PLC Systems Chapter 5.1 - Technical Guideline - Power Supply Provided by The Customer

Logistik + Informatik GmbH
Neustädter Straße 21
92711 Parkstein
Phone: +49 9602 600-0

Fax: +49 9602 600-211
E-mail: info@witron.de
PLC Systems
Chapter 5.1 – Technical guideline -
power supply provided by the customer
Power supply of group control

Translation of the original project basics
Project Ohio V1.2 FINAL, Date: Feb. 27, 2020

Reference no.: 0218031
Chapter 5.1 – Technical guideline - power supply provided by the customer
It is not permitted to copy any part of this document or share it with third parties without written approval
from WITRON. WITRON exclusively owns all copyrights to this document.
WITRON reserves the right to change respective to correct at any time the product specifications described
in this documentation. Any change we would make could not have a material impact on the system
performance or functionality without prior discussion with Metro. This clause is more to give us flexibility for
small design changes that may come out of detailed design or based on selected suppliers. These kind of
small changes would not be material to Metro in terms of system functionality or performance.
The programs described or specified in this document are provided on the basis of a licensed agreement and
may be used or copied only in compliance with the regulations of the licensing agreement.
All company and/or product names are trademarks and/or registered trademarks of the corresponding
proprietor.
© 2020 WITRON Logistik + Informatik GmbH, 92711 Parkstein
Editor history:
Date Version ID Description

2019-06-21 1.0 PD, OG Basic document
2019-10-28 1.1 CD Project version
2020-02-27 1.2 CD Added legal language above as requested by METRO

Project Ohio V1.2 FINAL, Date: Feb. 27, 2020, Reference no.: 0218031, Error! No text of specified style in document.
© 2020 WITRON Logistik + Informatik GmbH, 92711 Parkstein Page 2 of 24
Content Page
1 PREFACE AND GENERAL INFORMATION .............................................................................................4
2 ABBREVIATIONS ..........................................................................................................................5
3 STANDARDS AND REGULATIONS ......................................................................................................6
4 DEMANDS ON POWER SUPPLY .........................................................................................................7
4.1 SYSTEM STRUCTURE ................................................................................................................... 8

4.2 OVERVIEW OF STATISTICAL VALUES OF THE MAXIMUM ALLOWED VOLTAGE DROP ......................................... 9
5 INFORMATION PROVIDED BY WITRON .........................................................................................11
5.1 PROJECT-RELATED CALCULATIONS ................................................................................................ 11

5.1.1 PROVISIONAL CALCULATIONS OF THE COMPLETE TRANSFORMER CONNECTED LOAD S [KVA] ......................... 11
5.1.2 EXACT DETERMINATION OF CURRENT DEMAND AND CONNECTED LOAD OF INDIVIDUAL GROUP CONTROLS ......... 13
6 PROTECTIVE MEASURES PROVIDED BY THE CUSTOMER .......................................................................16
6.1 GENERAL ............................................................................................................................... 16

6.2 SCHEMATIC STRUCTURE ............................................................................................................. 19
6.2.1 SCHEME 3-POLE ...................................................................................................................... 19
6.2.2 SCHEME 4-POLE ...................................................................................................................... 20
7 CONNECTION IN THE INFEED PANEL ...............................................................................................21
8 EQUIPOTENTIAL BONDING AND LIGHTNING PROTECTION ...................................................................24

Preface and general information
1 Preface and general information
When planning an electrical system all the predetermined statistical values which are observed
in the respective country specifically applicable standards have to be observed and may not be
surpassed.
For questions about standards and regulations, please refer to the department for occupational
safety or electrical engineering.

Abbreviations
2 Abbreviations
Abbreviation Designation
I Power supply
IN Nominal current
IA Starting current
IK Short-circuit current
P Power
PN Nominal power
PA Starting power
PK Short-circuit power
PW Effective power
S Apparent power
cos ᵠ Effective power factor
U Nominal voltage
g Full-range fuses that are able to permanently carry currents until at least
their rated current and that are able to switch off currents from the lowest
melt flow to the rated breaking current
G Protection for general purposes
gG Full-range protection: general use, standard type

(virtually identical to the previous gL)
GC Group Control
(group control)
IP Infeed Panel
LP (Load Panel)

Standards and regulations
3 Standards and regulations
The currently valid standards and regulations have been considered.

Germany
 TAB 2007
Technical terminal conditions for the connection to the low-voltage system, BDEW
 DIN VDE 0100-520

Installation of low-voltage systems - Part 5-52: Selection and erection of electrical
equipment - Wiring systems
Germany + Europe
 DIN EN 60038; VDE 0175-1
CENELEC standard voltages
 DIN EN 60204-1; DIN VDE 0113-1

Safety of machinery - electrical equipment of machines - Part 1: General requirements
 DIN EN 60204-32; DIN VDE 0113-32

Safety of machinery - electrical equipment of machines - Part 32: Requirements for lifting
devices
Europe
 IEC 60364-5-52 (VDE 0298 Part 4)
France
 NF C15-100 COMPIL (OCTOBER 2010)
Norm for French standard of electrical installations
USA
 NFPA 70
 NFPA 70e
 NFPA 79
 NEC
Canada
 CSA Z 462
The instructions and information in the document

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Link:
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Demands on power supply
4 Demands on power supply
 TN-S grounded system

 3 x 400 V AC, PE, N, (five-conductor network), Central Europe
 3 x 415 V AC, PE, N, (five-conductor network), UK
 480Y/277 V AC, 3 phases, GRD, (four-conductor network), USA, Canada
 Frequency 50 Hz (60 Hz USA, Canada)
 External conductor sequence L1-L2-L3, clockwise field rotation
 No voltage fluctuations > ±10 % according to [IEC 60038]
 A reactive-current compensation system was not considered or recommended on the
part of WITRON. Due to the use of frequency converters, only a few inductive consumers
are operated directly on the grid. An on-site compensation system would have to be
choked and automatically regulated.
 The system provided by the customer must be implemented according to the electro-
magnetic environmental class 3 [IEC EN 61000-2-4 / DIN VDE 0839 Parts 2-4].
 Withing the logistics industry non-linear consumers are used, which typically lead to 5th
and 7th order harmonics. A harmonic compensation is not considered by WITRON.
However, it is recommended to provide active filters on site for all trades at a central
location.
 The cross section of the neutral conductor can be reduced according to the applicable
national standards. It must correspond to minimum 50 % of the relevant external
conductor cross section (L1, L2 or L3).
 It is mainly assumed that the load of the external conductor is symmetrical. There are
approx. 95 % three-phase consumers used.
 The feed-in cabinets (IP) are designed for a maximum conditional short-circuit current of
Icc = 35 kA.
 The supplier of the low voltage main distribution board has to inform WITRON in case of
larger short-circuit currents. Consequentially, required protective measures must be
taken together.
 On the part of WITRON, there is no over-voltage protection provided.
 The back-up fuse for the GC infeed panel must correspond to the gG characteristic of a
NH securing (on site).
USA/Canada:
The Arc Flash category shall only be 0 for WITRON group controls. An Arc Flash hazard
analysis according to the national standards or local regulations like [NFPA 70E or CSA Z462]
must be carried out by the customer. Protection devices, cables, etc. are to be selected
accordingly by the customer.
The professional engineer for the Arc Flash study has to inform WITRON in case of a higher
category than 0. Resulting from this, required measures have to be taken together.

4.1 System Structure
Central Europe:
Trafostation
Trafostation
Trafostation
3x400 V N/PE 50 Hz
3x 400V N/PE 50Hz
L1
L2
L3
N
PE
Betriebserde
Betriebserde
Betriebserde M
3~
Great Britain (UK):
Trafostation
TransformerStation
Transformer Station
3x415
3x 415V V N/PE
N/PE 50 Hz
50Hz
L1
L2
L3
N
PE
System
SystemEarth
Earth
System Earth M
3~
USA/Canada:
Transformer station
Transformer Station
Transformer Station
3x480Y/277
3x V
480V PE 60Hz GRD 60 Hz
L1
L2
L3
PE
SystemGround
Station Earth
Station Ground M
3~

4.2 Overview of statistical values of the maximum

allowed voltage drop
These specifications are to be observed for the electrical installation of a WITRON system:
The prescribed statistical values for the voltage drop from the point of connection to supply
system to the consumer are defined in France in the NF C15-100 COMPIL (OCTOBER 2010),
table 52W. The statistical values contained therein are derived from the "DIN VDE 0100-
520:2013-06, table G.52.1":
Low-voltage system directly supplied by a public power grid
 Lighting 3%
 Other current-using equipment 5%

Low-voltage system supplied by a private power grid

 Lighting 6 %
 Other current-using equipment 8 %
Additionally, for the safety of machinery and electrical equipment of machines also need to
comply with the predetermined statistical value regarding the voltage drop in conductors,
cables and wires from the DIN EN 60204-1:2014-10. In this standard, the section 12.5 defines
that the voltage drop from the point of connection to supply system to the consumer in any
power cable may not exceed 5% of the nominal voltage under usual operating conditions.
Thus, the maximum voltage drop of 5 % must be observed.
Witron defines that a voltage drop of maximum 3 % for load current circuits is permitted from
the infeed point of our system (terminal on the main switch in the infeed cabinet) to the last
consumer.
For the power supply on site a voltage drop of maximum 2 % is predetermined from the
transformator station to the infeed point.

Information provided by WITRON
5 Information provided by WITRON
5.1 Project-related calculations
5.1.1 Provisional calculations of the complete transformer

connected load S [kVA]
The following table provides data of a sample system. This system represents a standard
system that WITRON hands over to its end customers. The information provided in this table is
not the basis for the customer/planner to size the transformer as well as the low voltage main
distribution board.
The following information must be considered exemplary.

Position Description
Description
The following list shows an example of individual system components. The
component types and the number of components used depends on the
respective system.
Tote/tray conveyor system Wrapper
Rewinder Depalletizer "DEP"
Cardboard box conveyor system Transfer car
Pallet CRA Emergency stop controls
Miniload CRA Vertical conveyor
Pallet conveyor system Palletizer
Case Order Machine "COM" Special machines
Nominal power
The total nominal power can now be calculated from the added nominal currents
of the individual areas:
I ∗ √3 ∗ 400V ∗ cos 𝜑
P=
1000
Nominal current
WITRON already considered the following factors for the calculation method to
the currents for the individual areas:
The connected load of the individual motors from experiences of previous
projects
The expected energetic recovery into the network in % will be subtracted
A simultaneity factor, as all drives are never operated at the same time
The estimated number of drives from the design layout (sales phase)
The total nominal current can now be added from the nominal currents of the
individual areas
These calculations are based on the design layout (distribution). Due to project-
specific layout changes, these calculations can vary up to 20% in the detailed
design of the project!
Calculation of the apparent power for the transformer

Since the connected load of a transformer is indicated in kVA, this load has to be
calculated according to the following formula:
𝑃
𝑆=
cos 𝜑
Note:
The value of the effective power factor ranges within an area of 0.75 – 0.95.
The more frequency controllers (FUs) are available in the system, the
higher/better the factor.

5.1.2 Exact determination of current demand and connected load

of individual group controls
The different assembly groups will be divided again in the course of the project. The division
takes place in drives per group control. As a result, the total current demand of the individual
group controls can be calculated.
The following information must be considered exemplary.

Description
This part contains the individual system areas. Of course, these, depend on the
system (OPM, DPS, ...).
Meanwhile, the number and size of the individual group controls are specified
and explained by means of a short description.
Nominal power
The total nominal power can now be calculated from the added nominal currents
of the individual areas:
I ∗ √3 ∗ 400V ∗ cos 𝜑
P=
1000
The last unknown for the power calculation is the current that is described as
follows.
Nominal current
The exact total nominal current can now be added from the nominal currents of
the individual areas.
WITRON already considered the following factors for the calculation method to
the currents for the individual areas:
The quantity and the power consumption of the individual motors is yet known
and can be included in the addition.
The expected energetic recovery into the network in % will be subtracted.
A simultaneity factor, as all drives are never operated at the same time. The
factor depends on the system type and can range from 0.3 to 0.5.
Back-up fuses
After determining the exact nominal current, the back-up fuses can be specified.
An important goal is to achieve a selectivity of the system.
In the event of an error, selectivity means that only the over-current device that
is located directly in front of the fault location will be activated. The remaining
system parts are not affected and can be further used.
Based on the different start behaviors and associated high starting currents, the
following conveyor system areas are distinguished:
 Conveyor system for pallets
 Conveyor system for totes / trays / cardboard
 Conveyor system with dynamic elements, e. g. vertical conveyor and
transfer cars
 Miniload CRA
 Pallet CRA
Depending on their dynamics, the exact nominal currents of the areas will be
multiplied with a factor between 1.3 to 4.
Furthermore it is considered for the cranes on control-side that not all devices
will start at the same time, but step by step.
The required cable cross section of each GC infeed must be designed regarding to the
predefined back-up fuse.

Thereby, the following components must be considered:

• Wiring material
• Laying system
• Cable length
• Accumulation
• Ambient temperature

Protective measures provided by the customer
6 Protective measures provided by the customer
6.1 General
 As a protective measure for the electrical system, an over-current protective device will
be used as disconnection in the TN-S system.
 A RCD with a release current of 30 mA is required for the sockets (230 V/110 V) as
additional protection against indirect contact.
In North America, these sockets are only allowed for service works. Otherwise, different action
values will apply for RCDs.
 The selectivity of the system must be ensured.
Selectivity means that only the protective equipment that is located directly in front of the
fault location is switched off and the other system components continue to operate without
disruption in case of an electric arc. Selectivity limits the impacts of an error to a minimum and
avoids costs for a machine breakdown.
Fuse 1 Fuse 2

The tripping characteristic of the fuses plays an important role.

WITRON uses gG fuses or circuit breakers with similar characteristic for its infeed lines.
 g: Full-range fuses that are able to permanently carry currents until at least their rated
current and that are able to switch off currents from the lowest melt flow to the rated
breaking current
 G: Protection for general purposes
 gG: Full range protection: general use, standard type, virtually identical with the previous
gL
Time / current
limit
Virtual fusing
time
Effective
value of the
uninfluenced
current

peak value
Cut-off current

6.2 Schematic structure
6.2.1 Scheme 3-pole

6.2.2 Scheme 4-pole
4-pole disconnection is required in France and Norway.

Connection in the infeed panel
7 Connection in the infeed panel
Performances provided by the customer:

 Dimensioning, supply, and installation of the feed line
 Connection of the feed line including strain relief in the IP control cabinet, direct
connection at the main switch, as well as final electrical check of the feed line
 Data of an infeed panel ("IP" panel) is enclosed

 A base with a height of 200 mm is used.

 The customer provides one or a maximum of two feed lines per group control
 When dimensioning the infeed supply line the statistical values mentioned under "4.2
Overview of statistical values of the maximum allowed voltage drop" must be considered
and observed.
 The individual cross section may only be 300 mm²
 The implementation of the feed line will exclusively be carried out from below
 The strain relief rail of the infeed supply cable is included in WITRON's scope of supply
 The assembly and the test of the cables is done by the customer
The line connections "infeed of the relevant GC" are designed for copper conductors "CU". If
aluminum cables are used by the customer, it must be announced and coordinated prior to the
manufacturing of control cabinets.
The sample picture shows a 3-pole main switch for an operating capacity of 400 A, this
corresponds to a cable cross section of approx. 120 mm2 CU.

Connecting terminals at the main switch
Clamping unit main switch L1, L2, L3
Clamping unit N, PE
Pull-relief

Equipotential bonding and lightning protection
8 Equipotential bonding and lightning protection
The grounding installation of the whole building including the lightning protection, like the main
earthing terminals for the additional protective equipotential bonding per double rack or outside
single rack including crane railway as well as on platforms is provided by the customer.
WITRON creates a layout with all necessary terminal lugs.
The terminal lugs must protrude at least 1 m from the ground.
The terminal lugs in the area of the switch cabinets are to be equipped with an equipotential
bonding busbar provided by the customer.
Connection of an additional protective equipotential bonding on bodies which may be touched
indirectly:
 Rack system
 Platforms
 Rails
 Pallet positions
 Machines
 Cable channels
The conductor cross section is at least 4 mm² and green/yellow.
Not to be connected to the additional protective bonding conductor are:

 Protective fence elements
 Limit position buffer and stop plates
 PC stacks
 Control panels
 DLS uprights
 Contour check
 Cross-overs


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Logistik + Informatik GmbH

Phone: +49 9602 600-0

Power supply of group control

Project Ohio V1.2 FINAL, Date: Feb. 27, 2020

© 2020 WITRON Logistik + Informatik GmbH, 92711 Parkstein

Date Version ID Description

Chapter 5.1 – Technical guideline - power supply provided by the customer

1 PREFACE AND GENERAL INFORMATION .............................................................................................4

3 STANDARDS AND REGULATIONS ......................................................................................................6

4 DEMANDS ON POWER SUPPLY .........................................................................................................7

4.1 SYSTEM STRUCTURE ................................................................................................................... 8

5 INFORMATION PROVIDED BY WITRON .........................................................................................11

5.1 PROJECT-RELATED CALCULATIONS ................................................................................................ 11

6 PROTECTIVE MEASURES PROVIDED BY THE CUSTOMER .......................................................................16

6.1 GENERAL ............................................................................................................................... 16

7 CONNECTION IN THE INFEED PANEL ...............................................................................................21

8 EQUIPOTENTIAL BONDING AND LIGHTNING PROTECTION ...................................................................24

Chapter 5.1 – Technical guideline - power supply provided by the customer

1 Preface and general information

Chapter 5.1 – Technical guideline - power supply provided by the customer

cos ᵠ Effective power factor

G Protection for general purposes

gG Full-range protection: general use, standard type

Chapter 5.1 – Technical guideline - power supply provided by the customer

3 Standards and regulations

The currently valid standards and regulations have been considered.

 DIN VDE 0100-520

 DIN EN 60204-1; DIN VDE 0113-1

 DIN EN 60204-32; DIN VDE 0113-32

The instructions and information in the document

Chapter 5.1 – Technical guideline - power supply provided by the customer

4 Demands on power supply

 TN-S grounded system

Chapter 5.1 – Technical guideline - power supply provided by the customer

4.1 System Structure

Great Britain (UK):

Chapter 5.1 – Technical guideline - power supply provided by the customer

4.2 Overview of statistical values of the maximum

Chapter 5.1 – Technical guideline - power supply provided by the customer

Low-voltage system supplied by a private power grid

Chapter 5.1 – Technical guideline - power supply provided by the customer

5 Information provided by WITRON

5.1 Project-related calculations

5.1.1 Provisional calculations of the complete transformer

Chapter 5.1 – Technical guideline - power supply provided by the customer

Tote/tray conveyor system Wrapper

Rewinder Depalletizer "DEP"

Cardboard box conveyor system Transfer car

Pallet CRA Emergency stop controls

Miniload CRA Vertical conveyor

Pallet conveyor system Palletizer

Case Order Machine "COM" Special machines

Calculation of the apparent power for the transformer

Chapter 5.1 – Technical guideline - power supply provided by the customer

5.1.2 Exact determination of current demand and connected load

Chapter 5.1 – Technical guideline - power supply provided by the customer

Chapter 5.1 – Technical guideline - power supply provided by the customer

Thereby, the following components must be considered:

Chapter 5.1 – Technical guideline - power supply provided by the customer

6 Protective measures provided by the customer

 The selectivity of the system must be ensured.

Chapter 5.1 – Technical guideline - power supply provided by the customer

The tripping characteristic of the fuses plays an important role.