A New Species

The new Variable speed starter (VSS) from Eaton offers alternatives for drive engineering

The increasing automation of machines and the increasing legal requirements with regard to energy efficiency have resulted in a significant rise in the demand for variable frequency drives. At the same time the motor starter has established a strong position on the market. In order to bridge the gap between the two, Eaton is now offering a new device class: the Variable speed starter (VSS).

Electrical speed control using variable frequency drives continues to gain importance. The Motor Regulation EC 640/2009 of the European Union is a driving force here, stipulating the mandatory use of IE3 motors directly on the grid or likewise the use of IE2 motors with variable speed drives from 2015. This means that there is an increasing move away from the motor starter towards the variable frequency drive, particularly with simple applications.

Benefits of the motor starter and variable frequency drive combined

There is clearly a gap between these two most widely used methods of controlling electric motors. One the one hand, there is the motor starter with its easy handling and high level of reliability and yet limited functionality. On the other hand, the variable frequency drive provides the required variable motor speed and a wide range of functions, but involves a greater degree of complexity. The move towards the variable frequency drive therefore presents many users with some challenges since it is a highly complex device and normally requires a comprehensive knowledge of drive engineering.

As a pioneer and one of the leading specialists for all aspects of switching, protecting and driving motors, Eaton has developed a new device class that combines the benefits of the motor starter with those of the variable frequency drive. The so-called Variable speed starter (VSS) can be handled as easily as a motor starter but offers the possibility of variable speed control at the same time.

Simplicity at first glance…

Eaton is launching the new device class under the product name PowerXL-DE1, first of all in two sizes. The slim-line FS1 version with a width of only 45 mm is ideal for controlling motors up to 1.5 kW, while the FS2, double the width at 90 mm, is designed for ratings from 2.2 to 7.5 kW. At first glance, these devices are the embodiment of simplicity.

Their attractiveness lies in the fact that there are no buttons and operating elements. This makes a simple “out-of-the-box” installation possible, i.e. the installer just has to take the device out of the box, wire it up like a motor starter, and it is already operational. The fact that the DE1 requires no parameter setting means that the probability of installation errors is kept to a minimum and therefore also the time required up to commissioning. Three LEDs indicate the status and operating mode of the unit at a glance. The table provided directly on the device gives a clear explanation of the color coding and flash frequency.

...impressive trip free design at second

Besides simple handling, Eaton has also integrated the aspect of reliability into the new device class. The trip free design of the Variable speed starter (VSS) ensures maximum availability. This concept comprises the ability of the DE1 devices to detect the regenerative energy feedback from the motor and to thus lengthen the ramp automatically. It also includes a DC braking function and the function of automatically reducing the switching frequency to prevent the device temperature from being exceeded. However, in the event that a fault causes the device to switch off, the automatic restart function makes it possible to ensure continuous motor operation. This means that the manual reset of the fault is no longer necessary providing that safety is not impaired.

The benefits of the trip free design are easily demonstrated in practical applications. Imbalance can be a genuine problem in many applications where centrifugal forces are present (e.g. industrial washing machines). On the one hand the motor must accelerate the load, whilst on the other hand, the imbalance mechanically accelerates the motor so that it runs faster than set by the variable frequency drive. This results in regenerative energy feedback into the DC link circuit. Normally the energy must be discharged via a braking resistor. The DE1 offers a refined alternative: An internal algorithm ensures that this does not increase the DC link voltage to impermissible values and thus initiate a shutdown – and all that without the use of a braking resistor.

Fans are another area of application. The air flow in a pipe system can mean that fans often rotate when the driving motor is not switched on. If a speed controller is then required to switch the motor that is already rotating, the controller may be switched off in certain circumstances on account of overcurrent. With these kinds of applications, the DE1 Variable speed starter (VSS) is able to brake the motor with DC current before the motor actually starts in order to prevent the unwanted shutdown. The device therefore ensures fault-free operation even here.

A large market gap

The variable speed starters are factory fitted with internal EMC filters so that they are suitable for use in industrial networks as well as in public utility grids (category C1, C2, C3) without the need for other external EMC filters.

With this unique performance profile and its design for ambient temperatures from -10 to 50 °C (60°C with derating) the Variable speed starter (VSS) meets the demands of several applications on the market for which there was previously no ideal solution. This includes, for instance, applications for which a DOL starter and star-delta starter combination or a soft starter cannot be used since the motor draws a large starting current but does not permit a reduced starting torque. This also applies to materials handling applications, when machines or crushers have to be started up at once under full load after a stop. Even for many simple applications, such as in the field of transport technology, regular variable frequency drives are often overdimensioned, i.e. too elaborate, too expensive and complex.

Many machine builders, who are required to move media such as air or liquids, are now challenged by the requirement of the ErP Directive to design a new drive concept for fans and pumps in order to achieve the prescribed minimum efficiency values. If they have previously used a motor starter and controlled the flow rate mechanically or hydraulically, such as with throttle valves, they are now faced with the challenge of switching to a power-dependent control through the possibility of variable speed adjustment.

The variable speed starter is also ideal for applications requiring a fixed speed that cannot be implemented with the mains frequency. This is often the case in the wood industry where motors are run at high speeds (e.g. 18,000 rpm). The DE1 also offers an alternative where a constant speed is required, but where an IE3 motor cannot be used due to the different mechanical dimensions compared to IE2 motors.

Operation options: Screwdriver to remote keypad

The variable speed starter also offer considerably more options than is seen at first and second glance. A pluggable and universal configuration module, the DX-EXT-SET, enables the operator to change the most important parameters from the factory setting with a screwdriver – without the need for a keypad, software or manual. This means that ramp times, motor protection, mains frequency and terminal configuration can be set ergonomically. Once the parameters have been set via the operating elements on the front, the configuration module can “mechanically store” this parameter set, which can then be transferred directly to other variable speed starters – simply by plugging onto the DE1 device and pressing the Set button. This function simplifies and speeds up commissioning in series production or when replacing a device in the event of a fault.

Eaton also offers users external keypads with LED or OLED displays, already known from the PowerXL series, for an alternative method of parameterizing and operating the DE1, as well as a Bluetooth communication stick for the simple copying of parameters from one device to others. Like all devices of the PowerXL series, the DE1 is also compatible with Eaton's drivesConnect software. This software and the keypads enable up to 63 devices (DE1, DC1, DA1) to be combined in a drive network and now operate and parameterize them centrally as stations of the network. The DE1 comes with a Modbus interface as standard and can also be integrated directly in Eaton's innovative SmartWire-DT communication system.

The new PowerXL-DE1 Variable speed starters (VSS) that comply with the international CE, UL, cUL and cTick requirements thus provide machine and system builders with a cost-effective and at the same time highly reliable alternative for worldwide use in order to make applications with a previously constant speed more energy efficient and in compliance with the increasing international legal requirements.

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Crouzet DCmind Brush Motors - Product of the Year 2013

March 2014, the 40,000 technical and scientific readers of the American magazine Medical Design Briefs voted the DCmind Brush range of DC motors Product of the Year 2013. DCMind  Brush motors were selected for their outstanding technical merit and practical value.

DCmind Brush motors are incredibly quiet, even at full load, offer excellent efficiency and an exceptional service life, and have an extensive range of gearboxes and accessories. The low noise level (35 dB) of DCmind Brush motors makes them particularly suitable for the medical and biopharmaceutical sectors, as well as laboratories, industry and office equipment and systems. They can also be used in many other high performance applications such as pumps and valves, and also in the railway, military and aeronautical fields.

“The new DCmind Brush motor generation adds a uniquely differentiated premium product to our current offering”, says John Morehead, Crouzet Motors US National Sales Manager. “With its remarkably quiet operation, quality design and manufacturing, it greatly expands our application reach. Additionally, Crouzet’s eco-design strategy has cut the environmental impact of the product’s overall life cycle in half while at the same time improving the product’s
energy efficiencies.”

It is this extraordinary performance that won over the readers of Medical Design Briefs and made DCmind Brush the Product of the Year 2013.

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Hylec-APL now offers the DE01 range of pre-installed control stations which combine tough IP67 enclosures with hard wearing push button and selector switches reducing time spent on-site. Installation is further aided thanks to unique, snap-on brackets for easy wall, chassis and DIN mounting.

*  Variety of sizes and depths to accommodate different application requirements
*  Thick walls constructed from robust ABS material
*  Up to IP67 protection depending on switch options
*  Snap-on bracket mounting available for DIN rail or chassis / wall mounting
*  Selection of push button and selector switch types and combinations are available
*  Suitable for indoor and outdoor use in domestic, commercial and industrial applications
*  All products comply fully with ROHS and REACH standards

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7 new Chronos 2 Timers, 2 new Level Control Relays and 2 new Phase Control Relays are now available in a more compact DIN Rail package ideal for modular use

Crouzet Control, a brand of Custom Sensors & Technologies (CST), is pleased to announce the availability of 11 redesigned Chronos 2 Timers and Control Relays now available in an improved DIN rail modular housing with the same profile as the Crouzet C-lynx product family.

The 7 new 22.5 mm DIN Rail mounted Chronos 2 Timers (RA2R1, RQR1, RQR6, RU2R1 RU2R3, RU2R4 & RX2R1) replace timers previously offered in a 22.5 mm wide industrial housing. The new 22.5mm DIN rail mounted housing is also similar to the new 17.5 mm Chronos 2 Timers featuring the same terminal block position for perfect panel alignment. The new 22.5 mm timers also feature 2 SPDT relays rated at 8 A / 250 VAC and are just 8 mm higher than the 17.5 mm version with one output relay. New Chronos 2 timers have the same rated supply voltage and electrical specifications as previous industrial housing versions.

ENR and ENRM Level Control Relays have also been redesigned in a new 22.5 mm DIN Rail housing replacing 22.5 mm wide industrial models. A new universal supply voltage of 24 to 240 VAC VDC allows them to replace 8 existing part numbers with similar or improved features per model.

The new 17.5 mm MWS Phase Control Relay featuring an 8 A output rating replaces both the 17.5 mm MWS and 22.5 mm EWS series. The redesigned 22.5 mm EWS2 replaces the existing EWS2 featuring a more compact housing allowing modular installation.

All new Chronos 2 Timers and Control Relays are C-UL-US Listed, CE certified to the IEC Low Voltage Directive and compliant with the RoHS Directive.

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Hylec-APL offers a range of pre-installed control stations which combine tough IP67 enclosures with hard wearing push button and selector switches; helping installers to reduce time spent on-site. Installation is further aided thanks to unique, snap-on brackets for easy wall, chassis and DIN mounting.

*  Features a unique snap-on bracket for wall or DIN mounting.
*  Patented range of control stations available exclusively from Hylec-APL.
*  Up to IP67 protection depending on product.
*  5mm wall thickness provides enough strength to replace many metal enclosures.
*  Available with a huge range of buttons and switches; many variations available pre-assembled.
*  Delivered with two M20 threaded cable gland entries.

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CRYDOM’S WORLD CLASS SOLID STATE SWITCHING TECHNOLOGY IS NOW AVAILABLE IN THE SOLICON DRC SERIES OF SOLID STATE CONTACTORS WHICH OFFERS PERFORMANCE LEVELS NEVER REACHED BEFORE BY ANY CONTACTOR

Crydom is pleased to announce the new SOLICON DRC Series of AC Output Solid State Contactors. SOLICON solid state contactors are the most innovative compact DIN Rail Mounted, IEC standard based contactors in the market and combine all advantages of a solid state design with the functionality and simplicity of use of an electromechanical contactor.

SOLICON DRC Series solid state contactors are the only contactors for Motor Control in the market with:
- Maximum switching frequency of 9000 cycles/hour
- Embedded auxiliary contacts (Normally open and Normally closed)
- 100KA Short Circuit Current Rating
- The most frequently used AC and DC input control voltage configurations available (24VAC/DC, 120VAC, 230VAC)

These features make the SOLICON DRC Series unique in the market, beating similarly rated competitive products on each front with a broader working temperature range (-30ºC to +80ºC), better resistance to surge current (750 Amps), higher resistance to short circuit (2560 A2S), smaller size (height and depth) and greater life span (50 Million cycles).

All these premium features are included in both available SOLICON models:
- DRC3P, Solid State Contactor
- DRC3R, Reversing Solid State Contactor
Both models are rated up to 5HP @ 480VAC

The DRC3P is available in either instantaneous turn-on (typically used for Motor Control) or zero-crossing turn-on (more often used with resistive loads). Both are available with either 2 or 3 controlled legs.

The DRC3R reversing contactor also includes a control interlock feature that allows only Off, Forward and Reverse operation in a safe mode, while providing relevant cost reduction and high space saving.

Available with 2 operating voltage options (400 VAC and 480 VAC), 5 HP motor rated (except the DRC3P contactor with 3 controlled legs which is rated @ 3 HP) and including an LED input status indicator, the DRC3 can be used in combination with the most frequently used overload relays and thermal magnetic circuit breakers (Schneider Electric’s LRD and GV2) thanks to their full mechanical and electric compatibility.

Crydom’s SOLICON DRC Series contactors are C-UL-US Listed and compliant to IEC 60947-4-2 requirements. They are also CE certified to the IEC Low Voltage Directive and compliant to the IEC EMC and RoHS Directive.

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30 New AC Output models are added to the DRA Series including models with economical lower operating voltage range and models featuring 2 switched phases, all in compact DIN Rail Mountable packages

Crydom, a brand of Custom Sensors & Technologies (CST), is pleased to announce the availability of 30 new models in the popular DRA Series of AC output DIN Rail Mounted Solid State Contactors.

DRA Series 3 Phase Contactors now include new 2 switched phase versions particularly suitable for motor control circuits where the neutral connection is not needed or utilized.

DRA Series 3 Phase Motor Reversing Contactors now also include 400 VAC output voltage versions which maximize cost effectiveness when higher operating voltages are not required.

The 30 new DRA Series contactors have the same performance as previous models including 4 kV optical isolation, AC or logic compatible DC control inputs, both with input status indicators, UL approved AC motor and resistive load ratings of either 2.4 or 4.2 amps per phase. Motor reversing models also include a control interlock feature that allows only Off, Forward or Reverse operation.

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Diversified industrial manufacturer Eaton has launched a comprehensive range of power protection relays that are ideally suited for use in the company’s Medium Voltage (MV) switchgear. Thanks to the microprocessor-based design the devices make it possible to eliminate unnecessary trippings, isolate faults, and protect motors and cables, thus offering sophisticated protection for many power applications. The relays also provide detailed information that enables users to better manage their systems, subsequently contributing to a safe and reliable energy supply for applications in utility distribution networks and industrial environments or other power systems.

Eaton’s family of relays consists of devices for a broad range of protection and control tasks including directional and non-directional feeder protection, overcurrent and earth fault protection (OC&EF), voltage and frequency protection, motor and generator protection, generator and transformer differential protection, and power differential protection. These functions partly also include voltage measurement.

All relays have been designed according to the IEC 61850 standard and are internationally certified (KEMA, UL, Gost-R, CSA). An integrated user-friendly status display offers clear data visualisation and intuitive operation while plausibility checks prevent the user from accidently entering unacceptable inputs. The display allows for immediate evaluation of individual measurements on site. At the same time, direct connection with the SCADA system is easily possible via its control interface. As the relays feature analysis and graphical representation of the fault details, fault recording becomes extremely transparent. The integrated non-volatile disturbance recorder registers up to 120 s with 32 samples per cycle. Import and export of fault records can be done in the ASCII and Comtrade formats.

All current and ground current inputs are designed for 1 and 5 A. The relay terminals can easily be integrated into, and removed from, the switchgear enclosure. To ensure safe operation the current connections are equipped with automatic short circuit connectors. A wide range power supply unit covers all standard auxiliary voltages, both for AC and DC. Eaton also offers appropriate software that allows the user to adjust the nominal voltage of the voltage inputs and the switching thresholds of the digital inputs. Besides parameter setting and validity checks, the software supports offline configuration of all relay types, reading and evaluating statistical data and measuring values, commissioning functions as well as error analysis.

The Eaton relays have specifically been customised for the following Eaton MV switchgear systems: Xiria, Xiria E (extendable version), SVS, Power Xpert® FMX and UX.

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Eaton Corporation is offering a new plug-in unit for the NZM3 circuit-breaker. The NZM3 plug-in unit allows customers to exchange the circuit-breaker in a panel simply and quickly, and it also offers benefits during service work because the system section concerned can be disconnected simply and safely.

The housing design of the base has been adapted to that of the NZM3, so that all connection options provided by the main device can also be implemented in the base. For Eaton, safety has the highest priority, and the live parts in the base are therefore automatically protected from direct contact when the circuit-breaker compartment is pulled out. The circuit-breaker also disconnects automatically as soon as the mounting screws are loosened when the circuit-breaker is in the On position or when the circuit-breaker is pushed in. In the latter case, the circuit-breaker can then only be switched on if the mounting screws between the circuit-breaker and the plug-in unit base have been tightened.

Even with the wide range of features and capabilities provided by its products, simple operation and flexibility are top priorities for Eaton: Just fit the modified NZM3 with its rear terminal bolts into the guide, tighten the bolts, and the system is already operational. An auxiliary conductor plug-in device is also available as an option. This enables the connected shunt or undervoltage releases, auxiliary contactors and also the remote operator to be tested without having to fit the circuit-breaker into the panel.  In this way, correct operation can be tested prior to commissioning. Users also do not have to change the wiring when exchanging a circuit-breaker: The auxiliary conductor plug can simply be removed from its base, fitted onto the new terminal cables and operation is restored.

Technical specifications have been set to meet the wide range of requirements in the industrial sector and are impressive in every respect: The new plug-in unit on the NZM3 from 250 - 500A can be used without any derating up to an ambient temperature of 40°C, and this includes the extensive range of accessories. For more demanding applications, the full switching capacity of the NZM3 - up to 150kA at 415VAC - can be used. The circuit-breaker can also be fitted in many positions, either vertically or turned anticlockwise/clockwise by 90°.

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The PSR softstarter is the most compact of all the softstarter ranges, thereby making it possible to design compact starting solutions. The system concept with Manual Motor Starters and the PSR provides a far more compact starting solution than conventional star delta starter configurations.

Built-in by-pass reduces the energy loss and makes the connection easier and with only three potentiometers, the set-up couldn’t be simpler. The optimized ramping characteristics will ensure a very smooth start and stop for all applications.

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