Integrated system for safe and future-proof power distribution - Moeller

Special Publication
Integrated system for safe and
future-proof power distribution
Authors:
Dipl.-Betriebswirtin
Jutta Zacharias,
Dipl.-Ing.
Heinrich Moog
With power requirements
increasing all
over the world and the
continued increasing
pressure to cut costs,
there is an even greater
need for secure
investments through
which efficient
planning, assembly,
installation and
operation are ensured.
To meet these requirements,
cost-efficient
and standardised power
distribution systems
are needed that
customers can adapt
to the individual
requirements of their
projects. In short
what is needed is
maximum flexibility,
economy and
reliability.
www.moeller.net/xenergy
Think future. Switch to green. green

Integrated system for safe and
future-proof power distribution
With power requirements increasing all over the world and the
continued increasing pressure to cut costs, there is an even
greater need for secure investments through which efficient
planning, assembly, installation and operation are ensured. To
meet these requirements, cost-efficient and standardised power
distribution systems are needed that customers can adapt to the
individual requirements of their projects. In short what is needed
is maximum flexibility, economy and reliability.
Extensive safety requirements and
special standards have to be observed in
the power distribution sector. The consistent
use of the extensive assembly
and testing regulations as stipulated by
DIN EN 60439-1 (VDE 0660 Part 500):
2000-08 [1, 2] is therefore an important
requirement for the reliable and safe
operation of a switchgear and controlgear
assembly, i.e. a type-tested (TTA)
and partially type-tested (PTTA) assembly
for power and service distribution
boards (DIN EN 60439-3 (VDE 0660
Part 504):2002-05 [3, 4]). In compliance
with DIN EN 60204-1 (VDE 0113 Part
1):1998-11 [5, 6] the switchgear and
controlgear assembly, or switchboard
system for short, can likewise be used
as a type-tested/partially low-voltage
Jutta Zacharias is head of the
Power Distribution business unit
at Moeller GmbH in Bonn.
e-mail: jutta.zacharias@moeller.net
Dipl.-Ing. Heinrich Moog is head of
xEnergy product management at
Moeller GmbH in Bonn.
e-mail: heinrich.moog@moeller.net
Picture 1. In the divide between the demand
for greater safety, flexibility and load
capability on the one hand, and pressure to
cut costs on the other, Moeller's switchboard
system is a future-proof platform for resultoriented
solutions
control panel for machines. Apart from
the basic assembly and test requirements,
the relevant standards and regulations
also lay down the safety requirements
for electrical equipment, personnel
and system protection and also the
selection and dimensioning of electrical
equipment.
The extensive type testing for lowvoltage
switchboard systems contains
the following seven tests areas:
• Limit overtemperature,
• Dielectric strength,
• Short-circuit current capability,
Jutta Zacharias • Heinrich Moog
• Efficiency of the protective devices,
• Creepage and air clearances,
• Mechanical functions,
• IP protection.
The following functions are tested in the
switchgear and controlgear assembly in
the degree of protection for the corresponding
current class:
• Maximum current carrying capacity
of the electrical function units,
• Switching and protective devices in
mechanical and electrical combination
with the mounting systems including
the main busbars, dropper bars and
busbar links,
• All system components as integral
units in their functional mounting.
An additional test is carried out in the
protective conductor circuits of the system
panels in accordance with IEC/EN 60
439-1, section 8.2.4 - Verification of the
effectiveness of the protective circuit -
with the following tests:
• Section 8.2.4.1: Verification of the
effective connection between the
exposed conductive parts of the
assembly and the protective circuit by
measurement and
• Section 8.2.4.2: Verification of the
short-circuit strength of the protective
circuit by test.
Both tests must be verified by the
manufacturer (of each) and are particularly
important for personnel protection.
The results for the assembly of the
switchboard system are documented for
practical application by system suppliers,
such as in product catalogues;
selection and dimensioning documents;
assembly manuals; configuration and
engineering tools; certification of the
completed type tests for the declarations
of conformity by the system supplier.
The tests therefore guarantee reliable
system assembly, as well as verifying the
basic features with successfully completed
type tests (TTA). At the same time,
the reliable functioning of a switchboard
system during operation is also
verified – an important factor for a
future-proof and reliable power supply.
TTA/PTTA switchgear assemblies also
include those that are engineered and
assembled by local panel builders in
2 Heft 7/2004 •

xEnergy –
in the divide of panel building
Moeller's Kit system for the panel builder is a single-source development that has been designed
and thought through to meet the needs of the panel builder. xEnergy offers outstanding
efficiency, flexibility and stands out with its simplicity and functionality.
Technical system features
Standards DIN EN 60439-1 (VDE 0660 Part 500)
Type testing TTA
Internal separation Form 1 to Form 4
Rated operational voltage Ue 690V / 50Hz ... 60 Hz
Rated operational current Ie to 4 000 A
Rated short-time withstand resistance Icw bis 100 kA (Effektivwert), 1 s
Ambient temperature 35 °C (40 °C) to 45 °C (50 °C)
Degree of protection IP31/IP55
Network system TN-C / TN-C-S / TN-S / IT
Colour RAL 7035 (other colours on request)
Dimensions h 2 000 mm basic height without plinth,
w 425/600/800/1 000/1 200 mm,
d 400/600/800 mm
xEnergy – technical data
Mounting of Moeller IZM and NZM circuit-breakers up to 4000 A - application benefits:
• Clear and symmetrical design with only one circuit-breaker per section
reduces the number of busbar connections and saves mounting requirements,
• Internal separation up to Form 4 increases personnel and system protection,
• Circuit-breaker mounting kits for optimum assembly and packed as a unit,
• Fast and direct allocation of mounting kits for the mechanical fastening of circuitbreakers,
• High level of flexibility in the terminal area thanks to alternative connection options: Cable
terminal system, straps or busbar adapters.
Mounting of Moeller switching and protective devices up to 630 A - application benefits:
• Max. 38 fixed compartment modules in one section (h = 50 mm), to 40 A
• Max. 19 fixed compartment modules in one section (h = 100 mm), to 160 A
• Optimum device utilisation despite high packing density
• Simple module mounting to Form 2 on one mounting depth,
• Flexible module mounting to Form 4 with different device mounting depths, with standard
operating front,
• Highly flexible combination possible for functional areas and busbars in accordance with
EN 60439 (VDE 0660 Part 500) and national installation practice.
xEnergy – the new system offer in panel building – application benefits of the optimised
system platform up to 4 000 A:
• Low number of individual parts and modules,
• Suitable for universal use (DIN VDE, IEC, NF [France], UNE [Spain]),
• Can be combined flexibly,
• Low earth transition resistance for personnel protection,
• Efficient selection and configuration using Moeller ConFix
• Functionally packed into individual assemblies, supplied as flat pack
• Easy and fast to install – 30 minutes per section,
• Fully type-tested and designed for future requirements.
accordance with binding documents
and supplier specifications.
The construction of partially type-tested
assemblies (PTTA) involves the use
of both type-tested and non type-tested
functional assemblies. Test certificates
• Heft 7/2004
are equally required for PTTAs. These
can be provided by means of additional
type testing or by the derivation of
similar systems from type-tested
assemblies. Additional calculations are
also required depending on the type of
PTTA involved: Short-circuit (DIN IEC
1117 (VDE 0660 Part 509):1993-09 [7, 8])
and temperature rise (IEC/TR 60890).
1987-07 [9]).
Future-proof switchboard system –
the platform for results-based
solutions
The project business is defining and
shaping the market for low-voltage
switchboard systems. End customers
require individual solutions for their
specific requirements with an optimum
price-performance ratio. This kind of
financially flexible solution can only be
offered by a modular power distribution
system that is based on an intelligent
platform concept. The divide between
ever increasing demands in terms of
engineering and safety on the one hand,
and cost reduction on the other can
only be bridged by means of an innovative
generation of switchboard systems
(Picture 1).
xEnergy – the new power
distribution system generation
xEnergy, Moeller's new integrated system
range, stands for power distribution
systems that are specially designed for
the building infrastructure up to 4 000 A.
Moeller are single-source suppliers of an
intelligent system platform for switching
and protective devices that panel builders
can customise, assemble quickly and
handle easily. Based on many years of
practical experience in the building of
switchgear assemblies, Moeller has developed
the latest generation of switchboard
systems that incorporates the latest trends
and essential features. The individual switching
and protective devices, the associated
mounting system design and also
the switchgear are combined to form one
technical unit. This kind of system is both
economical and reliable at the same time,
as perfectly matched and type-tested functional
units have been developed as a
modular system. Exactly tailored function
modules that have been type-tested in
accordance with DIN EN 60439-1 (VDE
0660 Part 500), and available with internal
separation from Form 1 to Form 4, comply
with national installation requirements
(DIN VDE, IEC, NF [France], UNE [Spain])
(Picture 2). The system range consists of:
• Feeder and coupling sections for circuit-breakers
up to 4 000 A,
• Individually equipped outgoer sections
with fixed compartment modules for
switching and protective devices in-
3

Picture 2. xEnergy XP power sections, XF outgoer sections and XG system section
cluding motor starter combinations
up to 630 A,
• Outgoer sections up to 630 A for
switch-fuse strips, fuse rails and fuse
switch-disconnectors with different
mounting depths,
• Control sections and empty sections
for ancillary components such as
motor starters, PFC modules, frequency
inverters, soft starters or for
automation solutions,
• Mounting systems for rail-mounted
service installation devices for conventional
service distribution boards
up to 630 A.
Moeller supplies the full range, functionally
packed in individual elements
(flat pack) or according to customer
requirements as pre-assembled switchboards.
The system platform enables panel
builders to create individual solutions
that can be optimally designed to meet
the requirements of the end customer.
The basis of this is formed by Moeller's
integrative device world.
The Moeller system range offers more
than the sum of the individual components.
For this integrated system
platform, Moeller developed components
that can be integrated into a technical
unit without any problems. Two features
included are communication-enabled
circuit-breakers and the motor starters
with the combination plug connector
design. These components illustrate how
products can play their part in the
reliability and future investment security
of a modern switchboard system. None
of the components are overdesigned
even though the range offers the
flexibility required with only a few
product types, giving panel builders the
required degree of freedom to meet a
wide range of customer demands.
Open for networked
switching and protective devices
In the Moeller system, each individual
component plays its part in the reliability
and future investment security
of the power distribution system. The
trend towards communication-enabled
circuit-breakers is one example of this.
Circuit-breakers of Moeller's new
NZM device series direct the power to
the connected loads and disconnect
them in the event, for example, of an
overload or short-circuit. These systems
are designed for use in system and
cable protection, motor protection or
selective and generator protection. The
core of an NZM - the electronic
release- detects the actual currents and
determines from this important operating
and diagnostics data. This means,
for example, that load warnings or
overloads can be indicated via the
communication system and measures
can be initiated in time, before these
faults lead to a failure. The wide range
of the tripping parameters allows them
to be adapted to the loads as required.
This also increases selectivity, thus
allowing the planned disconnection of
individually failed building sections or
areas. Current and status monitoring, as
well as the remote operation of
switches and any possibly connected
motor starters, provide the basis for
cost-effective load and energy management
systems or the cost centre related
allocation of the energy used. These
new features are made possible by
means of the communication functions
and the software. The FDT (Field Device
Picture 3. xEnergy communicative up to the power management system
4 Heft 7/2004 •

Tool) technology here simplifies system
integration (Picture 3).
Reliable and fast planning
Components on their own are not
enough. A future-proof planning of
low-voltage switchboard systems must
be supported and documented with
suitable tools – such as for network
calculations, dimensioning and configuration.
This provides a verifiable
guarantee of the quality required for
safe and reliable power distribution.
Moeller offers a toolbox with this in
mind, enabling panel builders to plan
and document all their projects simply.
This ranges from tools for network
calculation, configuration, quotations,
system engineering to order handling.
The use of manufacturer tools, regardless
of the system data involved, allows
the switchboard system required to be
selected and configured precisely and
quickly, in accordance with international
requirements (Picture 4).
The future
xEnergy - the integrated and freely
combinable system range - consists of
switching and protective devices, the
mounting system, the switchboard
system including the planning and
calculation tools. The Moeller Kit
system is ideally tailored for safe and
• Heft 7/2004
reliable power distribution. Individual
projects, either in functional buildings,
office and industrial buildings can be
implemented quickly and economically.
Not only do customers save time,
money and space, they also benefit
from Moeller's excellent reputation for
safety – and without restriction in the
entire world of IEC/EN applications.
Literature
[1] DIN EN 60439-1 (VDE 0660 Teil 500):2000-08
Niederspannungs-Schaltgerätekombinationen
– Teil 1: Typgeprüfte und partiell typgeprüfte
Kombinationen. Berlin: Beuth
[2] IEC 60439-1:2004-04 Low-voltage switchgear
and controlgear assemblies – Part 1: Typetested
and partially type-tested assemblies.
Geneva/ Switzerland: Bureau Central de la
Commission Electrotechnique Internationale
[3] DIN EN 60439-3 (VDE 0660 Teil 504):2002-05
Niederspannungs-Schaltgerätekombinationen
– Teil 3: Besondere Anforderungen an Niederspannungs-Schaltgerätekombinationen,
zu deren
Bedienung Laien Zutritt haben – Installationsverteiler.
Berlin · Offenbach: VDE VERLAG
[4] IEC 60439-3:2001-05 Low-voltage switchgear
and controlgear assemblies – Part 3: Particular
requirements for low-voltage switchgear and
controlgear assemblies intended to be installed
in places where unskilled persons have access
for their use – Distribution boards. Geneva/
Switzerland: Bureau Central de la Commission
Electrotechnique Internationale
[5] DIN EN 60204-1 (VDE 0113 Teil 1):1998-11
Sicherheit von Maschinen – Elektrische
Ausrüstung von Maschinen – Teil 1: General
Requirements. Berlin · Offenbach: VDE
VERLAG
Picture 4. ConFix: xEnergy configuration tool for fast quotation and order processing.
[6] IEC 60204-1:2000-05 Safety of machinery –
Electrical equipment of machines – Part 1:
General requirements. Geneva/Switzerland:
Bureau Central de la Commission
Electrotechnique Internationale
[7] DIN IEC 1117 (VDE 0660 Teil 509):1993-09
Niederspannungs-Schaltgerätekombinationen
– Verfahren zur Ermittlung der
Kurzschlußfestigkeit von partiell typgeprüften
Schaltgerätekombinationen (PTSK). Berlin ·
Offenbach: VDE VERLAG
[8] IEC/TR 61117:1992-02 A method for assessing
the short-circuit withstand strength of
partially type-tested assemblies.
Geneva/Switzerland: Bureau Central de la
Commission Electrotechnique Internationale
(ISBN 2-8318-2210-6)
[9] IEC/TR 60890:1987-07 A method of
temperature rise assessment by extrapolation
for partially type-tested assemblies (PTTA) of
low-voltage switchgear and controlgear.
Geneva/ Switzerland: Bureau Central de la
Commission Electrotechnique Internationale
(ISBN 2-8213-1346-8)
[10] Moeller GmbH, Bonn: www.moeller.net ■
5

Moeller GmbH
Hein-Moeller-Str. 7-11
D-53115 Bonn
E-Mail: xenergy@moeller.net
Internet: www.moeller.net
© 2004 by Moeller GmbH
Änderungen vorbehalten
VER 4810-941 GB eye
Printed in the Federal Republic of Germany (07/04)
Artikel-Nr.: 285583
Xtra Combinations
Xtra Combinations from Moeller offers a range
of products and services, enabling the best
possible combination options for switching,
protection and control in power distribution
and automation.
Using Xtra Combinations enables you to find
more efficient solutions for your tasks while
optimising the economic viability of your
machines and systems.
It provides:
n Flexibility and simplicity
n Great system availability
n The highest level of safety
www.moeller.net/xenergy
All the products can be easily combined with one
another mechanically, electrically and digitally,
enabling you to arrive at flexible and stylish
solutions tailored to your application - quickly,
efficiently and cost-effectively. The products are
proven and of such excellent quality that they
ensure a high level of operational continuity,
allowing you to achieve optimum safety for your
personnel, machinery, installations and buildings.
Thanks to our state-of-the-art logistics operation,
our comprehensive dealer network and our
highly motivated service personnel in 80
countries around the world, you can count on
Moeller and our products every time. Challenge
us! We are looking forward to it!
Think future. Switch to green.
green