CONTACTRON

INTERFACE Training 2009

CONTACTRON

Matthias Borutta
Product Marketing
BU INTERFACE

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How to operate a motor ?

coils
contactors versus
depletion layer
electronics

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Motor control with mech. contactors

?
L1 L2 L3

PLC
K1
Contactor

U V W PE
Motor

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Motor control with reversing contactor

L1 L2 L3

K1 K2

U V W PE

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Motor control with Electronic Load Relays ELR
control part L1 L2 L3 load part

drive right - handed

rotation 24 V DC
control

drive left - handed

rotation 24 V DC
control t

supply 24 V DC locking
separation
stabilizing down time

U1 V1 W1
Motor

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The program

ELR 1 phase ELR - 1 kW ELR - 4 kW ELR - 7,5 kW ELR - 18,5 KW

(40 mm width) (40 mm width) (67,5 mm width) (147,5 mm width) (147,5 mm width)

20, 30 and 50 A 3 phase 3 phase 3 phase 3 phase

ELR and ELR-W ELR and ELR-W ELR and ELR-W ELR and ELR-W
(2 + 1)
Input: Input: Input: Input: Input:
24 V DC 24 V DC 24 V DC 24 V DC 24 V DC
120/230V AC 120/230 V AC 120/230 V AC 120/230 V AC 120/230 V AC

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1 phase solid state contactor
Design contactless – wear free

22,5mm and 45mm

> 109 switching cycles

Input Protection circuit

4 - 32 V DC
and 230 AC

Output Applications
I
50A
ELR 1/50-660
30A
ELR 1/30-660

20A ELR 1/20-660 U

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3 phase solid state contactor

Design Output protection Alarm-LED

Input

22,5 - 147,5mm

Output
3 x 2A, 3x9A, 3x16A and 3x37A

R
L

Input

24 VDC and 230 VAC types

start/stopp and
reversing All approvals

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Solid state contactor

Advantages:

 No contact wear / no bounce

 High switching frequencies
 Lifetime >109 switching cycles
 Output protection circuitry
 No cut off transients
 Low power control
 Not sensitive to environmental influences
(e.g. vibration, humidity …)

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Solid state contactor

Customer benefits:

 Increased operational reliability

 Reduced mounting costs
 No negative influence on other components in the cabinet
 No or reduced costs for service or exchange
 No or reduced costs for down-time

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CONTACTRON – “4 in 1” – Hybrid technology

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Mech. reversing contactor circuitry for Cat3
 Main circuit
F1
L1
F2
L2
F3
L3

K1
Emergency stop contactor
K2
Emergency stop contactor

Right contactor K3 K4 Left contactor

F4 Motor protection relay

M
3~

M1 PE

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Motor protection relay

 Protection with bimetal switch for overload

 Cut the control circuit with auxiliary contacts
 Automatic reset is possible
 No short circuit or line protection

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Motor protective circuit-breaker

 Protection with bimetal swith and electromomagnetic release for

short circuit or overload
 Cuts the main circuit directly
 Automatic reset is not possible
 Including short circuit or line protection

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Comparison

24 min. 8 min.
70 clamping points 23 clamping points

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Comparison

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“4 in 1” Reversing contactor circuitry for Cat3

 Main circuit with „CONTACTRON“

F1
L1
F2
L2
F3
L3

L1 L2 L3

K1
T1 T2 T3

M
3~

M1 PE

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CONTACTRON – “4 in 1” – functions and features

Combination of fast, wear and tear free

Solid State Relay (Hybrid)

and motor protection relay up to 4 kW

two versions for 2 A and 9 A

(1 kW / 4 kW)

Class 10A „curve“

„four in one“

right contactor, left contactor,

Motor protection relay and
emergency-stop-contactor

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“4 in 1” – functions and features

Voltage 550 V AC

Current 3 x 9 A or 3 x 2 A

signal output 1 PDT

(97, 96/98, 95)

24 VDC or 230 VAC control

auto reset / remote reset

LED status indication

107 switching cycles (electrical!)

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Princip hybrid circuit “4in1
L1 L2 L3
First two relays define the rotation direction for the
K1 K1 K2
motor. (Here not marked)
The currents I1, I2 and I3 are 0.
K2

V1 V2

K3 K3

I2

I1 I3

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Princip hybrid circuit “4in1
L1 L2 L3
After that the relay K1 and K2 close.
K1 K1 K2

The currents I1, I2 and I3 are 0.

The relays don´t see a current and they are
switch only „mechanical“ and arrive 3 * 107
K2
switching cycles!
V1 V2

K3 K3

I2

I1 I3

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Princip hybrid circuit “4in1
L1 L2 L3
Now both semiconductor V1 and V2 switch on.
K1 K1 K2

These resume the inrush current.

The currents I1,I2 and I3 flows. (Nominal motor
current). K2

For a short moment there is a power loss

about the semiconductor. V1 V2

K3 K3

I2

I1 I3

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Princip hybrid circuit “4in1
L1 L2 L3
The relay K3 bridge the semiconductor to
K1 K1 K2
reduce the power loss (bypass).
After that the semiconductor „sleep“.
At the switch off the process reverse. K2

Result: the semiconductor resume only the

switch on and switch off moments and the V1 V2

relays lead only the current and switch only K3 K3

without load (current) and realize in off state

a galvanic separation !

A microprozessor controls this. I1

I2

I3

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“4 in 1” – approvals

Maritime approvals
GL, Bureau Veritas, Lloyd Reg. of
Shipping, American Bureau of Ship. etc.

ATEX, EX (PTB)

UL and CSA

safe turn off

KAT 3 acc. EN 954

SIL 3 acc. EN 61508

Up to PL „e“ acc. EN 13849

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“4 in 1” – comparison

22,5 mm 135 - 180 mm

= + +
ELR „4 in 1“ Reversing contactor Motor protection Emergency stop
combination relay contactor

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“4 in 1”

ELR W3- 24DC/500AC-2I

ELR W3-230AC/500AC-2I

ELR W3- 24DC/500AC-9I

ELR W3-230AC/500AC-9I

Dimensions 99 x 22,5 x 114,5 mm

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Application Sample

Edge glueing machine

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Application Sample

Car wash street

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Application Sample

3 – 7 main drives 3 – 5 secondary drives

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Application Sample
Auxilary drives

Conveyor belts


Swarf conveyors

Filter systems
Oil fume extractor

All axis operated by Coolant sytems Cleaning stations

servo systems

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customers - applications

Spraying lines for the automotive

industry:
 huge projects in China, Mexico and Russia
 potential: a few thousands “4 in1” per year

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customers - applications
Hoppe
Bordmesstechnik
(ship building)

HEW
(steeple bell machines)

Wincor Nixdorf
(PET-bottle machines)

Witron
(logistics systems)
Test application

Kannegiesser
(laundry machines)
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customers - applications

BMW, VW, Daimler-Benz, Ford

(automotive)
Test applications

Siemens
Conveyor systems for airports and hospitals

Distribution/wholesaler
Bürkle
Rexel
RS Components
Sonepar

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Life with CONTACTRON

If you have questions, please

feel free to contact us