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  • Dri

    ves

    Moeller HPL0213-2001/2002

    Contents

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    DM4 Soft Starters

    PageSystem selection 11/010

    System overview 13/002

    DescriptionDM4 soft starters 13/004DE4-KEY-2 LCD keypad 13/005

    EngineeringWiring examples 13/006

    Selection data DM4 soft starters 13/013Assigned switching and protective elements 13/014

    DM4 soft startersDM4 basic units 13/018DE4-KEY-2 LCD keypad 13/019Documentation 13/019

    Technical dataDM4 Soft Starters 13/020

    Dimensions 13/028

  • Moeller HPL0213-2001/2002

    System Overview

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    SHIFT

    STOP

    RUN

    PRG

    1

    3

    5

    2

    4

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    13/003Moeller HPL0213-2001/2002

    System Overview

    Basic units

    DM4 soft starters 3Motor rating from 7.5 to 500 kW for in-line

    connection (upstream of load, standard) 11 to 900 kW for in-delta

    connection ( circuit)10 predefined standard applications allow DOL operation, and parameter set selec-tion via rotary switches

    Integrator time adjustable from 1 to 255 sEnergy-saving function optimizes effi-ciency coefficient and power factorAdjustable current limitation prevents high starting currentsActuator operation for 3-phase resistive and inductive loads from 16 to 900 A (400 V)

    Selection data a Page 13/013Ordering information a Page 13/018

    3

    Accessories

    DE4-KEY-2 LCD keypad 1Pluggable to DM4 soft starters, with 8 function keys and plain text display, language selectable (German/English)

    Ordering information a Page 13/019

    Communication cards 2DE4-COM-2Xserial RS485/RS232 interface

    DE4-NET-KSuconet K interfaceDE4-NET-DPPROFIBUS-DP interfaceDE4-NET-SINTERBUS interface

    Ordering information a Page 16/009

    Super fast semiconductor fuses 4Fuses for protecting semiconductors, either for direct installation in DM4 soft starters or for external mounting

    Selection data a Page 13/014Ordering information a Page 16/011

    Fuse base 5For external mounting of super fast semi-conductor fuses

    Ordering information a Page 16/011

  • Moeller HPL0213-2001/2002

    DescriptionDM4 Soft Starters

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    The units of the DM4 series round off the top end of Moellers soft starter program. With a rating range starting at 7.5 kW, the DM4 soft starters are suitable for demanding automation tasks. The key features of the DM4 range are: Current limitation High overload withstand capability Large rating range up to 500 kW

    (or 900 kW in in-delta connection) Predefined parameter sets for standard applications

    selectable All parameters also individually adjustable Keypad with plain text display (optional) Programmable relay and analog outputs Networkable Voltage regulator function (generalized phase control) can be implemented for

    each software changeover

    The units of the DM4 series are soft starters for standardthree-phase asynchronous motors. The connection type determines the rating range: In in-line connection (upstream of load, standard):

    7.5 kW to 500 kW at 400 V In in-delta connection: 11 kW to 900 kW at 400 V,

    each phase of the soft starter being connected in series with the individual motor windings (6 lines required, motor in delta circuit only).

    The DM4 soft starters are factory preset for the most common applications. For var-ious standard applications, parameter sets can be selected via an application selec-tor switch, thereby removing the need for manually configuring the device and the associated risk of errors.

    The preset, application-specific parameter sets can also be selected via an optional keypad with plain text display. All parameters can be displayed, edited and matched to specific applications with the keypad. The keypad is also required for reprogramming the soft starters digital and analog inputs and outputs.Interface modules can be used as an alternative to the keypad. The soft starters can be interfaced with a PLC via Suconet K, PROFIBUS-DP or INTERBUS. For defining parameters, via a PLC, the same functions are available as with the LCD keypad. The same software modules can be used for PLCs and fre-quency inverters.

    Pump drives:The soft start prevents sudden pressure surges. The mechanical load on the plant drops and the lifespan of the plant components is increased.

    Fan drives and compressors: The soft start prevents belt slippage, and therefore premature wear. This in turn lowers operating costs and increases plant life.

    Conveyors: Instead of starting with a jolt, the conveyor starts up gently and the transported items do not fall over. The mechanical stress on the conveyor is reduced and its lifespan therefore increased.

    Circular saws, bandsaws: Due to the current limitation at start-up, current peaks are avoided. This results in energy savings and reduced electricity bills and peak load tariffs.

    Agitators, mixers: as above. Mills, breakers: as above.

    DM4 soft starters/three-phase regulators: Product Features

    Operation as 3-phase soft starter

    Typical fields of application as soft starter

  • DescriptionDM4 Soft Starters, DE4-KEY-2 Keypad

    Moeller HPL0213-2001/2002 13/005

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    The DM4 units can be changed over by software to three-phase regulator operation. The rating range is 16 A to 900 A at 400 V (standard connection only, in-delta con-nection not possible).They can be operated both in pure regulator mode or with a closed-loop control cir-cuit. The units each have two analog inputs for setpoint/actual values and an additional built-in current feedback loop.For setting the parameters for actuator operation, a keypad or the serial interface with PC software is required.

    Heater loads: Continuous temperature regulation reduces the thermal and mechanical load on the heating elements and therefore increases their lifespan.

    Lighting control: Gentle lighting up of lamps reduce cold-state current consumption. By using the optimum operating point of the lights, energy consumption is lowered without reducing light output, and the lifespan is increased. This results in lower electricity bills and peak load tariffs.

    Ozone generators: Regulation of high-voltage transformers.

    Delivery of each device with complete documentation in PDF format on CD is in preparation. Printed versions are available on request.

    Documentation for DM4-340 soft starters a Page 13/019Documentation for DE4-KEY-2 keypads a Page 13/019

    The DM4 soft starters are factory preset for the most common applications. For var-ious standard applications, parameter sets can be selected via an application selec-tor switch.

    These parameter sets can also be selected with the DE4-KEY-2 keypad. With the keypad, all parameters can be viewed, edited and adapted for specific applications. In addition, the drive can be controlled using the keypad.

    The DE4-KEY-2 keypad has a two-line plain text display. Menus guide the user through the parameterization. The display language can be changed (German/English). During operation, the current motor current is displayed. Various status symbols conveniently indicate operating states. In the Stop state, a clear red LED on the Stop key is lit.

    To connect the keypad, it is simply plugged into the soft starter. It can be connected and disconnected during operation.The keypads intergral memory saves the entered parameter set and retains it even when the power is disconnected. Where several frequency inverters are used, the parameter set can therefore be copied from one frequency inverter to another.

    Operation as three-phase regulator

    Typical fields of application as three-phase regulator

    Documentation

    DE4-KEY-2 keypad

  • Moeller HPL0213-2001/2002

    EngineeringWiring Examples

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    Immediate disable without ramp function

    OperationFor this function, the circuit shown must be added to all of the following circuit options. The parameter settings required for input E2 are described in the manual.

    EMERGENCY STOP

    S1:S2:G1:

    OffOnEnable (E2 = 1 a enabled)

    Integration of the Z-relay Wiring

    S1:S2:G1:

    a

    b

    c

    d

    EMERGENCY STOP

    OffOnEnable (E2 = 1 a enabled)

    The motor-protective relays signal contacts are incorporated in the On/Off cir-cuit. Under fault conditions, the soft starter is inhibited without delay and the motor spins down. The K1M mains contactor drops out as soon as the Run relay drops out.The motor-protective relays signal contacts are incorporated in the soft start/stop circuit. Under fault conditions, the soft starter ramps down. The soft starter is de-energized, but the mains contactor remains on.To switch the mains contactor off as well, a second contact of the motor-pro-tective relay must be incorporated in the branch of the K1M mains contactor in addition to variant 2. After completion of the soft stop, the Run relay drops out, thereby cancelling the holding circuit of the K1M.Soft stopSoft start

    T1, T2: thermistor

    S1

    S2

    K1E2

    39

    K1

    K1

    G1

    13

    14

    K1M

    K1

    G1E1

    39

    E1

    39

    K2

    G1

    K2 G1 RUN

    Z1

    K2

    S4

    S3

    K1

    Z1

    K2

    K2

    S4

    S3

    S2

    S1

    Z1 K1

    Z1

    K2

    K2

    K1

    a b

    dd

    c

    G1

    L1L2L3

    L1L1

    2L2

    3L3

    2T1

    4T2

    6T3

    N

    N

    PE

    >I >I >I

    K1M

    Q1

    Z1

    F2

    T1 T2

    ~=

    M3

    +

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    Moeller HPL0213-2001/2002

    EngineeringWiring Examples

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    Soft starter with mains contactor (K1M)

    Operation

    EMERGENCY STOP

    S1:S2:S3:S4:a:b:

    OffOnSoft stopSoft startEnableSoft stopSoft start

    Wiring

    a: See Operation

    a b

    S1

    S2

    K1E1

    39

    E2

    39

    S4

    S3

    K1

    K1

    K2K1 K1 G1 RUNK2

    G1 K2 G1 K1M

    13

    14

    ~=

    ~=

    > > > > > >I I I I I I

    - The

    rmist

    or

    + T

    herm

    istor

    7

    MM1

    G1

    F2

    F1

    3~

    L1L2L3NPE

    L N E1 E2 39

    13

    K1;RUN K2;TOR K3 K4

    14 23 24 33 34 43

    1L1

    3L2

    5L3

    2T1

    4T2

    6T3

    +12 8 17

    62 63

    PE

    0 V

    Anal

    og

    Anal

    og O

    ut 1

    Anal

    og O

    ut 2

    0 V

    Anal

    og

    0 V

    (E1;

    E2)

    Star

    t/Sto

    p

    Enab

    le

    +12

    V D

    C

    REF

    1: 0

    10

    V

    REF

    2: 4

    20

    mA

    T1 T2

    K1M

    Q1

    motI

    Q2

    a

  • Moeller HPL0213-2001/2002

    EngineeringWiring Examples

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    Soft starter without separate mains contactor (K1M)

    Operation

    EMERGENCY STOP

    S1:S2:a:b:

    Soft stopSoft startEnableSoft stopSoft start

    Wiring

    a: See Operation

    ba

    E1

    39G1

    E2

    39G1K1

    S2

    K1

    K1

    S1

    ~=

    ~=

    > > > > > >I I I I I I

    - The

    rmist

    or

    + T

    herm

    istor

    7

    MM1

    mot

    G1

    F2

    3~

    L1L2L3NPE

    L N E1 E2 39

    13

    K1;RUN K2;TOR K3 K4

    14 23 24 33 34 43

    1L1

    3L2

    5L3

    2T1

    4T2

    6T3

    +12 8 17

    62 63

    PE

    0 V

    Anal

    og

    Anal

    og O

    ut 1

    Anal

    og O

    ut 2

    0 V

    Anal

    og

    0 V

    (E1;

    E2)

    Star

    t/Sto

    p

    Enab

    le

    +12

    V D

    C

    REF

    1: 0

    10

    V

    REF

    2: 4

    20

    mA

    T1 T2

    Q1

    I

    F1

    Q2

    a

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    Moeller HPL0213-2001/2002

    EngineeringWiring Examples

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    Soft starter with bypass and mains contactor (K1M)

    Operation

    EMERGENCY STOP

    S1:S2:S3:S4:a:b:

    OffOnSoft stopSoft startEnableSoft stopSoft start

    Wiring

    a: See Operation

    a b

    S1

    S2

    K1E2

    39

    E2

    39

    S4

    S3

    K2M

    K1

    K1 K1K2

    K1

    G1 G1

    K2

    K2

    G1 RUN

    K1M

    13

    14

    23

    24G1 TOR

    K2M

    ~=

    ~=

    > > > > > >III III

    MM1

    G1

    F2

    K1M

    3~

    L1L2L3NPE

    L N E1 E2 39

    13

    K1;RUN K2;TOR K3 K4

    14 23 24 33 34 43

    1L1

    3L2

    5L3

    2T1

    4T2

    6T3

    +12 8 1

    PE

    7

    7

    62 63

    0 V

    Anal

    og

    - The

    rmist

    or

    + T

    herm

    istor

    Anal

    og O

    ut 1

    Anal

    og O

    ut 2

    0 V

    Anal

    og

    0 V

    (E1;

    E2)

    Star

    t/Sto

    p

    Enab

    le

    +12

    V D

    C

    REF

    1: 0

    10

    V

    REF

    2: 4

    20

    mA

    T1 T2

    Q1

    K2M

    motI

    F1

    Q2

    a

  • Moeller HPL0213-2001/2002

    EngineeringWiring Examples

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    Soft starter with mains contactor (K1M), in-delta connectionOperation

    EMERGENCY STOP

    S1:S2:S3:S4:a:b:

    OffOnSoft stopSoft startEnableSoft stopSoft start

    Wiring

    a: See Operation

    a b

    S1

    S2

    K1E1

    39

    E2

    39

    S4

    S3

    K1

    K1

    K2K1 K1 G1 RUNK2

    G1 K2 G1 K1M

    13

    14

    ~=

    ~=

    > > > > > >III III

    MM1

    G1

    F2

    F1

    K1M

    3~

    L1L2L3NPE

    L N E1 E2 39

    13

    K1;RUN K2;TOR K3 K4

    14 23 24 33 34 43

    W1

    V1 U1

    1L1

    3L2

    5L3

    2T1

    4T2

    6T3

    W2

    V2 U2

    +12 8 1

    PE

    7

    7

    62 63

    0 V

    Anal

    og

    - The

    rmist

    or

    + T

    herm

    istor

    Anal

    og O

    ut 1

    Anal

    og O

    ut 2

    0 V

    Anal

    og

    0 V

    (E1;

    E2)

    Star

    t/Sto

    p

    Enab

    le

    +12

    V D

    C

    REF

    1: 0

    10

    V

    REF

    2: 4

    20

    mA

    T1 T2

    Q1 Q2

    motI

    a

  • Dri

    ves

    Moeller HPL0213-2001/2002

    EngineeringWiring Examples

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    13/011

    Soft starter with reversing circuit

    Operation

    EMERGENCY

    S1:S2:S4:S5:

    OffOnSoft stopSoft start

    a:b:

    c:d:

    EnableSoft stopSoft startForwardReverse

    Wiring

    a: See Operation

    bdca

    E1

    39G1K5

    S5 K5 K5

    S4

    13

    14

    K4

    G1 RUN

    K3E2

    39G1K1

    S2 K1 K1

    K1

    K2

    S1

    K3 K2M

    K2M

    K1M

    K1

    K2

    K1

    K3

    K4

    K2 K1M

    K1M

    K2M

    K4

    S1

    ~=

    ~=

    > > >> > >

    I I II I I

    Th

    erm

    istor

    + T

    herm

    istor

    7

    MM1

    mot

    G1

    F2

    3~

    L1L2L3NPE

    L N E1 E2 39

    13

    K1;RUN K2;TOR K3

    a

    K4

    14 23 24 33 34 43

    1L1

    3L2

    5L3

    2T1

    4T2

    6T3

    +12 8 17

    62 63

    PE

    0 V

    Anal

    og

    Anal

    og O

    ut 1

    Anal

    og O

    ut 2

    0 V

    Anal

    og

    0 V

    (E1;

    E2)

    Star

    t/Sto

    p

    Enab

    le

    +12

    V D

    C

    REF

    1: 0

    10

    V

    REF

    2: 4

    20

    mA

    T1 T2

    Q1

    K1MK2M

    I

    F1

    Q2

  • Moeller HPL0213-2001/2002

    Notes

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  • DM

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    13/013Moeller HPL0213-2001/2002

    Selection DataDM4 Soft Starters

    DM4...

    Power sectionMains supply voltage UL (45 65 Hz 0 %) 230 V 15 % to 460 V +15 %Control voltage 24 V to 230 V AC/DCRated operational current Ie 16 900 ARecommended motor rating

    In-line connection (upstream of load, standard)

    7.5 kW 500 kW (400 V)

    In-delta connection (in series with each motor winding)

    11 kW 900 kW (400 V)

    Internal bypass relay Standards IEC/EN 60 947-4-2Degree of protection IP20Fields of application Soft starting of three-phase asynchronous motors

    1-phase loads (heaters, lamps, electroplating)

    3-phase loads (heaters, lamps, electroplating)

    K

    3-phase motors KFunctionsFast switching (semiconductor contactor) (minimum ramp time 1s)Soft start function KReversing contactor function External solution requiredSuppression of closing transients

    K

    Current limitation KOverload monitoring KUnderload monitoring KAnalog inputs 1 x 0 10 V DC; 1 x 4 20 mAAnalog outputs 2 x 0 10 V DC, 10 mAProgrammable digital inputs 2Programmable relay outputs 4 make contacts, 3 of which floatingThermistor input KFault memory 5 faultsPre-programmed parameter sets 10 different standard applications:

    various fans, pumps and compressorsSuppression of DC components for motors

    K

    Potential isolation between power and control sections

    K

    Interfaces (optional) In preparation

    Notes K Standard fittings

  • Sele

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    Assi

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    Sw

    itchi

    ng a

    nd P

    rote

    ctiv

    e El

    emen

    ts

    DM4 Soft Starters

    DM4 Soft Starters

    Sele

    ctio

    n D

    ata

    Ass

    igne

    d Sw

    itchi

    ng a

    nd P

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    ctiv

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    Moe

    ller H

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    11-2

    001/

    2002

    M

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    0-16

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    DIL0

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    CL-

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    0/80

    A/66

    0VDM

    4-34

    0-15

    K15

    3029

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    + M

    -32-

    PKZ2

    (+ C

    L-PK

    Z2)

    DIL1

    MZ1

    -40

    DIL0

    MS0

    0UF1

    /80/

    80A/

    660V

    DM4-

    340-

    22K

    2244

    4144

    NZM

    7-63

    N-O

    BIDI

    L2M

    Z1-5

    7DI

    L1M

    S00U

    F1/8

    0/12

    5A/6

    60V

    DM4-

    340-

    30K

    3059

    5559

    NZM

    7-63

    N-O

    BIDI

    L2AM

    Z1-6

    3DI

    L2M

    S00U

    F1/8

    0/12

    5A/6

    60V

    DM4-

    340-

    37K

    3772

    6872

    NZM

    7-80

    N-O

    BIDI

    L3M

    80Z5

    -100

    /SK3

    DIL2

    MS0

    0UF1

    /80/

    200A

    /660

    VDM

    4-34

    0-45

    K45

    8581

    85N

    ZM7-

    100N

    -OBI

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    AM85

    Z5-1

    00/S

    K3DI

    L2M

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    0/20

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    60V

    DM4-

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    55K

    5510

    599

    105

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    7-12

    5N-O

    BIDI

    L4M

    115

    Z5-1

    25/S

    K4DI

    L3M

    8020

    .610

    .32-

    350

    DM4-

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    75K

    7514

    613

    414

    6N

    ZM7-

    160N

    -OBI

    DIL4

    AM14

    5Z5

    -150

    /SK4

    DIL4

    M11

    520

    .610

    .32-

    350

    DM4-

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    90K

    9017

    416

    117

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    ZM7-

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    DILM

    185

    Z5-2

    20/F

    F6DI

    LM18

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    110K

    110

    202

    196

    202

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    5Z5

    -220

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    DILM

    185

    20.6

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    0-13

    2K13

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    223

    124

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  • DM4 Soft StartersDM4 Basic Units

    DM

    4 So

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    13/018 Moeller HPL0213-2001/2002

    Type PriceSupply voltage Rated opera-

    tional currentRated output for 3h motors at 400 V

    Article no. See Price List Std.pack

    ULV

    IeA

    P

    kW

    Soft starters up to 37/55 kW 1)at 400 V

    190 520 V AC g 0 % 16 7.5 DM4-340-7K5207897

    1 off

    23 11 DM4-340-11K207898

    30 15 DM4-340-15K207899

    44 22 DM4-340-22K207900

    59 30 DM4-340-30K207901

    72 37 DM4-340-37K207902

    Soft starters up to 75/132 kW 1)at 400 V

    190 520 V AC g 0 % 85 45 DM4-340-45K207903

    1 off

    105 55 DM4-340-55K207904

    146 75 DM4-340-75K207905

    Soft starters up to 200/315 kW 1)at 400 V

    190 520 V AC g 0 % 174 90 DM4-340-90K207906

    1 off

    202 110 DM4-340-110K207907

    242 132 DM4-340-132K207908

    300 160 DM4-340-160K207909

    370 200 DM4-340-200K207910

    Soft starters up to 500/900 kW 1)at 400 V

    190 520 V AC g 0 % 500 250 DM4-340-250K207911

    1 off

    600 315 DM4-340-315K207912

    750 400 DM4-340-400K207913

    900 500 DM4-340-500K207914

    Notes 1) Ratings apply to in-line/in-delta connection.

  • DM

    4 So

    ft S

    tart

    ers

    13/019

    DM4 Soft StartersDE4-KEY-2 LCD Keypad, Documentation

    Moeller HPL0213-2001/2002

    Type PriceArticle no. See Price List Std.

    Keypad Allows all soft starter parameters to be adapted for any

    application. The drive can also be controlled via the keypad. Connection to soft starter by simply mounting/removing keypad,

    also during operation With retentive memory for parameters.

    In series operation, parameter sets can be transmitted from one soft starter to the other.

    Two-line plain text display Status symbols for indication of operating status

    DE4-KEY-2211291

    1 off

    Type PriceArticle no. See Price List Std.

    DocumentationDelivery of each device with complete documentation in PDF format on CD is in preparation. Printed versions are available on request.

    DM4-340 Soft Starter, Hardware and Engineering German AWB8250-1341D214791

    1 off

    English AWB8250-1341GB214792

    Soft Starter Configuration, Engineering German AWB8250-1346D214793

    English AWB8250-1346GB214794

    DE4-KEY-2 Keypad, Hardware and Engineering German AWB8240-1344D214795

    English AWB8240-1344GB214796

    Italian AWB8240-1344I223197

    Spanish AWB8240-1344E223198

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