G

9001 SO
d cer tifie

K K ft ZK N

DIL UNIVERSAL CONTACTORS

DIL universal contactors

GANZ KK Ltd.
applies a Quality control system according to the requirements of the standard

EN ISO 9001

Bridge Moving magnet

Coil Fixed magnet Auxiliary contact-unit

Moving contact Switching off mechanism Fixed contact

Terminal

Figure 1: construction of magnetic contactors DIL 2v, 2, 3, 4, 6

GANZ KAPCSOL- S KSZLKGYRT KFT.

2001.03.26

DIL universal contactors

1. Application and Types

The contactor range is primary to designed for switching electrical motors, independently switching motors operating in a motorstarter combination. Further they can be applied as automatic element of electrical equipments, and for switching electrical heating devices, and three-phase capacitors compensating the relative power as well. 1.1 Explanation of type-marks In the type-mark of the contactor-range the letters " DIL " relate to large durability (life or endurance), the numbers after the letters refer to the type-size, the further numbers give the quantity of making and breaking auxiliary contacts. The letter " d " means auxiliary contacts with overlapped displacement, the letter " f " refers to the possibility of fast connection. The letter " DC " indicate variant that is suitable for switching direct currents with main circuit, the letter " G " means operation with DC-voltage coil. 1.3 Marking of the terminals

1.2 Types The fast connecting elements (f) can be fitted only type DIL 00(L). The variant " d " can be implemented in all type-size. The control with DC-voltage requires a pair of overlapped break auxiliary contacts, therefore the mark of such type is " d/G ". The contactors DIL 00(L) - with the aid of a completting element size DIL 0 type also can be fixed on 35 mm mounting rail according to the standard EN 50022. The AC-voltage controlled contactors DIL 00L, DIL 00, DIL 0, DIL 2v, and DIL 2 can be equipped with cover which provides degree of protection IP 20. (Please specify in the order). The mark " IP 20 " is indicated on the packaging box but it is not indicated on the data-plate of the device. When connecting wires to the contactors having cover providing degree of protection IP 20, it is not necessary to remove the cover. Relevant standards: EN 60947, VDE 0660, IEC 158.

The marking system is according to the EN 60947- 4 -1 and EN 50011. On the upper (generally the feed) side the marks of the main contacts are: 1 L1; 3 L2; 5 L3 and on the lower (loading) side: 2 T1; 4 T2; 6 T3. The figures of the auxiliary contacts are always two digit numbers. The first number refers to the position of the auxiliary contact-block ( see the figure in 1.5 subclause), the second number refers to the function mode (made or break contact). delayed NC hurry-forward NO NC NO ... 1 ... 3 ... 1 ... 3

... 2

... 4

... 2

... 4

1.4 Contact operation and sequences Contact closing distances in these diagrams are only informatory! S [mm] 4

closing direction

3 2 1 0

13 23 33 43 51 61 71 81 14 24 34 44 52 62 72 82

13 23 33 43 53 61 71 83 14 24 34 44 54 62 72 84

13 23 33 43 51 61 71 81 14 24 34 44 52 62 72 82

13 23 33 43 53 61 71 83 14 24 34 44 54 62 72 84

DIL 00L- 44

DIL 00L- 62

DIL 00L- 44d

DIL 00L- 62d 1

GANZ KAPCSOL- S KSZLKGYRT KFT.

2001.03.26

DIL universal contactors

S [mm] 6 5

closing direction

4 3 2 1 0

1 3 5 13 21 31 43 2 4 6 14 22 32 44

1 3 5 13 21 31 43 2 4 6 14 22 32 44

1 3 5 13 21 31 43 2 4 6 14 22 32 44

1 3 5 13 21 31 43 2 4 6 14 22 32 44

DIL 00-52 S [mm] 11 10 9 8 7 6 5 4 3 2 1 0

DIL 00-52d

DIL 0-52

DIL 0-52d

closing direction

1 3 5 13 21 31 43 2 4 6 14 22 32 44

1 3 5 13 21 31 43 2 4 6 14 22 32 44

DIL 2v-22 DIL 2-22 DIL 3-22 DIL 4-22 DIL 6-22

DIL 2v-22d DIL 2-22d DIL 3-22d DIL 4-22d DIL 6-22d

1.5 HS... type auxiliary contact-blocks The contact-blocks can be fitted to the DIL 3, DIL 4 and DIL 6 contactors in different combinations. It is possible to turn them over by 180 and to reverse the order of blocks. It is not permitted to make a combination with four make-contact blocks!

Placing of auxiliary contact-blocks

GANZ KAPCSOL- S KSZLKGYRT KFT.

2001.03.26

DIL universal contactors

Contact closing distances of the auxiliary contacts: Position on 11 10 9 8 7 6 5 4 3 2 1 0 21 22 23 24 13 14 11 12 31 32 33 34 43 44 41 42 31 32 33 34 43 44 41 42 HS I-1 HS I-2 HS II-1 HS II-2 HS III-1 HS III-2

Position off

2. Control of contactors
When connecting AC or DC coils, the breaked wire should be connected to the point marked by A1, and the unbreaked (uninterrupted) wire should be connected to the point marked by A2. If the control circuit is earthed, the coil-output marked A2 should be connected to the earthed point, when mounting the contactor. Do not connect fuses in the interconnecting wire of the earthed terminal! If the control circuit voltage is not supplied by an earthed network, then in both wires of the control circuit may be applied fuse max. 10 A. 2.1 Operation by control circuit AC-voltage
AC L F

total stroke

longer overlap is needed, which makes short circuit at the additional resistance mounted on the contactor at the start of the operational process.

A1 K1 A2 = Uc

13 23 33 43 53 61 71 83

Re
14 24 34 44 54 62 72 84

DIL 00L- 62d/G

A1 K1 A2 = Uc

13 23 33 43 51 61 71 81

Re
14 24 34 44 52 62 72 82

DIL 00L- 44d/G

S1 13 14 A1 K1 A2 N 2 4 6 1 3 5

F S1 S2 K1, K2
K1

S2

Fuse ( max. gL 16 A ) Pushbutton OFF Pushbutton ON Contactor (at least with 1 pc make auxiliary contact)

A1 K1 A2 = Uc

5 21 13 31 43

Re
2 4 6 22 14 32 44

DIL 00... 6d/G

2.2 Operation by control circuit DC-voltage For DC-operation a breaking auxiliary contact with a

Because of the value of switched operational current an auxiliary contactor (HL-K(G)-21) is needed as follows: - for contactors DIL 2v and DIL2 with DC-coils 24 V, - for contactor DIL 3 with DC-coils 24 V or 48 V, - for contactors DIL 4 and DIL 6 with DC-coils 24 V, or 48 V, or 60 V. Power of R1 series resistance should be min. 16 W.

GANZ KAPCSOL- S KSZLKGYRT KFT.

2001.03.26

DIL universal contactors

Connection:

L+
B S1 S2 21 K2 22 A1 K1 A2 LK2 A2 K1: DIL 2v...6 /G K2: HL-K(G)-21 A1 13 K1 R1 K2 14
46 45

3.3 Switching of capacitive loads In case of switching capacitive loads the own resistance of the condenser is generally sufficient (the condenser discharges under 50 V within 60 s ). It is required to reach a discharge time less than 0,2 s, it can be carried out with the aid of a quick-discharge resistor, which (by two auxiliary contacts of the contactor) is connected to the condenser that is disconnected from the network.

L1 L2 L3

A1 HL-K(G)-21 contactor includes the wire marked by - - - line in the figure.

1 3 5

A2 2 4 6

R11
C1

R11

K1 DIL 2v DIL 2 DIL 3

Uc [ V-]

R1 [ ] 5%

R11 Without quick-discharge resistors

24 24 48 24

62 51 200 51 200 300

L1 L2 L3

DIL 4 DIL 6

48 60

A1 1 3 5

13 21 31 43

A2 2 4 6 14

22 32 44

3. Load of the main contacts

22 4 32 R1

3.1 Switching of AC-circuits See the selection diagrams on pages 11. , 12. , 13. 3.2 Switching of DC-circuits Main contacts can switch AC and DC power as well, exact values are indicated at the technical data. When mounting the device the user must make the series connection of main current paths as shown on page 7.

R11
C1

R11 R1

R11 With quick-discharge resistors

GANZ KAPCSOL- S KSZLKGYRT KFT.

2001.03.26

DIL universal contactors

4. Technical data

Technical data

DIL 00

DIL 0

DIL 2v

DIL 2

DIL 3

DIL 4

DIL 6

GENERAL DATA Rated insulation voltage [V] 690 500 690 8000 III 50 ; 60 Hz and 20 16 32 25 80 65 90 80 140 125 225 170 250 200

Rated impulse withstand voltage Uimp [ V ] Overvoltage category Rated frequency Conventional free air/ enclosed thermal current Ith / Ithe [ A ] Ambient temperature opened / enclosed [ C ] Relative humidity Mounting position Mounting means Masse Screw of terminal Crosssection of connecting wires [ mm2 ] 1 wire 2 wire solid stranded solid stranded AC- control DC- control 6 3 [ kg ] at 20 C : 90 % optional 35 mm rail or 2 pcs M 4 screws 0,3 M3
0,75...2,5 0,75...2,5 0,75...1,5 0,75...1,5

- 25 ...+ 50 / - 25 ...+40 ; at 40 C : 50 % ; at 50 C : 30 %

in vertical plane with vertical main current paths (deviation from vertical line may be max 30 ) 2 pcs M 5 screws 1,25 M5
4...35 4...25 6...16 4...10

3 pcs M 5 screws 2,3 2x M4

4...50 4...35 10...25 10...25

0,65 M4
1...6 1...4 1,5...4 1...2,5

1,25

3,4 2x M5
4...95 4...70 16...35 16...35

4,5 2x M6
25...120 25...95 16...50 16...50

Mechanical durability [ 106 c ] Electrical durability Climatic conditions

10 1,5 according to 5. clouse by standard IEC 68 7/6 6/4 IP 00 IP 20 max 3 (normal industrial environment) EN 60947-1 ; EN 60947-4 ; VDE 0660 ; IEC 158 7 / 4,5 7/4 10 / 8 IP 00 13 / 9

Shock-resistance (half-sinusoidal deflection sock[g] duration 20 ms) make/break Degree of protection Pollution degree Relevant standards

DIL 00L-... GANZ KAPCSOL- S KSZLKGYRT KFT.

5

2001.03.26

DIL universal contactors

Technical data

DIL 00

DIL 0

DIL 2v

DIL 2

DIL 3

DIL 4

DIL 6

M A I N C O N T A C T S Y S T E M with A C -load
Ue = 230 V AC-1 (resistive load, Y- connection) 400 V 500 V 690 V Fuse gL [ A ] 230 V (106c) (800 c/h) AC-2 and AC-3 400 V 500 V 690 V 230 V (3x104 c) AC-4 (200 c/h) 400 V 500 V 690 V 7 13 16 20 25 3,7 4 4 4 1,1 2,2 2,2 2,2 3 5 5 7,5 20 75 230 V AC-3 50 ... 60 Hz 400 V 500 V 690 V 230 V AC-4 50 ... 60 Hz 400 V 500 V 690 V Capacitive load 525 V 660 V 13 7 6 4 4 4,5 3,7 2 8 7 12,5 22 28 35 35 4 7,5 7,5 7,5 3 5,5 5,5 5,5 4,5 7 9 11 32 100 16 14 15 7 11 11 8,5 6 17 13 29 50 65 85 160 15 22 30 22 9 17 22 11 15 30 40 50 80 175 49 41 41 16 27 30 27 8 47 44 32 56 73 95 160 22 30 37 30 11 22 30 18,5 20 40 50 60 90 220 70 55 54 20 39 43 43 12 70 53 50 87 115 120 200 32 45 55 55 15 30 37 37 35 60 75 90 140 350 103 82 78 57 52 57 54 40 92 80 94 160 210 280 250 55 75 90 90 22 45 55 55 75 125 150 180 225 540 170 136 127 94 75 85 78 57 200 158 110 195 255 340 300 65 110 132 132 37 75 90 90 90 150 180 200 250 625 204 195 182 134 125 138 127 93 240 175

Switchable motor-power Pe [ kW ]

Switchable of capacitive loads [ kVAr ] (with possibility of connection to quickdischarge resistors 105 c)

230 V 400 V 525 V 660 V 3-pole

AC-1 50 ... 60 Hz

Rated operational current Ie [ A ]

GANZ KAPCSOL- S KSZLKGYRT KFT.

2001.03.26

DIL universal contactors

Technical data
Rated making capacity cos = 0,35 [A] cos = 1 230 V Rated breaking capacity [A] cos = 0,35 400 V 500 V 690 V gL Short-circuit protecting fuse [A] normal aM without welding of contacts gL aM

DIL 00 200 210 130 120 100 75 25 20 20

DIL 0 200 210 160 160 160 80 35 25 25

DIL 2v 840 840 720 720 600 350 160 125 125 100

DIL 2 840 840 720 720 700 400 160 125 125 100 2

DIL 3 1600 1620 570 570 800 620 200 160 125 100

DIL 4 2100 2200 1800 1800 1700 1070 250 200 200 160

DIL 6 2500 2600 2500 2500 1900 1120 315 250 200 160

Type of coordination a sh. c. prot. Power dissipation per pole [W] at Ith at Ie (AC-3 ; 400V) 3,8 0,7 7,5 1,5 22 5

25 12

25 9

75 22

116 49

M A I N C U R R E N T S Y S T E M with DC - load
DC-1 Conventional free air/ enclosed thermal current (220 V) Ith / Ithe [ A ] 60 V Switchable motorpower Pe [ kW ] Rated operational current Ie [ A ] DC-5* DC-3* 110 V 220 V 60 V 110 V 220 V

10/10

16/16

60/60

85/80

140/125

225/170

250/200

-/5 - / 2,5

2 / 23 2 / 10

6 / 65 8 / 45

- / 140
13 / 140 15 / 82

- / 225
24 / 225 40 / 200

- / 250
35 / 250 45 / 225

- / 1,3 - / 0,6

2 / 22 2 / 11

3 / 30 3 / 15

- / 140
13 / 140 13 / 70

- / 225
24 / 225 35 / 212

- / 250
30 / 250 40 / 200

_ < 60 V DC

Series connection of the current paths > 60 V DC

Single-pole breaking * Three poles in series connection

Double-pole breaking

GANZ KAPCSOL- S KSZLKGYRT KFT.

2001.03.26

DIL universal contactors

Technical data

DIL 00

DIL 0

DIL 2v

DIL 2

DIL 3

DIL 4

DIL 6

CONTROL SYSTEM
Rated control circuit voltage Uc [ V ] Powerconsumption of coil (bi = 100 %) range limits of operate limits of release
[50 Hz]

AC DC [x Uc ] [x Uc ] 40 / 31 8,5 / 3 62 8 8 ... 16 5 ... 13 12 ...14 24 ... 220

24 ...600 42 ... 220 60 ... 220

42 ...600 110 ... 220

AC and DC : 0,85 ... 1,1 AC : 0,4 ... 0,6 70 / 41 10 / 3 65 12 10 ... 24 7 ... 15 15 ...18 210 / 25 / 8 250 18 25 ... 38 7 ... 15 28 ... 32 9 ... 12 25 ... 34 22...47 DC : 0,2 ... 0,45 310 / 34 / 11 300 435 / 46 / 16 360 14 21 ... 38 9 ... 14 31 ... 34 20 ... 34 580 / 50 / 15

AC

operate [ VA / W ] hold operate hold AC off on DC off [ VA / W ] [W] [W] on

Operating time [ ms ] (at 100 % Uc )

DC

10 ... 15 27 ... 30 29...33

16 ... 19 10000 5000 5000 3000

18 ... 20 max. 3000 max. 1000

Switching frequency [ c / h ] (without load) *

AC - control DC - control

c / h 7000
6000 5000 4000 3000 2000 1500 1000 800 600 500 400 300 200 150 100 0 10 20 30 40 50 60 70 80 90 100 %

9000

Switching frequency

Switching frequency as a function of the motorpower and the utilization category. (The time of arc in AC-categories: < 20 ms)

AC-1 , AC-3

AC-4

DIL-2v...6

Motorpower

Pe ( kW )

* in case of loaded main current paths the switching frequency should be chosen according to the above figure.

GANZ KAPCSOL- S KSZLKGYRT KFT.

2001.03.26

DIL universal contactors

Technical data

DIL 00

DIL 0

DIL 2v

DIL 2

DIL 3

DIL 4

DIL 6

AUXILIARY CONTACT SYSTEM

Execution Rated insulation voltage Rated impulse withstand voltage Overvoltage category Conventional free air thermal current 6 6 2 4 1,5 6 2,5 1,5 0,6 0,1 / 0,5 / 1 / 2 / 3 0,01 / 0,03 / 0,05 / 0,15 / 1 16 IP 00 or IP 20 max 3 (normal industrial environment) solid Crosssection of connection wires [ mm2 ] 1 wire stranded 2 wires solid stranded * DIL 00L-... 0,75 ... 2,5 0,75 ... 1,5 0,75 ... 1,5 0,75 ... 2,5 IP 00 Ui [V] Uimp [V]
690 500*

built-in the device

HS- type, fitted on the device 690 6000 III

Ith [A] 230 V

Rated operational current Ie [ A ]

AC-15 cos = 0,7

400 V 500 V 24 V

DC-13 L / R 15 ms

60 V 110 V 220 V

Electrical durability AC-15 , 230 V

[106 c] 6/4/3/2/1 A

DC-13 , 220 V 6/4/2/1/0,25 A Fuse without welding of contacts Degree of protection Pollution degree

gG [ A ]

GANZ KAPCSOL- S KSZLKGYRT KFT.

2001.03.26

DIL universal contactors

Specific technical data of DIL 00L-... auxiliary contactors The DIL 00L-44(d) and DIL 00L-62(d) auxiliary contactors can be applied particularly for switching magnetic coils, magnetvalves and small electric motors. Rated operational currents, which should be taken into consideration: AC-15 cos = 0,7 230 V 6 A 400 V 4 A 24 V 4 A 60 V 5 (2,5) A 110 V 3 (1,5) A 220 V 3 (0,6) A 24 V 4 A 60 V 4 A 110 V 2,5 (0,8) A 200 V 1,5 (0,6) A x=1 x=2 x = 2 (1) x = 3 (1) x=2 x=2 x = 3 (1) x = 3 (1)

Switching frequency c/h 100 200 300

3 years 0,6 1,2 1,8

5 years 1 2 3 x 106 c

10 years 2 4 6

x 106 20 10 5

DC-13

L/R

15 ms

DIL 00L a) Relations between r a t e d operational current and durability

L/R

15 ms

AC-15
2 1 0,5 0,2

DC-13

x = number of series conneted current-paths. In the cases marked by (1) an RC circuit is needed to be connected in paralell to the disconnecting place for arcquenching. (C = 1 F, R = 0,5

0,1 0,01 0,02 0,05 0,1 0,2 0,5 1

5 10

A Ie

c/h
5000

Rated making capacity

AC-15 DC-13

cos

= 0,7

200 A 1,1 Ie 230 V 80 A 400 V 44 A 1,1 Ie

DIL 00L
2000

L / R 200 ms cos = 0,7

1000 500 200

AC-15

Rated breaking capacity

AC-15 DC-13

b) Relations between permissible switching frequency and switchable rated operational current (guiding value)

DC-13
100 0 1 2 3 4 5 6 7 8 9 10

A Ie

5. Selection guide for DIL universal contactors

5.1 Selection of magnetic contactors The required durability of magnetic contactors is an important parameter. If the expected endurance (in years) of the machine and the switching frequency are known, the required durability of the contactor is determinable, with the consideration of 50 weeks/year and 40 working hours/week. In utilization categories AC-2, AC-3 and AC-4 the number of switching per hour - at a certain operational frequency - significantly influences the switching power. The relation is shown in the figure below. Max. switching frequencies allowed: DIL 00(L)-.../G 5000 c/h DIL 00(L)-... 10000 c/h DIL 0-52 5000 c/h DIL 0-52/G 3000 c/h others 3000 c/h others 1000 c/h 10

c/h
10000 8000 6000 5000 4000 3000 2000 1500 1000 800 600 500 400 300 200 150 100

DIL...

AC-2, AC-3.

AC-4

DIL...

0 10 20

30 40

50

60

70

80

90 100 %

c) Relations between switching frequency and motorpower switchable by contactor Figure 5.1

GANZ KAPCSOL- S KSZLKGYRT KFT.

DIL universal contactors

5.2 Selection characteristics

Rated motorpower (three-phases) in kW, 50...60 Hz (400 V)

kW
200 110 75 55 45 30 22 18,5 15 11 7,5 5,5 4 3 2,2 1,5 1,1 0,8 0,55 0,01 0,02 0,04 0,06 0,1 0,2 0,4 0,6 1 2 Durability of contactors (Million cycles) 3 4 5 6 8 10 15

DIL 6 DIL 4
DIL 3 DIL 2 DIL 2v

Operating characteristics: Starting from zero revs, stopping at rated revolution number. Make: up to 6 x Ie ; break: 1 x Ie Utilization category: 99,9 % AC-3 + 0,1 % AC-4 Tipical applications: compressors, pumps, valves, ventillators, lifts, conveyors, excalators, elevators, mixers, centrifuges, air conditioning systems, general drives in manufacturing and processing manchines.

DIL 0 DIL 00

DIL

Figure 5.2.1: Values of durability at normal switching conditions for squirrel cage motors

kW
200 110

A
370

Rated motorpower (three-phases) in kW, 40...60 Hz (400 V)

75 55 45 37 30 22 18,5 15 11 7,5 5,5 4 3 2,2 1,5 1,1 0,8 0,55

DIL 6 DIL 4 DIL 3 DIL 2 DIL 2v

142 105 85 72 57

23

Cuurrent of motor

43 36 30 16 12 8,5 6,5 5 3,5 2,5 2 1,6

Operating characteristics: 50 % Starting from zero revs, stopping at rated revolution number. Make: up to 6 x Ie ; break: 1 x Ie 50 % Starting from standing position, stopping at rated r e v o l u t i o n n u m b e r, i n c h i n g , reversing, plugging. Make: up to 6 x Ie ; break: 6 x Ie Utilization category: 50 % AC-3 + 50 % AC-4 Tipical applications: hall-cranes, electric tractions, conveyors, ram engines, centrifuges, drives for manufacturing and processing machines, chipping machines.

DIL 0 DIL 00

0,01 0,02 0,04 0,06 0,1

0,2

0,4 0,6

3 4 5 6 8 10

DIL

Durability of contactors (Million cycles)

Figure 5.2.2: Values of durability at heavy duty switching conditions for squirrel cage motors (mixed operation)

GANZ KAPCSOL- S KSZLKGYRT KFT.

11

2001.03.26

DIL universal contactors

kW
160 110

Rated motorpower (three-phases) in kW, 50...60 Hz (400 V)

75 45 30 22 17 11 7,5 5,5 4 3 2,2 1,5 1,1 0,8 0,55 0,37

DIL 6 DIL 4 DIL 3 DIL 2 DIL 2v

Operating characteristics: Inching, plugging reversing Make: 2,5 x Ie ; break: 2,5 x Ie Utilization category: 100 % AC-2 reversing without short-circuit. Tipical applications: auxiliary drives of cranes, rolling mills, charging machines and special drives for manufacturing and processing machines.

DIL 0

0,01 0,02 0,04 0,06 0,1

0,2

0,4 0,6

3 4 5 6 10 15

DIL

Durability of contactors (Million cycles)

Figure 5.2.3: Values of durability at heavy duty switching conditions for slip-ring motors

kW
110 90 75 55 45 37 30 22

DIL 6

Rated motorpower (three-phases) in kW, 50...60 Hz (400 V)

DIL 4 DIL 3 DIL 2 17 DIL 2v

11

Operating characteristics: Inching, plugging reversing Make: 6 x Ie ; break: 6 x Ie Utilization category: 100 % AC-4 reversing without short-circuit. Tipical applications: printing machines, wire-drawing machines, centrifuges, special drives for manufacturing and processing machines.

7,5 5,5 4 3 2,2 1,5 1,1 0,8 0,55 0,37 0,25

DIL 0

DIL 00

0,01 0,02 0,04 0,06 0,1 0,2 0,3 0,4 0,6

3 4 5 6 10 15

DIL

Durability of contactors (Million cycles)

Figure 5.2.4: Values of durability at extreme switching conditions for squirrel cage motors

12

GANZ KAPCSOL- S KSZLKGYRT KFT.

2001.03.26

DIL universal contactors

1000

Operating characteristics: Ohmic and low inductive loads Make: up to 1,5 x Ie ; break: 1 x Ie Utilization category: AC-1 DIL 6 DIL 4 DIL 3 DIL 2 DIL 2v DIL 0 DIL 00 Tipical applications: electric heaters, resistance fumaces.

Operational current (A) 400 V

250 225 140 90 80 55 35 30 20

10 7 5 4 3 2 1 0,01 0,02 0,03 0,05 0,1 0,2 0,3 0,5 0,7 1 2 3 5 7 10 15

DIL

Durability of contactors (Million cycles)

Figure 5.2.5: Values of durability at light switching conditions for resistive loads in continuous duty

5.3 Examples for selection of devices Example 1 Single-phase load, utilization category AC-1. It is given Pe = 75 kW, Ue = 400 V 50 Hz. The required electric durability is: 0,5 x 106 cycles. Ie = Pe / Ue = 187,5 A Suggested contactor: DIL 4. We can choose DIL 2v contactor, if the terminals of contactor are connected paralell on the both side of contactor, the load decreases to 1/2,5 in one contact. In this case DIL 2v contactor is suitable for use up to 1 Million cycles, because Ie = 75 A. Example 2 Three-phase load, utilization category AC-1. It is given a load with Pe = 172 kW. Ue = 400 V 50 Hz. The required durability is 0,7 Million operation cycles. The rated operational current: Pe 172 x 103 Ie = = = 248 A Ue 3 400 3 No one of the DIL contactors are able to switch this current for the needed durability. In this case two contactors shall be connected in paralell:

GANZ KAPCSOL- S KSZLKGYRT KFT.

13

2001.03.26

DIL universal contactors

One of these contactors shall be rated to 60 % of loading current, in our example this value is 248 x 0,6 = 149 A . In the figure 5.2.5 the point of intersection of this current and the 0,7 Million cycles determines the DIL 4 contactor, therefore in this case 2 pcs DIL 4 contactor should be connected in paralell. (If the expected durability is 0,5 x 106 cycles, it would be enough to select 1 pc DIL 6 type contactor). Example 3 Three-phase load, normal working conditions, utilization category AC-3. Given a squirrel cage inducation machine with rated power Pe = 15 kW, Ue = 400 V 50 Hz. Starting from zero revs, stopping at rated revolution number (full running speed). Expected durability of machine is 3 years. Switching frequency: 250 c/h. The required durability of contactor: T = 3 years x 50 weeks x 40 hours x 250 c/h = 1,5 x 106 cycles. According to figure 5.1/c in utilization category AC-3 at 250 c/h frequency the contactor can be used up to 100 % considering motorpower. Selection is made in accordance with figure 5.2.1. At 15 kW power up to 1,5 Million operation cycles DIL 2v contactor should be applied. (Treal = 2,2 Million cycles). Example 4 Utilization category: AC-4. It is given a squirrel cage induction motor with rated power Pe = 11 kW, Ue = 400 V 50 Hz.Starting from zero revs, reversion, inching, plugging are possible. The expected durability of machine: 2 years. Switching frequency: 300 c/h. The required durability of the contactor: T = 2 years x 50 weeks x 40 hours x 300 c/h = 1,2 x 106 cycles. According to figure 5.1/c in the utilization category AC-4 at the frequency of 300 c/h the contactor can be used up to 90 % considering motor-power only, this way the authorative power is 11/0,9 = 12,22 kW and up to 1,2 Million cycles the DIL 6 contactor should be selected. Example 5 In case of mixed load, when the contactor is working not in one utilization category only but performing a certain percentage of operations in other category also, the following general formula can be given to determinate electrical durability: Durability of the contactor in normal (AC-3) utilization category: T1 ; in extreme (AC-4) category : T2. The percentile value of the latter quantity: p. T1 So the durability of contactor in mixed utilization category is: T= p T1 1+ ( -1) 100 T2 In practice the mixed or combinated application from 90 % AC-3 and 10 % AC-4 conditions is alredy qualified heavy duty load. The figure 5.2.2 shows characteristics for division 50-50 %.

Example 6
It is given a squarell cage induction motor with rated power Pe = 30 kW. It should be worked with star-delta starting. Switching frequency: 3/min, i.e. 20 cycles/hour. Ue = 400 V 50 Hz. Utilization category: AC-3, three-phase load. The expected life-time of machine: 4 years. The required durability of contactor: T = 4 years x 50 weeks x 40 hours x 20 c/h = 160 x 103 cycles. The DHC 2 star-delta combination is suitable for this duty. Ie = 55 A. It should be selected the overload (thermal) relay type H6, with current-range 43...62 A. The value of the motor's rated operational current (55 A) should be adjusted by the knob. The running up time of the motor is about 15 s, therefore the star-delta timer is type YDG 2...24 s.

14

GANZ KAPCSOL- S KSZLKGYRT KFT.

2001.03.26

DIL universal contactors

6. Dimensions
DIL 00-52 DIL 00L-44 DIL 00L-62 54 34 9 94 M4

59

48

4,8

34 DIL 0-52/c 74 4,8 54 8,5 9 88 M4

56

68

54

DIL 00-52 d/G 54 34 106

59

48

50

85

35

10

DIL 0-52 d/G 103 9 M4

100

10

GANZ KAPCSOL- S KSZLKGYRT KFT.

2001.03.26

56
15

c-DIL 0

48

DIL universal contactors

DIL 2v-22

DIL 2-22 c b
a b c d

5,5

13,5 M5
DIL 2v-22

104 DIL 2-22

85

111

70

b
b a DIL 3-22 DIL 4-22 a d

DIL 6-22

13,5

c d M5
a=b c d=e f g DIL 3-22 DIL 4-22 DIL 6-22 136 131 118 70 127 158 141 136 70 147 182 150 150 70 166

7,5

DIL 2v-22 d/G

DIL 2-22 d/G

e b

DIL 3-22 d/G

DIL 4-22 d/G

DIL 6-22 d/G

128

85

65

15

15

7. Accessories
The following accessories and additional details can be ordered for DIL magnetic contactors: AC operating coils DC operating coils with series resistance HS auxiliary contact-units DC arc-quenching chambers (from DIL 2v to DIL 6) blade terminals for all auxiliary contacts and coil connections

16

GANZ KAPCSOL- S KSZLKGYRT KFT.

2001.03.26

Rated operational currents of a.c. motors:

The undermentioned value of the rated operational currents are related to electric motors (AC, inner and surface cooling, 1500 r.p.m.). Direct starting : 6 x Ie the running up time : 5 s Star-delta starting : 2 x Ie the running up time : 15 s The range of currents for star-delta starting are legible on the surface of the thermal relay as well. The value of the motor's rated current should be adjusted by the turn knob. The current-values of fuses are valide for Y/ starting of slip-ring motors. In case of bigger rated and starting currents, or/and running up times it should be used bigger fuses (characteristic gG). Rated current of NH-fuses of characteristic aM should be chosen to equal value of the motors' rated current.

Motor

230 V Motor Ie Fuse In direct Y/ Motor Ie

400 V Fuse In direct Y/ Motor Ie

500 V Fuse In direct Y/ Motor Ie

690 V Fuse In direct Y/

Rated power

Power factor

[ kW ]
0,06 0,09 0,12 0,18 0,25 0,37 0,55 0,75 0,8 1,1 1,5 2,2 2,5 3 3,7 4 5 5,5 6,5 7,5 8 11 12,5 15 18,5 20 22 25 30 37 40 45 51 55 63 75 80 90 100 110 129 132 140 147 160

Efficiency

cos
0,7 0,7 0,7 0,7 0,7 0,72 0,75 0,8 0,8 0,83 0,83 0,83 0,83 0,84 0,84 0,84 0,84 0,85 0,86 0,86 0,86 0,86 0,86 0,86 0,86 0,86 0,87 0,87 0,87 0,87 0,87 0,88 0,88 0,88 0,88 0,88 0,88 0,88 0,88 0,88 0,88 0,88 0,88 0,88 0,88

%
59 60 61 61 62 64 69 74 74 77 78 81 81 81 82 82 83 83 84 85 85 87 87 87 88 88 89 89 90 90 90 91 91 91 91 91 91 92 92 92 92 92 92 93 93

[A]
0,38 0,55 0,76 1,1 1,4 2,1 2,7 3,3 3,6 4,9 6,2 8,7 9,8 11,6 14,2 15,3 18,9 20,6 23,7 27,4 28,8 39,2 43,8 52,6 64,9 69,3 75,2 84,4 101 124 134 150 168 181 207 245 260 292 325 358 420 425 449 472 502

[A]
1 2 2 2 4 4 4 6 6 10 10 16 16 20 25 25 35 35 35 35 50 63 63 80 100 100 100 125 125 160 160 200 200 250 250 315 315 400 400 500 500 500 630 630 630

[A]
1 2 2 2 2 4 4 4 4 6 10 10 16 16 20 20 25 25 25 35 35 50 50 63 80 80 80 100 125 160 160 160 200 200 200 250 315 315 400 400 500 500 500 630 630

[A]
0,22 0,33 0,42 0,64 0,88 1,22 1,5 2 2,1 2,6 3,5 5 5,7 6,6 8,2 8,5 10,5 11,5 13,8 15,5 16,7 22 25 30 37 40 44 50 60 72 79 85 97 105 119 140 147 170 188 205 242 245 260 273 295

[A]
1 1 2 2 2 4 4 4 4 4 6 10 10 16 16 16 20 20 25 25 25 35 35 50 63 63 63 80 80 100 100 125 125 160 160 200 200 250 250 250 315 315 315 315 400

[A]
1 1 2 2 2 2 2 4 4 4 4 6 10 10 10 10 16 16 16 20 20 25 35 35 50 50 50 63 63 80 100 100 100 125 125 160 160 200 250 250 250 250 315 315 315

[A]
0,16 0,24 0,33 0,46 0,59 0,85 1,2 1,48 1,57 2,1 2,6 3,8 4,3 5,1 6,2 6,5 8,1 8,9 10,4 11,9 12,7 16,7 19 22,5 28,5 30,6 33 38 44 54 60 64,5 73,7 79 90,5 106 112 128 143 156 184 186 200 207 220

[A]
1 1 1 1 2 2 4 4 4 4 4 6 6 10 16 16 16 16 20 20 20 25 35 35 50 50 50 63 63 80 80 100 100 125 125 160 160 160 200 200 250 250 250 250 315

[A]
1 1 1 1 2 2 2 2 2 4 4 6 6 10 10 10 10 10 16 16 16 20 25 25 35 35 50 50 50 63 63 80 80 100 100 125 125 160 160 200 200 200 250 250 250

[A]
0,7 0,9 1,1 1,5 2 2,9 3,5 4,9 6,7 9 13 17,5 21 25 33 42 49 60 82 98 118 140 170

[A]
2 2 2 4 4 6 6 10 16 16 25 25 35 35 50 63 63 80 125 125 160 200 200

[A]
2 2 2 2 4 4 4 6 10 10 16 20 25 35 35 50 63 63 100 125 125 160 200

GANZ KAPCSOL- S KSZLKGYRT KFT.

2001.03.26