A WIRTGEN GROUP COMPANY

BASIC ELECTRIC TRAINING

Hardware
Content

Structure main cabinet Frequency drives

Motor protection switch Terminals
Motor protection relay Connection motor

Motor protection relay ZEV Emergency stop relays

Current monitoring relays RCD-switch
Contactors

Relays

Control units
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Example

STRUCTURE
MAIN CABINET

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Hardware | Structure main cabinet
Same structure of the electric cabinet at
all machines
Power supply

Basic function of the parts is

the same at all machines!
Motor protection switch

Differences:
Contactor
Manufacturer
Size
Motor-protection-relay
Power

Terminals

Cable
with or without plug

Electric motor
(star or delta)

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Values
Function

MOTOR PROTECTION
SWITCH

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Hardware | Motor protection switches
Current: adjustable
Have to be adjusted equivalent to
the current of the electrical motor

Protection against:
Short circuit
Overload (current too high)
Missing phase

Function: bi-metal
Siemens Siemens
„old“ model „new“ model
Reset: manually

Schneider
motorstarter

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Values
Function

MOTOR PROTECTION
RELAY

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Hardware | Motor protection relays
Current: adjustable
Have to be adjusted equivalent to
the current of the electrical motor

Protection against:
Short circuit
Overload (current too high)
Missing phase

Function: bi-metal

Reset: automatically after

bi-metal cooled down

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Values
Function
Troubleshooting

ELECTRICAL
MOTOR-PROTECTION-
SWITCH „ZEV“

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Hardware | ZEV
Current: adjustable
Have to be adjusted to the rated
current of the motor

Protection against:
Short circuit
Overload (current too high)

ZEV Missing phase

Current sensor Over temperature motor

Connection cable
Function: electronic
Message from ZEV to PLC
PLC switches OFF the drive

Reset: automatically (5min)

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Hardware | ZEV
The ZEV consist of:
Evaluation unit
ZEV Current sensor
M10013726
Connection cable

Current sensor
ZEV-XSW-25 M10019255
ZEV-XSW-65 M10013727
ZEV-XSW-145 M10021185
ZEV-XSW-820 M10019256

Connection cable
ZEV-XVK-20 M10013728
ZEV-XVK-80 M10019257

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Hardware | ZEV
Settings

Motor current

Tripping characteristic / Class 5 -40

Reset: manually / automatically

…

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Hardware | ZEV
Settings
…

Ground fault protection

Auxiliary contact NC

Auxiliary contact NO
…

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Hardware | ZEV
Faults / relay tripped

Overload

Overtemperature

Ground fault

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Hardware | ZEV
Faults / relay tripped

Missing phase

Current imbalance

System fault
1 Sensor fault / damaged cable
2 EEPROM fault (internal storage)
3 Evaluation unit

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Values
Function
Troubleshooting

CURRENT MONITORING
RELAY

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Hardware | Current monitoring relays
Current: adjustable
Have to be adjusted to the rated
current of the motor

Protection against:
Overload (current too high)

Function: electrically
Message from device to PLC
PLC switches OFF the drive

Reset: automatically

Siemens Siemens 3UG4

3RR22 as overload relay at the crusher motor of
z.B. MC120 / MR122 / MC125 /…

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Hardware | Current monitoring relays
Current: adjustable
Main terminals (input)
Have to be adjusted to the rated
Display for current of the motor
parameter / status

Arrow button for adjustments Protection against:

Overload (current too high)
Enter button for adjustments

Function: electrically
Message from device to PLC
Auxiliary contacts PLC switches OFF the drive

Reset: automatically
Main terminal (output)

Auxiliary contact NC (31/34)

Power supply 24V DC

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Hardware | Current monitoring relays
Current: adjustable
Have to be adjusted to the rated
current of the motor

Protection against:
Current monitoring relay
Overload (current too high)
Main terminals (input)

Function: electrically
Main terminals (output)
Message from device to PLC

Power supply 24VDC

PLC switches OFF the drive

Reset: automatically

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Hardware | Current monitoring relays
There are two programing menus available:
„Run“ by pushing the SET-button short
„SET“ by pushing the SET-button long

With pushing the SET-button long again you’ll get back to the main menu.

Independent of the selected menu it’s possible to get to the next parameter with pushing the SET-button short.
With the arrow buttons it is possible to change the selected parameter.

OFF
Rated current

OFF

OFF

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Basic | Current monitoring relays
0,8A
15-30 seconds
7-10 seconds

5 minutes

no

no

no

no

Is

NC

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Values
Function

CONTACTORS

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Basic | Contactors
Differences:
NC contact
Manufacturer
Switching contact Size / power
NO contact e.g. 7,5kW, 11kW, 15kW,…
Coil voltage A1/A2
24V DC or 230V AC
Moving core Amount of the auxiliary contacts

Contacts are activated as soon as

Coil there’s power at A1/A2.
Connection coil
Switches 3 phases to the motor
L1 / L2 / L3
Fix core

Available including auxiliary contacts:

NC 11/12, 21/22,…
NO 13/14, 23/24,…

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Values
Function

RELAYS

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Hardware | Relays
Difference:
Manufacturer
Size / power
e.g. 2A, 4A, 15kW,…
Coil voltage A1/A2
24V DC or 230V AC
Amount of contacts

Contacts are activated as soon as

there’s power at A1/A2.
Mechanical or electrical contacts.
Same working principle as contactors,
just for less power and less contacts!

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Overview of types

CONTROL UNITS

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Hardware | Control units
Consists of the PLC (computer) and
different extensions e.g.:
Input modules
Output modules
Analogue modules
Canbus modules

Different manufacturers:
VIPA PLC of MREVO2
Siemens
VIPA
Schneider
Bosch Rexroth

Schneider PLC (M258) of MC EVO

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Overview

TERMINALS

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Hardware | Terminals

Terminal Terminal Terminal Terminal

1 contact 1 contact 2 contact 3 contact
2 connections 3 connections 4 connections 6 connections

5 6
3 4 3 4
1 2 1 2 3 1 2 1 2

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Star / Delta

CONNECTION MOTOR

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Hardware | Connection motor
It’s possible to connect an electric motor in 2 ways:
DELTA STAR STAR or DELTA

The connection depends on the construction

of the motor

After a motor has been changed , the new motor

have to be connected corresponding to the data plate

400V AC 3-phase
Between 2 phases 400V AC
Between 1 phase and N/ground 230V AC

L3 L3 If the motor rotates in the wrong direction,

two phases have to be changed.
E.g. L1 with L2 or L2 with L3
L2 L2

L1 L1

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Hardware | Connection motor

Red marked area:

230/400V instead of 400/690V, means that a single coil of the motor can handle max. 230V.
In this case, the engine has to be connected in STAR mode

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Overview
Function

FREQUENCY DRIVES

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Hardware | Frequency drives
Different manufacturers:
Control Techniques / Emerson
Schneider

Used to control the speed of electric

motors. (screen, vibrating feeder, feeding
belt,…).
Different sizes, depending of the drive.
Different settings and parameters

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Hardware | Frequency drives
The speed of an electric motor depends on the frequency.
With a frequency drive it’s possible to change the frequency and so the speed.

Motors without frequency drives are operated with the generator frequency (diesel speed)!
Values: voltage constant, 400V AC
current maximum = 100%, actual current depends on the mechanical load of the motor
frequency variable, higher frequency = higher speed, e.g. 50Hz =1000rpm, 60Hz = 1200rpm

Vibrating motors Generator, 400V

Speed depends on the 1500rpm = 50,0 Hz
setted frequency. 1600rpm = 53,3 Hz
1700rpm = 56,7 Hz
1800rpm = 60,0 Hz

Frequency drive
Converts the input frequency to
the required frequency
Input 50-60 Hz // Output 35(20)-55 Hz

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Overview
Function
Troubleshooting

RCD-SWITCH

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Hardware | RCD
=004+S-T1
summation current transformer
=004+S-F3
RCD tripping device
=004+S-K1
under voltage relay
Signal from RCD to the
under voltage relay

If the RCD detects a ground fault, it

switches off the voltage to the under
voltage protection.

Then the under voltage protection will

switch OFF the main switch!

Faultmessage: “undervoltage” as the RCD

has no feedback contact to the PLC

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Hardware | RCD

From main switch

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Hardware | RCD
Troubleshooting RCD (resedual current protection device)

The RCD will trip, if there is any ground fault at the machine!

Possible reason / most common:

Shortcut or a bad isolation of a electric motor (contact from L1/L2/L3 to the chassis)
Shortcut in a cable between L1/L2/L3 to PE (e.g. cable squashed,…)
Shortcut in a cable between and chassis (cable is squashed and gets connection to the chassis)
Water in the motor / connection box,…

There’s only one RCD for each machine including all drives. To troubleshoot these faults do following:
Start the machine in manual mode.
Start each drive separately.
If e.g. the feeder is switched on and the RCD trips, the fault is located.
After that, disconnect one of the two feeder motors, if the RCD trips again the faulty drive is located (motor or cable)
Visible check of the cable
Check the motor and the cable with a isolation multimeter.

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Overview

EMERGENCY STOP
RELAYS

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Hardware | Emergency stop relays
Different manufacturers:
PILZ, Schneider, Siemens
Function is always the same
2 channels (CH)
Power supply
24V DC / 230V AC
Switches off the drives, partial 24V DC and
on the latest machines the main switch.

„Control voltage BEFORE e-stop“

24V DC available after the control
voltage is switched ON.

„ Control voltage AFTER e-stop“

24V DC available after the e-stop
is acknowledged.

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THANK YOU FOR

YOUR ATTENTION!
Basic Electric Training l Hardware

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