Table 1. IEC Power Control Devices. Type Description Cost Electrical Operations. Soft starters or drives that gradually start and stop motors.

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1 IEC Power Control Devices Training Manual XT Training Module New Information March 08 Contents Description Page Overview Contactors Overload Relays (Bimetal) Starters Electronic Overload Relays Reversing Contactors Contactor Accessories Contactor Coils Manual Motor Protectors Combination Style Starters Overview This training module focuses on Eaton s newest line of IEC Power Control, called XT. The XT line consists of the following components: Contactors Overload Relays (Bimetal and Electronic) Starters Coils and Accessories Manual Motor Protectors Combination Style Controllers Power Control products consist of devices that are used to start, stop and protect motors. There are several types of power control devices that are used for various applications, see Table. Table. IEC Power Control Devices Description Cost Electrical Operations Reduced Voltage NEMA IEC Definite Purpose (DP) Soft starters or drives that gradually start and stop motors. Contactors and overload relays with a complete line of accessories and ratings. Large in size. Contactors, overload relays, and MMPs with a complete line of accessories and ratings. Small in size. Contactors and overload relays with a limited line of accessories and ratings. Small size. IEC Power Control devices are a very common choice because they provide a good balance of features, ratings, and performance, all at an economical price. IEC contactors are designed according to a global standard called International Electrotechnical Commission (IEC). This global standard enables power control and other devices to share a common base High to million Moderate to million Common Approvals UL, CSA UL, CSA Low. million UL, CE, CSA, KEMA, CCC, etc. Low 0 to 00 thousand UL, HACR Common Applications High inertia motors or fragile applications Motor control centers OEM machine control applications Heating, AC, and Refrigeration for design, ratings, and classification. Although IEC is a global system, each country has its own set of governing standards. For example, Underwriter s Laboratories (UL) is an organization that writes safety standards for electrical products in the U.S. In order for IEC contactors to be used in the U.S., they must also be tested and approved by UL. TR0000E

2 Training Manual Page Effective: March 08 IEC Power Control Devices Contactors Contactors are devices used to start and stop motors. They include a set of contacts that open and close when the coil is energized. When contacts close, power can flow to the motor enabling the motor to operate. Unlike a manual switch, contactors can be operated remotely. This means an operator can Table. Catalog Numbering System Contactors start a motor without opening the control panel by using pushbutton controls, or a PLC can operate the contactor. Table shows the catalog numbering system for XT contactors, and Table lists the IEC and UL ratings that are used when selecting the XT contactor. X T C E B 0 A As you can see, the B-frame and C-frame contactors include either a NO or a NC auxiliary contact. Auxiliary contacts will be discussed in a later section. XT Contactor B-Frame Series XT = XT Series CE = Contactor Size 000 = IEC AC- Amp Rating Frame B = B-Frame C = C-Frame D = D-Frame Coil Voltage A = V AC B = 0V AC C = 80V AC E = 8V AC T = V AC TD = V DC Aux. Contacts 00 = 0NO 0NC 0 = 0NO NC = NO 0NC Table. Contactor Selection, Frames B D IEC Ratings UL Ratings Aux. I e (A) I e = I th Maximum kw Maximum -Phase Motor Rating, UL/CSA Contacts (A) Ratings AC- AC- Frame B Frame C 8 8 Frame D AC- (60 C) Phase Motors 0 60 Hz -Phase hp Ratings -Phase hp Ratings / V 80/ 00V V 660/ 690V V 0V V 0V V 60V V / / / / / / -/ -/ -/ -/ -/ -/ -/ -/ -/ -/ / -/ NO NC NO NC NO NC NO NC NO NC NO NC NO NC Catalog Number Screw Terminals XTCE00B_ XTCE00B0_ XTCE009B_ XTCE009B0_ XTCE0B_ XTCE0B0_ XTCE0B_ XTCE0B0_ XTCE08C_ XTCE08C0_ XTCE0C_ XTCE0C0_ XTCE0C_ XTCE0C0_ XTCE00D00_ XTCE00D00_ XTCE06D00_ TR0000E

3 IEC Power Control Devices Training Manual Effective: March 08 Page Select an XT contactor for a hp, 60V motor with a NO auxiliary and a V AC Coil: What is the frame size for this contactor? The AB part number 0-C6D is rated for HP at 60V (UL) and 6 amps per AC- (IEC) and has a V AC coil and a NO aux. Cross reference this part number according to UL and then to IEC: UL: IEC: Overload Relays (Bimetal) Overload relays are devices that monitor the current going to the motor. If too much current is flowing to the motor, there could be a problem with the motor or the load it s pulling. Continued operation in this condition could damage the motor. Overload relays are designed to take a contactor offline in the event of an overcurrent situation. Overload relays are selected based on the desired ampere protection level for the motor. When selecting overload relays, it is important to be sure to match the overload frame size with the contactor frame size, so that the overload will mount correctly to the contactor. Overload relays have a current range that is set to the appropriate protection level by adjusting the dial on the face of the overload relay. It is best to select an overload that has a range where the desired full load current setting is in the middle to lower portion of the range if possible, especially if the exact full load current is unknown. This way, the end user will be able to adjust the overload relay per regulation. Overloads are selected based on the full load amp (FLA or FLC) and the service rating of the motor. If the service factor is less than., then the target amp setting is 0.9 times the FLA. If the service factor is. or greater, then the target amp setting is the FLA. Service factors of. are very common. For example, if a motor has an.6 FLA and a. service factor, the target amp setting would be.. Assuming the contactor used for this application is an XT B-frame, the overload selection would be part number XTOB0BC, which has an overload setting range of 9 amps. Tables and show the overload numbering system and the selection table. Table. Catalog Numbering System Overload Relay X T O B 0 B C Series XT = XT Series Coil Voltage C = Class A XT Overload Relay B-Frame OB = Bimetallic Overload Size 000 = Amp Size Frame B = B-Frame C = C-Frame D = D-Frame There are two types of overload relays, bimetallic and electronic. Bimetallic overloads have heaters that bend during an overcurrent situation to trigger a mechanism that changes the state of the auxiliary contacts. The contactor is wired in such a manner that it is taken offline if the overload trips. TR0000E

4 Training Manual Page Effective: March 08 IEC Power Control Devices Table. Overload Relay Selection, Frames B D Overload Releases, I r Frame B Direct Mount Frame C Direct Mount Frame D Direct Mount Contact Sequence A/ / Contact Configuration For Use with Contactor Amp Range A A A A A A A A A A 9 A A 8 A 8 A 8 A 8 A 8 A 8 A 8 A 8 A 8 A 8 A 8 A 8 A A 0 6A 0 6A 0 6A 0 6A 0 6A 6A Short-Circuit Protection (A) Fuse Maximum Circuit Coordinationnation, Coordi- Breaker gg/gl gg/gl CEC/NEC Fuse Catalog Number XTOBP6BC XTOBPBC XTOBP0BC XTOBP60BC XTOB00BC XTOBP6BC XTOBPBC XTOB00BC XTOB006BC XTOB0BC XTOB0BC XTOB06BC XTOBP6CC XTOBPCC XTOBP0CC XTOBP60CC XTOB00CC XTOBP6CC XTOBPCC XTOB00CC XTOB006CC XTOB0CC XTOB06CC XTOB0CC XTOB0CC XTOB0DC XTOB06DC XTOB0DC XTOB00DC XTOB0DC XTOB06DC Select a C-frame XT contactor for a hp, 60V motor with a NO auxiliary and a V AC Coil: Select an overload relay for the contactor selected previously for a desired amp setting of amps: TR0000E

5 IEC Power Control Devices Training Manual Effective: March 08 Page Starters A starter consists of a contactor assembled with an overload relay. Starters can be ordered as components and assembled in the Table 6. Catalog Numbering System Starters field or as a fully assembled device. Selecting a starter uses the same selection rules as for contactors and overload relays, but combined into a single part number. X T A E B 0 A 0 0 Table 6 shows the catalog number system for XT starters. Series XT = XT Series Overload Size 000 = Max. Amp Setting XT Starter AE = Contactor & Overload Size 000 = IEC AC- Amp Rating Frame B = B-Frame C = C-Frame D = D-Frame Coil Voltage A = V AC B = 0V AC C = 80V AC E = 8V AC T = V AC TD = V DC Aux. Contacts 00 = 0NO 0NC 0 = 0NO NC = NO 0NC Select an XT starter for a hp, 60V motor (Full Load Current = 0A) with a NO auxiliary and a V AC Coil: What is the frame size for this starter? Break down catalog part number XTAE009BA0 into its component part numbers: Contactor: Overload Relay: Pull these components from your inventory and assemble them together to make the starter. TR0000E

6 Training Manual Page 6 Effective: March 08 IEC Power Control Devices Table. Full Voltage Non-reversing -Pole Starters with Bimetallic Overload I e (A) Maximum kw Ratings AC- Maximum -Phase Motor Rating Auxiliary AC- AC- -Phase Motors 0 60 Hz -Phase hp Ratings -Phase hp Ratings Contacts Frame B Frame C / V / 00V V 660/ 690V V V V 0V V 60V V / / / / -/ -/ -/ -/ -/ -/ -/ -/ -/ -/ NO NC NO NC NO NC NO NC NO NC NO NC NO NC Catalog Number XTAE00B XTAE00B0 XTAE009B XTAE009B0 XTAE0B XTAE0B0 XTAE0B XTAE0B0 XTAE08C XTAE08C0 XTAE0C XTAE0C0 XTAE0C XTAE0C0 Table 8. XTOB and XTOT Overload Relay Suffix Motor Full Load Amperes Frame B Frame C Suffix Code P6 P P0 P60 00 P6 P P6 P P0 P60 00 P6 P For Use with Contactor Amp Range A A A A A A A A A A 9 A A 8 A 8 A 8 A 8 A 8 A 8 A 8 A 8 A 8 A 8 A 8 A 8 A A Overload Relay Catalog Number XTOBP6BC XTOBPBC XTOBP0BC XTOBP60BC XTOB00BC XTOBP6BC XTOBPBC XTOB00BC XTOB006BC XTOB0BC XTOB0BC XTOB06BC XTOBP6CC XTOBPCC XTOBP0CC XTOBP60CC XTOB00CC XTOBP6CC XTOBPCC XTOB00CC XTOB006CC XTOB0CC XTOB06CC XTOB0CC XTOB0CC TR0000E

7 IEC Power Control Devices Training Manual Effective: March 08 Page Electronic Overload Relays The XT line of IEC power control also has an electronic overload relay called the C96. Electronic overload relays serve the same purpose as bimetallic overload relays, but they use a circuit board to monitor current instead of a bimetal element. Electronic overloads have larger amp setting ranges than bimetals, generate less heat, and they also have excellent phase loss and phase imbalance protection. Tables 9 show the part numbering structure for the electronic overload relay, the electronic overload starter, the selection table for the direct mount electronic overload (XT Frames B D) and the selection table for stand-alone electronic overloads. As is true for the bimetal overloads, the overload is selected based on the desired amp setting and matching contactor frame size. Table 9. Catalog Numbering System Overload Relay (Electronic) C 9 6 A A P 0 S E L A X Device C96 = C96 Electronic Overload Relay Frame Size A = mm B = 6 mm C = mm Feature Set Reset = Standard A = Auto C96 Electronic Overload Relay Max. Amperes Current Rating Frame A ( mm) P0 = = = 008 = = 6. 0 = 9 Frame B (6 mm) 0 = = Frame C ( mm) 0 = 0 0 Stand-Alone Overload Relay Suffix AX = All Frame Sizes XT IEC Adapter Suffix Frame B XB = 0. 0.A 0..0A A.6 8A 6. A Frame C XC = 0. 0.A 0..0A A.6 8A 6. A Class SEL = Selectable Frame D XD = 6. A 9 A A Frame F G XF = A TR0000E

8 Training Manual Page 8 Effective: March 08 IEC Power Control Devices Table. Catalog Numbering System Starter (with Electronic Overload) X T A E B 0 A E 0 0 Series XT = XT Series Overload Size 000 = Max. Amp Setting AE = Contactor & Overload Size 000 = IEC AC- Amp Rating Frame B = B-Frame C = C-Frame D = D-Frame Coil Voltage A = V AC B = 0V AC C = 80V AC E = 8V AC T = V AC TD = V DC Aux. Contacts 00 = 0NO 0NC 0 = 0NO NC = NO 0NC Table. Electronic Overload Relay Selection (for XT Frames B C) FLA Suffix XT IEC Contactor Catalog Range Frame Size / Width Number (Amps) Standard Class Standard Class ///0 ///0 mm Overload Frame Size EP0 B / mm C96AAP0SELXB 0..0 E00 B / mm C96AA00SELXB E00 B / mm C96AA00SELXB.6 8 E008 B / mm C96AA008SELXB 6. E0 B / mm C96AA0SELXB EP0 E00 E00 E008 E0 C / mm C / mm C / mm C / mm C / mm C96AAP0SELXC C96AA00SELXC C96AA00SELXC C96AA008SELXC C96AA0SELXC Table. Electronic Overload Relay Selection (Stand-Alone) FLA Range (Amps) Standard Class ///0 Catalog Number mm Overload Frame Size C96AAP0SELAX 0..0 C96AA00SELAX C96AA00SELAX.6 8 C96AA008SELAX 6. C96AA0SELAX 9 C96AA0SELAX 6 mm Overload Frame Size C96BA0SELAX C96BASELAX Select an electronic overload for a stand-alone application for a motor with a full load current of amps: Select an XT starter (with an electronic overload) for a hp (60V) motor with a full load current of amps: List the components of the starter from the previous question: Contactor: Overload Relay: TR0000E

9 IEC Power Control Devices Training Manual Effective: March 08 Page 9 Reversing Contactors Reversing contactors enable motors to operate in a forward and reverse operation. They consist of two contactors that are interlocked together such that both contactors cannot be operated at the same time. Reversing contactors can be interlocked both mechanically (by using the mechanical interlock) and electrically (by using NC auxiliary contacts wired with the opposing coil from the opposing contactor). Table lists the mechanical interlocks by frame size. Table. Mechanical Interlock Selection for XT Frame B G For Use with XTCE00B XTCE0B, XTCF0B Pkg. Qty. Catalog Number XTCEXMLB XTCE08C XTCE0C XTCEXMLC XTCE00D XTCE06D XTCEXMLD XTAE080F XTCE0G XTCEXMLG The XT line also has wiring link kits that make wiring a reversing contactor much faster to install. The following table lists the reversing link kits for the XT. IMPORTANT NOTE: The reversing link kit for the B-frame contactors includes an electrical interlock wiring link for contactors that have a NC aux contact built in to the contactor. If the contactors you have chosen have a NO aux contact instead of a NC, do not use the electrical interlock wiring link, as this will cause both contactors to attempt to pull in and will result in chattering. Table shows the reversing link kits for XT. Table. Mechanical Interlock Selection for XT Frame B G For Use with Pkg. Qty. Catalog Number XTCE00B XTCE0B XTCEXRLB XTCE08C XTCE0C XTCEXRLC XTCE00D XTCE06D XTCEXRLD XTCE080F XTCE0G XTCEXRLG Select the mechanical interlock for the B-frame contactor: Select the reversing link kit for the B-frame contactor: Pull () B-frame contactors and the B-frame mechanical interlock from your inventory and use the instruction pub to assemble a reversing contactor. Using the reversing contactor built in the previous practice section, install the reversing B-frame reversing link kit using the instruction pub to finish assembly of the reversing contactor. TR0000E

10 Training Manual Page Effective: March 08 IEC Power Control Devices Contactor Accessories The XT line has a variety of accessories from auxiliary contacts to timers to plug-in surge suppressors. The most commonly used accessory is the auxiliary contact. An auxiliary contact is a device that assembles to the contactor either on the front (face) or the side of the contactor, and contains contacts that change state in concert with the power pole contacts inside the contactor. Auxiliary contacts can be used to turn on a pilot light, signal a PLC that the contactor is closed, or can be used for a variety of other types of control activities. The most common use for an auxiliary contact is to enable continued operation of a contactor without having an operator to continually push a start button. Auxiliary contacts come in a variety of combinations of normally open (NO) and normally closed (NC) contacts. This means that the contact in a NO aux contact is open when the contactor is not in operation. When the contact in the contactor closes, the NO auxiliary contact also closes. A NC auxiliary would remain closed unless the contacts in the contactor close. As is true with overload relays, accessories should be selected to match the contactor frame size. In some cases, there are other specifications, such as coil voltage, that must match the corresponding specification of the contactor. These accessory attributes can be found in the selection tables for the contactor accessories in the catalog. Table shows the general numbering scheme for just a few of the contactor accessories, but all accessories generally follow this same system. Table. Catalog Numbering System Contactor Accessories X T C E X M L B Series XT = XT Series CE = Contactor X = Accessory Frame B = B-Frame C = C-Frame D = D-Frame, etc. Accessory ML = Mechanical InterLock RL = Reversing Link VS = Varistor Surge Suppressor CLK = Common Link Kit ( contactors) SDB = Star-Delta Bridge PB = Paralleling Bridge etc. TR0000E

11 IEC Power Control Devices Training Manual Effective: March 08 Page Contactor Coils Contactor Coils The XT line of contactors includes coils with a variety of voltages for replacement or exchange purposes. Many distributors stock contactors with one common coil voltage and a variety of contactor coils with other coil voltages. This way, they can easily switch out coils if they get a request for a contactor of a different coil voltage. This helps minimize the total cost of inventory. Contactor coils are selected based on the frame size and the desired coil voltage. Table 6 lists the numbering scheme for the XT contactor coils. Coils are only available for C-frame contactors and larger. Table 6. Catalog Numbering System Contactor Coils X T C E R E N C O I L C T D Series XT = XT Series CE = Contactor REN = Renewal Part REN = Renewal Part Frame C = C-Frame D = D-Frame etc. Coil Voltage A = V AC B = 0V AC C = 80V AC D = 600V AC E = 8V AC T = V AC TD = V DC etc. All contactor frames can have replaceable coils except the B-frame. For about the same price as the coil, the entire B-frame contactor can be replaced. Select a replacement coil for a C-frame contactor that is rated for 80V AC: Pull the coil part selected in the previous question and a C-frame contactor from your inventory and practice switching out the coils. Use the instructions to assist you with the coil exchange. TR0000E

12 Training Manual Page Effective: March 08 IEC Power Control Devices Manual Motor Protectors MMP B-Frame Like contactors, Manual Motor Protectors (MMPs) are devices used to start and stop motors. They differ from contactors in that they can only be operated manually, not remotely like contactors. MMPs have overload protection (similar to the overload relay). They also have short circuit protection, similar to breakers. This means they are designed to interrupt high current in the event of a short circuit. In some countries, MMPs can be used in the same applications as breakers. The XT line of MMPs have two operator types: pushbutton style and rotary style. Tables and 8 show the numbering structure of the XT MMP. Table. Catalog Numbering System Overload Relay (Bimetal) X T P R 0 B C Series XT = XT Series Coil Voltage C = Class A PB = Pushbutton Style PR = Rotary Style Frame B = B-Frame D = D-Frame Size 000 = Amp Size MMPs are selected similarly to overload relays in that the FLA is multiplied by 0.9 for service factors less than. to determine the target amp setting and the FLA is the target amp setting for service factors equal to or larger than.. Even though MMPs have HP ratings, these ratings should only be used as a guide. The MMP cannot adequately protect a motor if the amp range is too large or too small for the motor. The following table lists the selection table for the B-frame XT rotary style MMPs: Table 8. Rotary MMP Selection for XT Frames B G (Bimetal) Rated Uninterrupted Current I u = I e (Amps) Frame B FLA Adjustment Range / Overload Release I r (Amps) Short Circuit Release I rm (Amps) Maximum Motor Ratings Maximum kw Rating AC- P (kw) -Phase 0V V V 00V V Maximum hp Rating P (hp) UL 08/CSA C. No. -Phase 0V 0V 80V 600V / -/ -/ / -/ -/ / / -/ -/ / -/ 0 Screw Terminals Catalog Number XTPRP6BC XTPRPBC XTPRP0BC XTPRP6BC XTPR00BC XTPRP6BC XTPRPBC XTPR00BC XTPR6PBC XTPR0BC XTPR0BC XTPR06BC XTPR0BC XTPR0BC XTPR0BC Select a manual motor protector for a -/ hp motor with a FLA of A and a service factor of.: TR0000E

13 IEC Power Control Devices Training Manual Effective: March 08 Page Combination Style Starters Combination style starters consist of a manual motor protector assembled with a contactor. This relatively new type of starter is growing in popularity because it can be used in place of a breaker/fuse block, contactor and overload relay. Combination style starters install more quickly and require less space that the traditional scheme. There are two types of combinations style controllers: one with a line side adapter and one without a line side adapter. The line side adapter increases the voltage creepage clearance on the line side of the combination style starters. The line side adapter is required for UL08 F combinations. Combination style starters are selected using the same rules as manual motor protectors. Tables 9 and show the numbering scheme and a portion of the selection table for the combination style controllers. Table 9. Catalog Numbering System Combination Style X T S C 0 0 B B A Series XT = XT Series SC = Combined Style FC = UL08 F Combination Motor Controllers Size 000 = Amp Size Coil Voltage A = V AC B = 0V AC C = 80V AC E = 8V AC T = V AC TD = V DC Contactor Frame B = B-Frame C = C-Frame D = D-Frame XT Combination Starter MMP Frame B = B-Frame C = C-Frame Table. Factory Assembled Motor Protective Device with Thermal and Magnetic Trip + Contactor FLA Adjustment Range / Overload Release I r (Amps) Select Manual Motor Protectors by full load amperes. Maximum Motor Ratings (kw, hp) are for reference only. For additional voltages not listed, see Table - on Page -8 of the Control Catalog. Short-Circuit Release I rm (Amps) Frame B MMP + Frame B Contactor Maximum Motor Ratings P Maximum Motor kw Rating AC- P (kw) Maximum hp Rating P (hp) Assembled Manual Motor Controller Three-Phase Three-Phase Non-reversing 0V V V V V 0V 80V 600V Catalog Number / / Using the above table, select a combination style controller for a hp motor (80V) with a. service factor, a FLA of 9 amps and a coil voltage of V AC: -/ -/ / / / / / / -/ -/ / / / / / -/ XTSCP6BB_ XTSCPBB_ XTSCP0BB_ XTSCP6BB_ XTSC00BB_ XTSCP6BB_ XTSCPBB_ XTSC00BB_ XTSC6PBB_ XTSC0BB_ XTSC0BB_ XTSC06BB_ TR0000E

14 Training Manual Page Effective: March 08 IEC Power Control Devices Combination style controllers can be either purchased as an assembled device, or can be built from stocked components. Table lists the components used in the assembly of the combination style starters for the B-frame. Table. Factory Assembled Motor Protective Device with Thermal and Magnetic Trip + Contactor Assembled Manual Motor Controller Non-reversing XTSC Frame B MMP + Frame B Contactor XTSCP6BB_ XTSCPBB_ XTSCP0BB_ XTSCP6BB_ XTSC00BB_ XTSCP6BB_ XTSCPBB_ XTSC00BB_ XTSC6PBB_ XTSC0BB_ XTSC0BB_ XTSC06BB_ FLA Adjustment Range / Overload Release I r (Amps) Component Catalog Numbers Manual Motor Protector XTPRP6BC XTPRPBC XTPRP0BC XTPRP6BC XTPR00BC XTPRP6BC XTPRPBC XTPR00BC XTPR6PBC XTPR0BC XTPR0BC XTPR06BC Combination Connection Kit Contactor XTCE00B_ XTCE00B_ XTCE00B_ XTCE00B_ XTCE00B_ XTCE00B_ XTCE00B_ XTCE00B_ XTCE00B_ XTCE009B_ XTCE0B_ XTCE0B_ Manual Motor Protector Auxiliary Contact XTPAXFA XTPAXFA XTPAXFA XTPAXFA XTPAXFA XTPAXFA XTPAXFA XTPAXFA XTPAXFA XTPAXFA XTPAXFA XTPAXFA Using the above table, list the components of the starter selected in the previous section: Pull these components from stock and use the instructions to build the assembled starter. TR0000E

15 IEC Power Control Devices Training Manual Effective: March 08 Page TR0000E

16 Eaton Corporation Electrical Group 00 Cherrington Parkway Moon Township, PA 8 United States 8-ETN CARE (8-86-) Eaton.com 08 Eaton Corporation All Rights Reserved Printed in USA Publication No. TR0000E/CPG March 08