wiring, communication and busbar system - barr-thorp€¦ · • telemecanique gv2 manual starters...

Schneider Electric Brands

Wiring, Communicationand Busbar SystemFor Motor Power-Starter Components

Class 8502

CONTENTS

Description PageSelection Guide. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 & 3Components with Spring Terminals using QUICKFIT™ Technology . . . . . . . . . . 5 - 8Communication Modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9 & 10Choice of Connection between Module and PLC . . . . . . . . . . . . . . . . . . . . . . .11 & 12Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 - 16Dimensions and Schematics. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 - 23AK5 Pre-Assembled Panel Busbar System . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 - 34

This document provided by Barr-Thorp Electric Co., Inc. 800-473-9123 www.barr-thorp.com

Wiring, Communication and Busbar System for Motor Power-Starter ComponentsMotor Power-Starter Components

2

Functions

Types of product

For contactors

Type of starter

Coil control

Use with motor power-starters

Number of motor power-starters

Connection of earth cables

Connection via

Type of connection or bus

Number of channels

Pages

(1) With LAD3B upstream termina

HP Ratings (maximum for a moto

10 hp 480 V / 600 V

5 hp 220 V / 240 V

3 hp 208 V

Th

MOTOR POWER-STARTER COMPONENTS

Selection Guide

LAD3• APP2R• APP2D••

QUICKFIT™ technology for assembly and connection of motor starter components with spring terminals, without using tools.

Power connection kit Power/control splitter box Control connection module

D-Line

Non-reversing and reversing Non-reversing Reversing

— With Relay

Without Relay

With Relay

Without Relay

— 8 starters (1) —

1 2, 3, 4 limited to 50 A 1

— —

— HE10 connector or adaptor for communication module

—

—

—

8

l block

LAD3

LAD2

·

·APP2D

APP2R·

·

r)

© 2001 Schneider Electric All Rights Reserved 7/01

is document provided by Barr-Thorp Electric Co., Inc. 800-473-9123 www.barr-thorp.com


7/01

This

Selection Guide

APP1CH APP1CV/1CE APP1CAS2 APP1C••0/3 APP1C••2/5

Communicate with the processing device (i.e. PLC)

Communication modules

—

—

—

—

—

—

Connectorto PLCs Terminal block AS-i bus Other buses

HE10 Screw or spring AS-i 2 addresses CAM Open, Device NetInterbus S and S optical, Profibus DP and DP optical

8I/8O 16I/8O 8I/8O 16I/8O 32I/24O

10

APP1C·

3© 2001 Schneider Electric All Rights Reserved

document provided by Barr-Thorp Electric Co., Inc. 800-473-9123 www.barr-thorp.com


4

Th

General Presentation: Power and Control Components

QUICKFIT™ is a modular system which standardizes and simplifies the implementation of motor power-starters with its prewired control and power circuits.Hence, installation of a motor power-starter is quick, simple, and flexible with no wires needed for interconnection between devices. In addition, this system enables the motor power-starter to be customized at a later date. The system reduces maintenance time and optimizes panel space by reducing the number of terminals, the amount of ducting, and intermediate interfaces.

The following solution is offered:• A solution using QUICKFIT™ technology for TeSys™ motor power-starter components with spring terminals: D-Line contactors (9 to 32 A) and the

GV2ME motor manual starters.

Tego Power Design definition softwareThis software on CD-ROM enables the motor power-starter application to be graphically defined according to the manual starters and contactors used. It determines which Tego Power products are required for the application. Referencing labels can also be created for the starters.

How to Build TeSys™ Motor Power-Starters with Spring Terminals The motor power-starters concerned are those formed by combining:• GV2M manual starters• with 9 to 32 A D-Line (LC1) contactorsConsisting of simple parts, Tego Power QUICKFIT™ technology is used to create motor starter assemblies up to 20 hp/ 460 V (15 kW/400 V).

The main components which make up this range are:

For the power circuit:• a power kit comprising, for each starter, a plate (4) for mounting the

contactor and the manual starter, and the two power connection modules (3a, 3b)

• a power splitter box (1) for 2, 3 or 4 starters• an upstream terminal block (5) for a power supply up to 63 A (16 mm2) • a downstream terminal block (6) for connecting the motor power supply

cables and the earth cables (6 mm2)

For the control circuit:• a control splitter box (2) for 2, 3, or 4 starters, with control-command

data on HE10 connector. The data on 4 to 8 starters can be fed back directly to the PLC via an 8I/8O or 16I/8O Telefast cable or to a fieldbus module (Device Net, CAN Open, AS-i, FIP, Interbus, Profibus) See page 3.

• a control circuit connection module (7) which plugs directly into the contactor and the manual starter. This module concentrates the motor starter control-command data. It integrates the manual starter status data in the prewiring of the contactor control circuit.

• contactor coil control voltage is limited to AC 12 to 240 volts, or DC 24 to 125 volts when using control connection module with electromechanical relay APP2D• and DC 24 to 48 volts when using control connection module without electromechanical relay APP2D•D.

♦ LAD35 kit contains one LAD31 mounting plate, and two LAD34 power connection modules.

General Presentation: Communication Modules

GeneralCommunication modules are used to send I/O data from a QUICKFIT™ motor power-starter configuration to the PLC.

The communication modules are selected according to the type of connection required (see page 9): • parallel mode (modules, terminal blocks, or HE10) • serial mode via the bus (CAN Open, Device Net, AS-i bus, Interbus S, or Profibus DP modules)

The communication modules are the same, whether the TeSys™ motor power-starter system uses spring or screw terminals.

How to Build TeSys™ Motor Power-Starter System with Communication Modules

Motor power-starters can be connected to a PLC or a bus in two ways:• by direct connection from the control circuit splitter box (2) with 4 starters, with an HE10 connector (8I/8O), or two HE10 connectors (16 I and 8 O)• by a communication module (9) using an APP-2CX adaptor plate (8)

6

3b

3a

1

7

4 52

f LAD31 APP2R

LAD3B

LAD32

LAD34

LAD33APP2D

·

·

9 28APPIC APP2CX APP2R

f

··



Wiring, Communication and Busbar System for Motor Power-Starter ComponentsComponents for Spring Terminals using QUICKFIT™ Technology

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COMPONENTS WITH SPRING TERMINALS USING QUICKFIT™ TECHNOLOGY

Description: Power Connectors

The motor power-starters concerned are those created by combining:

• Telemecanique GV2 manual starters (mainly GV2ME) with an operating limit of 80% of full load current at 60°C ambient temperature, up to 690 V (see page 14).

• with 9 to 32 A Telemecanique D-Line contactors (LC1).

The main components which make up this range are:

For the power part:• power kits• power splitter boxes• upstream and downstream terminal blocks

For the control-command part:• power and control splitter boxes• control connection modules

Used with communication modules (see pages 4 and 9), these motor power-starters exchange control-command data with PLCs or a bus. They can also communicate directly with PLCs via a Telefast HE10 cable.

How to Assemble Power ComponentsPower kits LAD3• Each motor power-starter requires a power kit which consists of a plate (4) and 2 QUICKFIT™ technology power connection modules (3a, 3b).The plate is used for mounting TeSys™ D-Line contactors (13), with spring terminals, non-reversing or reversing, equipped with an AC or DC coil, 9 to 32 A, and the GV2ME4 manual starter only. This plate is mounted on a 35 mm omega rail or screwed onto a base plate.The two power connection modules (3a and 3b) are identical regardless of the rating of the contactor, up to 32 A. The lower power connection module (3b) connects the power between the contactor and the manual starter. The upper power connection module (3a) connects the power between the splitter box (1) and the manual starter (12).

Splitter box LAD32• Splitter boxes (1) are available for 2, 3, or 4 starters. They can be combined to create motor power-starters up to 63 A per power supply. A reversing starter occupies a width equivalent to that of 2 direct starters. Direct supply of power to the splitter boxes is possible up to 25 A, 12 AWG (4 mm2).

Upstream terminal block LAD3B The upstream terminal block (5) performs two functions:• power supply up to 63 A, 6 AWG (16 mm2).• power supply between two connected splitter boxesThe upstream terminal block plugs into the splitter box using QUICKFIT™ technology. It is positioned on the splitter box or straddling the two splitter boxes, and takes up a width equivalent to two motor power-starters.

Downstream terminal block LAD33The downstream terminal block (6) performs two functions:• connects motor power supply cables up to 10 AWG (6 mm2).• connects the motor earth cablesIn addition, the terminal block enables quick connection and disconnection for maintenance, avoiding the risk of phase reversal. The downstream terminal block plugs into the down-stream spring terminals on the contactor using QUICKFIT™ technology.

♦ LAD35 kit contains one LAD31 mounting plate, and two LAD34 power connection modules.

3a

4 1 5

3b

6

13

12

LAD31

GV2...

LC1D...

LAD33

LAD34

LAD38LAD32·

f




6

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Description: Control Connection Modules

Power and control splitter boxes APP2R••These have the same specifications as the power splitter box (1) described on page 5. They are used to gather control-command data from the motor power-starters.Power and control splitter boxes (1, 2) for 2, 3, or 4 starters can be combined to create up to 8 starters. A reversing starter takes up the space of two direct starters. The mechanical assembly of two splitter boxes connects the control-command data and the power supply to the coil control. The coil control can be AC or DC, up to 250 V.

Three types of splitter boxes are available:• APP2R•E with one 30-way HE10 connector for connection to the APP1C• communication module, using the APP2CX adaptor plate (these splitter

boxes are also available for 2 or 3 starters)• APP2R4H1 with one HE10 connector with 8I/8O, for direct connection to the PLC via a Telefast cable: the data communicated to the PLC for each

starter is the coil control (1 output) and the contactor status (1 input), for up to 8 starters• APP2R4H2 with two HE10 connectors (one for 16 inputs, the other for 8 outputs) for direct connection to the PLC via a Telefast cable: the data

communicated to the PLC for each starter is the coil control (1 output), the contactor status (1 input) and the manual starter status (1 input), for up to 8 starters

The range is completed by splitter boxes which have an APP2R•AS AS-i bus link. Parallel link splitter boxes can be connected together up to 63 A, with no limit to the number of starters.

Two types of splitter boxes are available specifically for AS-i:• 2 starters, 2I/1O per APP2R2AS starter: the data communicated to the PLC for each starter is the coil control (1 output), the contactor status (1

input) and the circuit-breaker status (1 input)• 4 starters, 1I/1O per APP2R4AS starter: the data communicated to the PLC for each starter is the coil control (1 output), the contactor status (1

input).Control splitter boxes (1) are also available on their own, as replacement parts. They are mounted, by the user, on LAD32• power splitter boxes.

Control circuit connection modules APP2D••The control circuit connection module (7) plugs directly into the control terminals on the GV2 manual starter and the contactor, using QUICKFIT™ technology. It connects to the control splitter box (2) via its upper part. Mechanical locking ensures good quality connections and a firm hold.It is compatible with all contactor ratings up to 32 A.These modules are available in 4 versions: with or without a contactor coil control relay, and non-reversing or reversing starter. The version without a relay is designed to control the contactor coils with no interface, generally at 24 Vdc.The connection module integrates, in its lower part, the external shunt (7a) for connecting an external contact in series with the contactor coil or forced local control (according to the schematics on pages 18 & 19). The second item of contactor status data is available on a connector (7b) which is left to the choice of the user.

1 2 7

7b7a

LAD32 APP2R APP2D· ·




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Selection: Control Splitter Boxes for Various Connection Types

Three types of splitter boxes are available, depending on the required connection to the PLC:

• Direct connection to the PLC via HE10 connector and Telefast cable• Connection to the control system via communication module• Connection to the control system via AS-i bus

Direct Connection via 8I/8O HE10 ConnectorAn HE10 connector, on the top of the APP-2R4H1 control splitter box (1), provides the contactor status (1 input) and the coil control (1 output) for each starter.This HE10 connector can feed data back to up to 8 starters.The Telefast cable (3) is chosen according to the PLC environment (see pages 11 and 12).

Direct Connection via 16I/8O HE10 ConnectorsTwo HE10 connectors, on the top of the APP2R4H2 control splitter box (2), provide the circuit-breaker status (1 input), the contactor status (1 input) and the coil control (1 output) for each starter.These HE10 connectors can feed data back to up to 8 starters.The Telefast cables (3) are chosen according to the PLC environment (see pages 11 and 12).

Connection via Communication Module APP1C••• The APP2R•E control splitter boxes (2) (2, 3, or 4 starters) are connected to the PLC via a Tego module APP1C••• (9). An APP2CX adaptor (8) must be used to connect the module to the control splitter box.These modules can feed data back to up to 8 starters.The module is selected according to the type of connection required: terminal block, HE10 connector, or bus (see page 9).The advantages of using Tego modules are:- the ability to use terminal block connection,- when connecting using an APP1CH HE10 connector and APP1CAS2 AS-i connector, it is possible to choose, for each starter, feedback of the status either of the contactor, or the circuit-breaker, and to use the available I/O for external data, if there are fewer than 8 starters, or to access the Interbus S, Profibus DP, CAN Open, Device Net buses.

Direct Connection via AS-i bus, with no Communication ModuleThere are two versions for direct connection of the control splitter box to the AS-i bus:• APP2R2AS splitter box for 2 starters, providing the circuit-breaker status (1 input), the contactor status (1 input) and control of the coil (1 output) for

each starter• APP2R4AS splitter box for 4 starters, providing the contactor status (1 input) and control of the coil (1 output) for each starterIn both cases, it is possible to connect as many starters as required, up to 50 A.

2

11

8E/8S

8E/8S16E16S API

API

APE-1R1628

2

HE10

HE10

11

11

11

11

11

2

1111

11 HE10

HE10

16E

8S 16 SAPI

API

ABE-7ACC02

2

11 11

11

2

89




8

APP2R4H1

LAD35

LAD3B

LAD33

APP2D1•

Th

Splitter Boxes (refer to items 1 & 2 in the drawing on pages 4 & 5)

DescriptionType of Control-cmd Connection onControl System Side

No. of I/O per StarterNo. of Starters per Unit

Catalog NumberWeight lb. (kg)

50 A power splitter box — —

2 LAD322 0.26 (0.120)

4 LAD324 0.53 (0.240)

50 A power and control splitter box

1 x HE10 8I/8O (1) 1I/1O 4 APP2R4H1 0.77 (0.348)

1 x HE10 16Iand 1 x HE10 8O (1)

2I/1O 4 APP2R4H2 0.79 (0.358)

Via module APP1C••• (2) —

2 APP2R2E 0.40 (0.178)

4 APP2R4E 0.77 (0.348)

AS-i (3)2I/1O 2 APP2R2AS 0.44 (0.200)

1I/1O 4 APP2R4AS 0.83 (0.380)Splitter Box ExtensionA total of up to eight starters is permissible after extensions.(a) LAD322, LAD324, APP2R4H1, APP2R4H2, APP2R2E, APP2R4E: Use similar module for extension. It can be for 2 or 4. Starter capacity as per

need. Example: For extending LAD322, one or more of LAD322 can be used.(b) APP2R2AS, APP2R4AS: Use similar module for extension.

Example: For extending APP2R2AS, use another APP2R2AS.

Power Connection Components for One Starter (refer to items 3 & 4 in the drawing on pages 4 & 5)

Description Kit Consists of: Catalog NumberWeight lb. (kg)

Assembly and power connection kit1 LAD31 plate for GV2ME and 2 LAD34 power connection modules LAD35 0.20 (0.078)

Reversing kit (4) 1 set of busbars and 1 mechanical interlock LAD32 0.09 (0.040)

Power Connection Accessories for One Starter (refer to items 5 & 6 in the drawing on pages 4 & 5)

DescriptionMax. Connection Cross-Section

Use Catalog NumberWeight lb. (kg)

Upstream terminal block (50 A max) 16 mm2 (6 AWG) Power supply of 1 or 2 power splitter boxes or power control splitter box

LAD3B 0.47 (0.212)

Downstream terminal block (50 A max) 6 mm2 (10 AWG) Connection of motor cables LAD33 0.11 (0.050)

Control Connection Module for One Starter

DescriptionD-Line Coil Voltage

Type of Coil Control Relay

Type of Starter

Catalog NumberWeight lb. (kg)

Control connection module (integrating contact block GVAE20)

ac12 to 240 Vor dc 24 to 125 V

Electromechanical (5)

Direct APP2D1 0.26 (0.120)Reversing APP2D2 0.51 (0.230)

dc 24 to 48 V Without relay (6)Direct APP2D1D 0.24 (0.110)Reversing APP2D2D 0.48 (0.220)

Spare or Replacement Parts (refer to item 7 in the drawing on pages 4 & 4)

DescriptionType of Control-cmd Connection onControl System Side

No. of I/O per Starter

No. of StartersSold in Lots of

Unit Catalog Number

Weight lb. (kg)

Plate for mounting a GV2ME manual starter

— — 1 10 LAD31 0.10 (0.042)

Power connection module

— — 1 10 LAD34 0.04 (0.018)

Control-command splitter box (single, for mounting on a power splitter box)

1 x HE10 8I/8O 1I/1O 4 1 APP2R4H3 0.24 (0.108)

1 x HE10 16I and1 x HE10 8O

2I/1O 4 1 APP2R4H4 0.26 (0.118)

Per module APP1C••• (2) —

2 1 APP2R2C 1.30 (0.058)

4 1 APP2R4C 0.24 (0.108)

AS-i (3)2I/1O 2 1 APP2R2A 1.8 (0.080)

1I/1O 4 1 APP2R4A 0.31 (0.140)Replacement electromechanical relay (for control connection module) — 1 10 APP2ER 0.02 (0.010)

(1) Cables with 20-way Telefast HE10 connector, in accordance with selection table on page 12.(2) Connection to an APP-1C••• module via APP-2CX adaptor (see page 10).(3) Available 1st quarter 2002.(4) To create a D-Line reverser, use 2 LC1-D contactors, 1 assembly and power connection kit and 1 reversing kit.(5) Relay supplied mounted on the front panel of the control connection.(6) The use of D-Line low consumption contactors is recommended.



Wiring, Communication and Busbar System for Motor Power-Starter ComponentsSelecting Communication Modules

7/01

PLC

ABF•

APP1•

APP1CIB2

This

COMMUNICATION MODULES

Selection: Communication Modules and Accessories

Selection of the communication modules depends on the type of connection required:• by removable screw or spring terminal blocks• parallel via HE10 connector and Telefast cable• serial via bus (AS-i bus, Interbus S and S optical, Profibus DP and DP optical, CAN Open or Device Net modules).In the QUICKFIT™ version (spring terminals), connecting a module to the APP2R power and control splitter box requires the fitting of an APP2CX adaptor.

Terminal block connectionAPP1CV and APP1CE modules are 16 input/8 output - screw or spring - removable terminal block modules which can be used for wire-to-wire connection of data from the circuit-breaker and contactor contacts as well as the coil control outputs of each motor starter. The removable terminal blocks are supplied with the modules.

Parallel connection via HE10 connectorThe APP1CH 1 module is an 8 input/8 output module, fitted with an HE10 connector for fast connection to PLCs using a prefabricated Telefast cable (see selection guide, page 11). Connection to a TSX Micro PLC is direct, using the TSX DMZ16DTK 8I/8O module 2 and the ABFH20H••0 or TSX CDP••3 Telefast cable 3.

Serial connection via busThe APP1CAS2 AS-i module is an 8 input/8 output module on AS-i bus (2 addresses).The APP1CIB0 Interbus S and APP1CIB3 Interbus S fibre optic modules, APP1CPF0 Profibus DP and APP1CPF3 Profibus DP fibre optic modules, APP1CCO0 CAN Open and APP1CDN0 Device Net modules are 16 input/8 output modules for connecting APP1B• sub-bases.The APP1CIB2 Interbus S and APP1CIB5 Interbus S fibre optic, APP1CPF2 Profibus DP and APP1CPF5 Profibus DP fibre optic, and APP1CCO2 CAN Open and APP1CDN2 Device Net modules are 32I/24O modules in total, i.e.:• 16 inputs/8 outputs for connecting APP1B• sub-bases with up to 8 starters• an additional 2 x 8I/8O available on 2 HE10 connectors 4 compatible with the Telefast cables, and therefore with the APP1CH HE10 module 1 and

with the ABE7H16CM•1 or ABE7•16M111 Telefast 8I/8O sub-base or the APE1B24M Tego Dial sub-base.

Notes on 8 input/8 output modulesThe APP1CH (HE10 connector) and APP1CAS2 (AS-i 8I/8O) modules are fitted with a 4-switch system for making the following selections:• switches C and D: option to feed back to the PLC either data from the circuit-breaker contact, or from the contactor on each of the 8 starters• switch E: an external input can be selected for each of the 4 end starters (nos 5 to 8) if the starter is not being used• switch F: an external output can be selected for each of the 4 end starters (nos 5 to 8) if the starter is not being used The position of switches C, D, E, F can be defined using Tego Power Design software.

Communication Module Selection Table

Type of ConnectionNumber of I/O Available for APP1B• Sub-base

Number of HE10 Connectors (1)

Number of I/O per HE10

Catalog Number

HE10 connector 8I/8O – – APP1CH

Removable screw terminal block 16I/8O – – APP1CV

Removable spring terminal block 16I/8O – – APP1CE

ASi bus 8I/8O – – APP1CAS2

Interbus S bus 16I/8O0 – APP1CIB0

2 8I/8O APP1CIB2

Interbus S optical bus 16I/8O0 – APP1CIB3

2 8I/8O APP1CIB5

Profibus DP bus 16I/8O0 – APP1CPF0

2 8I/8O APP1CPF2

Profibus DP optical bus 16I/8O0 – APP1CPF3

2 8I/8O APP1CPF5

CAN Open bus 16I/8O0 – APP1CCO0

2 8I/8O APP1CCO2

Device Net bus 16I/8O0 – APP1CDN0

2 8I/8O APP1CDN2

(1) HE10 connector for connecting either the APP1CH module, an ABE7H16CM•1 or ABE7•16M111 Telefast sub-base, or the APE1B24M Tego Dial Dialbase interface.

4 1

33

3

1

8 starters 8 starters 8 starters

ABE7orAPE1B24M

···



Wiring, Communication and Busbar System for Motor Power-Starter ComponentsSelecting Communication Modules

10

APP1CH

APE1R1628

ABE7ACC02

APE1PAD21

Th

Communication Modules (1) (refer to item 8 in the drawing on page 4)

Description Type of Connection or BusNo. of HE10 Connectors (2)

Catalog Number Weight lb. (kg)

Communication modules with terminal block

Screw APP1CV 0.86 (0.390)

Spring APP1CE 0.78 (0.356)

Communication modules with connector

HE10 – APP1CH 0.75 (0.343)

Communication modules via bus

AS-i (3) – APP1CAS2 0.91 (0.416)

Interbus S– APP1CIB0 1.17 (0.530)

2 APP1CIB2 1.17 (0.530)

Interbus S optical– APP1CIB3 1.17 (0.530)

2 APP1CIB5 1.17 (0.530)

Profibus DP– APP1CPF0 1.17 (0.530)

2 APP1CPF2 1.17 (0.530)

Profibus DP optical– APP1CPF3 1.17 (0.530)

2 APP1CPF5 1.17 (0.530)

CAN Open– APP1CCO0 1.17 (0.530)

2 APP1CCO2 1.17 (0.530)

Device Net– APP1CDN0 1.17 (0.530)

2 APP1CDN2 1.17 (0.530)

Accessories for Communication Module (refer to item 8 on page 4 and the items on page 7)

Description SpecificationsOrder in Multiples of:

UnitCatalog Number

Weight lb. (kg)

Adaptor For APP1C•�communication modules 1 APP2CX 0.28 (0.130)

HE10 intelligent splitter box 16 I/16 O (2 x 8 I/8 O)

24 V Ue/30 V max. Output type: 2.6 W tungsten filament lamp

1 APE1R1628 0.28 (0.130)

Splitter subbase 16 channels (2 x 8) 1 ABE7ACC02 0.16 (0.075)

Self-stripping connector(for external I/O on APP1CH and APP1CAS2 modules)

2 pin, 5 mm intervals Wire cross-section: 0.75 mm2 16 APE1PAD21 0.44 (0.020)

Connector withvampire clip for AS-i bus

Yellow 5 LA9Z32825 0.22 (0.100)

Design Definition Software

Description Language Support Version Catalog Number Weight lb. (kg)

Definition softwareEnglishand French CD-ROM 01 APP2C00M 0.22 (0.100)

(1) Use adaptor APP2CX for connecting a QUICKFIT™ version module (spring terminals). (2) For connecting additional external I/O.



Wiring, Communication and Busbar System for Motor Power-Starter ComponentsChoice of Connection between Module and PLC

7/01

PLC

Brand/TypeConnectioModularity

Telemecanique Micro

8 In + 8 Out

16 In + 16 O

Telemecanique Premium

16 In + 16 O

Telemecanique TSX 47107 16 In + 16 O

ModiconCompact 984/ A120 16 In + 16 O

ModiconQuantum

32 In + 32 O

April 32 In + 32 O

Siemens95U/100U

8 In + 8 Out

16 In + 16 O

Siemens115U

8 In + 8 Out

16 In + 8 Ou

Siemens135/155U

8In + 8 Out

16 In + 8 Ou

SiemensS7300

8 In + 8 Out

16 In + 16 O

SiemensS7400

8 In + 8 Out

16 In + 16 O

Allen BradleySLC500

16 In + 16 O

32 In + 32 O

(1) 8 inputs + 8 outputs remain av

(2) 8 outputs remain available on A

This

Choice of Connection between the Splitter Box Communication Module (APP1CH) and the PLC

Components Necessary for Connecting the PLC

n PLC Terminal Blocks

Compatible PLC Cards

Communication Module or Control Splitter Box with 8I/8O

Control Splitter Box 16I/8OO

Telefast Cables Splitter Box16 In + 16 Out

Splitter Box16 (2x8)

APP1CH or APP2R4H1/H3

APP2RH2/H4 ABFH20H••0TSX CDP••3

APE1R1628(1)

ABE7ACC02 (2)

— TSXDMZ16DTK 1 1

ut — TSXDMZ64DTK1 1 1

1 2 1

ut —TSXDEY32D2K/64D2K,TSXDSY32T2K/64T2K,TSXDEY16FK

1 1 1

1 2 1

ut —

TSXBLK71 + TSXDET32••,TSXBLK91 + TSXDST3292

1 1 1

1 1 1

ut —DA0216, DAP216/217, DE0216, DEP217/220, DEP216

1 1 1

1 1 1

ut — DDI353/853, DD03531 1 1

1 1 1

ut —IDB3224, QDB3205, QPA3205

1 1 1

1 1 1

(included in Telefast cable)

4218MA12/4318MA11 4418MA11/4518MA11 1

ut 6EP 5••••AA00

4828MA131 1 1

1

6EP 5••••1AA00

4207LA11, 4307LA12, 4417LA11, 4517LA11/21

1

t 1

6EP 5••••1AA00

4204UA14, 4304UA14, 4414UA14, 451UA14

1

t 1

6ES79213AB000AA0

3211B•0•0AA0, 3221B•0•0AA0

1

ut 1

6ES79213AB000AA0

4211B•0•0AA0, 4221B•0•0AA0

1

ut 1

ut — 1746OB16/1746IB161 1 1

1 1 1

ut — 1746IB32, 1746OV32, 1746OB32

1 1 1

1 1 1

ailable. To connect a second APP1CH module or APP2••• 8 input + 8 output control splitter box, use an additional ABFH20H••0 or TSXCDP••4 cable.

BE7ACC02. To connect them to a second AAP2•••16 input/8 output control splitter box, use an additional ABFH20••0 or TSXCDP••3 cable.



Wiring, Communication and Busbar System for Motor Power-Starter ComponentsChoice of Connection between Module and PLC

12

ABFH20H••0 orTSXCDP•••

ABFH20H••1

ABFH28H••0

2

1

2

1

2

2

2

1

1

1

1

1

Th

Telefast Cables for Connection to the PLC

ABFH14H••0

ABFS16••H0

ABF ABF ABFM16H••1

ABFH32H••0

ABFH16H••0

ABFM32H••0

ABFA32H••0H40H••0 H40H••1 R16H••0 R16H••1 M16H••0

1 1

1 1

2

2

2

2

1

1

1

1 1

1 1

1

1 1

1 1

1 1

1 1

1 1



Wiring, Communication and Busbar System for Motor Power-Starter ComponentsSpecifications

7/01

Type of Sub-base and Standard

Approvals

Degree of protection

Resistance to incandescent wire

Shock resistance

Vibration resistance

Withstand to electrostatic dischar

Withstand to radiated fields

Immunity to rapid transients

Surge withstand

Immunity to radio electrical fields

Ambient air temperature

Space required around mounted a

Degree of pollution

Fixing of the assembly

Suitable wire cross-sections

V

Vc

Connection of pins to the circuit-b

3-phase Power Circuit

Maximum currentp

p

GV2 operating limit

Maximum current per starter

Insulation voltage

Operating voltage

U imp

Rated frequency

Conditional rated short-circuit cu

Permissible rated short time curre

Control Circuit Specific

Contactor coil control voltag

This

Specifications

General Environment

Splitter Box APP-2R••, LAD-32•IEC 60439-1

UL, CSA (pending)

Conforming to IEC 60529 IP 40 (mounted assembly)

Conforming to IEC 60695-2-1 °F (°C) 1760 (960)

Conforming to IEC 6068-2-27 11 ms and 15 gn (half sinewave)

Conforming to IEC 6068-2-6 and BV/LR gn 5…300 Hz: 4 and 3…100 Hz: 0.7

ges Conforming to IEC 61000-4-2 Level 3

Conforming to IEC 61000-4-3 V/m 10 (26…1000 MHz)

Conforming to IEC 61000-4-4 Level 3

Conforming to IEC 61000-4-5 Kv 2 in common mode, 0.6 in differential modeWave form: 1.2/50 µs - 8/20 µs

Conforming to IEC 61000-4-6 V 10 (0.15 to 80 MHz)

Operation in floor-standing enclosure °F (°C) 23 to 140 (- 5 to + 60)

Operation in wall-mounted enclosure °F (°C) 23 to 104 (- 5 to + 40)

Storage °F (°C) -40 to 158 (- 40 to + 70)

ssembly For inserting cables and heat dissipation in (mm) > 1.2 (30)

3

35 mm rail or 2 x Ø 5.5 mm screws per plate for GV2-ME

oltage supply for power

Number of wires 3

Tightening torque lb-in (N•m) 19.4 (2.2)

Flexible cable with end AWG (mm2) 6 (16)

Flexible cable without end AWG (mm2) 4 (25)

Solid cable AWG (mm2) 4 (25)

oltage supply for contactor oil control

Number of wires 2

Tightening torque lb-in (N•m) 7.0 (0.8)

Flexible cable with end (maximum) AWG (mm2) 16 (1.5)

Flexible cable without end (max.) AWG (mm2) 14 (2.5)

Solid cable (maximum) AWG (mm2) 14 (2.5)

reaker or contactor terminals Tightening torquepower lb-in (N•m) 15.0 (1.7)

control lb-in (N•m) 10.6 (1.2)

Specifications

er power supply Conforming to IEC 60439-1 A63 (single power supply to one or more sub-bases or splitter boxes)

er sub-base Conforming to IEC 60439-1 A 50

80% of Imax at 60° C ambient temp. (see page 12)

A 32 (for 16A and above, keep one blank slot on right and left sides)

V 750

V 690

kV 6

Hz 50-60

rrent Isc at 415 V Conforming to IEC 60439-1 kA 50

nt Icw Conforming to IEC 60439-1 kA 9.1 (for 70 ms)

ations

eV ac 5 to 250

V dc 5 to 250




14

Circuit-Breaker Catalog Num

GV2ME06

GV2ME07

GV2ME08

GV2ME10

GV2ME14

GV2ME16

GV2ME20

GV2ME21

Electromechanical ReType of connection block

Specifications of the ERated voltage at Us

Energization threshold at 40 °C

Drop-out voltage at 20 °C

Maximum operating voltage

Maximum current at Us

Drop-out current at 20 °C

Maximum power dissipated at Us

Disappearance of voltage

Specifications of the EType of contact

Maximum switching voltage

Operating current frequency

Maximum current of the contact

Other Specifications o

Maximum operating time at Us(including bounce)

Maximum switching frequency

Mechanical durability

Dielectric strength

Rated impulse withstand voltage

Primary/secondary rated insulati

Maximum current for 500,000 ope

(1) Thermal release adjustment ran

Th

GV2 Circuit-breaker Current Limitation at 60°C Ambient Temperature with QUICKFIT™ System

ber GV2 Rating (1) Maximum Current of GV2 with QUICKFIT™ System

1 - 1.6 A 1.28 A

1.6 - 2.5 A 2 A

2.5 - 4 A 3.2 A

4 - 6.3 A 5 A

6 - 10 A 8 A

9 - 14 A 11.2 A

13 - 18 A 14.4 A

17 - 23 A 18 A

lay SpecificationsAPP 1D1A, 1D2A, 1K1B, 1K2B, 1ER, 2D1, 2D2, 2ER

lectromechanical Relay Control Circuit (PLC end)

V dc 24

V dc 19.2

V dc 2.4

V dc 30

mA 15

mA 1

W 0.36

ms 5

lectromechanical Relay Output Circuit1F

Vac 250

Vdc 250

Hz 50/60

A 4

f the Electromechanical RelayBetween coil energization and closing of the contact ms 10

Between coil de-energization and opening of the contact

ms 5

At no-load Hz 10

At Ie Hz 0.5

In millions of operating cycles 20

V 1000 (50/60 Hz) - 1 min

kV 2.5

on voltage V 300

rations24 V - DC13 A 0.6

230 V - AC15 A 0.9

ge.




7/01

Type of Module

Number of channelsInp

Ou

Display of supply voltages (V In, V

Input specifications

Sup

Ma

Tot

Output specifications

Op

Ma

Tot

Connection to the sub-base

No. of 20-way HE10 connectors p

Connection of the 24 V supply

Connection of external I/O

This

Specifications of Parallel Link Communication Modules and Control Splitter Boxes

APP1CV, APP1CE APP1CH APP2R4H1/H3 APP2R4H2/H4

uts 16 8 8 16

tputs 8 8 8 8

Out) By LED By LED – –

ply voltage Vdc 24 24 24 24

x. current per channel mA 20 20 20 20

al max. current mA 320 160 160 320

erating voltage V dc 24 dc 24 dc 24 dc 24

x. current per channel mA 500 100 500 500

al max. current A 1 1 2 2

By 30-way, HE10 connector

er Telefast cable – 1 (8I/8O) 1 (8I/8O) 1 (16I) and 1 (8O)

By removable connector at intervals of 5.08 mm, providedWire cross-section: 14 AWG (2.5 mm2) without end, 16 AWG (1.5 mm2) with endTightening torque: 7.1 lb-in (0.8 N•m)

By removing connector at intervals of 5.08 mm, not provided. Wire cross-section: 14 AWG (2.5 mm2) without end, 16 AWG (1.5 mm2) with end. Tightening torque: 7.1 lb-in (0.8 N•m)




16

Type of Module

Ambient air temperature

Number of channelsInputs

Outpu

Power supply

Display

Current drawn on the bus

Inputs

Outputs

AS-i profile

Connection to the sub-base

Connection of external I/O

Connection to the bus

Specifications of the CType of kit

Communing link for the power

Opera

Max. c

Communing link For the coil control

Opera

Communing link for the I/O control

Opera

Th

Communication via Bus Modules

APP1CAS2APP1CIB0/3, APP1CCO0 APP1CPF0/3, APP1CDN0

APP1CIB2/5, APP1CCO2APP1CPF2/5, APP1CDN2

°F (°C) 32 to 131 (0 to + 55) 32 to 131 (0 to + 55) 32 to 131 (0 to + 55)

8 16 16 + (2 x 8 external on HE10) = 32

ts 8 8 8 + (2 x 8 external on HE10) = 24

Via the AS-i bus External by removable connector at intervals of 5.08 mm

By LED (I/O and power supply) By LED (I/O communication and faults)

mA < 280 x 2 – –

V 24

mA 5 per input

V 24

mA 50 per output (relay compulsory) 500 per output

S7.0 x 2 –

By 30-way HE10 connector By 30-way HE10 connector

– – By 2 x 20-way HE10 connectors

By 2-way removable connector at intervals of 0.2" (5.08 mm)

APP1CIB0, AAP1CIB2:

APP1CPF0, AAP1CPF2:APP1CC0•, AAP1CDN•:

APP1CIB3, AAP1CIB5: APP1CPF3, AAP1CPF5:

2 shielded SUB-D 9 connectors:- male for signal input- female for signal outputShielded SUB-D 9 connector5-way connector at intervals of 0.2" (5.08 mm).F-SMA fibre optic connectorHP-SIMPLEX fibre optic connector

onnection KitAPP1EL

ting voltage Ue V 690

urrent per phase A 32

ting voltage Ue V 250

ting voltage Vdc 24



Wiring, Communication and Busbar System for Motor Power-Starter ComponentsDimensions

7/01

Communication Modu

APP

1CAS2

1CIB•

1CPF•

1CC0•

1CDN•

Mounted Assembly (fo

128.7

8

5.1

0

3.6091,54.44

1135.78147

1

2

3

4

5

6

7

2

This

DIMENSIONS

le APP1C••• Adaptor APP2CX Splitter Sub-Base ABE7ACC02

Intelligent Splitter Box APE1R1628

a

1.37" (35 mm)

1.77" (45 mm)

1.77" (45 mm)

1.77" (45 mm)

1.77" (45 mm)

r components with spring terminals, using QUICKFIT™ System)

Manual Starter Support PlatePower Connection ModulePower Splitter BoxControl Splitter BoxUpstream Terminal BlockControl Connection ModuleDownstream Terminal Block

b " (mm) b1 " (mm) + " (mm)

2 starters 3.54 (90) 5.55 (141) 0.21 (5.55)

4 starters 7.09 (180) 9.1 (231) 0.35 (9.09)

8 starters 14.9 (380) 16.18 (411) 0.63 (16.18)

a

102.

7

254

501.96

10.0

4.04

.3

251

1.3735

25

41

01

47

5.7

8

1.8848 2.24

57

1.9650

2.75

701.37

35

0.615

A B C2.28

58

3.46880.86

48 2.2457

3.5

90

1.37

350.

86 22

0.615

Dual Dimensions inchesmm

9.01

229

5.90

150

1.37 35

9.72

247

10.9

427

8

b1

b1.3735

0.6216

12.5

231

8



Wiring, Communication and Busbar System for Motor Power-Starter ComponentsSchematics

18

Th

SCHEMATICS

APP2D1

APP2D1D (24 Vdc)

2324

1314

1314

- KM1C

E2 x

E1 x

0 V

S x

- Km1

- Q1

+ VIn2221

(N)

(+)

(Ph)

(-)

acdc

acdc

2324

1314

1314

- KM1

C

E2 x

E1 x

S x

0 V

- Q1

+ VIn2221




7/01

This

APP2D2

APP2D2D (24 Vdc)

2324

1314

1314

- KM1

C

E2 x

E1 x0 V

S x

- Km1

- Q1

+ VIn

2221

1314

- KM2

C

E1 x0 V

S x

- Km2

+ VIn2221

Shunt

(N)(+)

(N)(+)

(Ph )(-)

acdc

acdc

acdc

2324

1314

1314

- KM1

C

E2 x

E1 x

S x

0v

- Q1

+ VIn

2221

1314

- KM2

C

E1 x

S x

+ VIn2221

Shunt




20

APP

Can Open APP1CCO2 and D

Interbus S, APP1CIB2 CommWith the exception of X1 and X2, the scheme

– K

M1

X2 KM

I.1

– Q

1

– Q

8

X1B

A

QI.1

QI.8

A Sub-base.B Communication module.X1 Removable terminal block for connX2 Removable terminal block for connX3 Removable terminal block for connX4 Removable terminal block for I/O 2

BX3

1

X2X1

A

– Q

1

– Q

4

– K

M4

– K

M1

(1)

(1) Can Open or Device Net bus A Sub-base.B Communication module.X1 Removable terminal block, 5 pins, fX2 Address switch.X3, X4 20-way HE10 connectors for conneX5 Removable terminal block, 4 pins, a

B

IN OU

T

X2X1

X1 Male SUB-D connector for the InterX2 Female SUB-D connector for the In

Th

1CE and APP1CV Communication Modules

evice Net APP1CDN2 Communication Modules

unication Module Profibus DP, APP1CPF2 Communication Module is identical to that shown above. With the exception of X1 and X2 the scheme is identical to that shown above.

– K

m1

– K

m8

X4X3 Km

O.1

–

Km

O.8 + –+

– K

M8

KM

I.8

V In V Out

24 V power supply:VIn: inputsVOut: outputs

ecting circuit-breaker contacts 1 to 8 (terminals QI.1 to QI.8).ecting contactor contacts 1 to 8 (terminals KMI.1 to KMI.8).ecting interface relays 1 to 8 (terminals KmO.1 to KmO.8).4 V power supply.

X4

1 8 9 16 17

18

19 20 17

18

19 20

24 V

IN

0 V

CO

M

24 V

OU

T

0 V

CO

M

0 V

CO

M

24 V

IN

24 V

IN

0 V

CO

M

24 V

OU

T

0 V

CO

M

24 V

IN

0 V

CO

M

24 V

OU

T

0 V

CO

M

8 9 16 17

18

19 20

X5

– K

A1

– K

A4

– K

A5

– K

A8

– Q

5

– Q

8

– K

M8

– K

M5

or connecting the bus.

cting 8 external inputs and 8 external outputs.t intervals of 5.08 mm, for connecting the 24 V IN and 24 V OUT module power supplies.

bus S input.terbus S output.

BX2X1

X1 Female SUB-D connector for the Profibus DP connection.X2 Address switches.




7/01

This

APP-1CH Communication Module, Scheme and Operating Principle

Switches C and D are used to select feedback from the contactor or circuit-breaker contact (pins 1 to 8 on the HE10 connector) for each starter. In addition, on the last 4 starters, it is possible to choose between feedback from the contactor or circuit-breaker contacts and an external input (switch E and pins 5 to 8 on the HE10 connector). External inputs are connected to terminals I.4 to I.7.Interface relays are connected to pins 9 to 16 on the HE10 connector. For the last 4 starters, it is possible to choose either coil control (Km5 to Km8) or connection of local external outputs (terminals Q.4 to Q.7) using switch F

.

APP-1CAS2, Communication Module, Scheme and Operating PrincipleSame operating principle as the APP-1CH module: switches E and F are used to select the local I/O and switches C and D are used to select the contactor or circuit-breaker contact. With this module, the data is fed back to the PLC via the AS-i bus.

X4X3X2

– K

m1

– K

m5

– K

m4

– K

m8

X1

A

B

1 4 5 8 9 12 13 16 1724

V IN

0 V

IN

24 V

OU

T

0 V

OU

T

18 19 20

–+ –+ VIn VOut

Q.4 – –Q.7 –I.4 + I.7 + + –+

– K

M1

– Q

1

– K

M4

– Q

4

C

E

F

– K

M5

– Q

5

– K

M8

– Q

8

D

Local inputs Local outputs

24 V power supply:VIn: inputsVOut: outputs

Option of connecting 4 local external inputs and 4 local external outputs: selection via switches F and E.

– K

m1

– K

m5

– K

m4

– K

m8

X4X3

O.5 – O.8 –

X2

I.5 + I.8 +

– K

M1

– Q

1

– K

M4

– Q

4

C

E

F

– K

M5

– Q

5

– K

M8

– Q

8

D

E1

E4 + – E5

E8

S1

S5

S4

S8

A

B

AS

-i –

AS

-i –

AS

-i +

AS

-i +

AS

-i –

AS

-i +

Bus AS-i

Local inputs Local outputs

Option of connecting 4 local external inputs and 4 local external outputs: selection via switches F and EA Sub-base.

B Communication module.X1 20-way HE10 connector.X2, X3 Removable terminal blocks, 8 pins, at intervals of 5.08 mm, for connecting 4 external inputs and 4 external outputs.X4 Removable terminal blocks, 4 pins, at intervals of 5.08 mm, for the I/O 24 V power supply (APP-1CH) or for the AS-i bus (APP-1CAS2).C, D Switches for selecting between feedback to the PLC from the circuit-breaker or contactor status contact for each of the 8 starters. E Switch for each of the last 4 starters (5 to 8), for selecting between feedback to the PLC of the circuit-breaker or contactor status (result of

switch D) or an external input (if the starter is not used).F Switch for each of the last 4 starters (5 to 8), for selecting between controlling the contactor coil or an external output (if the starter is not used).



Wiring, Communication and Busbar System for Motor Power-Starter ComponentsCommunication Modules: Configuring Input and Output Switches

22

APP1CAS2 communication modules: pSwitch C

Power-starter components 1 to 4

DP No. 1 DP No. 2 DP No.3

CB Cont. CB Cont. CB Co0 v v v1 v v v2 v v v3 v v v4 v v v5 v v v6 v v v7 v v v8 v v v9 v v v10 v v v11 v v v12 v v v13 v v v14 v v v15 v v v

Switch Positions CorrespondInputData on the state of:8 manual starters (1 to 8)8 contactors (1 to 8)4 circuit-breakers and 4 external inpu4 contactors and 4 external inputs

Example of the Procedure to 1 Select the required data on the

ChannelDataThen, in the table below:

2 Select the display for switch C, Shade in the 4 columns correspThe horizontal line containing th

3 Select the display for switch D, Shade in the 4 columns correspThe horizontal line containing th

4 Select the display for switch E, Shade in columns W and X for cThe horizontal line containing th

5 Select the display for switch F, fShade in the 4 coil columns for The horizontal line containing th

Switch CPower-starter components 1 to 4

DP No. 1 DP No. 2 DP No. 3

CB Cont. CB Cont. CB Co0 v v v1 v v v2 v v v3 v v v4 v v v5 v v v6 v v v7 v v v8 v v v9 v v v10 v v v11 v v v12 v v v13 v v v14 v v v

15 v v v

Explanation of the Symbols Used

Th

Communication Modules: Configuring Input and Output Switchesrocedure for configuring input switches C, D and E, and output switch F. The table below can be used to set the position of the switches on the front panels of the modules.

Switch D Switch E Switch F

Power-starter components 5 to 8 Power-starter components 5 to 8 or external inputs

Control of power-starter components 5 to 8 or external outputs

DP No. 4DP No. 5or W

DP No. 6or X

DP No. 7or Y

DP No. 8 or Z

DP W or I5

DP X or I6

DP Yor I7

DP Zor I8

DP No. 5 or Q5

DP No. 6 or Q6

DP No. 7 or Q7

DP No. 8 or Q8

nt. CB Cont. CB Cont. CB Cont. CB Cont. CB Cont. W I5 X I6 Y I7 Z I8 Coil 5 Q5 Coil 6 Q6 Coil 7 Q7 Coil 8 Q8v v v v v v v v v v v v v 0v v v v v v v v v v v v v 1v v v v v v v v v v v v v 2v v v v v v v v v v v v v 3v v v v v v v v v v v v v 4v v v v v v v v v v v v v 5v v v v v v v v v v v v v 6v v v v v v v v v v v v v 7

v v v v v v v v v v v v v 8v v v v v v v v v v v v v 9v v v v v v v v v v v v v 10v v v v v v v v v v v v v 11v v v v v v v v v v v v v 12v v v v v v v v v v v v v 13v v v v v v v v v v v v v 14v v v v v v v v v v v v v 15

ing to Configuration SelectedSwitches C D E Output Switch F

Control of:0 0 0 4 motor power-starter 015 15 0 4 external outputs 15

ts 0 Insignificant 1515 Insignificant 15

be used to Set the Display for Input Switches C, D and E, and Output Switch F 8 input channels and 4 output channels

Input Output1 2 3 4 5 6 7 8 5 6 7 8CB CB CB Contactor Contactor CB External External Contactor CB Contactor CB

which is reserved for motor power-starter components 1 to 4 only.onding to the circuit-breaker for channels 1, 2 and 3, and to the contactor for channel 4.e four shaded 5 indicates the number of switch C to be displayed: 8.

for the motor power-starter components and external inputs 5 to 8.onding to the contactor for channel 5, to the circuit-breaker for channel 6, and the 2 columns for channels 7 and 8 (external inputs).e four shaded 5 indicates the four display options for switch D as being: 1, 5, 9 or 13.

for the last 4 inputs.hannels 5 and 6, and columns I7 and I8 for external inputs 7 and 8.e four shaded 5 indicates the number of switch E to be displayed: 12.

or the 4 outputs.channel 5, Q6 channel 6, coil channel 7, Q8 channel 8.e four shaded 5 indicates the number of switch F to be displayed: 10.

Switch D Switch E Switch FPower-starter components 5 to 8 Power-starter components 5 to 8 Control of power-starter components

or external inputs 5 to 8 or external outputsDP No. 4 DP No. 5 DP No. 6 DP No. 7 DP No. 8 DP W DP X DP Y DP Z DP No. 5 DP No. 6 DP No. 7 DP No. 8

or W or X or Y or Z or I5 or I6 or I7 or I8 or Q5 or Q6 or Q7 or Q8nt. CB Cont. CB Cont. CB Cont. CB Cont. CB Cont. W I5 X I6 Y I7 Z I8 Coil 5 Q5 Coil 6 Q6 Coil 7 Q7 Coil 8 Q8

v v v v v v v v v v v v v 0v v v v v v v v v v v v v 1v v v v v v v v v v v v v 2v v v v v v v v v v v v v 3v v v v v v v v v v v v v 4v v v v v v v v v v v v v 5v v v v v v v v v v v v v 6v v v v v v v v v v v v v 7

v v v v v v v v v v v v v 8v v v v v v v v v v v v v 9v v v v v v v v v v v v v 10v v v v v v v v v v v v v 11v v v v v v v v v v v v v 12v v v v v v v v v v v v v 13v v v v v v v v v v v v v 14

v v v v v v v v v v v v v 15

: Coil = state of output to a coil contactor I = external inputQ = state of output to any external circuit DP W, DP X, DP Y, DP Z = input selected by the state of DP (CB or contactor)



Wiring, Communication and Busbar System for Motor Power-Starter ComponentsSchematics for using Components with Screw Terminals

7/01

Control-command circ(conforming to standards “Low volta

1 - Direct starter with relay and with

3 - With forced local control, wired oA shunt for forced local control can a

A Sub-base.B Communication module.X1, X4 HE10 connector, removaQ1 Thermal-magnetic motor(1) Km1: APP-1ER interface(2) KM1: contactor coil.(3) External shunt on lower c(4) To communication modu(5) Control voltage of contac(6) Control unit (optional) for(7) 2-position auto/manual s

Accessories for commSplitter sub-base ABE7ACC02

– Km1

24 V

(1)X1

X4

B A

– Km1

24 V

(1)X1

X4

B A

B

A

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15

This

X

uit diagrams for a direct starter created using components with screw terminals.ge installation regulations” C 15-100 and “Machine safety” NF EN 60205-1)

front-mounted auxiliary contact GV-AE20. 2 - Direct starter without relay, with front-mounted auxiliary contact GV-AE20.

n shunt (3) - (APP-1////D connection blocks not used GV-AE20 used). lso be wired with APP-1////D connection blocks

ble terminal block (See below). circuit-breaker. relay.

onnection block. It can be used to connect an external input.le.tor coils. forced local control.elector switch (optional).

unication modules Intelligent splitter box APE-1R1628

1314

2324

1314

– KM1– KM1

(4)

(4)

(3)

(2) (5)

U1

U2

– Q1

+ VIn

1314

2324

1314

– KM1– KM1

24 V

(4)

(4)

(3)

(2) (5)

U1

U2

– Q1

X1

X4B A

+ VIn

1314

2324

1314

– KM1– KM1

(4)

(4)

(3)(7)

(2) (5)

U1

U2

– Q1

+ VIn

(6)

21

C

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20

16 17 18 19 20 1 2 3 4 5 6 7 8 9 16 17 18 19 20

9 16 17 18 19 20

24 V

OU

T

1 8

0 V

OU

T

24 V

IN

0 V

IN X29 16 17 18 19 201 8X1

9 16 17 18 19 201 8

X4

9 16 17 18 19 201 8

X3



Wiring, Communication and Busbar System for Motor Power-Starter ComponentsPre-Assembled Panel Busbar System

24

2

810

6

11

13

2

1

7

6

Th

AK5 GENERAL INFORMATION

3 41 5 5

9

12

5

10 15 14

8

12




7/01

This

The assembly of automated control and distribution panels requires the use of products that are simple and quick to mount and cable.

The AK5 pre-assembled busbar system meets these criteria by incorporating prefabricated elements which provide 3 principal functions:

Current Supply

Pre-assembled 160 A (at 35 °C) 4-pole busbar system (1).

The busbar systems are available in 6 lengths: 344 (13.5"), 452 (17.8"), 560 (22"), 668 (26.3"), 992 (39"), and 1100 mm (43.3").

An incoming supply terminal block (2) is located at the extreme left of the busbar system.

“Knock-out” partitions allow cabling from above or below to the terminal block connections (3), which are protected by a removable cover (4).

Current Distribution

The tap-offs (5) clip onto the busbar system with instantaneous mechanical and electrical connections to the busbar.

Two ratings are available: 16 and 32 A.

The tap-off units not only ensure rapid mounting but also provide visual “symmetry” for the power distribution circuit and complete safety when accessing under live circuit conditions.

Component Mounting

Component mounting plate incorporating electrical tap-off.

— Tap-off rating: 25 A or 50 A. (No UL rating on 50 A)

The mounting plates clip onto the mounting rail (11), which also supports the busbar system, and at the same time make electrical connection via the incorporated tap-off.

Two types of mounting plates are available:

— Single plate (6) height 4.14" (105 mm) with bolt-on 35 mm wide ( rail (7). This omega rail may be bolted in one of two positions, each with a 10 mm vertical step,

— Double plate (8) and (14) height 7.48" (190 mm) with two bolt-on 35 mm wide ( rails (9) mounted on 100 mm mounting centers. Each rail may be bolted in one of four positions, each with a 10 mm vertical step. These mounting plates are supplied with connectors (12) to allow wiring between control and protection devices.

Bolt-on width extension plates (10) are also available for mounting wider components. Using a lateral end stop (15) in conjunction with these plates also supports the AK5-JB busbar system when used vertically.

A control terminal block (13), comprising of a support plate bolted onto the single or double mounting plates and a 10-pole plug-in block, enables connection of the control circuit wires, c.s.a. 16 AWG (1.5 mm2 max.).

NOTE: Numbers in (parenthesis) corresponds to the drawing on page 24.




26

Pre-assembled Panel Busbar

Conforming to standards:Approvals

UL File Number

CSA File Number


Flame resistance

Number of conductors

Supply current

Rated operational frequency

Rated operational current

Rated insulation voltage

Operational voltage

Maximum permissible peak current

Maximum let-through energy

Short-circuit (1) and overload protec

Wiring

Mounting position

(1) For conditions where condition(2) Using lateral end stop AK5BT0

Th

AK5 SPECIFICATIONS

System Characteristics

EC 439UL, CSA, DNV, LROS

E161251 CCN NMTR

LR 89150 Class 6228 01

Against access to live parts IP XXB conforming to IEC 60529

- Conforming to IEC 60695 - Conforming to UL 94

°C 850 (incandescent wire)V0

AK5JB14• 4

c

Hz 50 or 60

Ambient air temperature 35 °C A 160

Derating coefficient K applicableto rated operational current

°C 35 40 45 50 55 60

for ambient temperature greater than 35 °C K 1 0.96 0.92 0.88 0.83 0.78

- Conforming to IEC 60439-1 - Conforming to UL and CSA

VV

690 600

- Conforming to IEC 60439-1 - Conforming to UL, CSA

VV

Off-load plugging-in and unplugging, with supply switched on400480

- Conforming to IEC 60439-1 - Conforming to UL, CSA

VV

Plugging-in and unplugging with supply switched off690600

kA 25

A2s 1 x 107

tion Type of protection Square D circuit breaker Fuses

161N 161H aM gF

Rating A 160 160 160 160

Prospective short-circuit current kA 25 50 100 100

Operational current A 160 160 160 160

Maximum c.s.a. Minimum c.s.a.

Flexible cable with cable end mm2 70 2.5

Solid cable mm2 70 2.5

Stranded cable AWG 2/0 8

Tightening torque N•m 10 N•m; 88 lb-in

Horizontal or vertical (2) Fixing with screws supplied

al short-circuit current exceeds 25 kA.1 in conjunction with mounting plates AK5PA.




7/01

Tap-off Characteristics

Type

Conforming to standards

Approvals


Polarity

Number of conductors and conductor c.s.a. (UL cables)

Conductor colors

Permissible current


Rated peak current


Conductor insulation

Mounting Plate/Tap-ofType

Conforming to standards

Approvals


Polarity

Number of conductors and conductor c.s.a. (UL cables)

Permissible current


Rated peak current


Conductor insulation

Characteristics of MouType

Material

Surface treatment

This

AK5PC12PH

AK5PC13

AK5PC32LPH

AK5PC33PC33L

IEC 60439

UL, LROS, CSA, DNV

Against access to live parts: IP XXB conforming to IEC 60529

Phase+Phase

3-phasePhase+ Phase

3-phase

AWG (mm2) 2 x 14 (2 x 2.5) 3 x 14 (3 x 2.5) 2 x 12 (2 x 4) 3 x 12 (3 x 4)

Black Black Black Black

A 16 16 32 (25 A UL rated) 32 (25 A UL rated)

V 690 conforming to IEC 60439-1

kA 6

A2s 100,000 200,000

PVC 105 °C

f Characteristics

AK5PA231PA232PA232S

AK5PA532

IEC 60439

UL, LROS, CSA, DNV

Against access to live parts: IP XXB conforming to IEC 60529

3-phase 3-phase

AWG (mm2)

3 x 12(3 x 4)

2 x (3 x 12)2 x (3 x 4)

A 25 50

V 690 conforming to IEC 60439-1

kA 6

A2s 200,000

PVC 105 °C

nting Rails AM1DL201 and AM1DL2017“Top hat” " (width 75 mm, depth 15 mm)

2.5/32" (2 mm) sheet steel

Zinc chromate




28

Mounting Plate with Tap-off

W

H

N

R

GV Manual StartersGV2•01 to •22 (up to 1 side-mount a

GV2•01 to •22 (up to 2 side-mount aor 1 side-mount trip unit)

GV2•01 to •22 (up to 2 side-mount aand 1 side-mount trip unit)

GV2M32, GV3M01 to M40 (no limit mount aux blocks)

GV Manual Starters + CGV2•01 to •20 (up to 1 side-mount a+ LC1D09 to D18 (no side-mount bl

GV2•01 to •20 (up to 2 side-mount aor 1 side-mount trip unit)+ LC1D09 to D18 (up to 2 LA8D••• b

GV2•01 to •20 (up to 2 side-mount aand 1 side-mount trip unit) + LC1D09 to D18 (up to 2 LA8D••• b

GV2•01 to •22 (up to 2 side-mount aor 1 side-mount trip unit) + LC1D09 to D18 (up to 2 LA8D••• b

GV2•01 to •22 (up to 2 side-mount aand 1 side-mount trip unit)+ LC1D09 to D18 (up to 2 LA8D••• b

GV3M01 to M40 (with or without GV+ LC1D09 to D32 (no LA8 aux) Mounted side by side

GV3M01 to M40 with GV1•• + LC1D09 to D32 (with up to 1 LA8 Mounted side by side

GV Manual Starters + RGV2•01 to •20 (no limit on GV aux b+ LC2D09 to D18 (no side-mount bl

GV2•01 to •20 (no limit on GV aux b+ LC2D09 to D18 (up to 1 LA8D••• b


GV2•01 to •22 (no limit on GV aux b+ LC2D25 to D32 (no side-mount bl



♦ Applications up to 25A only.

Th

AK5 APPLICATION INFORMATION

AK5PA231 AK5PA232 AK5PA232S AK5PA532

idth in mm 54 54 108 108

eight in mm 105 190 190 190

o. of 18 mm pitches 3 3 6 6

ated current 25A 25A 25A 50A (not UL rated for 50 A)

Number of 18 mm Pitches used on the Busbar Systemux block) 3 – – –

ux block 4 – – –

ux block 5 – – –

on side- – – – 6

ontactorux block)

ocks) – 3 – –

ux block

lock)– 4 – –

ux block

lock)– 5 – –

ux block

lock) ♦– 4 – –

ux block

lock) ♦– 5 – –

1•• aux) – – – 7

aux) – – – 8

eversing Contactorlocks) ocks)

– – 6 –

locks) lock)

– – 7 –

locks) locks) – – 8 –

locks) ocks) ♦ – – 7 –

locks) lock) ♦ – – 8 –

locks) locks) ♦

– – 9 –




7/01

Mounting Plate with Tap-off

W

H

N

R

Type of StarterIntegral 18 Starter

LD1LB030 (no add-on blocks)

LD1LB030 (up to 2 LA1LB add-on b

LD1LB030 (up to 3 LA1LB add-on b

Integral 32 ® StarterLD4LC030 (no aux blocks)

LD4LC030 (up to 2 LA1LC aux block



LD4LC030 (with 1 LA1LC01• aux bloreset module LA1LC052•, and up toLA1LC030 aux block)

LD4LC030 (with 1 LA1LC01• aux bloreset module LA1LC052•, and up toLA1LC030 aux block)

Reversing Integral 18 SLD5LB130

LD5LB130 with up to 2 LA1LB add-o

LD5LB130 with up to 3 LA1LB add-o

� Applications up to 25 A only.� Using AK5PE17 extension plat� Auxiliary block LA1LC010 coun

This

AK5PA231 AK5PA232 AK5PA232S AK5PA532

idth in mm 54 54 108 108

eight in mm 105 190 190 190

o. of 18 mm pitches 3 3 6 6

ated current 25A 25A 25A 50A (not UL rated for 50 A)

Number of 18 mm Pitches Used on the Busbar System

3 – – –

locks) 4 – – –

locks) 5 – – –

4 � � – – 6

s) � 5 � � – – 6

s) � 6 � � – – 6

s) � 7 � � – – 7

ck and 1 1 7 � � – – 7

ck and 1 2 8 � � – – 8

tarter– – 6 –

n blocks – – 7 –

n blocks – – 8 –

e in combination with AK5PA231 mounting plate.ts as two normal auxiliary blocks. (It is twice the width of the other LA1LC blocks.)




30

Mounting Plate Used With

AK5PA231

Integral 18

Integral 18 + 1 a

Integral 18 + 2 a

Integral 18 + 3 a

GV2 + up to 1 s

GV2 + up to 2 s

GV2 + up to 2 s

Integral 32 (no a

AK5PA231+ AK5PE17 �

Integral 32 (1 au

Integral 32 (2 au

Integral 32 (3 au

Integral 32 (4 au

Integral 32 (withand 1 reset mod

GV3 (no limit on

AK5PA532

Integral 32 (up t

Integral 32 (4 au

Integral 32 (withand 1 reset mod

GV2 + LC1D09

GV2 + LC1D09

AK5PA232 �

GV2 + LC1D09

GV2 + LC1D25

GV2 + LC1D25

AK5PA232S �

GV2 + LC2D09

GV2 + LC2D09

GV2 + LC2D09

GV2 + LC2D25

GV2 + LC2D25

GV2 + LC2D25

� Auxiliary block LA1LC010 cou� Applications up to 25 A only. � For installations using a GV pl

1. Determine how many GVs c2. Determine how many contac

the number of side mounted3. Choose the smaller of the tw

NOTE: For combination

Th

Maximum Number of Components per Busbar System

AK5 Bus-bar

JB143 JB144 JB145 JB146 JB149 JB1410

4 6 8 10 16 18

ux block 4 6 8 10 16 18

ux block 3 4 6 7 12 14

ux block 2 4 5 6 10 12

ide-mount aux block 4 6 8 10 16 18

ide-mount aux block or 1 side-mount trip unit 3 5 6 8 13 15

ide-mount aux block and 1 side-mount trip unit 2 4 5 6 10 12

ux blocks) � � 3 4 6 8 13 14

x block) � � 2 4 5 6 10 12

x blocks) � � 2 3 4 5 9 10

x blocks) � � 2 3 4 5 8 9

x blocks) � � 1 2 3 4 7 8

1 LA1LC01• aux block ule LA1LC052) �

1 2 3 4 7 8

side-mount aux blocks) 2 3 4 5 8 9

o 3 aux blocks) 2 3 4 5 8 9

x blocks) 1 2 3 4 7 8

1 LA1LC01• aux block ule LA1LC052) � 1 2 3 4 7 8

to D18 (no aux blocks) 4 6 8 10 16 18

to D18 (up to 1 LA8D••• block) 3 5 7 9 15 16

to D18 (up to 2 LA8D••• blocks) 3 4 6 7 12 13

to D32 (up to 1 LA8D••• block) � 3 4 6 7 12 14


to D18 (no side-mount blocks) 2 3 4 5 8 9

to D18 (up to 1 LA8D••• block) 1 2 3 4 7 8

to D18 (up to 2 LA8D••• blocks) 1 2 3 4 6 7

to D32 (no side-mount blocks) � 1 2 3 4 6 7



nts as two normal auxiliary blocks. (It is twice the width of the other LA1LC blocks).

us a contactor mounted one above the other, follow the steps below for determining the maximum number of devices per busbar:ould be installed from the AK5PA231 section above. Be sure to properly select the number of side mounted auxiliaries that will be used.tors could be installed from the AK5PA232 (for non-reversing contactors) or AK5PA232S (for reversing contactors) section above. Be sure to properly select auxiliaries that will be used.o numbers from step 1 and 2.

s of components not shown, refer to table on pages 28-29 to determine spacing required.




7/01

AK5JB143

AM1DL201

AK5PC33

AK5PA231

AK5PA232S

AK5PA532

This

AK5 SELECTION INFORMATION

160 Ampere Three Phase Busbar System

Maximum Number of Tap-offs or Mounting Plates

Total Number of 18 mm “Pitches”

36 mm (3 phase)Tap-Offs

Std (54 mm) Mounting Plate

Double-width (108 mm) Mounting Plate

Busbar Length Catalog Numberin mm

12 6 4 2 13.39 344 AK5JB143

18 9 6 3 17.64 452 AK5JB144

24 12 8 4 21.85 560 AK5JB145

30 15 10 5 26.05 668 AK5JB146

48 24 16 8 38.69 992 AK5JB149

54 27 18 9 42.90 1100 AK5JB1410

Mounting Rail

Must be used for Mounting Plate Tap-offs.

Description Material Depth (mm) Length (mm) Catalog Number

75 mm Omega Rail2 mm steel with 10 microns of zinc chromate 15 2000 AM1DL201

Bus Tap-Offs

Plugs into Busbar for Wiring to a Separately Mounted Device.

WidthRated Current

Wire LengthSold in Lots Of

Catalog Number(mm) (in) (mm) (in)

36 1.42 16 A 200 7.87 6 AK5PC13

36 1.42 32 A 250 9.84 6 AK5PC33

36 1.42 32 A 1000 39.37 6 AK5PC33L

Mounting Plate Tap-Offs

Combines a Bus Tap-off with a Prefabricated Mounting Plate for Convenient Mounting of Contactors, GV Manual Starters, and Integral Self-protected Starters.

Application (See page 30 for mounting restrictions)

Width In (mm)

Height In (mm)

Number of DIN Rails Required

Number of18 mm Spaces

Rated Current

Catalog Number

GV2 Manual Starter Integral 18 Starter 2.15 (54) 4.13 (105) 1 3 25 A AK5PA231

GV2 + Contactor 2.15 (54) 7.48 (190) 2 � 3 25 A AK5PA232

GV2 + Reversing Contactor Reversing Integral 18 4.25 (108) 7.48 (190) 2 � 6 25 A AK5PA232S

Integral 32 Starter GV3 + LC1D Contactor (mounted side by side) 4.25 (108) 7.48 (190) 1 6 50 A AK5PA532

� Mounting plate tap-offs with 2 DIN rails include a 25 A rated prefabricated connector for easily wiring the top component to the bottom component.




32

AK5PE17

AK5BT01

Th

Extension Plate

Used to Support Wider Components. Bolts onto Standard Width Plate, After Having Removed the DIN Rail.

ApplicationAttach Mounting Plate

Width In (mm)

Height In (mm)

Number of DIN Rails

Number of 18 mm Spaces Required

Catalog Number

Integral 32 (for applications less than 25 A)

AK5PA231 2.79 (71) 4.13 (105) 1 4 AK5PE17

GV2 + Contactor (with or without side-mounted auxiliaries)

AK5PA232 2.79 (71) 7.48 (190) 2 4 AK5PE27

Side Stop

Used to Secure Components on Mounting Plates when AK5 Busbar is Mounted Vertically.

Description Sold in Lots Of Catalog Number

Metal side stop clip 4 AK5BT01




7/01

This

AK5 DIMENSIONS

Busbar System AK5JB•••

AK5ain (mm)

Gin (mm)

No. of18 mm Points

AK5PC33 AK5PC33L AK5PC13

JB143 13.54 (344) 12.99 (330) 12

JB144 17.80 (452) 17.24 (438) 18

JB145 22.05 (560) 21.50 (546) 24

JB146 26.30 (668) 25.75 (654) 30

JB149 39.06 (992) 38.50 (978) 48

JB1410 43.31 (1100) 42.76 (1086) 54

Mounting Plates Incorporating Tap-offs 25 AAK5PA231

Single Width Extension PlatesAK5PE17

3.23 82

1.18

30

3.1179

1.77 453.19 81

G

a

1.79

45.5

1.4035.5

1.5038

1.81460.59

15

2.1354

2.0953 (1)

4.13

105

0.3910

0.287

0.5915

2.8071

2.0953 (1)

4.13

105

0.3910





34

Th

Z

Mounting Plates Incorporating Tap-offsAK5PA232

Double Width Extension PlateAK5PE27

Mounting Plates Incorporating Tap-offsAK5PA232S AK5PA532

Mounting Rails AM1DL201 (length 2000 undrilled)AM1DL2017

Side StopAK5BT01

1.8146

0.5915

2.1354

3.94

100

0.3910

1.5740

7.48

190

2.0953 (1)

0.287

0.5915

2.8071

0.3910

3.94

100

7.48

190

2.0953 (1)

47 0.3910

2.4863

4.17106

0.3910

3.94

100

7.48

190

2.0953 (1)

2.4863

7.48

190

3.6693

4.17106

2.95 75

25.59650

0.5915 29.53

750

28.54725

0.4912.5

0.9825

1.9750 27.56

700

Ø 0.27 x 0.576.8 x 14.5

0.266.5

Ø0.266.5

0.27 x 0.576.8 x 14.5

0.0

30.

8

0.6115.5

0.79 20

0.287

0.87 22

0.17 4.2





7/01

This

NOTE: Related product catalogs for additional information are listed below:

8502CT9901 R2/01 IEC Contactors and Starters2520CT0001 Manual Motor Starters, Controllers and Protectors, Type GV2, GV3, and GV79421CT0001 Manual Control Switches and Disconnects, Type Vario GS1, and LK3



Catalog No. 8502CT0101 July 2001 © 2001 Schneider Electric All Rights Reserved

Square D Company8001 Highway 64 EastKnightdale, NC 27545 USA1-888-SquareD(1-888-778-2733)www.squared.com

Schneider Canada Inc.19 Waterman Avenue, M4B 1 Y2Toronto, Ontario1-800-565-6699www.schneider-electric.ca

This document provided by Barr-Thorp Electric Co., Inc. 800-473-9123 www.barr-thorp.com

wiring, communication and busbar system - barr-thorp€¦ · • telemecanique gv2 manual starters...

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