ZEV Moeller Eaton Electronic Motor Overload Relay 20-240 V AC/DC 50/60Hz

ZEV Moeller Eaton Electronic Motor Overload Relay 20-240 V AC/DC 50/60Hz

1.Overview of the ZEV Moeller Eaton

Eaton Moeller's ZEV electronic overload relay is designed to provide high-precision, full-function protection for three-phase AC motors ranging from 1 A to 820 A. It can replace traditional thermal relays and is widely used in applications such as pumps, fans, compressors, and conveyor lines where starting time and protection levels are critical. Core Functions
Overload Protection: 8 trip curves (Class 5–40), covering starting times up to 40 seconds.
Phase Loss Protection: Trips within 2 seconds of any phase loss.
Phase Unbalance Protection: Trips if the phase difference is ≥ 40%.
Ground Fault Protection: Adjustable from 0.3–20 A by connecting an external zero-sequence transformer (ZEV-XSW series).
PTC Thermistor Input: Directly connects to the motor winding PTC for dual overtemperature protection.
Pre-alarm: Provides a passive contact signal at 90% of the trip threshold, facilitating PLC pre-processing.
Self-Diagnostics: Real-time monitoring of the internal MCU, EEPROM, and transformer status, with fault codes displayed on the LCD.

2.Core Features:

Technical Parameters
Current Range: 1 A–820 A (Same frame, only the toroidal transformer needs to be replaced)
Control Power Supply: 24–240 V AC/DC, auto-sensing, 50/60 Hz
Main Circuit Voltage: Maximum 690 V
Auxiliary Contacts: 2 CO (1 NO + 1 NC), expandable to 4 CO
Protection Rating: IP20 (terminals), IP65 front (with transparent cover)
Operating Temperature: -25°C…+60°C
Mounting: 35 mm DIN rail or directly under the DILM contactor, no additional drilling required
Certifications: CE, UL, CSA, CCC

Highlights

The toroidal transformer is 58 times smaller than a traditional CT, saving 70% cabinet space. A built-in LCD and four-button menu display clearly show current, trip cause, and phase symbol, eliminating the need for additional instruments for on-site commissioning. The multi-voltage module automatically recognizes 24–240 V, allowing for global inventory with a single model, reducing maintenance costs. SKU
Pluggable communication module (ZEV-COM-ETH/ZEV-COM-PROFIBUS) allows remote reading of current and trip history, supporting predictive maintenance. When combined with Eaton DILM contactors, it forms an integrated "starter + protection" solution, reducing wiring by 80%.

Typical Applications
Water treatment: Submersible pumps with long-cycle soft starting, Class 20 curves prevent nuisance operation.
Cold chain logistics: Low-temperature compressors with frequent reverse rotation, phase imbalance protection prevents winding overheating.
Automotive welding lines: Robotic motors are sensitive to ground faults. The ZEV+XSW transformer trips at 0.3 A, ensuring personal safety.
Data center cooling towers: Real-time current is connected to SCADA via an Ethernet module for energy efficiency analysis and fault warning.

Ordering Tips
Base unit: ZEV (24–240 V)
Current transformer: ZEV-XSW-... (Select according to the rated motor current, e.g., for 150 A, select ZEV-XSW-150)
Communication Module: ZEV-COM-ETH (RJ45) / ZEV-COM-PROFIBUS (DB9)
Zero-sequence Transformer: ZEV-XVK-80 (80 mm aperture, maximum 20 A ground fault)

3.Product details pictures

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