Think future. Switch to green

www.moeller.net/xenergy

Think future. Switch to green.

Special Publication

Integrated system for safe and future-proof power distribution

Authors:

Dipl.-BetriebswirtinJutta Zacharias,

Dipl.-Ing. Heinrich Moog

With power require-

ments increasing all

over the world and the

continued increasing

pressure to cut costs,

there is an even greater

need for secure

investments through

which efficient

planning, assembly,

installation and

operation are ensured.

To meet these require-

ments, cost-efficient

and standardised power

distribution systems

are needed that

customers can adapt

to the individual

requirements of their

projects. In short

what is needed is

maximum flexibility,

economy and

reliability.

etz_sonderdr_lay8-GB 30.07.2004 13:21 Uhr Seite 1

2 Heft 7/2004 •

Extensive safety requirements andspecial standards have to be observed inthe power distribution sector. The con-sistent use of the extensive assemblyand testing regulations as stipulated byDIN EN 60439-1 (VDE 0660 Part 500):2000-08 [1, 2] is therefore an importantrequirement for the reliable and safeoperation of a switchgear and control-gear assembly, i.e. a type-tested (TTA)and partially type-tested (PTTA) assemblyfor power and service distributionboards (DIN EN 60439-3 (VDE 0660Part 504):2002-05 [3, 4]). In compliancewith DIN EN 60204-1 (VDE 0113 Part1):1998-11 [5, 6] the switchgear andcontrolgear assembly, or switchboardsystem for short, can likewise be usedas a type-tested/partially low-voltage

control panel for machines. Apart fromthe basic assembly and test require-ments, the relevant standards and regu-lations also lay down the safety require-ments for electrical equipment, person-nel and system protection and also theselection and dimensioning of electricalequipment.

The extensive type testing for low-voltage switchboard systems containsthe following seven tests areas:• Limit overtemperature,• Dielectric strength,• Short-circuit current capability,

• Efficiency of the protective devices,• Creepage and air clearances, • Mechanical functions,• IP protection.The following functions are tested in theswitchgear and controlgear assembly inthe degree of protection for the corres-ponding current class:• Maximum current carrying capacity

of the electrical function units,• Switching and protective devices in

mechanical and electrical combinationwith the mounting systems includingthe main busbars, dropper bars andbusbar links,

• All system components as integralunits in their functional mounting.

An additional test is carried out in theprotective conductor circuits of the sys-tem panels in accordance with IEC/EN 60439-1, section 8.2.4 - Verification of theeffectiveness of the protective circuit -with the following tests:• Section 8.2.4.1: Verification of the

effective connection between theexposed conductive parts of theassembly and the protective circuit bymeasurement and

• Section 8.2.4.2: Verification of theshort-circuit strength of the protectivecircuit by test.

Both tests must be verified by themanufacturer (of each) and are particu-larly important for personnel protection.The results for the assembly of theswitchboard system are documented forpractical application by system supp-liers, such as in product catalogues;selection and dimensioning documents;assembly manuals; configuration andengineering tools; certification of thecompleted type tests for the declarationsof conformity by the system supplier.

The tests therefore guarantee reliablesystem assembly, as well as verifying thebasic features with successfully comp-leted type tests (TTA). At the same time,the reliable functioning of a switch-board system during operation is alsoverified – an important factor for afuture-proof and reliable power supply.

TTA/PTTA switchgear assemblies alsoinclude those that are engineered andassembled by local panel builders in

Integrated system for safe andfuture-proof power distribution

With power requirements increasing all over the world and thecontinued increasing pressure to cut costs, there is an evengreater need for secure investments through which efficientplanning, assembly, installation and operation are ensured. Tomeet these requirements, cost-efficient and standardised powerdistribution systems are needed that customers can adapt to theindividual requirements of their projects. In short what is neededis maximum flexibility, economy and reliability.

Jutta Zacharias • Heinrich Moog

Jutta Zacharias is head of the Power Distribution business unit

at Moeller GmbH in Bonn.e-mail: jutta.zacharias@moeller.net

Dipl.-Ing. Heinrich Moog is head ofxEnergy product management at

Moeller GmbH in Bonn.e-mail: heinrich.moog@moeller.net

Picture 1. In the divide between the demandfor greater safety, flexibility and loadcapability on the one hand, and pressure tocut costs on the other, Moeller's switchboardsystem is a future-proof platform for result-oriented solutions

3• Heft 7/2004

accordance with binding documentsand supplier specifications.

The construction of partially type-tes-ted assemblies (PTTA) involves the useof both type-tested and non type-testedfunctional assemblies. Test certificates

are equally required for PTTAs. Thesecan be provided by means of additionaltype testing or by the derivation ofsimilar systems from type-testedassemblies. Additional calculations arealso required depending on the type of

PTTA involved: Short-circuit (DIN IEC1117 (VDE 0660 Part 509):1993-09 [7, 8])and temperature rise (IEC/TR 60890).1987-07 [9]).

Future-proof switchboard system –the platform for results-basedsolutions

The project business is defining andshaping the market for low-voltageswitchboard systems. End customers require individual solutions for theirspecific requirements with an optimumprice-performance ratio. This kind offinancially flexible solution can only beoffered by a modular power distributionsystem that is based on an intelligentplatform concept. The divide betweenever increasing demands in terms ofengineering and safety on the one hand,and cost reduction on the other canonly be bridged by means of an innova-tive generation of switchboard systems(Picture 1).

xEnergy – the new powerdistribution system generation

xEnergy, Moeller's new integrated sys-tem range, stands for power distributionsystems that are specially designed forthe building infrastructure up to 4 000 A.Moeller are single-source suppliers of anintelligent system platform for switchingand protective devices that panel builderscan customise, assemble quickly andhandle easily. Based on many years ofpractical experience in the building ofswitchgear assemblies, Moeller has deve-loped the latest generation of switchboardsystems that incorporates the latest trendsand essential features. The individual swit-ching and protective devices, the asso-ciated mounting system design and alsothe switchgear are combined to form onetechnical unit. This kind of system is botheconomical and reliable at the same time,as perfectly matched and type-tested func-tional units have been developed as amodular system. Exactly tailored functionmodules that have been type-tested inaccordance with DIN EN 60439-1 (VDE0660 Part 500), and available with internalseparation from Form 1 to Form 4, complywith national installation requirements(DIN VDE, IEC, NF [France], UNE [Spain])(Picture 2). The system range consists of: • Feeder and coupling sections for cir-

cuit-breakers up to 4 000 A,• Individually equipped outgoer sections

with fixed compartment modules forswitching and protective devices in-

Moeller's Kit system for the panel builder is a single-source development that has been de-signed and thought through to meet the needs of the panel builder. xEnergy offers outstan-ding efficiency, flexibility and stands out with its simplicity and functionality.Technical system featuresStandards DIN EN 60439-1 (VDE 0660 Part 500)Type testing TTA Internal separation Form 1 to Form 4Rated operational voltage Ue 690V / 50Hz ... 60 HzRated operational current Ie to 4 000 A Rated short-time withstand resistance Icw bis 100 kA (Effektivwert), 1 sAmbient temperature 35 °C (40 °C) to 45 °C (50 °C) Degree of protection IP31/IP55 Network system TN-C / TN-C-S / TN-S / ITColour RAL 7035 (other colours on request)Dimensions h 2 000 mm basic height without plinth,

w 425/600/800/1 000/1 200 mm, d 400/600/800 mm

xEnergy – technical data Mounting of Moeller IZM and NZM circuit-breakers up to 4000 A - application benefits:• Clear and symmetrical design with only one circuit-breaker per section

reduces the number of busbar connections and saves mounting requirements,• Internal separation up to Form 4 increases personnel and system protection,• Circuit-breaker mounting kits for optimum assembly and packed as a unit,• Fast and direct allocation of mounting kits for the mechanical fastening of circuit-

breakers,• High level of flexibility in the terminal area thanks to alternative connection options: Cable

terminal system, straps or busbar adapters.

Mounting of Moeller switching and protective devices up to 630 A - application benefits:• Max. 38 fixed compartment modules in one section (h = 50 mm), to 40 A• Max. 19 fixed compartment modules in one section (h = 100 mm), to 160 A• Optimum device utilisation despite high packing density• Simple module mounting to Form 2 on one mounting depth,• Flexible module mounting to Form 4 with different device mounting depths, with stan-

dard operating front,• Highly flexible combination possible for functional areas and busbars in accordance with

EN 60439 (VDE 0660 Part 500) and national installation practice.

xEnergy – the new system offer in panel building – application benefits of the optimisedsystem platform up to 4 000 A:• Low number of individual parts and modules,• Suitable for universal use (DIN VDE, IEC, NF [France], UNE [Spain]),• Can be combined flexibly, • Low earth transition resistance for personnel protection,• Efficient selection and configuration using Moeller ConFix• Functionally packed into individual assemblies, supplied as flat pack• Easy and fast to install – 30 minutes per section,• Fully type-tested and designed for future requirements.

xEnergy – in the divide of panel building

cluding motor starter combinationsup to 630 A,

• Outgoer sections up to 630 A forswitch-fuse strips, fuse rails and fuseswitch-disconnectors with differentmounting depths,

• Control sections and empty sectionsfor ancillary components such asmotor starters, PFC modules, fre-quency inverters, soft starters or forautomation solutions,

• Mounting systems for rail-mountedservice installation devices for con-ventional service distribution boardsup to 630 A.

Moeller supplies the full range, func-tionally packed in individual elements(flat pack) or according to customerrequirements as pre-assembled switch-boards.

The system platform enables panelbuilders to create individual solutionsthat can be optimally designed to meetthe requirements of the end customer.The basis of this is formed by Moeller'sintegrative device world.

The Moeller system range offers morethan the sum of the individual com-ponents. For this integrated systemplatform, Moeller developed componentsthat can be integrated into a technicalunit without any problems. Two featuresincluded are communication-enabledcircuit-breakers and the motor starterswith the combination plug connectordesign. These components illustrate howproducts can play their part in thereliability and future investment securityof a modern switchboard system. Noneof the components are overdesignedeven though the range offers the

flexibility required with only a fewproduct types, giving panel builders therequired degree of freedom to meet awide range of customer demands.

Open for networked switching and protective devices

In the Moeller system, each individualcomponent plays its part in the re-liability and future investment securityof the power distribution system. The

trend towards communication-enabledcircuit-breakers is one example of this.

Circuit-breakers of Moeller's newNZM device series direct the power tothe connected loads and disconnectthem in the event, for example, of anoverload or short-circuit. These systemsare designed for use in system andcable protection, motor protection orselective and generator protection. Thecore of an NZM - the electronicrelease- detects the actual currents anddetermines from this important opera-ting and diagnostics data. This means,for example, that load warnings oroverloads can be indicated via thecommunication system and measurescan be initiated in time, before thesefaults lead to a failure. The wide rangeof the tripping parameters allows themto be adapted to the loads as required.This also increases selectivity, thusallowing the planned disconnection ofindividually failed building sections orareas. Current and status monitoring, aswell as the remote operation ofswitches and any possibly connectedmotor starters, provide the basis forcost-effective load and energy manage-ment systems or the cost centre relatedallocation of the energy used. Thesenew features are made possible bymeans of the communication functionsand the software. The FDT (Field Device

4 Heft 7/2004 •

Picture 2. xEnergy XP power sections, XF outgoer sections and XG system section

Picture 3. xEnergy communicative up to the power management system

5• Heft 7/2004

Tool) technology here simplifies systemintegration (Picture 3).

Reliable and fast planningComponents on their own are not

enough. A future-proof planning oflow-voltage switchboard systems mustbe supported and documented withsuitable tools – such as for networkcalculations, dimensioning and con-figuration. This provides a verifiableguarantee of the quality required forsafe and reliable power distribution.Moeller offers a toolbox with this inmind, enabling panel builders to planand document all their projects simply.This ranges from tools for networkcalculation, configuration, quotations,system engineering to order handling.The use of manufacturer tools, regard-less of the system data involved, allowsthe switchboard system required to beselected and configured precisely andquickly, in accordance with inter-national requirements (Picture 4).

The futurexEnergy - the integrated and freely

combinable system range - consists ofswitching and protective devices, themounting system, the switchboardsystem including the planning andcalculation tools. The Moeller Kitsystem is ideally tailored for safe and

reliable power distribution. Individualprojects, either in functional buildings,office and industrial buildings can beimplemented quickly and economically.Not only do customers save time,money and space, they also benefitfrom Moeller's excellent reputation forsafety – and without restriction in theentire world of IEC/EN applications.

Literature

[1] DIN EN 60439-1 (VDE 0660 Teil 500):2000-08

Niederspannungs-Schaltgerätekombinationen

– Teil 1: Typgeprüfte und partiell typgeprüfte

Kombinationen. Berlin: Beuth

[2] IEC 60439-1:2004-04 Low-voltage switchgear

and controlgear assemblies – Part 1: Type-

tested and partially type-tested assemblies.

Geneva/ Switzerland: Bureau Central de la

Commission Electrotechnique Internationale

[3] DIN EN 60439-3 (VDE 0660 Teil 504):2002-05

Niederspannungs-Schaltgerätekombinationen

– Teil 3: Besondere Anforderungen an Nieder-

spannungs-Schaltgerätekombinationen, zu de-

ren Bedienung Laien Zutritt haben – Installa-

tionsverteiler. Berlin · Offenbach: VDE VERLAG

[4] IEC 60439-3:2001-05 Low-voltage switchgear

and controlgear assemblies – Part 3: Particular

requirements for low-voltage switchgear and

controlgear assemblies intended to be installed

in places where unskilled persons have access

for their use – Distribution boards. Geneva/

Switzerland: Bureau Central de la Commission

Electrotechnique Internationale

[5] DIN EN 60204-1 (VDE 0113 Teil 1):1998-11

Sicherheit von Maschinen – Elektrische

Ausrüstung von Maschinen – Teil 1: General

Requirements. Berlin · Offenbach: VDE

VERLAG

[6] IEC 60204-1:2000-05 Safety of machinery –

Electrical equipment of machines – Part 1:

General requirements. Geneva/Switzerland:

Bureau Central de la Commission

Electrotechnique Internationale

[7] DIN IEC 1117 (VDE 0660 Teil 509):1993-09

Niederspannungs-Schaltgerätekombinationen

– Verfahren zur Ermittlung der

Kurzschlußfestigkeit von partiell typgeprüften

Schaltgerätekombinationen (PTSK). Berlin ·

Offenbach: VDE VERLAG

[8] IEC/TR 61117:1992-02 A method for assessing

the short-circuit withstand strength of

partially type-tested assemblies.

Geneva/Switzerland: Bureau Central de la

Commission Electrotechnique Internationale

(ISBN 2-8318-2210-6)

[9] IEC/TR 60890:1987-07 A method of

temperature rise assessment by extrapolation

for partially type-tested assemblies (PTTA) of

low-voltage switchgear and controlgear.

Geneva/ Switzerland: Bureau Central de la

Commission Electrotechnique Internationale

(ISBN 2-8213-1346-8)

[10] Moeller GmbH, Bonn: www.moeller.net �

Picture 4. ConFix: xEnergy configuration tool for fast quotation and order processing.

Moeller GmbHHein-Moeller-Str. 7-11D-53115 Bonn

E-Mail: xenergy@moeller.netInternet: www.moeller.net

© 2004 by Moeller GmbHÄnderungen vorbehaltenVER 4810-941 GB eyePrinted in the Federal Republic of Germany (07/04)Artikel-Nr.: 285583

Xtra Combinations

Xtra Combinations from Moeller offers a rangeof products and services, enabling the best possible combination options for switching, protection and control in power distribution and automation.

Using Xtra Combinations enables you to findmore efficient solutions for your tasks while optimising the economic viability of your machines and systems.

It provides:n Flexibility and simplicityn Great system availabilityn The highest level of safety

All the products can be easily combined with oneanother mechanically, electrically and digitally,enabling you to arrive at flexible and stylish solutions tailored to your application - quickly,efficiently and cost-effectively. The products areproven and of such excellent quality that theyensure a high level of operational continuity, allowing you to achieve optimum safety for yourpersonnel, machinery, installations and buildings.

Thanks to our state-of-the-art logistics operation,our comprehensive dealer network and our highly motivated service personnel in 80 countries around the world, you can count onMoeller and our products every time. Challengeus! We are looking forward to it!

www.moeller.net/xenergy

Think future. Switch to greenThink future. Switch to green.

etz_sonderdr_lay8-GB 30.07.2004 13:21 Uhr Seite 2