems up to 5000 A.The operation of the system couldn't besimpler, despite its complexity. Themodular design enables the creation ofintelligent combinations.Switching and protective devices, as wellas the associated mounting technologyand extensive housing components areperfectly matched and form both atechnical as well as an economic unit.This practically oriented system platformenables individual project design,maximum flexibility and fast production inthe workshop. On the one hand, this savestime, money and space, whilst type testedmounting units offer a higher level ofsafety. The modular system canfurthermore be extended with little effort tomeet future requirements. 25. Eaton Wiring Manual Eaton power distribution equipmentEaton Wiring Manual 06/1100 The panel builder is provided with efficient0-23tools for tasks ranging from planning toquotations, right through to ordering. Theentire range is supplied in functional flatpacks or as pre-assembled switchcabinets.System features: Rated operational voltage 400 to 690 V AC Rated operational current 630 to 5000 A Rated short-time withstand current to100kA (1 s) Main busbar current to 5000 A Dropper bar current up to 2000 A Sheet steel housing for combination andseparate mounting Degree of protection to IP31 and IP55 Colour RAL 7035 Internal separation up to Form 4 Dimensions: Height 2000 mmWidth 425, 600, 800, 850, 1000, 1100, 1200,1350 mmDepth 400, 600, 800, 1000 mmAvailable technologies Fixed mountingRemovable compartmentsWithdrawable compartmentsxEnergy XP (Power) Incoming units/feeder units, outgoersand couplings with NZM or IZMcircuit-breakers up to 5000 A Circuit-breakers in fixed mounting orwithdrawable units 3 or 4 pole circuit-breakers Internal separation up to Form 4 Cable connection from top or bottom Incomer system for drill-free cableconnection 26. Eaton Wiring Manual Eaton power distribution equipmentEaton Wiring Manual 06/110 0 xEnergy XF (Fixed) compartment design Outgoers with PKZ or NZM0-24circuit-breakers up to 630 A Circuit-breakers in fixed mounting orwithdrawable units 3- or 4-pole circuit-breakers Outgoers with SL fuse-strip units up to630 A Individual outgoers, e.g. controllers,motor starters, small energy outgoers, Internal separation up to Form 3 or Form 4 Cable connection from top or bottomxEnergy XR (Removable) removablecompartment design Outgoers with PKZ and NZMcircuit-breakers up to 630 A Outgoers with strip-type switch-fuseunits up to 630 A Flexible surface mounting using plug-incontacts Plug-in modules and switch-fuse unitsexchangeable under conditions Straightforward maintenance, minimaldowntime Internal separation up to Form 4 Cable connection from top or bottom 27. Eaton Wiring Manual Eaton power distribution equipmentEaton Wiring Manual 06/11xEnergy XW (Withdrawable) 00withdrawable compartment design Outgoers with PKZ and NZMcircuit-breakers up to 630 A Outgoers for motor starters up to 250 kW Empty drawer-units for every application Uniform, straightforward operation for alldrawer-unit sizes No special tool required Flexible assembly with plug-in contacts(incoming and outgoing) Withdrawable modules exchangeablewhilst live Unambiguous position indication forOperation, Test, De-energized Straightforward maintenance, minimaldowntime Internal separation up to Form 4 Cable connection from top or bottomxEnergy XG (General) empty sections Power factor correction Mounting system for subdistributionsystem with modular installation devices Control technology with Sasy60i andxStart Individual fixed mounted components onmounting plate0-25 28. Eaton Wiring Manual Eaton power distribution equipmentEaton Wiring Manual 06/110 0 xVtl add-on boardThe xVtl side-by-side distribution system isdesigned to take switchgear forapplications up to 2500 A.0-26Typical uses are as power distributionsystems in utility buildings or as controlpanel enclosures in industry. This is wherethe xVtl can demonstrate the benefits of itsrugged design.The xVtl is a stable, side-by-sidemountabledistributor made of sheet steel that is alsobest suited for stand-alone installation. Itprotects persons from coming into directcontact with conducting parts and evenfrom possible electric shock, and reliablyfends off damaging exterior influences. Itcarries out these functions according tothe specific requirements, with protectiondegrees of IP40 or IP55.While the former issuited to diverse uses in functionalbuildings such as schools or hospitals, it isalso recommended for harsher conditionssuch as wind energy systems, or inindustry, in a foam-type polyurethanesealing design. Abrasion-proof protectionagainst corrosion is guaranteed thanks tostructured paint finish using a powdercoating RAL 7035.Overall, the technical design of the xVtlLcomplies with the IEC/EN 62208 andEN 60529 standards, as well as with 29. Eaton Wiring Manual Eaton power distribution equipmentEaton Wiring Manual 06/1100 IEC 60439-1, as long as it is used as a0-27low-voltage energy distribution system.System features: Common platform with xEnergy: Severaldesign elements such as mountingframes, bottom and top plates, as well asside and rear panels can be used for bothxVtl and xEnergy. Installationmounting systems : Profi+, EPand IVS Rated operational voltage 415 V AC Rated operational current to 2500 A Rated short-time withstand current to65 kA (1 s) Sheet steel housing for combination andseparate mounting Degree of protection to IP40 and IP55 Colour RAL 7035 Internal separation up to Form 2 Dimensions:Height 1400, 1600, 1800, 2000 mmWidth 425, 600, 800, 850, 1000, 1100, 1200,1350 mmDepth 400, 600, 800 mmxVtl low-voltage energy distributionsystem Incoming units /feeder units, outgoersand couplings with NZM and IZMcircuit-breakers up to 2500 A Outgoers with SL fuse-strip units up to630 A Internal separation up to Form 2 Circuit-breakers in fixed mounting orwithdrawable units 3- or 4-pole circuit-breakers Cable connection from top or bottom Incomer system for drill-free cableconnection Outgoers with NZM circuit-breakers Compensation sections Individual fixed mounted components onmounting plate 30. Eaton Wiring Manual Eaton power distribution equipmentEaton Wiring Manual 06/110 0 xVtl subdistribution system Installation mounting systems Profi+, EP0-28and IVS Mounting modules for for NZM NH switch-disconnectors Low-voltage h.b.c. fuse switchdisconnectors Busbar mounting fuses Modular installation devices Individual devicesxVtl control centres Control technology with Sasy60i andxStart Individual fixed mounted components onmounting plate Air conditioning and ventilation Automation engineering 31. Eaton Wiring Manual Eaton power distribution equipmentEaton Wiring Manual 06/11Modular switchgear systems MODAN 00The MODAN is a type-tested modularpower distribution system in compliancewith IEC/EN 61439-1. It is used whereverlarge amounts of energy have to bedistributed safely and reliably or wheremotor controllers have to be integrated intoprocesses.MODAN combines the greatest possibleflexibility with safety and reliability, as wellas profitability for the long term.Straightforward engineering, effectivecommissioning and fault-free operation bythe modular construction using Eatonproducts for switching, protection, controland visualization.Full and comprehensive integration of theprimary control is implemented on the basisof networked functional groups.For personnel and system protection, thearc fault protection systemARCONcan beintegrated without problems.MODAN P Power Operating voltage 400 to 690 V AC Rated operational current 630 to 6300 A Short-circuit strength to 100 kA (1 s) Connection from top and bottom forcables and busbars (LX, LD, BD) Internal partitioning up to Form 4b0-29 32. Eaton Wiring Manual Eaton power distribution equipmentEaton Wiring Manual 06/110 0 MODAN R Removable Section for up to 15 removable0-30compartments for power outgoers andmotor starters or Section for up to 27 fuse combinationunits Flexible surface mounting using plug-incontacts Plug-in modules exchangeable whilstlive Straightforward maintenance andreduced downtimeRemovable compartments Power outgoers up to 630 A Motor starters up to 90 kW Module is for plugging in, i. e. theincoming unit is removable 33. Eaton Wiring Manual Eaton power distribution equipmentEaton Wiring Manual 06/11MODAN W Withdrawable 00 Section for up to 30 drawer units forpower outgoers and motor starters High packing density Uniform, straightforward operation for alldrawer-unit sizes No special tool required Withdrawable modules exchangeablewhilst live Straightforward maintenance andminimal downtime Internal partitioning up to Form 4bMODAN for withdrawable units Power outgoers up to 630 A Motor starters up to 200 kW Drawer-unit is withdrawable, i. e. allelectrical connections are plugconnections Exchangeable whilst live All drawer units positions lockable Unambiguous and clearly visibleindication for all possible drawer unitpositions (Operation, Test, De-energized)0-31 34. Eaton Wiring Manual Eaton power distribution equipmentEaton Wiring Manual 06/110 0 ARCON arc fault protective systemMaximum personnel and system safety,especially during continuous productionprocesses, made possible using theARCON arc-fault protection system. Thesystemoffers protection from 6 to 100 kArmsarc fault current.Detection of the arc faults is by light andcurrent sensors. The evaluation unitARC-EL3ARC-EM IZMARC-ATc d e a0-32responds when light and current signalsare present. A tripping signal is applied tothe quenching device and to the feedercircuit-breakers. The fault arc is quenchedin less than 2 ms. The system can be putback into operation as soon as the fault iseliminated and the quenching device isrenewed.ba Current transformerb ARC-SL... linear light sensorc Electronic evaluation unit (slave)ARC-EL3d Electronic evaluation unit (master)ARC-EMe ARC-AT quenching device ARCON Quenching device 35. Eaton Wiring Manual Eaton power distribution equipmentEaton Wiring Manual 06/11Sheet steel wall-mounting enclosure CS with mounting plate 000-33The robust CS enclosure series with solidsheet steel is used wherever a particularlyeffective protection against direct contactwith live parts or the protection of allinstalled equipment from harmful externalinfluences is required. Thanks to its highdegree of protection to IP 66 (UL/CSATypes 1, 12) with a continuous foampolyurethane gasket, water, oil or dirt isprevented from penetrating inside theenclosure. This makes the CS enclosureparticularly suitable for subdistributionboards in control panels in industrial andutility buildings, as well as for machinebuilding applications.The stable sheet steel enclosure meets therequirements of impact resistancecategory IK09 to EN 62262. Impact resistantmetal locks provide additional safety. Thehinge pins with quick change technologyenable the door hinge to be replacedquickly since each metal pin can beremoved without any tools. Wall fixingbrackets enable the switch cabinet to bemounted on a wall.The PHZ-A comfort rotary handle withlocked position indication clearly shows onthe outside whether the cylinder is in theopened or closed position. The comfortrotary handle can be retrofitted quickly,without the need to remove the standardlock - thus eliminating the need for the useof rotary levers.The galvanized sheet steel mounting platewith a maximum thickness of 3mmensuresthe safe installation of the switchgear andbasic EMC protection.The CS enclosure can be turned through180, so that the cables can be fed in eithervia the top or bottom. The large flange plateopenings allow the fitter more flexiblehandling. 36. Eaton Wiring Manual Eaton power distribution equipmentEaton Wiring Manual 06/110 0 The foam gasket of the flange plate savesusers the time required for gluing in foamrubber seals. Both flange and mountingplates are incorporated in the groundingconcept, thus eliminating the need for anadditional protective ground connection.0-34Their powder coated surface provides anabrasion and corrosion resistantprotection. As a special service, Eaton alsooffers individual solutions tailored tocustomer specifications.Compact distribution board for flush mounting and surface mountingKLV-U flush mounted compact distributionboardThe plastic enclosure suitable for cavitywalls offers an outstanding level of stabilitywhilst the flat design of the sheet steel doormakes it inconspicuous in any room. Anadjustment tolerance of up to 18 mm forcompensating any unevenness in wallsand plaster significantly simplifies flushmounting in wall openings.The zero and protective ground terminalsare already prefitted. The KVL-Udistribution board enclosure withprotection class II and degree of protectionIP30 are available in 1 to 4-row versionseach with 12 + 2 module widths.The following door variants are available:Sheet steel door flat and super flat, plasticdesign door white and transparent.BC-A surface mounted compactdistribution boardWherever it is not possible to install incavity walls, the rugged BC-A surfacemounted compact distribution boardprotects the inside from mechanicaldamage and harmful environmentalinfluences. In addition to degree ofprotection IP30, the unit meets therequirements of protection class II whenused in conjunction with the back plate andthe cover plate.In spite of its compact dimensions, up to 4rows of 13 space units are available foreach distribution board enclosure. TheBC-A surface mounted compactdistribution board comes standard withwhite and transparent doors. 37. Eaton Wiring Manual Eaton power distribution equipmentEaton Wiring Manual 06/11IVS service distribution system The IVS service distribution board up to 00630 A is primarily used for the safe andeconomical power supply in industrial,building and commercial applications.The range therefore includes wall andstandard enclosures, each with protectionto IP30 and IP54.The mounting space with an even divisioninto standard 250 x 375 mm sectionsensures a particularly clear design.Planning, ordering and mounting are thussimplified accordingly. The link between the enclosure and themounting units is the mounting systemwith insulated support brackets. Themounting system can be lifted out of theenclosure after the plates have beenremoved and the screws released. A number of mounting units that aretailored to original Eaton switching andprotective devices allow for time savingand simple mounting. Insulated covers are used for protectingthe mounting units from direct contact.Applicable standard for manufacturing isIEC EN 60439-1 "Type-tested low-voltageswitchgear assemblies.0-35 38. Eaton Wiring Manual Eaton power distribution equipmentEaton Wiring Manual 06/110 0 K terminalThe connection terminal consists of acombination of several very stable terminalblocks. It is used for connecting two orseveral conductors.A very wide range is available as standardwith 6 sizes and terminal capacities from16to 3 x 240 mm (160 to 1000 A).0-36Copper conductors can be inserted quicklyinto the box terminals from above withoutbending.The Eaton terminals are designed forcopper strips or busbars as well as copperconductors. Each terminal pair is mouldedin a plastic Duroplast shell. Each of the 6sizes is available from stock as a 1-pole,3-pole, 4-pole or 5-pole terminalcombination.Accessories such as the transparentplastic cover, auxiliary conductorterminals or conversion kits also enablethe creation of your own terminal variants. 39. Eaton Wiring Manual Eaton power distribution equipmentEaton Wiring Manual 06/11CI insulated distribution boards, totally insulated 000-37The assembly of the CI systemdemonstrates its flexibility. Whether as anindividual enclosure, wall-mounted or floorstanding distribution board of any size, themodular CI insulated distribution board upto 1600 A always offers the right solution inharsh ambient conditions.The modular system makes it easy to adaptto a wide range of conditions. IP65 protection ensures protection fromdust, humidity and water jets, Pressure relief by means of liftablecovers with spring-loaded enclosurebolts, "Total insulation" provides maximumpersonnel protection and operationalsafety. Transparent neutral cover allowsunrestricted view, Lock mechanism actuated with cylinderlock or tool, Floor standing distribution boards withbase covers for routing, fixing orcovering large cable cross-sections.Enclosed distribution boards aretype-tested switchgear assemblies (TTA)in accordance with VDE 0660 part 500 orType Tested Assemblies (TTA) to IEC 60439. 40. Eaton Wiring Manual Eaton power distribution equipmentEaton Wiring Manual 06/110 0 SASY60i busbar system for the worldmarketThe SASY60i modular busbar system fromEaton is designed for effective powerdistribution in the control panel.Thanks to the innovative mountingtechnology feeder and outgoingcircuit-breakers can be mounted quicklyand compactly. SASY60i is safe andreliable.In conjunction with the latest generation ofEaton motor protective circuit-breakersand other circuit-breakers, the SASY 60iprovides a universal, UL certified solutionfor switching, controlling, protecting anddistributing energy. Together with theappropriate switching and protectivedevices, the busbar system is designed forworldwide use.0-38The larger clearances and creepagedistances required in compliance with theUL 508A in America have been consideredin the construction of the busbarcomponents.When used in North America, the insulatedbottom plate must be mounted under thesystem. Components approved for IECsuch as NH fuse switch-disconnectors orD busbar mounting fuses can also suitablefor perfectly matched fitting.As SASY60i requires few systemcomponents the new Eaton busbar systemalso reduces the stock-keeping andordering required.These benefits naturally also apply toEaton's SASY185i and SASY Compactbusbar systems. 41. Eaton Wiring Manual 06/111-111Switching, control, visualizationPageSmartWire-DT communication system 1-2The way to the safe machine 1-29Timing relays 1-36EMR measuring and monitoring relays 1-40System overview Relay, MFD-Titan 1-43Engineering Relay, MFD-Titan 1-50Programming Relay, MFD-Titan 1-77HMI-PLC - Systematic visualization andcontrol 1-94Compact PLC universal compactcontrollers 1-108Modular PLC 1-113Modular I/O system 1-124Software 1-130 42. Eaton Wiring Manual 06/11Switching, control, visualization1-21 1SmartWire-DT communication systemConnect don't wireThe main part of a control system for amachine is these days carried out by a PLC.Typically the PLC is mounted in a controlpanel at a central position in the system.The control of the switchgear is carried outvia special cables from the input andoutput terminals of the PLC for the controland return signals. With a decentralizedconfiguration the switchgear and theremote input/output system are connectedin the same way.The SmartWire-DT communication systemreplaces the control wiring previouslyrequired between the PLC inputs/outputsand the switching devices. In this way, theinputs/outputs of the PLC are relocated tothe switching devices. Pluggablecommunication modules are used for thistask. The communication is implementedvia an 8-pole ribbon cable. Special deviceplugs are used for connecting thecommunication modules to the cable. Theswitchgear is supplied on the controlcircuit side by the connection cable.The SmartWire-DT system reduces the time required for the controlwiring and wiring test, saves space in the control cabinetbecause cable ducts are unnecessaryand reduces the number of inputs/outputsrequired at the PLC.The length of a SmartWire-DT network canbe extended up to 600 meters. Up to 99stations can be connected.You can use the SmartWire-DT technologyflexibly. The connection via standardfieldbus systems (e.g. PROFIBUS,CANopen) enables SWD gateways to beused on the controller platforms of manymanufacturers. Another option is the use ofEaton automation components (e.g. XV100visualization system) with an integratedSmartWire-DT interface. 43. Eaton Wiring Manual 06/11Switching, control, visualization SmartWire-DT communication system1-311Evolution in the switchboardBefore Today 44. Eaton Wiring Manual 06/11Switching, control, visualization SmartWire-DT communication system1-41 11 268 924 403534313229 31201926275 7 7775522 23212422 2525222827 393028 23 25 25363834 7 7 5 3773353461815 17 1411 137777 71213710735345616 45. Eaton Wiring Manual 06/11Switching, control, visualization SmartWire-DT communication system1-5111 Programmable logic controller PLC2 SmartWire-DT gateway3 Data plugs Sub-D 9 pole4 SmartWire-DT HMI-PLC5 SmartWire-DT blade terminal 8 pole6 SmartWire-DT ribbon cable 8 pole7 SmartWire-DT device plug 8 pole8 SmartWire-DT I/O modules9 SmartWire-DT connection for NZM10 NZM circuit-breaker11 SmartWire-DT contactor module12 DILM contactor13 SmartWire-DT contactor modules withManual-0-Automatic switch14 PKZM0 motor-protectivecircuit-breaker15 SC motor-starter combination16 SmartWire-DT PKE module (motorstarter)17 Motor-starter combination with PKEelectronic motor-protectivecircuit-breaker18 DS7 Softstarter with PKE electronicmotor-protective circuit-breaker19 SmartWire-DT powerfeed module20 SmartWire-DT universal station, frontfixing21 SmartWire-DT LED elements, frontfixing22 RMQ-Titan fixing adapters for frontmounting23 RMQ-Titan indicator light24 SmartWire-DT function elements forfront fixing25 SmartWire-DT operating elements26 SmartWire-DT control panel cableentry for ribbon to round cable27 SmartWire-DT plug connector28 RMQ-Titan surface mounting enclosure29 SmartWire-DT card for functionelements, base-fixing30 SmartWire-DT LED elements for basefixing31 SmartWire-DT function elements forbase fixing32 SmartWire-DT universal station forbase fixing33 SmartWire-DT adapter forribbon/round cable for top-hat railmounting34 SmartWire-DT PKE module(motor-protective circuit-breaker)35 PKZ12, PKE32 motor-protectivecircuit-breaker36 PKE 65 motor-protectivecircuit-breaker37 Network termination for 8 pole ribboncable38 DS7 soft starter39 SmartWire-DT round cable, 8-pole40 SmartWire-DT planning and orderingaid, SWD-Assist 46. Eaton Wiring Manual 06/11Switching, control, visualization SmartWire-DT communication system1-61 1PKE communication via SmartWire-DTMotor-starter combinations fitted with PKEcan transfer the following information viaSmartWire-DT:I_max Maximum motor current (relative): shows the single-phasecurrent (single-phase load) or the maximum current in theappropriate phase (three-phase load).Thermal image of themotorShows the temperature curve of the motor; stated in %,Overload warning function possibleType of trip block display Shows the type of trip block currently in use.Display of set OverloadvalueShows the currently set value for the overload release.Display of time-lag classvalueShows the currently set time-lag class (Class 520).PKE switching statedisplayShows the currently set ON/OFF switching state.DILM contactorswitching stateShows the currently set ON/OFF switching state.Trip indication overload Shows a differentiated Overload fault indication.Trip indicationshort-circuitShows a differentiated Short-circuit fault indication.Trip indication PhasefailureShows a differentiated Phase failure fault indication.Trip indication Test Shows a differentiated Tripping via test function faultindication.ZMR function Overload relay function: When the ZMR function is set, thecontactor disconnects in the event of an overload. The PKEmotor-protective circuit-breaker remains switched on(ON setting).The contact is reset with the MANUAL/AUTO function viaPKE-SWD-32. 47. Eaton Wiring Manual 06/11Switching, control, visualization SmartWire-DT communication system1-711Overload relay function (ZMR)The ZMR function enables the motor to beswitched off by the connected contactor inthe event of an overload. To do this the PKEsends the switch off command for thecontactor to the PKE-SWD-32 via the datacable of the PKE32-COM.The trip in response to a motor overloadoccurs if the thermal motor image of thePKE reaches 110 %.This value remains set until the thermalmotor image has gone below the 100 %level and the operational readiness of thecontactor is restored.The reclosing readiness of the contactorcan be selected by the two manual andautomatic operating modes of the ZMRfunction.The ZMR function can only be used inposition "A" of the 1-0-A switch.In the event of a phase unbalance andactivated ZMR function, the value of thethermal motor image is raised from 100 %to 110 % after a trip.The switched off contactor's readiness toreclose is restored when the value fallsbelow 100 %.The ZMR function must not be activatedwith reversing starters since this operationdoes not ensure the disconnection of thesecond contactor in the event of anoverload.ZMR Manual modeIn "manual" ZMR operating mode, theretriggering of the contactor must beacknowledged beforehand.ZMR Automatic modeIn "automatic" ZMR mode, the contactor isready to reclose immediately after thethermal image drops below 100 %.Danger!If the switch on command for the contactoris sent in "automatic" ZMR mode, the motorstarts up automatically after the thermalmotor image falls below 100 %.Never disconnect the communication linkbetween the PKE-SWD-32 and the PKE tripblock after an overload with the ZMRfunction activated, as this can cause thecontactor to switch on if a switchcommand is present. 48. Eaton Wiring Manual 06/11Switching, control, visualization SmartWire-DT communication system1-81 1DOL starter with PKZThe DOL starters are assembled from aPKZM0 and a DILM7 to DILM32 contactor.The connection to SmartWire-DT isimplemented with the DIL-SWD-32-..module. This is fitted directly on thecontactor and connected via the SWDdevice plug with the SWD communicationcable.SWD4-8SF2-5In addition to contactor control, twofeedback signals can be sent to theSmartWire-DT system on eachSmartWire-DT module for DILM.The SmartWire-DT module for DILM drivesthe contactor so that terminals A1-A2 mustno longer be wired.The auxiliary contact X3-X4 is factory fittedwith a link. If electrical interlocks areenvisaged in the application, the link canbe removed and a potential-free contactcan be connected.Two feedback inputs to the programmablelogic controller are provided at thethree-pole terminal X0-X1-X2. If required,potential-free auxiliary contacts of the PKZmotor protective circuit-breaker can beconnected to these two feedback inputs(e.g. NHI-E--PKZ0 standard auxiliarycontact, AGM2--PKZ0 differentialtrip-indicating auxiliary contact).Figure, page 1-10Reversing starter with PKZThe reversing starters are made up of aPKZM0 motor-protective circuit-breakerand two DILM7 to DILM32 contactors. ADIL-SWD-32- SmartWire-DT module isfitted to each contactor and connected tothe SWD communication cable via theSWD external device plug.In addition to contactor control, twofeedback signals can be sent to theSmartWire-DT system on eachSmartWire-DT module for DILM.The SmartWire-DT modules for DILM drivethe contactors so that the connectionterminals A1-A2 of the contactors need nofurther wiring, with the exception of theDILM12-XEV link. The auxiliary contactX3-X4 is factory fitted with a link. For theelectrical interlocking of the twocontactors this bridge is removed and theauxiliary breaker (contacts 21-22) of theother contactor is linked in as apotential-free contact.Two feedback inputs to the programmablelogic controller are provided at thethree-pole terminal X0-X1-X2. If required,potential-free auxiliary contacts of the PKZmotor protective circuit-breaker can beconnected to these two feedback inputs(e.g. NHI-E--PKZ0 standard auxiliarycontact, AGM2--PKZ0 differentialtrip-indicating auxiliary contact).12SWD4-8SF2-5+15VSWD4-8SF2 SWD4-8SF2+ 15V 49. Eaton Wiring Manual 06/11Switching, control, visualization SmartWire-DT communication system1-911The wiring sets DILM12-XRL andPKZM0-XRM12 must only be used to createa reversing starter when the reversinglinksDOL starters with PKZ are replacedwith DILM12-XR. The A2 connections of thecontactors must not be bridged.Figure, page 1-11 50. Switching, control, visualization SmartWire-DT communication systemEaton Wiring Manual 06/111-101 1DOL starters with PKZ8L1 SmartWire-DTL2L3-Q11X11 3 5I I I2 4 61 3 52 4 6U V WPEU V W PEPEM3 ~-M1-Q11.13 1.211.14 1.22 4.434.44 4.134.144.434.44-Q1 -Q181.131.14-Q11X0 X1 X2 X3 X4A1A2+ I >24 V0 VDC 51. Switching, control, visualization SmartWire-DT communication systemEaton Wiring Manual 06/111-11Reversing starter with PKESmartWire-DT SmartWire-DT11L1L2L3-Q11SmartWire-DT-Q12 -Q11X11 3 5I I I2 4 61 3 52 4 6U V W-Q12 1 3 52 4 6PEU V W PEPEM3 ~-M1-Q11.13 1.211.2221221.14 4.434.44 4.134.144.434.44-Q1 -Q11.131.14-Q11X0 X1 X2 X3 X4821228A1A2-Q12X0 X1 X2 X3 X48A1A2+ I >24 V0 VDC24 V0 VDC 52. Eaton Wiring Manual 06/11Switching, control, visualization SmartWire-DT communication system1-121 1DOL starter with PKEThe DOL starters are assembled from aPKE12/ PKE32 with the PKE-XTUA-tripblock and a DILM7 to DILM32 contactor.The connection to SmartWire-DT isimplemented with the PKE-SWD-32module. This is fitted to the contactor andconnected to the SWD communicationcable via the SWD device plug.The PKE32-COM is used as acommunication link between thePKE-SWD-32 and the PKE trip block. ThePKE-SWD-32 receives the data of the PKEtrip block via the PKE32-COM and makesthis available as input data on theSmartWire-DT network.The PKE32-COM is fitted on the PKE basicdevice (PKE12 or PKE32) and is connectedwith the appropriate interface of thePKE-SWD-32.The auxiliary contact for the electricalenable X3-X4 is connected at the factorywith a link. If electrical locks are envisagedin the application, the link can be removedand a potential-free contact can beconnected.The auxiliary contact for the electricalenable can be used on the PKE-SWD-32 forsafety-related control sections (e.g. safetyshutdown of the drive).Figure, page 1-1412+15V+ 15V 53. Eaton Wiring Manual 06/11Switching, control, visualization SmartWire-DT communication system1-1311Reversing starter with PKEThe reversing starters are made up from aPKE12/PKE32 with a PKE-XTUA-tripblock and two contactors DILM7 toDILM32. The PKE-SWD-32 is fitted on oneof the two contactors of the reversingstarter. Unlike DOL starters, the control ofthe second contactor for reversing startersmust be implemented with a SmartWire-DTcontactor module (DIL-SWD-32-). BothSWD modules are then connected to theSWD communication cable via the SWDdevice plug.The "Enable" X3-X4 auxiliary contact isfactory fitted with a link. For the electricalinterlocking of the two contactors this linkis removed and the auxiliary breaker(contacts 21-22) of the other contactor islinked in as a potential-free contact.The auxiliary contact for the electricalenable X3-X4 can be used on thePKE_SWD-32 for safety-related controlsections. The wiring sets DILM12-XRL andPKZM0-XRM12 must not be used for theassembly of the reversing starters.The A2 connections of the contactors mustnot be bridged.Figure, page 1-15 54. Switching, control, visualization SmartWire-DT communication systemEaton Wiring Manual 06/111-141 1DOL starters with PKE8L1 SmartWire-DTL2L3-Q11X12 4 61 3 52 4 6U V WPEU V W PEPEM3 ~-M1-Q118X3 X4A1A21024 V0 VDC-Q11 3 5I I I 55. Switching, control, visualization SmartWire-DT communication systemEaton Wiring Manual 06/111-15Reversing starter with PKE11L1L2L3-Q11SmartWire-DT-Q12 -Q11X11 3 52 4 6U V W-Q12 1 3 52 4 6PEU V W PEPEM3 ~-M12122-Q11821228A1A2-Q12X0 X1 X2 X3 X48A1A224 V0 VDC24 V0 VDCX3 X4PKE-SWD-322 4 6DIL-SWD-32-...10SmartWire-DT-Q11 3 5I I I 56. Eaton Wiring Manual 06/11Switching, control, visualization SmartWire-DT communication system1-161 1Star-delta starterWith SmartWire-DT modules for DILM They control the contactors so that theterminals A1-A2 of the contactors do nothave to be wired. A return signal is alsogiven back to the SmartWire-DT system viathe SWD contactor modules for DILM.The terminals X3-X4 are supplied with abridging connection. For the electricalinterlocking of the two contactors thisbridge is removed and the auxiliary breaker(contacts 21-22) of the other contactor islinked in as a potential-free contact.Figure, page 1-18With SmartWire-DT I/O-moduleEU5E-SWD-4D2R The SmartWire-DT I/Omodule actuates thecontactor Q11 via the digital relay outputQ0. The further procedure is the same asthat of a conventional star-delta starter.The inputs of the SmartWire-DT I/O moduleare used to implement return signals to theSmartWire-DT system.Figure, page 1-19With SmartWire-DT contactor module andETR4-51 timing relay The SWD contactor module for DILMcontrols the mains contactor Q11 so thatthe terminals A1-A2 do not have to bewired. A return signal is also given back tothe SmartWire-DT system via the SWDprotective module for DILM.The control and the changeover betweenstar contactor and delta contactor havethe same wiring and function as theconventional star-delta starter assembly.Figure, page 1-20 57. Eaton Wiring Manual 06/11Switching, control, visualization SmartWire-DT communication system1-1711With PKE and SWD modules for DILM The star-delta starters are made up from aPKE12/PKE32 with a PKE-XTUA-tripblock and three contactors DILM7 toDILM32. The PKE-SWD-32 is fitted to themains contactor of the star-delta starter.The star and delta contactor is actuatedwith SmartWire-DT contactor modules(DIL-SWD-32-).All SWD modules are then connected tothe SWD communication cable via theSWD device plug.The "Enable" X3-X4 auxiliary contact isfactory fitted with a link. For the electricalinterlocking of the star and delta contactorthis link is removed and the auxiliary NCcontact (contacts 21-22) of the othercontactor is linked in as a potential-freecontact.The auxiliary contact for the electricalenable X3-X4 can be used on thePKE_SWD-32 for safety-related controlsections.The wiring sets DILM12-XRL andPKZM0-XRM12 must not be used for theassembly of a star-delta starter.The A2 terminals of star and deltaconnections must not be bridged.Figure, page 1-21With PKE, SWD modules for mainscontactor DILM and ETR4-51 timing relay The star-delta starters are made up from aPKE12/PKE32 with a PKE-XTUA-tripblock and three contactors DILM7 toDILM32. The PKE-SWD-32 is fitted to themains contactor of the star-delta starter.The star-delta contactor is actuated in aconventional circuit. The PKE-SWD-32module is connected to the SWDcommunication cable via the SWD deviceplug. The wiring sets DILM12-XRL andPKZM0-XRM12 can be used for theassembly of a star-delta starter.Figure, page 1-22 58. Switching, control, visualization SmartWire-DT communication systemEaton Wiring Manual 06/111-181 1Star delta starter with 3 SmartWire-DT contactor modulesSmartWire-DT SmartWire-DT SmartWire-DT SmartWire-DT8 8 8 81.53-Q1221X1 X2 X3 X424V0VDC-Q1322-Q11X0 X1 X2 X3 X424V0VDCX0-Q122122-Q13X1 X2 X3 X424V0VDCX0-Q11.54DIL-SWD-32DIL-SWD-32-...DIL-SWD-32-...L1L2L3-Q11X11 3 5I I I1 3 52 4 6U1 V1 W1U1 V1 W1-Q121 3 52 4 6 -Q131 3 52 4 6PEV2 W2 U2V2 W2 U2PEPE-M1 M 3 ~-Q12 4 6 59. Switching, control, visualization SmartWire-DT communication systemEaton Wiring Manual 06/111-19SmartWire-DT star-delta starter with EU5E-SWD-4D2R I/O moduleL01SmartWire-DT11-K2SmartWire-DT13141.53131414V+ I0 I3 V+ 88-Q1-Q11-Q12-Q13+24 V DC1.54676822-Q13 21A1 -Q13-Q1257-K1 5822-Q12 21A1A2A1A2A21.53-Q1 1.5413-K2 14-Q11 -K1L02I1 I21323 24Q113 14Q0-K1-Q11 -Q12-M1M3~1 3 52 4 6 -Q13 1 3 52 4 61 3 52 4 6U1 V1 W1 PEU1 V1 W1V2 W2 U2PEL1L2L3-Q11 3 5 1.531.54I> I> I>2 4 6V2 W2 U2PEX1 60. Switching, control, visualization SmartWire-DT communication systemEaton Wiring Manual 06/111-201 1Star delta starter with SmartWire-DT contactor module and ETR4-51 timing relayL0128171817-K1 -K1-Q132221-Q122221A1-Q13 -Q12A2SmartWire-DT SmartWire-DTA1A2A1A2-Q11.531.54-Q111314L028 8-K1L1L2L3-Q11X11 3 5I I I1 3 52 4 6U1 V1 W1U1 V1 W1-Q121 3 52 4 6 -Q131 3 52 4 6PEV2 W2 U2V2 W2 U2PEPE-M1 M 3 ~-Q12 4 6-Q111.53X0 X1 X2 X3 X424V0VDC-Q11.54 61. Switching, control, visualization SmartWire-DT communication systemEaton Wiring Manual 06/111-21Star delta starter with PKE and SWD modules for DILM8 8 8 8111.53-Q1221X1 X2 X3 X424V0VDC-Q1322SmartWire-DTSmartWire-DT10SmartWire-DT SmartWire-DT SmartWire-DT-Q11X0 X1 X2 X3 X424V0VDCX0-Q122122-Q13X1 X2 X3 X424V0VDCX0-Q11.54PKE-SWD-32DIL-SWD-32-...DIL-SWD-32-...L1L2L3-Q11X11 3 5I I I1 3 52 4 6U1 V1 W1U1 V1 W1-Q121 3 52 4 6 -Q131 3 52 4 6PEV2 W2 U2V2 W2 U2PEPE-M1 M 3 ~-Q12 4 6 62. Switching, control, visualization SmartWire-DT communication systemEaton Wiring Manual 06/111-221 1Star delta starter with PKE, SWD module for mains contactor DILM and ETR4-51 timing relayL0128171817-K1 -K1-Q132221-Q122221A1-Q13 -Q12A2SmartWire-DT SmartWire-DTA1A2A1A2-Q11.531.54-Q111314L028 8-K110-Q11X0 X1 X2 X3 X424V0VDCPKE-SWD-32L1L2L3-Q11X11 3 5I I I2 4 61 3 52 4 6U1 V1 W1U1 V1 W1-Q121 3 52 4 6 -Q131 3 52 4 6PEV2 W2 U2V2 W2 U2PEPE-M1 M 3 ~-Q1 63. Eaton Wiring Manual 06/11Switching, control, visualization SmartWire-DT communication system1-2311NZM circuit-breakersThe NZM-XSWD-704 SmartWire-DTmodule is used for querying acircuit-breaker with an electronic release(NZM2, 3, 4) via a PLC, i.e. the On/Off/Tripposition of the switch and the actualcurrents. An optionally installed remoteoperator can also be actuated via themodule. The NZM-XSWD-704 is fitted on atop-hat rail and is connected to the NZMvia a 2.0 m data cable. The auxiliarycontacts and the remote operator arewired separately. The connection to theSmartWire-DT ribbon cable isimplemented via the SWD device plug.a SmartWire-DT connectionb Data cable NZM with NZM-XSWD-704c Auxiliary contacts in NZMd XMC energy metering device (external)e Remote operator LT306.230.3TripOFFON0 V, N70 71 72 74+, P24 V GNDI024 VI1S0+S0-Q00 VQ10 V 200 mA 200 mANZM-XRDNZMHIA HINM22-K01M22-K10 64. Eaton Wiring Manual 06/11Switching, control, visualization SmartWire-DT communication system1-241 1Pilot Devices Simple pilot devices can be integrateddirectly in the SmartWire-DTcommunication system without any timeconsuming wiring. The function elementsare snap fitted in the M22-A fixing adapterand then connected to the SWDcommunication cable via the SWD deviceplug.SWD-8SF2-5SWD4-LFThe switch position indications of thecontrol elements and activation of theindicator are implemented with theSmartWire-DT communication system. Thefunction elements stated in the table areavailable.These function elements are eachavailable in two versions for front or basefixing. Base fixing elements can becombined to form remote operating anddisplay devices using the M22-SWD-Icards and the M22-I.. surface mountingenclosures to IP65.M22-SWD-KM22-SWD-LEDM22-SWD-NOPM221 3 2 1 3 2 1 3 2INOUTOFFONM22-SWD-K(C)11 Function element with one changeover contactM22-SWD-K(C)22 Function element with two changeover contactsM22-SWD-LED LED function elements in white (W), red (R), green (G) orblue (B)M22-SWD-K11LED Function element with one changeover contact and one LEDin white (W), red (R), green (G) or blue (B)M22-SWD-K22LED Function element with two changeover contacts and one LEDin white (W), red (R), green (G) or blue (B) 65. Eaton Wiring Manual 06/11Switching, control, visualization SmartWire-DT communication system1-2511Digital and analog signal processingThe following SWD modules are availablefor processing digital or analoginput/output signals:The modules are fitted directly on thetop-hat rail and then connected with theSWD communication cable via the SWDdevice plug.The modules can be fitted directly in theproximity of the sensors/actuators to beconnected. This also reduces theremaining wiring required.The following applications are possible: Connection of AC contactors or highrated contactors > DILM32 that do nothave a connection option for theDIL-SWD-module. For this use theEU5E-SWD-4D2R module. Connection of auxiliary contacts tomodules with digital inputs Connection of digital actuators withoutintegrated SWD functionality (signallights, timing relays ..) Connection of any analog inputs/outputsa SmartWire-DT cable with externaldevice plugb SmartWire-DT diagnostics LEDc Status display of inputs and outputs(optional)d Input/output terminalse External supply (optional)EU5E-SWD-8DX 8digital inputsEU5E-SWD-4DX 4digital inputs withtransmitter supplyEU5E-SWD-4D4D 4 digital inputs and4 digital outputsEU5E-SWD-4D2R 4 digital inputs and2 relay outputs 3 AEU5E-SWD-X8D 8 digital outputsEU5E-SWD-4AX 4analog inputs0 10 V, 0 20 mAEU5E-SWD-2A2A 2 analog inputs and2 analog outputs0 10 V, 0 20 mAEU5E-SWD-4PT 4 temperature inputsPT100, PT1000,Ni1000 66. Eaton Wiring Manual 06/11Switching, control, visualization SmartWire-DT communication system1-261 1Safety-related applicationsFor most applications, disconnection in theevent of an emergency or thedisconnection by the opening of theprotective doors is also required in additionto normal operational switching.The SmartWire-DT system is not designedfor the transfer of safety relevant signals.Using the configuration described below,the SmartWire-DT system can however beused for safety relevant switch offs.In an emergency the control voltage for thecontactor coils can be switched off via theenabling paths of the safety relay. By usingadditional SmartWire-DT Power modules,contactor groups are made that can beswitched off together in an emergency.This type of circuit can be used to createcontrol systems up to PL c in accordancewith EN ISO 13849-1 (PL = PerformanceLevel). The safety relay in this examplemust be PL c or higher (e.g.ESR5-NO-41-24VAC-DC).Figure, page 1-27Feedback circuit The auxiliary contact integrated in thecontactor is a mirror contact according toIEC/EC 60947-4-1. Using this contact thestate of the main contacts can be reliablysignalled. The mirror contact can beincluded into the feedback circuit of thesafety relay so that the safety relay onlygives a new enable signal when thecontactor is open.Measures for higher safety category In many applications control systems witha performance level of PL d or PL e(PL = Performance Level) toEN ISO 13849-1 are required. Controlsystems with PL d can be set up using anadditional group contactor which isconnected in series upstream of the motorfeeders. The control voltage for the motorcontactors as well as for the groupcontactor is switched off in an emergencyvia the safety relay. This redundantdisconnection circuit enables theimplementation of PL d control systems.The safety relay used must comply with PLd or higher to achieve this safety category(e.g. ESR5-NO-31-24VAC-DC).Further information on safety engineeringfor machines and plants is provided in theEaton Safety Manual: www.eaton.eu/shb 67. Switching, control, visualization SmartWire-DT communication systemEaton Wiring Manual 06/111-27Actuating circuit for safety relevant applicationA1 X0 X1 X2A2 X3 X411L1L2L3PEI I I-Q1-K01-K0224 0-K01-T01-F01K1-S02I I I-Q1400 0eeeee-F0224 V 0V 24 V 0 V-K03AUXSmartWire-DT-F0321222122A1 A2 Y1 Y2 Y3 1314K12324333441422~ H-K0124 V 0 V-F0413142324POW AUXA1 X0 X1 X2A2 X3 X4-Q11ConfigBusPowerA1 X0 X1 X2A2 X3 X4-Q12A1 X0 X1 X2A2 X3 X4-Q13A1 X0 X1 X2A2 X3 X4-Q14-Q158 88 8 8RESETRESETPOWERCONTROL-LOGICGateway Power-FeederIn Out8SWDInNETOutOut-S01 fEMERGENCY-STOP 68. Switching, control, visualizationSmartWire-DT communication systemEaton Wiring Manual 06/111-281 1Mains circuit for safety relevant applicationL1L2L3PEPEU V W PEU V W PEM3~-M1-Q11 3 5I> I> I>2 4 6-Q11-M11 3 52 4 6U V W PEU V W PEM3~-M1-Q21 3 5I> I> I>2 4 6-Q12-M21 3 52 4 6U V W PEU V W PEM3~-M1-Q31 3 5I> I> I>2 4 6-Q13-M31 3 52 4 6U V W PEU V W PEM3~-M1-Q41 3 5I> I> I>2 4 6-Q14-M41 3 52 4 6U V W PEU V W PEM3~-M1-Q51 3 5I> I> I>2 4 6-Q15-M51 3 52 4 6 69. Eaton Wiring Manual 06/111-29Switching, control, visualization11The way to the safe machineThe international standard EN ISO 12100-1Safety of machinery - Basic concepts,general principles for design provides thedesign engineer with detailed assistancein the identification of hazards and theresulting risks to be assessed.This therefore lays down the technicalmeasures for the reduction of hazards.The parts of machine control systems thathandle safety tasks are defined as thesafety-related parts of control systems(SRP/CS). Safety-related control systemscomprise the entire safety functionconsisting of the input level (sensor), thelogic (safety signal processing) and theoutput level (actuator).For reducing risks by means of SRP/CS,Eaton offers the right components withsafety technology in accordance with themost stringent requirements stipulated inthe safety standards EN 954-1, EN ISO13849-1 and EN IEC 62061. The appropriatesafety functions are used according to theapplication area and in compliance withthe required risk reduction.Further information on the previous and thenew international safety standards as wellas circuit examples for a wide range ofapplications are provided in the latestversion of the Eaton Safety ApplicationsTechnical Guide PU05907001Z-EN.The safety manual helps you by means ofpractical safety circuit examples and theassociated calculations to determinesafety performance in accordance withEN ISO 13849-1 and IEC 62061.The Safety Manual is available online or inprint: Register at www.eaton.eu/shb and workonline with the Safety Manual ordownload the PDF version free of charge. Order the current printed version fromyour wholesalers or your Eaton customerservice: PU05907001Z-EN,Article no. 119906 70. Switching, control, visualization The way to the safe machineEaton Wiring Manual 06/111-301 1Detecting hazards quickly with RMQ-Titanand FAK emergency-stop buttons.Motion safety under control withLS-Titan position switches.Safe switching, disconnection and controlwith T rotary switches and Pswitch-disconnectors.Safe monitoring and processing with ESRsafety relays and easySafety control relay.Reliable disconnection with DILMcontactors and CMD contactor monitoringdevice.Further technical information on theindividual safety products is provided atwww.eaton.com/moellerFast and secure detectionSafe monitoring and processingReliable shut down 71. Switching, control, visualization The way to the safe machineEaton Wiring Manual 06/111-3111Logic units to ensure safety functionsSafety logic units enable the hardwarerequired to be considerably reduced andprimarily restricted to the sensor/actuatorlevel. Eaton offers two logic series: ESR5 Electronic safety relays easySafety control relay suitable forsafety circuits.Safety relays of the ESR5 series offer theoptimum solution for each application withtailored safety functions. The internal logicof the safety relay monitors the wiredsafety circuits and activates the enablecontacts in fault-free condition.The easySafety control relay offers a hostof integrated safety relays in the form ofsafety function blocks in a single device,thus offering maximum flexibility in aconsiderable space saving design.easySafety is used for monitoring alltypical safety devices and alsoimplementing the control tasks required onthe machine.The ESR safety relays or the easySafetycontrol relay enable applications to beimplemented that meet the most stringentsafety requirements in accordance withinternational standards: Category 4 to EN 954-1 Performance level PL e acc. toEN ISO13849-1 Safety Integrity Level SIL CL 3 accordingto IEC 62061 Safety Integrity Level SIL 3 according toIEC 61508Eaton ensures the required level ofpersonal or process protection using thesafety products approved by TVRheinland for both simple and complexmachines. 72. Switching, control, visualization The way to the safe machineEaton Wiring Manual 06/111-321 1Monitoring a movable guard with ESR5Moving guards such as safety doors, gatesand flaps can be used to provide protectionfrom accessible hazardous areas. Theposition of moving guards is detected withposition switches or non-contactingcontact sensors that are monitored andevaluated with a safety logic unit. A riskanalysis supplies the necessary degree ofrisk reduction by the guard.FunctionThe safety logic unit provides two separateinput circuits for two-channel applications,which monitor the sensor (such as theposition switch of an interlock device).After the input circuits are closed, thesafety relay can be started by means of areset button. This activates the enable andsignal current paths and switches on theconnected actuators. Positively drivenauxiliary contacts of the actuators areused by the safety relay to diagnosepossible safety states.Safety technical assessmentB 1 2 3 4CatPL a b c d eSIL 1 2 3Cat. according to EN 954-1PL according to EN ISO 13849-1SIL according to IEC 62061 73. Switching, control, visualizationThe way to the safe machineEaton Wiring Manual 06/111-33Circuit example: Two-channel guard door monitoring with ESR51124 V0 V24V10V114 13-B222 21-B1-Q222 21-Q122 21A1A2S22 S12S33S11S21S3434 33K2ESR5-NO-21-24VAC-DC-K11K114 1324 23-F12 1-Q1A2 A1-F22 1-Q2A2 A1Power24 V AC/AC24 V DCL1L2L3PEL1L2L3I > I > I >T1T2T3U1-X1-Q22 14 36 5-Q12 14 36 5-Q3UVWM3PEV1W1PEL1L2L3N/OactuatedLogic 74. Switching, control, visualization The way to the safe machineEaton Wiring Manual 06/111-341 1Stopping in case of emergency witheasySafetyThe Emergency-stop function is anadditional protective measure and is notpermissible as the sole means ofprotection. Machinery Directive2006/42/EC stipulates however that everymachine must be provided with a devicefor stopping in an emergency (Emergencystop). The degree of risk reduction by theEmergency stop device must bedetermined by means of a risk assessment.If the immediate disconnection of thepower supply does not cause hazardousstates, you can use an uncontrolled Stopfunction in accordance with Stop category0 to EN ISO 13850.FunctionThe Emergency-stop actuator S4 must bein the enable position (NC contacts closed)so that the enable signal can be issued viathe RESET pushbutton S3. Pressing theSTART pushbutton S1 starts the hazardousmovement. The self-latching function andits interruption are implemented in theprogram. The two contactors drop out, anda restart is possible by pressing the STARTactuator. If the hazardous movement isstopped by pressing the Emergency-stopactuator S4, the enable for outputs QS1 andQS2 is removed and the contactors dropout. A restart is only possible after theEmergency-stop actuator is reset andenabled by pressing the RESETpushbutton. The drive can be brakedactively by using output QS4. However, thisoption is not included in the safetyconsideration since the frequency inverterdoes not support the safe brakingoperation.Safety technical assessmentB 1 2 3 4CatPL a b c d eSIL 1 2 3Cat. according to EN 954-1PL according to EN ISO 13849-1SIL according to IEC 62061 75. Switching, control, visualization The way to the safe machineEaton Wiring Manual 06/111-35Circuit example: Two-channel Emergency-stop monitoring with easySafetyIS1 IS2 IS3 IS4 IS5 IS6 IS7 IS8 IS9 IS10 IS11 IS12 IS13 IS1411+24 V0 V1 2-F2Output 1x Relay / 6A 4x Test Signal+24V 0V QS1 QS2 QS3 QS4 T1 T2 T3 T4ES4P-221-DMXD14x Transistor / 0,5ADC 24V Input 14 x DCNETALTOK-K1DELESC1QR12+24V 0V 0VP1P2P3P41 2-F1-S114 13-S222 21-Q1 A2 A1K14-T1K11-Q2A2 A1-Q3A2 A1-Q222 21-Q122 21 14 13-S3-S422 2112 11L1L2L3PET1 L1T2 L2U1-X1PEL3PE3 L 3 T I >U L1V L2WL+DC-DC+K12K14K11 P24-T11252 L14 L26 L38 PE-R2V2W1PEU1U2V1W2-R1-Q22 14 36 5-Q12 14 36 5-Q4I > I >U1V1W1M3 PEV1W1PE2 1-QR114 13-Q3L1L2L3PEStart Stop ResetEMERGENCYSTOP 76. Eaton Wiring Manual 06/11Switching, control, visualization1-361 1Timing relaysElectronic timing relays are used incontactor control systems which requireshort reset times, high repetition accuracy,high operating frequency, and a longcomponent lifespan. Times between 0.05 sand 100 h can be easily selected and set.The switching capacity of electronic timingrelays complies with the utilizationcategories AC-15 and DC-13.In terms of the actuating voltages there arewith timing relays the followingdifferences: Version A (DILETand ETR4)Universal devices:DC 24 to 240 VAC 24 to 240 V, 50/60 Hz Version W (DILETand ETR4)AC devices:AC 346 to 440 V, 50/60 Hz ETR2(as modular installation device toDIN 43880)Universal devices:DC 24 to 48 VAC 24 to 240 V, 50/60 Hz(ETR2-69-D: 12 to 240 V, 50/60 Hz)The functions of each of the timing relaysare as follows: DILET11, ETR4-11,ETR2-11Function 11 (on-delayed) ETR2-12Function 12 (off-delayed) ETR2-21Function 21 (fleeting contact onenergization) ETR2-42Function 42 (flashing, pulse initiating) ETR2-44Function 44(flashing, two speeds; can beset to either pulse initiating or pauseinitiating) Multifunction relays DILET70,ETR 4-69/70Function 11 (on-delayed)Function 12 (off-delayed)Function 16 (on- and off-delayed)Function 21(fleeting contact onenergization)Function 22 (fleeting contact onde-energization)Function 42 (flashing, pulse initiating) Function 81 (pulse generating)Function 82 (pulse shaping)ON, OFF Multifunction relay ETR2-69(-D)Function 11 (on-delayed)Function 12 (off-delayed)Function 21 (fleeting contact onenergization)Function 22 (fleeting contact onde-energization)Function 42 (flashing, pulse initiating)Function 43 (flashing, pause initiating)Function 82 (pulse initiating) Star-delta timing relays ETR4-51Function 51 (on-delayed)With both DILET70 and ETR4-70 an externalpotentiometer can be connected. Uponconnection, both timing relaysautomatically recognize that apotentiometer is fitted.The ETR4-70 has a special feature.Equipped with two changeover contactswhich can be converted to two timingcontacts 15-18 and 25-28 (A2-X1 linked) orone timing contact 15-18 and anon-delayed contact 21-24 (A2-X1 notlinked). If the link A2-X1 is removed, onlythe timed contact 15-18 carries out thefunctions described below. 77. Switching, control, visualization Timing relaysEaton Wiring Manual 06/111-3711Function 11On-delayedThe actuating voltage Us is applied via anactuating contact to the terminals A1 andA2.After the set delay time the changeovercontact of the output relay goes to theposition 15-18 (25-28).Function 12Off-delayedAfter the supply voltage has been appliedto the terminals A1 and A2, the changeovercontact of the output relay remains in theoriginal position 15-16 (25-26). If theterminals Y1 and Y2 in the DILET70 arelinked by a potential-free N/O contact or, inthe case of the ETR4-69/70 or ETR2-69, apotential is applied to B1, the changeovercontact changes without delay to theposition 15-18 (25-28).If the connection between the terminalsY1Y2 is now interrupted, or B1 isseparated from the potential, once the settime has elapsed, the changeover contactreturns to its original position 15-16(25-26).Function 16On- and Off-delayedThe supply voltage Us is applied directly tothe terminals A1 and A2. If the terminals Y1and Y2 in the DILET70 are linked by apotential-free N/Ocontact, or in the case ofof the ETR4-69/70 a potential is applied toB1, after a set time t the changeovercontact goes to the position 15-18 (25-28).If the connection Y1-Y2 is now interrupted,or B1 is separated from the potential, thechangeover contact goes back to itsoriginal position 15-16 (25-26) after thesame time t.Function 21Fleeting contact on energizationAfter the voltage Us has been applied to A1and A2, the changeover contact of theoutput relay goes to position 15-18 (25-28)and remains actuated for as long as the setfleeting contact time.A fleeting pulse (terminals 1-2, 15-18) ofdefined duration is therefore producedfrom a two-wire control process (voltageon A25/A28) by this function.tA1-A215-18A1-A2Y1-Y2B115-18(25-28)tA1-A2Y1-Y2B115-18(25-28)t tA1-A215-18t (25-28) 78. Switching, control, visualization Timing relaysEaton Wiring Manual 06/111-381 1Function 82Pulse shapingAfter the supply voltage has been appliedto A1 and A2, the changeover contact ofthe output relay remains in the rest position15-16 (25-26). If the terminals Y1 and Y2 inthe DILET70 are linked by a potential-freeN/O contact, or in the case of theETR4-69/70 or ETR2-69, a potential isapplied to B1, the changeover contactchanges without delay to the position 15-18(25-28).If Y1Y2 is now opened again, or B1 is iskept with the potential, the changeovercontact remains actuated until the set timehas elapsed. If, instead, Y1Y2 remainclosed or B1 is separated from thepotential for longer, the output relaylikewise changes back to its rest positionafter the set time. An output pulse ofprecisely defined duration is thusproduced in the pulse shaping function,irrespective of whether the input pulse viaY1Y2 or B1 is shorter or longer than the settime.Function 81Pulse generating with fixed pulseThe actuating voltage is applied to theterminals A1 and A2 via an actuatingcontact. After the set delay time haselapsed the changeover contact of theoutput relay goes to position 15-18 (25-28)and returns to its original position 15-16(25-26) after 0.5 s. This function is thereforea fleeting pulse with a time delay.Function 22Fleeting contact on de-energizationA1-A2Y1-Y2The supply voltage Us is present directly atA1 and A2. If the terminals Y1 and Y2 of theDILET70 that have been shorted (DILET-70potential-free) at any time beforehand areopened again, or with ETR4-69/70 orETR2-69 the contact B1 becomespotential-free again, the contact 15-18(25-28) closes for the duration of the settime.Function 42Flashing, pulse initiatingAfter the voltage Us has been applied to A1and A2, the changeover contact of theoutput relay changes to position 15-18(25-28) and remains actuated for as long asthe set flashing time. The subsequentpause duration corresponds to the flashingtime.A1-A2Y1-Y2B115-18(25-28)tA1-A215-18t 0.5 s (25-28)B115-18(25-