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Emotron Softstarter User Manual

1. Fig 29 Selecting the parameter sets via digital input When the parameter sets are selected via digital inputs they are activated as in Table 20 Activate the parameter changes via digital input by setting menu 241 to Digln Table 20 Parameter set Set Ctrl 1 Set Ctrl 2 Parameter set 0 1 0 D 1 NOTE The selection via the digital inputs is immediately activated The new parameter settings will be activated on line also during Run 0 0 1 1 NOTE The default parameter set is parameter set A Example Manual and automatic control In an application manual control is used to prepare for service position After service the process is switched to automaic control mode This can be solved by using one set of parameters to activate manual control mode i e control signals via I O and a second set of parameters to activate running in automatic control mode i e control signals from PLC via fieldbus CG Drives amp Automation 01 5980 01r0 Main features 41 7 2 2 Configuration of parameter sets When the parameter set selection is done in menu 241 the settings for the particular application or control mode can be done Parameter set A is default which means that all changes done to the default settings in the menu system are saved under parameter set A To reset a parameter set to the default values go to menu 243 Default gt Set and choose the ex
2. 12 12 1 12 2 12 3 12 4 12 5 13 13 1 13 2 13 3 13 3 1 13 3 2 13 4 OPON Saien a a scans 137 External control panel 137 EmoSOftCOM ssirsasa irmaos dec dana 137 VO Board ssa scan trata eiti lien keane 137 PIG APT OO EE 137 Serial communication and fieldbus 137 Technical data 139 General electrical specifications 141 Semi conductor fUSES seems 141 Environmental conditions 142 Derating at high Temperature 142 Derating at high altitude ANE 143 Control power and I O signal connectors 144 INGO arias ile 145 Appendix 1 Menu List 147 Appendix 2 Trip message communication data 164 CG Drives amp Automation 01 5980 01r0 1 Introduction The Emotron TSA softstarter is intended for controlling the start and stop of standard three phase asynchronous motors A built in powerful digital signal processor DSP gives the softstarter high performance and very good control of the starting and stopping of the application Several options are available listed in chapter 12 page 137 that enable you to customize the softstarter for your specific needs NOTE Read this instruction manual carefully before installing connecting or working with the softstarter Users This instruction manual is intended for 1 3 Warranty The warranty applies when the equipment is installed operated and maintained accor
3. Maximum Alarm Level 4112 In this menu the set Maximum Alarm Level is shown on the right hand side of the display area F At the same time the actual value of the shaft power is viewed on the left hand side of the display area F the value within brackets Since the actual shaft power is always visible in this menu it allows you to easily setup a suitable maximum alarm level The value of the maximum alarm level is given as a percentage of the nominal motor power 223 i e a step of 1 is equal to 1 of the nominal motor power When the actual shaft power shown within brackets in the display exceeds the set alarm level the Maximum Alarm Delay timer menu 4113 will start counting down When the delay time has elapsed an alarm will be generated according to the selected Maximum Alarm Action in menu 4111 This menu can be set manually to the required alarm level or it can be set indirectly by performing an Autoset 4112 MaxAlarmLev Run FA Pshart 116 Default 116 Range O 200 of nominal motor power 223 Example The Max Alarm Level is set to 80 This means that when the output shaft power exceeds 80 of the nominal motor power the alarm delay timer starts counting down Maximum Alarm Delay 4113 When the load level exceeds the alarm level for a continuous period longer than the set Max Alarm Delay time the selected Maximum Alarm
4. Bpy full soeed reached running with bypass enabled a Function Status value position 0 0 0 0 0 0 0 1 Parameter Set A B C D Key 1 0 A 0 stopped EE Operation Parameter Set Thy ramp brake with command Stopped 0 A 0 222 Operation thyristors Int Ext keyboard 1 Rem remote Source of Run Key keyboard external or Stop command internal or both Com communication option 333 Integer values and bits used Bit Integer representation 1 0 Active Parameter Set where O A 1 B 2 C 3 D Operation 4 2 O Stopped 1 Thyristor driven motor 2 Bypass driven motor Source of Run Stop command where 7 5 O Rem 1 Keyboard internal external 2 Com 3 Spare 4 VIO 5 Internal keyboard 6 External keyboard 15 8 Reserved for future use Warning 722 This menu displays the actual or last warning condition A warning occurs if the softstarter is close to a trip condition but still in operation During a warning condition the red trip LED will flash as long as the warning is active Read only 722 Warning Stp warning message The active warning message is displayed in menu 722 Ifno warning is active the message No Error is displayed The following warning or trip messages are possible 116 Functionality CG Drives amp Automation 01 5980 01r0 Table 32 Trip and
5. End Torque at Start 333 Used with start method linear square torque control 333 EndTorqueSt Stp FA 150 Default 150 Range O 250 of Th 78 Functionality CG Drives amp Automation 01 5980 01r0 Initial Voltage 334 Used with start method voltage control 334 Init Volt Stp IN Default 30 Range O 90 of Un mot 221 Current Limit 335 A current limit can be added to all starting methods This regulates the current during the start ramp until full voltage is reached The start attempt is continued during the set start time in menu 336 Should the current still be at the current limit when the start time has expired this will be indicated by a warning message Current Limit and an optional alarm action as set in menu 236 Current Limit Alarm Action Linear or square torque ramp with current limit The motor torque is controlled according to either a linear or a square ramp as selected in menu 331 The current limit regulator is activated when the current is reaching the chosen value in 335 and switched off when full output voltage is reached or the start time has expired 336 Should the current fall to a value below the set current limit the current controller will be deactivated and the torque ramp reactivated The original slope remains for the continued torque ramp therefore the resulting total starting time will in this c
6. PT100 Alarm 232 The PT100 menus are only shown if a PT 100 option board is connected PT100 Alarm Action 2321 2321 PT100 AA stpfiMl No Action Default No Action No Action O HardTrip 1 For a definition see Table 21 page 45 Soft Trip 3 Warning 4 Motor Class 2322 Only visible if the PTC PT100 option board is installed Set overload the class of motor used The trip levels for the PT 100 sensor will automatically be set according to the setting in this 2313 Mot 1 Class es Stp Ami 10 2322 Motor Class Defaut Sze Zand up 10 Ru 2 O Class 2 Default F 140 C 3 1 Class 3 A100 C O 5 2 Class 5 E115 c 1 10 A 3 Class 10 A B120 c 2 10 4 Class 10 F140 c 3 20 5 Class 20 F Nema 4 30 6 Class 30 a 40 7 Class 40 HIES C 9 CG Drives amp Automation 01 5980 01r0 Functionality 63 PT100 Inputs 2323 Two PT100 option boards B1 and B2 may be connected enabling up to six PT100 inputs With menu 2323 PT100 Inputs you can select which PT100 inputs that should be supervised i e which are allowed to generate a trip warning when the temperature exceeds the limit set in menu 2322 Motor Class PT100 input 1 2 and 3 are equal to input 1 2 and 3 on the first PT100 option board B1 PT100 input 4 5 and 6 are equal to input 1 2 and 3 on the second PT100 option boar
7. 122 Functionality CG Drives amp Automation 01 5980 01r0 9 Serial communication The softstarter provides the possibility of different types of serial communication e Modbus RTU via RS232 RS485 USB and BT e Fieldbuses such as Profibus DP and DeviceNet e Industrial Ethernet such as Modbus TCP Profinet IO and EtherCAT See 12 Options on page 137 for available communication option boards 9 1 Modbus RTU There is an asynchronous unisolated RS232 serial communication interface on top of the Emotron TSA unit It is also possible to use the isolated RS485 or USB option boards if installed The protocol used for data exchange is based on the Modbus RTU protocol originally developed by Modicon The softstarter acts as a slave with address 1 in a master slave configuration The communication is half duplex It has a standard non return zero NRZ format The baud rate is fixed to 9600 with fixed address 1 on board RS232 port but it is adjustable for the USB and RS485 option boards The character frame format always 11 bits has e one start bit e eight data bits e two stop bits e no parity It is possible to temporarily connect a personal computer with for example the software EmoSoftCom programming and monitoring software to the RS232 connector on top of the Emotron TSA unit This can be useful when copying parameters between softstarters etc For permanent connection of a personal computer y
8. Default Current 8 2 Main Setup 200 The Main Setup menu contains the most important settings to get the softstarter operational and set up for the application It includes different sub menus concerning the control of the unit motor data and protection utilities and automatic reset of faults This menu will instantaneously adapt to installed options and show the required settings 8 2 1 Operation setup 210 Selections concerning the used motor sofistarter mode control signals and serial communication are described in this submenu and is used to set the softstarter up for the application Language 211 Select the language used in the control panel display Once the language is set this selection will not be affected by the Load Default command 211 Language str English Default English English 0 English selected Svenska 1 Swedish selected Nederlands 2 Dutch selected Deutsch 3 German selected Fran ais 4 French selected Espanol 5 Spanish selected Pycckun 6 Russian selected Italiano 7 Italian selected Cesky 8 Czech selected Turkce 9 Turkish selected Select Motor 212 This menu is used if you have more than one motor in your application Select the motor to define It is possible to define up to four different motors M1 to M4 in the softstarter For parameter set handling including motor sets M1 M4 see section 8 2 5 page 66
9. Over Voltage Level 4322 This menu is available if overvoltage alarm is enabled in menu 4321 Here the voltage level for an overvoltage alarm is entered expressed as a percentage of the nominal motor voltage As soon as any line voltage exceeds this voltage level for a time period equal to the set delay time in menu 4323 an overvoltage alarm will occur and the action selected in menu 4321 will be executed Under Voltage Level 4332 This menu is available if the undervoltage alarm is enabled in menu 4331 Here the voltage level for an undervoltage alarm is entered expressed as a percentage of the nominal motor voltage As soon as any line voltage falls below this voltage level for a time period equal to the set delay time in menu 4333 an undervoltage alarm will occur and the action selected in menu 4331 will be executed 4322 OverV Level 4332 UnderV Level Stp FA 115 Stp FA 85 Default 115 of nominal motor voltage 221 Default 85 of nominal motor voltage 221 Range 100 150 of nominal motor voltage 221 Range 75 100 of nominal motor voltage 221 Over Voltage Alarm Delay 4323 In this menu the response delay for the voltage unbalance alarm as set in 4321 and 4322 is selected Under Voltage Alarm Delay 4333 In this menu the response delay for the voltage unbalance alarm as set in 4431 and 4432 is selected
10. e 89 eh La 91 Analogue Input 510 91 Digital Inputs 520 erre 94 Analogue Output 530 95 Relays DO Tiida 97 Virtual 1 Os 560 ires 99 Logical Functions and Timers 600 100 Comparators 610 Logic outputs 620 Blue SR Flip flops 640 Counters 650 20000 ica Clock Logic 660 aee Operation Status TO 114 Operation values 710 114 StatuS 720 iii 116 Stored Values 730 119 Real time clock settings 740 119 View Trip Log 800 120 Trip Message Log 810 ennen 120 Trip Messages 820 890 121 Reset Trip Log 8A0 System Data TIOoOO naonnet eneee neren enee TSA Data 920 litio Serial communication 123 Modbus RTU oi 123 Parameter Sets iii aie ee 123 Motor datan aa 124 Start and stop Commande sssssssssssesnesnesnesenrneennn ee 124 Process Value iii 124 Description of the Elnt formats 125 Softstarter theory 127 Background theory 127 Reduced voltage starting 128 Other starting methods 130 Use of softstarters with torque control 132 Troubleshooting Diagnoses and Maintenance 133 Trip conditions causes and remedial action 133 Technically qualified personnel Opening the softatarter Maintenance i cs scccccsecscsiees sccsesseacy cevdesecssvsceseedcesene Troubleshooting list
11. 212 Select Motor stpll M1 Default M1 0 M2 1 Motor Data is connected to selected M3 2 motor M4 3 CG Drives amp Automation 01 5980 01r0 Functionality 57 Action Control 215 This function is used to select the source for run and stop commands and for jog control This is described in section 7 1 page 39 Run Stop Control 2151 2151 Run Stp Ctrl SC Remote Default Remote Remote O Start stop command via digital input Int Ext Start stop command via internal or external keyb control panel Start stop command via serial Com 2 E communication Spare 3 Reserved for future use Intkeyb 5 Start stop command via internal control panel Ext keyb 6 Start stop command via external control panel Jog Control 2152 In this menu the control source for the jog function is selected If the Jog FWD and Jog REV keys are to be used one of the keyboard alternatives must be selected in this menu and the keyboard must be locked in menu 218 See section 7 1 3 page 40 for settings regarding the jog functions 2152 Jog Ctrl settings see menu group 250 Autoreset See also section 7 3 5 page 50 about reset and autoreset functions WARNING If the Run input signal is active high and level controlled the motor will start at the reset command 216 Res
12. 4323 OverV Del 4333 UnderV Del Stp A 1s Stp A 1s Default 1s Default 1s Range 1 90s Range 1 90s 90 Functionality CG Drives amp Automation 01 5980 01r0 Phase Reversal Alarm 434 If this function is activated an alarm will be issued if the wrong phase sequence is detected prior to a start Phase Reversal Alarm Action 4341 In this menu the alarm action for a phase reversal alarm is selected The softstarter will detect the phase sequence prior to each start attempt If the actual phase sequence does not match the allowed phase sequence set in menu 4342 the action chosen in this menu will be executed To enable the phase reversal alarm a motor has to be connected and the mains voltage has to be switched on The alarm is only valid at starting attempts 4341 PhaseRevAA stp H No Action Default No Action No Action O Hard Trip 1 For a definition see Table 21 page 45 Soft Trip 3 Warning 4 Allowed Phase Sequence 4342 In this menu the allowed phase sequence is selected 4342 AllowedSequ Stp FA L123 Default L123 Selection L123 and L321 8 5 1 0 500 Main menu with all the settings of the standard inputs and outputs of the softstarter 8 5 1 Analogue Input 510 Submenu with all settings for the analogue inputs Analogue Input Function 511 Sets the function for the Analogue input Scale and range are defined b
13. 614 There are 4 analogue comparators that compare any available analogue value with two adjustable levels The two levels available are Level HP and Level LO There are also two analogue comparator types selected in menu Comparator Type an analogue comparator with hysteresis and an analogue window comparator The analogue hysteresis type comparator uses the two available levels to create a hysteresis for the comparator between setting and resetting the output This function gives a clear difference in switching levels which lets the process adapt until a certain action is started With such a hysteresis even an unstable analogue signal can be monitored without getting a nervous comparator output signal Another feature is the possibility to get a fixed indication that a certain level has been passed The comparator can latch by setting Level LO to a higher value than Level HP The analogue window comparator uses the two available levels to define the window in which the analogue value should be within for setting the comparator output Digital Comparator Setup 615 618 There are also 4 digital comparators that compare any available digital signals 100 Functionality CG Drives amp Automation 01 5980 01r0 Setup Analogue Comparator 1 611 Analogue comparator 1 parameter group Analogue Comparator 1 Value 6111 Selection of the analogue value for Analogue Comparator 1 CA1 The a
14. Max Pre Alarm and two underload alarms Min Alarm and Min Pre Alarm The load monitor function is not active during stop ramps jogging or braking For the start ramp you can choose to delay the activation of the load monitor by using start delay menu 416 It is common that the minimum and maximum alarms are set to give a soft or hard trip while the pre alarms are used to give an indication that an over or underload situation may be close by displaying a warning message e g Mon MinPreAl If the operation has been interrupted due to a load monitor alarm a reset and a new start signal is needed to continue operation Autoreset for the load monitor alarms can be activated under menu 254 For manual reset see Manual reset on page 50 Load monitor alarm levels There are two alternative ways to set the load monitor alarm levels 1 Manual configuration in which up to four Alarm Levels are set directly Fig Autoset configuration for which the alarm levels are automatically set based on Normal Load four Alarm Margins Fig 33 Common for both methods is that the resulting alarm levels are given as a percentage that refers to the nominal motor power 223 being 100 However the way to set the levels differs between the two methods NOTE When using the load monitor check that the nominal motor power is set properly in menu 223 46 Main features
15. REV that indicate if the REV key is activated or not The factory default setting is Of To change selection or value via the control panel the and keys are used see section 6 4 1 page 35 For bus communication the integer value O is used to select Off in the example Integer 1 represents REV To change selection by bus communication refer to the description in Chapter 9 page 123 Read only 1st Line 2nd Line 56 Functionality CG Drives amp Automation 01 5980 01r0 8 1 1 1stLine 110 This menu sets the content of the upper row in the menu 100 Preferred View If Process Value is selected the menu shows the value of the selected process source in menu 321 110 1st Line Stp El Power Default El Power Dependent on menu Process Val 0 Process value Torque 2 Torque Shaft Power 4 Shaft power El Power 5 Electrical power Current 6 Current Heatsink Tmp 10 Heatsink temperature Motor Temp 11 Motor temperature SoftstStatus 12 Softstarter status Run Time 13 Run Time Energy 14 Energy Motor temp is only visible if you have the option PTC PT100 board installed and a PT100 input is selected in menu 2323 8 1 2 2nd Line 120 Sets the content of the lower row in the menu 100 Preferred View Same selection as in menu 110 120 2nd Line Sr Current
16. Stp FA RS232 Default RS232 RS232 0 RS232 Fieldbus reset see note below Fieldbus option mounted e g Profibus Fieldbus 1 DeviceNet Modbus TCP or EtherCAT USB 2 USB RS485 or Bluetooth option RS485 BT mounted NOTE Toggling the setting from Fieldbus to RS232 in this menu will perform a soft reset re boot of the Fieldbus module Future options Address 2622 Enter the unit address for the softstarter NOTE This address is valid only for communication via the RS485 and USB options 2622 Address Stp FA 1 Default 1 Selection 1 247 Fieldbus 263 Set up the parameters for fieldbus communication 263 Fieldbus Stp fA CG Drives amp Automation 01 5980 01r0 Functionality 73 Address 2631 Enter or view the unit node address of the softstarter Read amp Write access for Profibus and DeviceNet Read only for EtherCAT 2631 Address Stp A 62 Default 62 Range Profibus 0 126 DeviceNet 0 63 Node address valid for Profibus RW DeviceNet RW and EtherCAT RO Future option Process Data Mode 2632 Enter the mode of process data cyclic data For further information see the Fieldbus option manual 2632 PrData Mode Stp Basic Default Basic None 0 3 Control status information is not used 4 byte process data control status Pasi St information is used Rea
17. else f int evalue m powl10 abs evalue e else f value return f 126 Serial communication CG Drives amp Automation 0 5980 01r0 10 Softstarter theory In this chapter different starting methods for induction motors are explained and compared The functionality of softstarters with torque control and their advantages and limitations compared to other starting methods are explained First a brief account of the background theory of starting induction motors will be given in section 10 1 Thereafter the different starting methods based on the usage of reduced voltage will be described and compared This chapter will also cover softstarters with torque control In section 10 3 some common starting methods based on other physical principles are explained With this information some limitations of the reduced voltage starters will become clear In section 10 4 there is a brief analysis of which applications may benefit from using a softstarter 10 1 Background theory The following two sections deal with motors with squirrel cage rotors In contrast to a wound rotor the squirrel cage rotor consists of straight conductors which are short circuited together at both ends When such a motor is connected directly to the line voltage it will typically draw a starting current of about 5 to 8 times its nominal current while the resulting starting torque will be about 0 5 to 1 5 times its nominal torque In th
18. eos umer fe S E ao ums fumo mo fm o TT 20 motorbata RR CC A TZ 232 mcr voma fenm peon mo Tae Motas fo fass fume DL 232 Ian DIE No aoton Ier mo mo SSCS 2322 motor css F00 49065 um Jum if 2323 prao0mputs Ta fase Jum Jum E IS SJ E n OOOO N NIN N AJOJN N N O N N 00 N N OI 233 PTC Alarm 2332 PTC Inputs PbPTC 43763 CG Drives amp Automation 01 5980 01r0 147 SD E PS EE Ae E e E a C luese umae Ju e fin Jos ETT fue ss feio ws pers fim fore 255 Gurrim ar Haro tap fasse Jun Jl o Sand 0 Es 266 Lod for GP No Gory sia Um fare jus Dee st wos TT sti moved Jor OM ums fm O asia Acwawst Jo Je Di fue TT 282 moras O o o 0 E O e fumei mo 0 fasza prog for usos rompio fem afe for iso long amis fem SSCS 2524 tockedRotor Jor O asos oee fem T 227 ourtim Jor asi TEST fem 255 coment lor usos fumei fem sa fra SSCS SS 2541 Mama Jor pos long tmis fem SSS 2542 asen fom 43089 fiomgi is Em TT 2545 ine Jon Yasar me eas ene saa minnan Jor usos long amis im EIERE EELER rasan Bana lor usos fimeisis im 2551 overteme of o iris fem SSS 2552 TUTTO fo pma CESTO em SSCS 256 Manso O 2561 Phase input ow prs fr em O zesoen fo aorr Jumeisis fem ssa fonenn lor usos long t is en DD E E Modbus RTU 2631 address a J Ju Ju 2632 PrData mode Basie J De ium PSC Ia ES
19. The Trip Message Log 800 can be useful for determining why certain trips recur at certain moments The trip log records the time of the trip in relation to the run time counter Under each trip message the values of a number of parameters are saved See Table 33 page 120 11 1 1 Technically qualified personnel Installation commissioning demounting making measurements etc of or at the softstarter may only be carried out by personnel technically qualified for the task 11 1 2 Opening the softstarter WARNING Always switch off the mains and control supply voltage if it is necessary to open the softstarter WARNING If it is necessary to open the softstarter or any part of the system motor cable housing conduits electrical panels cabinets etc in order to inspect or take measurements as suggested in this instruction manual it is absolutely necessary to read and follow the safety instructions in the manual The connections for the control signals and the switches are isolated from the mains voltage Always take adequate precautions before opening the softstarter 11 2 Maintenance The Emotron TSA softstarter is designed to require a minimum of servicing and maintenance There are however some things which must be checked regularly For model size 2 and up there is an internal fan that should be inspected and cleaned from dust if necessary If softstarters are built into cabinets also check and
20. without notice Motor 2t Alarm 231 This function makes it possible to protect the motor from overload as published in the standard IEC 60947 4 2 The alarm limit is set according to the levels defined by the Motor 12 Class in menu 2313 Once exceeded an alarm will occur and the action chosen in menu 2311 is performed The alarm remains active until the I t value is below 95 before allowing a reset or an autoreset see more detailed description in menu 2521 62 Functionality CG Drives amp Automation 01 5980 01r0 Motor tr Alarm Action 2311 2311 Mot 1 t AA StpfWMl1 Soft Trip Default Soft Trip No action O 12t motor protection is not active Hard Trip 1 Soft Trip 3 For a definition see Table 21 page 45 Warning 4 Motor I2t Current 2312 This menu enables both downrating and uprating use of motors with a service factor gt 1 00 of the thermal motor protection 2312 Mot I1 tCurr Stp FAM1 100 Default 100 Range 0 150 of the nominal motor current In mot 224 Motor tr Class 2313 Classification according to 1EC60947 4 2 defining the starting capacities of the motor in order to avoid thermal Used Thermal Capacity 2314 This menu shows the used thermal capacity of the motor i e the actual Ur value divided by the maximum Tt value expressed in 2314 Used Th Cap Read only Stp AMI XX
21. 1 is delayed with the set value in this menu See also Fig 59 page 104 6152 CDI Set Dly Stp fA 0 00 00 0 Default 0 00 00 0 hours minutes seconds Range 0 00 00 0 9 59 59 9 Digital Comparator 1 Reset Delay 6153 The reset of the output signal for the digital comparator 1 is delayed with the set value in this menu See also Fig 59 page 104 6153 CDI Res Dly Stp A 0 00 00 0 Default 0 00 00 0 hours minutes seconds Range 0 00 00 0 9 59 59 9 Digital Comparator 1 Timer Value 6154 The actual timer value for digital comparator 1 is viewed in this menu 6154 CD1 Tmr Val Stp IA 0 00 00 0 Default 0 00 00 0 hours minutes seconds Range 0 00 00 0 9 59 59 9 Setup Digital Comparators 2 4 616 618 Refer to the description of Digital Comparator 1 Default for CD2 6161 is Digln 1 For CD3 6171 the default is Trip and for CD4 6181 the default is Ready 8 6 2 Logic outputs 620 Logic 1 621 By means of an expression editor the input signals can be logically combined into the logics function to create a logic output signal The expression editor has the following features The following input signals can be used CA1 CA4 CD1 CD4 L1 L4 T1Q T4Q F1 F4 and CTR1 CTR2 The following inverted input signals can be used 141 144 D1 D4 L1 L4 T1Q T4Q F1 F4 and ICTRI ICTRA The following logical operators a
22. Always use standard commercial fuses slow blow e g gl gG types to protect the wiring and prevent short circuiting To protect the thyristors against short circuit currents superfast semiconductor fuses can be used if preferred The normal guarantee is valid even if superfast semiconductor fuses are not used Operating and maintenance personnel 1 Read the whole instruction manual before installing and putting the equipment into operation 2 During all work operation maintenance repairs etc observe the switch off procedures given in this instruction as well as any other operating instruction for the driven machine or system See Emergency below 3 The operator must avoid any working methods which reduce the safety of the device 4 The operator must do what he can to ensure that no unauthorised person is working on the device 5 The operator must immediately report any changes to the device which reduce its safety to the user 6 The user must undertake all necessary measures to operate the device in perfect condition only Phase compensation capacitor Ifa phase compensation capacitor is to be used it must be connected at the inlet of the softstarter not between the motor and the softstarter Installation of spare parts We expressly point out that any spare parts and accessories not supplied by us have also not been tested or approved by us Installing and or using such products can have a negative eff
23. Analogue comp 3 inverted output Run Signal 67 can be used to control the mains CA A 25 Analogue comparator 4 output contactor IAA 26 Analogue comp 4 inverted output Loc Rem 68 Local Rem function is active CD 1 27 Digital comparator 1 output Acc 69 Acceleration along the acc ramp IDL 28 Digital comp 4 inverted output Dec 70 Deceleration along the dec ramp CD 2 29 Digital comparator 2 output Digin 1 71 Digital input 1 ID2 30 Digital comp 2 inverted output SC E CD 3 31 Digital comparator 3 output EA ER ID3 32 Digital comp 3 inverted output Digin 4 ENER CD A 33 Digital comparator 4 output RunSignalFWD 75 dd lear togeth r with ID4 34 Digital comp 4 inverted output ERR ae Relay signal used together with T1Q 35 Logic timer 1 output Run REV signal 1110 36 Inverted logic timer 1 output OperationFWD 77 Positive speed 70 5 i e forward T20 37 Logic timer 2 output clockwise direction T2Q 38 Inverted logic timer 2 output OperationREV 78 ee EE T3Q 29 Logie timer Sgutput ManRst Trip 79 Any active trip condition that needs a IT3Q 40 Inverted logic timer 3 output manual reset T4Q 41 Logic timer 4 output Alarm 80 Alarm triggered IT4Q 42 Inverted logic timer 4 output Alarm ex LM 81 Alarm triggered except load monitor L1 43 Logic output 1 Overvolt 90 Overvoltage alarm active trip or UN 44 Logic output 1 inverted Warning L2 45 Logic output 2 Com Error 97 nce NO eror active trip g
24. CG Drives amp Automation 01 5924 01r0 Application guidelines 27 28 Application guidelines CG Drives amp Automation 01 5924 01r0 5 Getting started This chapter is a step by step guide that will show you the quickest way to get the motor shaft turning We will show you two examples with remote control and control panel operation WARNING J Mounting wiring and setting the device into operation must be carried out by properly trained and qualified personnel 5 1 Check list Check that the motor and supply voltage corresponds to the values on the rating plate of the softstarter Mount the softstarter Chapter 2 page 9 Connect the 3 phase mains supply cables to the connec tions on top of the softstarter section 3 1 page 12 Connect the motor cables to the connections in the bottom of the softstarter section 3 1 page 12 e Connect control supply voltage section 3 1 page 12 e Ensure that the installation complies with the appropriate local regulations Remote I O operation e Connect the I O control cables section 3 3 page 15 e Switch on the 3 phase mains supply voltage and control supply voltage e Select language menu 211 section 8 2 1 page 57 e Set the motor data menu 220 227 section 8 2 3 page 60 e Set real time clock menu 740 section 8 7 4 page 119 e Perform a test run with external I O start command Control panel operation e Switch on
25. CG Drives amp Automation 01 5980 01r0 Getting started 29 5 3 Default toggle loop In order to make it easier to setup the initial data there is a default toggle loop see Fig 18 This loop contains the necessary menus that need to be set before starting the softstarter the first time Press the Toggle key to enter e g menu 740 then use the next keys to go to the submenus 741 and so forth and enter the parameters When you press the Toggle key again the next toggle menu is displayed Toggle loop To submenus Fig 18 Default toggle loop 5 4 Remote I O operation Generally external signals are used to control the softstarter and the motor This example demonstrates the set up for a standard motor for which an external start button will be used Connect the control signal cables The minimum wiring for a remote controlled start is shown in Fig 19 below In this example the motor softstarter will run with forward rotation For other wiring examples see section 3 4 page 16 It is recommended to use screened control signal cables with flexible wire up to 1 5 mn or solid wire up to 2 5 mm Connect an external start button between terminal 18 24 VDC and 11 Digln 1 Run FWD Change the setting in menu 21A to Level level control Change setting for Digln 2 in menu 522 to Off NOTE Default setting is edge control menu 21A set to Edge in order to comply with the Machine directi
26. Default Operation AnOut Function Maximum 5336 With AnOut Function Min the physical minimum value is scaled to selected presentation The default scaling is dependent on the selected function of AnOut 531 See Table 26 page 96 off 0 Output is not active and constantly low Output is made constantly high i e On 1 for checking circuits and trouble shooting Operation 2 See Fig 54 No Operation 3 Inverted operation 5336 AnOutFcMax Bypass mode 4 See Fig 54 The speed is increasing or decreasing Acc D co Dec S along the acc ramp dec ramp No Trip No Trip condition active Stp Al Max Default Max Min O Min value Max 1 Max value Trip A Trip condition is active User defined 2 Define user value in menu 5337 6 7 AutoRst Trip 8 Autoreset trip condition active 9 Warning A Warning condition is active NOTE Itis possible to set AnOut up as an inverted output signal by setting AnOut Min gt AnOut Max See Fig 52 The softstarter is ready for operation and to accept a start command This means that the softstarter is powered up and in good working condition Ready 10 AnOut Function Value Maximum 5337 With AnOut Function VaMax you define a user defined value for the signal Only visible when User defined is selected in menu 5334 The output current is higher than the motor nomi
27. Normal Load is expressed as a percentage of the nominal motor power i e 100 normal load equals the motor power set in menu 223 The Alarm Margins are set under menu 417 and Normal Load is automatically registered when activating the autoset function in menu 4175 AutoSet Alarm The actual Normal Load value can then be viewed in menu 4176 Every time a new Autoset Alarm command is executed the actual shaft power value will be updated as the Normal Load value with the alarm levels following this Autoset can also be activated using a remote signal edge triggered by setting the function of any digital input to Autoset NOTE A manual change of any of the Alarm Levels in 411 414 will override the Autoset monitor settings and the Normal Load will be reset to Off P of Ph mot Autoset 4175 Max Alarm Margin Max Pre Alarm Margin 4172 I 4176 Normal Load 4173 Min Pre Alarm Margin Min Alarm Margin K D Start Delay Normal operation zone O Pre alarm zone O Min and max alarm zone b Min Pre Alarm Delay Action D RUN command D Start delay timer A Alarm action t s Min Alarm Max Pre Alarm Max Alarm Delay 4143 Delay Delay Action Action Action Fig 33 Autoset load monitor alarm margins 48 Main features CG Drives amp Automation 01 5980 01r0 Load monitor alarm
28. Press E 5 Then press the until P is displayed and press Ea 6 Repeat until you have entered kPa Confirm with E 323 User Unit Stp FN Default No characters shown When sending a unit name you send one character at a time starting at the rightmost position Process Minimum 324 This menu is only visible if a process source is selected in menu 321 This function sets the process value that corresponds to the minimum input signal 324 Process Min Stp FN 0 000 Default 0 000 Kange 0 000 10000 ge 10000 10000 F Anln F Bus PT100 Process Maximum 325 This menu is only visible if a process source is selected in menu 321 The function sets process value that corresponds to the maximum input signal 325 Process Max Stp Al 10 00 Default 10 00 Range 0 000 10000 CG Drives amp Automation 01 5980 01r0 Functionality 77 8 3 3 Start setting 330 Submenu with all the functions for starting Start method 331 The available start methods are Linear or Square Torque Control A properly configured torque controlled start will lead to a linear speed increase and low starting current without current peaks Fig 40 shows the torque ramps for linear torque control and square torque control The Initial Torque value is setin menu 332 and the value for End Torque at Start is set in menu 333 Torque 1 Linear 2 Sq
29. Soft Trip with the corresponding alarm delays 10 seconds in menu 4113 Max Alarm Delay and 5 seconds in 4143 Min Alarm Delay Since the normal load condition shaft power for the pump is 50 of the nominal motor power 223 the Max Alarm Level 4112 is set to 70 Finally the Min Alarm Level 4142 is set to 10 which is reached during e g pump cavitation conditions This configuration results in the following sequence of events as illustrated in Fig 34 A The load monitor function is activated when the set start delay time 30 seconds has expired B A maximum alarm condition is triggered but since the load returns to a safe level within the set alarm delay time i e lt 10 seconds no alarm action is performed C A new maximum alarm condition is triggered D When the set alarm delay time 10 seconds has expired the maximum alarm action is executed in this case a soft trip Pload 70 50 Normal 10 O LA Time Fig 34 Example 1 Manually set load monitor function Example 2 Auto setting alarm margins To block the load monitor during the start up a start delay of 30 seconds is selected in menu 416 In this case a motor used in a conveyor application must be protected It is only of interest to apply a maximum alarm and maximum pre alarm therefore the alarm actions for the minimum alarm 4141 and the minimum pre alarm 4131 are set to No action
30. Softstarter cabinet Fig 84 External control panel in mounting cassette 12 2 EmoSoftCom EmoSoftCom is an optional software that runs on a personal computer It can also be used to load parameter settings from the softstarter to the PC for backup and printing Recording can be made in oscilloscope mode Please contact CG Drives amp Automation sales for further information Each I O option board 2 0 provides three extra relay outputs and three extra isolated digital inputs 24V This option is described in a separate manual Maximum two option boards can be mounted I O or PTC PT100 12 4 PTC PT100 Part number Description 01 3876 58 PTC PT100 2 0 option board The PTC PT 100 2 0 option board for connecting motor thermistors and max 3 PT100 elements to the softstarter is described in a separate manual Maximum two option boards can be mounted I O or PTC PT100 12 5 Serial communication and fieldbus Part number Description 01 5385 54 TSA Isolated RS485 module 01 5385 55 TSA Profibus module 01 5385 56 TSA DeviceNet module 01 5385 59 TSA Modbus TCP module 01 5385 60 TSA EtherCAT module 01 5385 61 TSA Profinet IO 1 port module 01 5385 62 TSA Profinet IO 2 port module 01 5385 63 TSA Isolated USB module For communication with the softstarter there are several option modules There are different options for Fieldbus communicati
31. This menu shows the software version number of the softstarter Fig 73 gives an example 922 Software Stp v1 00 Fig 73 Software version example Table 34 Information for Modbus and Profibus number software version Bit Example Description 7 0 30 13 8 4 Minor version Major version Release type O V release version 1 P pre release version 2 B Beta version 3 a Alpha version 15 14 0 Table 35 Information for Modbus and Profibus number option version Bit Example Description 7 0 07 Minor option version 15 8 03 Major option version CG Drives amp Automation 01 5980 01r0 Functionality 121 NOTE It is important that the software version displayed in menu 922 is the same software version number as the software version number written on the title page of this instruction manual If not the functionality as described in this manual may differ from the functionality of the softstarter Build Info 9221 9221 Build Info Stp Default YY MM DD HH MM SS Unit Name 923 Option to enter a name of the unit for service use or customer identity The function enables the user to define a name with max 12 characters Press the keys to enter graphic symbols from the same list as for User defined Unit 323 page 76 See also Editing parameter values page 35 923 USER 15 Stp Default No characters shown
32. allowed start set in menu 2354 has decreased to zero 2552 Start Limit Stp FA Off Default Off Off 0 Off 1 3600 1 3600 1 3 600 s CG Drives amp Automation 01 5980 01r0 Functionality 71 Mains failure autoreset 256 The following menus are intended for autoreset of different mains fault conditions Phase Input loss autoreset 2561 Asa phase input failure cannot be detected in a stopped state the delay time counter starts counting immediately after the alarm action has been executed When the delay time has elapsed the alarm will be reset and a restart attempt will automatically be made 2561 Phase Input Stp FA Off Default Off Off 0 Off 1 3600 1 3600 1 3 600 s Voltage Unbalance autoreset 2562 In this menu the delay time for an autoreset of a voltage unbalance alarm 441 is set The delay time starts counting when the fault is removed Usually the mains voltage will not be available to the softstarter in a stopped state as the mains contactor is deactivated In this case a voltage unbalance failure cannot be detected in a stopped state and the delay time starts counting immediately after the alarm action has been executed When the delay time has elapsed the alarm will be reset and a restart attempt will automatically be made 2562 Volt unbal Stp A Off Default Off Off 0 off 1 3600 1 3600 1 3 600 s Overvolta
33. synchronous speed when the motor voltage is switched off This is valid for most applications as the load speed usually decreases because of frictional losses in gears or belt drives when the voltage is switched off However this method is less suitable for loads with very high inertia in which case the reverse current brake is more efficient When the dynamic vector brake is used no additional connections or contactors are needed The actual speed is detected and if this is above a certain limit the dynamic vector brake is executed For lower speeds the DC brake is activated CG Drives amp Automation 01 5980 01r0 Functionality 81 Reverse Current Brake This braking method is especially suitable for quickly stopping heavy loads with high inertia A very high braking torque can be applied to the motor even close to synchronous speed However before applying a high braking torque it should be checked whether the motor the gear or belt drive and the load can withstand the high mechanical forces To avoid harmful vibrations it is generally recommended to select the lowest braking torque possible that still fulfils the demands for a short braking time The braking is accomplished by phase reversal of the current To enable this two external mains contactors are needed which are controlled by the relay outputs of the softstarter The connection is showed in Fig 14 page 18 During start and full voltage operation the first con
34. the motor data must be saved under different motor data sets selected in menu 212 See also Handling motor data in parameter sets on page 42 7 1 6 Process information To set up the softstarter for a process value menu group 320 is used under which a process signal and its limits can be configured This can be used to create start and stop commands from process value levels All the actual operational data can be viewed in the menu group 700 Operation Status The softstarter is by default set to present the operational data using SI units If needed this could be changed to US units in menu 21C 40 Main features CG Drives amp Automation 01 5980 01r0 7 2 Working with parameter sets Parameter sets can be used to set the softstarter up for different applications such as different motors used and connected start and stop methods alarm settings control sources etc With the four parameter sets different control options can be configured with respect to quickly changing the behaviour of the softstarter It is possible to adapt the softstarter online to altered behaviour This is based on the fact that at any desired moment any one of the four parameter sets can be activated during operation via the digital inputs or the control panel A parameter set consists of virtually all changeable parameters in the menu system Exceptions are some parameters that can only have one and the same value regardless
35. 0 FWD key deactivated FWD 1 FWD key activated REV key 2175 The REV key gives a start with reverse left rotation if activated in this menu The function requires a reversing contactor The rotation direction must also be permitted in menu 219 Rotation 2175 REV key Stp FA Off Default Off Off 0 REV key deactivated REV 1 REV key activated Lock Code 218 To prevent the keyboard being used or to change the setup of the softstarter and or process control the keyboard can be locked with a password This menu Lock Code 218 is used to lock and unlock the keyboard Enter the password 291 to lock unlock the keyboard operation see section 6 4 1 page 35 If the keyboard is not locked default the selection Lock Code will appear If the keyboard is already locked the selection Unlock Code will appear When the keyboard is locked parameters can be viewed but not changed The control keys START REV FWD and STOP RESET and the jog keys JOG REV FWD can still be used if their functions are set to be controlled from the keyboard 218 Lock Code stp A Default 0 Range 0 9999 Rotation 219 Overall limitation of motor rotation direction This function limits the overall rotation to reverse or forward direction or to allow both directions This limit is prior to all other selections e g if the rotation is limited to fo
36. 01 5980 01r0 Example 4 Reverse start functionality The digital inputs can be configured to enable starting a motor in two different directions with the use of the programmable relays R1 and R2 A connection example is shown in Fig 15 For the following description of start forward reverse functionality the following settings for the digital inputs are assumed Menu Description Setting 521 Digital input 1 terminal 11 Run FWD default 522 Digital input 2 terminal 12 Stop default 523 Digital input 3 terminal 16 Run REV CAUTION Very high torque force can arise when the motor is reversed from running at full speed in one direction to running at full speed in the opposite direction WARNING If configured according to the description J relays R1 and R2 will never be activated at the same time There is a time delay of 100 ms for the change over between the relays However if the relays are not configured properly they may be activated at the same time 100 240V 10 L1 L2 L3 PE L N PE LA e e e N N ll IM NA A Relay 1 Relay 2 PTC O O e Ces wes O O O O O O O O L1 L2 L3 PE L N PE 21 22 23 24 33 31 32 69 70 a A R1 R2 R3 l TELEL Digln1 Digin2 10V Anin GND Digln3 Digln 4 24V AnOut 24V T1 T2 T3 PE t 12 13 14 15 16 17 18 19 20 o wm wm O O O O O O O O O O O D 2 D Run FWD Stop
37. 1000 7 1001 2 1110 1 111I 0 0000 1 0001 2 0010 6 0110 0111 The value represented by the Emotron floating point format is m 10e To convert a value from the Emotron floating point format to a floating point value use the formula above To convert a floating point value to the Emotron floating point format see the C code example below Example floating point format The number 1 23 would be represented by this in Emotron floating point format F EEEE MMMMMMMMMMM 1 1110 00001111011 F 1 gt floating point format used E 2 Example resolution If you write the value 1004 to a register and this register has 3 significant digits it will be stored as 1000 In the Emotron floating point format F 1 one 16 bit word is used to represent large or very small numbers with 3 significant digits If data is read or written as a fixed point i e no decimals number between 0 32767 the 15 bit Unsigned integer format F 0 may be used Detailed description of Emotron floating point format e3 e0 4 bit signed exponent Gives a value range 8 7 binary 1000 0111 m10 m0 11 bit signed mantissa Gives a value range 1024 1023 binary 10000000000 01111111111 A signed number should be represented as a two complement binary number like below M 123 The value is then 123x107 1 23 Example 15bit unsigned integer format The value 72 0 can be represented as the fi
38. 22 50777000 E Jm Del Solo Rm um um O xampu JS Jm um um TT Sloaz fe pem um Jum TT fexie inputs ES Jm um um dP SSCS fox tops fe em um um TT xs itinpw a fea fasso um um O zo ttsetoy emm asao Dua pos assi Ju act Jane O S fassa June amos um O Suloeen Je Done IS a in um O DI o fis fomos fim O ee er eee oito qr ek gt CG Drives amp Automation 01 5980 01r0 155 25 ET ST a A T T DI fio fomos fim fex2s 12002 fe eo um um TT earo Re um um TT CCT pe fumos Jum Jum o Salzen een fassa Jum im um E Doo mim a DI o ui aos im O Salzen een fasar Dahl Do oo int um Dio o fis fuma um EREECHEN IN IES INSI LIN CT TAN INN DI fis in aos June emo quam que qm qm e232 int oat ase um EG joxs3 isop1 fe fars Dr ES COTA be ee fore esso RK ist um um dP SSCS 626 impus ES fases um um TT esos fe pases um um TT Err fea pr um Jum Selen Been Ise Dach SSS BEE EE PD oo ia a CI Joes Jace AO ca Jue 2 DI o aos fim feo ideo UMA area qm Jl EE 225 CITE fe um um IN 6204 tainp JS asi um um SSCS feats EIC PAI Ja LEI um um IAS EZ CUTTER fon Ja um Jum IS EIERE 9205 ra mpura m Je Jum Jl wi ajajalalalajalalalalala 156 CG Drives amp Automation 01 5980 01r0 A Modbus Inst Menu Parameters Default settings EE EE E ss fun n um Sd Des SC June ES DO fio fume team a DI o fis fum
39. 3 0 mm and 9 20 Hz acc 1 g 10 m s According to IEC 60721 3 3 Contamination Chemically active substances class 3C3 conformal coating all printed circuit boards are coated Mechanically active substances class 3S1 no sand dust lt 0 01 mg m deposited lt 0 4 mg m2 h Biological conditions class 3B1 no risk for harmful biological attacks mould fungus animals etc Storage Ambient temperature 25 C to 70 C Atmospheric pressure 86 106 kPa Relative humidity Max 95 non condensing 13 3 1Derating at high temperature The Emotron TSA softstarter is made for operating at maximum 40 C ambient temperature without derating Above this temperature it is necessary to ensure that insufficient cooling does not impair the performance of the softstarter therefore a derating is done At temperatures of above 40 C the derating of the nominal current is 2 per centigrade The Emotron TSA softstarter can be operated at an ambient temperature of up to 55 C in which case it can only be operated at 70 of the nominal current WARNING To resist temperatures above 40 C the clock battery see 3 2 page 14 must be changed to a BR2032 type battery Example A motor with the following data is going to be used in an ambient temperature of 50 C Voltage 400 V Current 70 A normal duty Power 37 kW Due to the high temperature the TSA model 52 070 will no longer be ade
40. 4 524 the default is Reset Additional digital inputs 529 to 52E Additional digital inputs with I O option board installed B1 Digln 1 529 B2 Digln 3 52E B stands for board 1 and 2 is the number of the board which is related to the position of the I O option board on the option mounting plate The functions and selections are the same as for DigIn 1 521 Default settings are Off 8 5 3 Analogue Output 530 Submenu with all settings for the analogue output Selections can be made from application and softstarter values in order to visualise actual status Analogue output can also be used as a mirror of the analogue input Analogue Output Function 531 Sets the function for the analogue output Scale and range are defined by AnOut Advanced settings 533 531 AnOut Fc Stp FA Current Default Current Off 0 Analogue output not active Torque Actual torque Actual process value according to Ge Process feedback signal Shaft Power A Actual shaft power NOTE To activate the parameter set selection menu 241 must be set to Digln 0 Current 6 Actual current 0 El power 7 Actual electrical power 1 Anin 10 Mirror of received signal value on Anin 1 Line Voltage 14 Mains supply Therm Cap 15 Used thermal capacity CG Drives amp Automation 01 5980 01r0 Functionalit
41. 60 Hz and the default nominal values on motor data e g voltage are adapted to US standards See also 1 7 2 Definitions and Table 23 page 61 NOTE In edge control mode at least one digital input 21C Units must be programmed to Stop because the RunFWD Stp fN SI and RunREV commands are only able to start the softstarter Default SI SI O Sl units 21A Level Edge US 1 US units Stp fA Edge Default Edge The inputs are activated or deactivated by a continuous high or low signal Is Leve S commonly used if for example a PLC is used to operate the softstarter The inputs are activated by a transition Edge 1 for Run and Reset from low to high and for Stop from high to low CAUTION Level controlled inputs DO NOT comply with the Machine Directive if the inputs are directly used to start and stop the machine NOTE Edge controlled inputs can comply with the Machine Directive see Chapter 1 5 1 page 6 if the inputs are directly used to start and stop the machine Units 21C In this menu you select the units which will represent the different parameter values in the menus including those read via serial communication SI units When SI is selected the default units will be e Power kW Torque Nm e Temperature C Nominal motor frequency is preset to 50 Hz and the nominal values on motor data are preset according to
42. 6118 CAl Tmr Val Default Hysteresis Stp A 0 00 00 0 Hysteresis O Hysteresis type comparator Default 0 00 00 0 hours minutes seconds Window 1 Window type comparator Range 0 00 00 0 9 59 59 9 Analogue Comparator 1 Set Delay 6116 The output signal for the analogue comparator 1 is delayed with the set value in this menu See Fig 59 6116 CA1 Set Dly Stp FA 0 00 00 0 Default 0 00 00 0 hours minutes seconds Range 0 00 00 0 9 59 59 9 Set delay Reset delay Setup Analogue comparators 1 4 612 614 Refer to the descriptions for analogue comparator 1 Setup Digital Comparator 1 615 Digital comparators parameter group Digital Comparator 1 Input 6151 page 120 Selection of the input signal for digital comparator 1 CD1 The output signal CDI is set high if the selected input signal is active See Fig 60 The output signal can be programmed to the relay outputs or used as a source for the virtual connections 560 6151 CDI Stp A Operation Default Operation Fig 59 Setlreset delay of output signal i Same selection as in menu Relay 1 Selection 551 page 97 104 Functionality CG Drives amp Automation 01 5980 01r0 cD1 Input signal for CD1 6151 Digital comparator 1 Fig 60 Digital comparator Digital Comparator 1 Set Delay 6152 The activation of the output signal for the digital comparator
43. Action in menu 4111 is activated 4113 MaxAlarmDel Stp IA 0 5s Default 0 5s Range 0 1 90s 84 Functionality CG Drives amp Automation 01 5980 01r0 Maximum Pre Alarm 412 These menus contain the settings for the load monitor maximum pre alarm Maximum Pre Alarm Action 4121 Setting of the alarm behaviour when a Maximum Pre Alarm has been detected 4121 MaxPreAlAct Minimum Pre Alarm 413 These menus contain the settings for the load monitor minimum pre alarm Minimum Pre Alarm Action 4131 Setting of the alarm behaviour when a Minimum Pre Alarm has been detected 4131 MinPreAlAct No Action stp A No Action Stp fA Default No Action Default No Action No Action O No Action O Hard Trip 1 Hard Trip T For a definition see Table 21 page 45 For a definition see Table 21 page 45 Soft Trip 3 Soft Trip 3 Warning 4 Warning 4 Maximum Pre Alarm Level 4122 The value of the maximum pre alarm level is given as a percentage of the nominal motor power 223 When the actual shaft power shown within brackets in the display exceeds this level the Maximum Pre Alarm Delay timer menu 4123 will start counting down When the delay time has elapsed an alarm will be generated according to the selected Maximum Pre Alarm Action in menu 4121 This menu can be set manually to the required alarm
44. CAC YO E T erpe oS NN festi oKirineon een o niin fem SSCS E O TO Jen O Dio o fist ong fim DEER fessos long amin fem SSS PD oo fia A im DI 0 pongas fim essas Jo Je fumei im TT festa oKidateot fo Je CTE fem SSCS fests oKiweckaay fo Jet Di Jum SSS CG Drives amp Automation 01 5980 01r0 159 6621 charimeon Jena Jane LI AA eng Jet Dio fo fes CTE fim OD EA Jean asse ET CN OOS AA enn Jen Do fosso pongas fem e23 erzan jo Je ioga fem 5524 forzas fo assa ioga fem lalala gt 6625 Cik2Weekday 0 43627 Long 1 1 JEt o 700 oper status TT Pages Notes Long Elnt Lo Long 71K Used Th Cap DiglnStatus 725 Analogueln AnalogueOut 728 10 StatusB2 mo operation 1rpm 1 1 C 0 001 as set in 322 Long 1 see n 721 TSA Status RelayStatus 727 10 StatusB1 72B CD1 4 31024 Long 1 0 1 Eln t Ulnt Ulnt Ulnt 1 1 Ulnt 1 1 Long 1 1 Long 1 1 Ulnt 1 1 Ulnt 1 1 Ulnt 1 1 Ulnt 1 1 Ulnt Ulnt Ulnt Ulnt Elnt Elnt Ulnt Ulnt Ulnt Ulnt n Page 116 160 CG Drives amp Automation 01 5980 01r0 Menu Parameters Frag rosen faoss umin Jue KEES Frat runtime ooo stor foem fem TT E os a E Dio Do fis CESTO fim enem o um im 0 752 Mainstime oo0000 feor hoem fem TT D oe E O DIO fasso e fim ss fem om Je Jamie rrsai astenew fo o um mo dP CSCS o jk da ma ime _Joowo0o 2920 long
45. CG Drives amp Automation 01 5980 01r0 Manually set alarm levels See Fig For the manual load monitor settings the Alarm Levels 411 414 are set directly as a percentage of the nominal motor power menu 223 The actual shaft power signal value is displayed together with the Alarm Level value to facilitate setting See example on the right Example 4112 MaxAlarmLev Run fd 104 116 P of Ph mot Manual setting Max Alarm Level Max Pre Alarm Level ae Min Pre Alarm Level Min Alarm Level I Normal operation zone Pre alarm zone O Min and max alarm zone d lt gt RUN command D Start delay timer A Alarm action A l l t s D Start Delay Min Pre Alarm Min Alarm Max Pre Alarm Max Alarm 416 Delay Delay Delay 4123 Delay Action 4131 Action Action Action Fig 32 Manually set load monitor alarm levels Main features 47 CG Drives amp Automation 01 5980 01r0 Autoset function with alarm margins See Fig 33 The quickest way to adapt the monitor to different load situations is to use the Autoset function which automatically applies four Alarm Margins to a registered Normal Load level whilst the motor is running The Alarm Margins are set as a percentage added to or subtracted from the Normal Load which is the shaft power during normal operation conditions See calculations in Table 24 page 86 The
46. De Jl zesamen JJ Dei Jon 148 CG Drives amp Automation 01 5980 01r0 NO EE 2642 com ietime foss aos Jazz Gelee 0000 Jg D Jl SEELEN E p pooo CE TAN IAS fosso ra umas Jum 2652 Mic agas 900000000000 2705 Di um SEELEN SERGE EEGEN SERGE BEES zess ETICO 0000 Ji Del O p poo poma maa e S E CO p fooso rms umas Jum C fosso ima umas um O IN EECHELEN SEENEN SEELEN Do fosso pons umas Jum reese once for LEC um um SSS essea fo pa uni mo TT 2552 STEIN O faz Du Jum l t Jo fume fuma Jum o 2666 FBSgnatii fo Jet Dez ur 2660 FBSgnati fo 42815 Do Ji else O Je uan ur 266 FBSgnati5 E 4285 Dez ur 266c FBSgnatio o ase Dr Jur ECON Board pe por TEN CITA IS EELER EELER e E C Deele Jg Du Jum EELER 2697 jMsGerors Jg Di Jl fesse tourer Je Du Il eiert CG Drives amp Automation 01 5980 01r0 149 Modbus Inst Fieldbus Modbus po enen en Jk Ge ESSES eee pes Jesse Jo Je s sang o Nes EE ee EE ESSES Page 78 Peers st senmonos Jeep asor Di jum TT 332 Int Torque fos Jam fume iene fone DT ff 337 Torque Boost 3372 Ulnt 1 0 1s 841 stop method co asrer Umas um 342 endrrave Jor faer22 Tamer fumo o 343 Sewon 100 um uma ue EREECHEN sas somme fs fars umis joe O 346 Racen foss uno Um um o aar emstreng rx ferar umism fumo o 349 swrenrenos sor aereo umism um S jaan fo
47. Default Off Off 0 off 1 3600 1 3600 1 3 600 s CG Drives amp Automation 01 5980 01r0 Functionality 69 PT100 autoreset 2522 The delay counter starts counting when all PT 100 inputs are below the set temperature in menu 2322 2522 PT100 Stp FN Off Default Off Off 0 Off 1 3600 1 3600 1 3 600 s PTC autoreset 2523 The delay counter starts counting when all PTC values are below their respective limit This means that if e g only the internal power board PTC is present the PB PTC resistance has to go down to 2 260 Ohm which decides the minimum time before autoreset The time set in this menu is then added on to the time for cooling down For corresponding resistance limits regarding PTC option boards please refer to the PTC PT100 board 2 0 instruction manual 2523 PTC Stp fq Off Default Off Off 0 Off 1 3600 1 3600 1 3 600 s Locked Rotor autoreset 2524 In this menu the delay time for an autoreset of a locked rotor alarm is set As a locked rotor cannot be detected in stopped state the delay time starts counting immediately after the alarm action has been executed When the delay time has elapsed the alarm will be reset and a restart attempt will automatically be made 2524 LockedRotor Stp FA Off Default Off Off 0 Off 1 3600 1 3600 1 3 600 s Current Limit autoreset 2525
48. Drives amp Automation 01 5980 01r0 145 M Product standard EMC 6 T Machine Directive sesse 6 Protection class u un 10 Technical data oia 139 Mains supply coccoccoccccncnononnnnnncnonanonos 29 PTIOO srs 64 The Application Functions List 23 Maintenance nssr 1 136 PT100 temperature sssssssesesersssssse 115 Thermal capacity 63 69 115 Memory A iai antas fi ek atta EK 64 Thermal motor protection 33 63 69 Menu Q TIME adan 119 A Quid Serup Guide memo E ae 8 RE 64 R JOG IS astrais ice arenas 109 QAI ai dal 64 Reduced voltage Starting e 128 A 118 DI ddr 65 Relay output remete 907 Toggle amas rica 58 DIAS td ts 65 Relay mata 97 Toggle Key coccion 35 Dita 65 A 99 Torque LIO ee oia 66 Relay 3 io a ic ested ee 99 Actual seccionales 114 Main menu oo cece eeeeeeees 37 SEALS A ee Bat 117 Analogue output oo eee 95 Menu Structure esseere 37 Remote control ceccccccccccecceccecscecceeceeee 51 BOOSt O deeg 80 Mike apta A EE 58 Braking uta 82 MG BUS siii ita 123 Rolo taa oleada 56 Control eosiianseippui teis 78 80 Modbus TCP 123 137 Revered current brake 81 82 Initial ia 78 Monitor function E DEE 25 Ramp supe ni a 78 Pa ND ro SEL RR RR heise 87 Dto based sin eee ra ariana 64 Shaft ssa tara 114 MOON ptos ue 5 57 RS232 485 A A eg 73 Tightening commons 12 Motor cos phi power factor 62 RUN reis ash A 34 UNIS aiii 60 Moto
49. Fig 44 Direct on line start in combination with current limit at start If the regulator still is in active mode when the start time expires a Current Limit alarm is issued and the alarm action set in menu 236 is executed If the softstarter is not tripped for current limit time out the current regulator is deactivated and the switch on period is increased to full on with the slope of the 6 s ramp 335 Curr Limit Stp A Default off Range Off 150 500 of In mot 224 CG Drives amp Automation 01 5980 01r0 Functionality 79 NOTE Even though the current limit can be set as low as 150 of the nominal motor current value 224 this minimum value cannot be used generally If the current limit is set too low in relation to the application s requirements the motor will not be able to accelerate the load NOTE Check that the nominal motor current is set properly in menu 224 if the current limit functionality is used Start Time 336 The start time is defined as the time during which a start attempt is done This menu is directly accessible for all start methods in menu 331 except DOL However if combined with a current limit in menu 335 the start time function is also available for DOL 336 Start Time Stp IN 10s Default 10s Range 1 60s Torque Boost 337 In specific applications torque boost is required for the start The to
50. Mode Stp FN Delay Default Delay Off 0 Timer off Hals 1 Delays the activation of the output y signal according to menu 6313 Interval timer for output signal Alternate 2 according to menus 6314 and 6315 Prolongs the activation of the output onime S signal according to menu 6314 Timer 1 Delay 6313 This menu is only visible when Timer Mode 6312 is set to Delay When Timer 1 is triggered in menu 6311 the set value in this menu will delay the activation of the Timer 1 output signal TIQ 6313 Timerl Dly Stp IA 0 00 00 0 Default 0 00 00 0 hours minutes seconds Range 0 00 00 0 9 59 59 9 CG Drives amp Automation 01 5980 01r0 Functionality 109 Timer 1 T1 6314 This menu sets the on time for the Alternate and On time modes in menu 6312 only visible when one of these two modes has been selected If Alternate mode is selected and Timer 1 is triggered on signal set up in 6311 the timer will automatically keep switching from the on time 6314 Timer 1 T1 to the off time 6315 Timer 1 T2 Hence the output signal T1Q will alternate between active on and inactive off See Fig 62 If On time mode is selected in 6312 and Timer 1 is triggered in 6311 the timer will extend the activation on time of the output signal T1Q to the set value in 6314 Timer 1 T
51. PRY 8 8 put Short circuit proof and overload proof Analogue input 0 10 v 210 oe mA ang Impedance to terminal 15 0 VDC voltage signal 14 4 20 mA Factory setting is 4 20 mA 20 KO current signal 250 Q S1 jumper for U I selection 15 GND common O VDC signal ground 16 Digital input 3 Factory setting is Set Ctrl 1 0 4 V gt 0 8 27 V gt 1 Max 37 V for 10 sec 17 Digital input 4 Factory setting is Reset Impedance lt 3 3 VDC 4 7 KQ gt 3 3 VDC 3 6 kQ EA 24 VDC 5 Max current from 24 VDC 50 ma 18 Control signal supply 1 voltage to digital input Short circuit proof and overload proof Analogue output contact 19 Analogue output Factory setting is Current 0 10 V 2 10 V min load impedance 700 Q 0 20 mA and 4 20 mA max load impedance 500 Q a 24 VDC 5 Max current from 24 VDC 50 mA 20 Control signal supply 2 voltage to digital input Short circuit proof and overload proof CG Drives amp Automation 01 5980 01r0 Connections 15 Earthing plate with slots for tie wraps Shielded control signal cable Fig 11 Control cable feedthrough NOTE Shielded control cable must be used for option board connections 3 4 Wiring examples Always ensure the installation complies with the appropriate local regulations Minimum wiring for remote controlled start is shown in Fig 19 page 30 in which level control is applied menu 2
52. Process Source 321 Selection of the signal source for the process value used to start and stop of the motor The signal levels are given in menus 324 and 325 The process source can be set to act as a function of the process signal on analogue input via a communication bus or temperature input via a PT100 board The selection F x indicates that a process unit and scaling is needed set in menus 322 325 This makes it possible to e g use pressure sensors to measure flow etc If F AnIn is used Process Val must be selected in menu 511 321 Proc Source Stp FA Off Default Off Off 0 No process source selected Function of analogue input E g via PID SR y control 380 PT100 4 Temperature as process value F Bus 7 Function of communication value NOTE If F Bus is chosen in menu 321 see section 9 5 Process value page 124 Process Unit 322 Selection of the unit for the process value This menu is only visible ifa process source is selected in menu 321 Process Source 322 Proc Unit Stp Al Default off off 0 No unit selection 1 Percent C 2 Degrees Centigrade F 3 Degrees Fahrenheit bar 4 Pressure in bar Pa 5 Pressure in Pascal Nm 6 Torque Hz T Frequency rom 8 Revolutions per minute m3 h 9 Cubic metres per hour gal h 10 Gallons per hour ft h 11 Cubic feet per hour User 12 User defin
53. Ramp times not set correctly Readjust the start and or stop ramp time Motor too large or too small in relation to load Change to another motor size The monitor function does not work No or false alarm or pre alarm It is necessary to input nominal motor data for this function Set alarm levels not valid Input nominal motor data in menus 221 228 Adjust alarm levels and response delays The alarm can not be reset Check reset control in menu 216 The alarm can only be reset if the alarm condition is removed e g PTC PT100 or heatsink temperature alarm can only be reset after the temperature is decreased 136 Troubleshooting Diagnoses and Maintenance CG Drives amp Automation 01 5980 01r0 12 Options The available standard options are briefly described here Some of the options have their own instruction or installation manual For more information please contact your supplier 12 3 1 OBoard Part number Description NOTE Emotron TSA softstarters have as standard coated control boards and coated option boards 01 3876 51 1 0 option board 2 0 12 1 External control panel Part number Description 01 5406 00 Panel kit complete including panel These options may be useful for example for mounting control panel in a cabinet door Fig 84 Maximum distance between softstarter and external control panel is 3 metres
54. Reset Delay 621A The reset of the output signal for the Logic 1 function is delayed with the set value in this menu Compare to Fig 59 page 104 621A L1 Res Dly Stp Al 0 00 00 0 Default 0 00 00 0 hours minutes seconds Range 0 00 00 0 9 59 59 9 Logic 1 Timer Value 621B The actual timer value for logic 1 is viewed in this menu 621B L1 Tmr Val Stp IN 0 00 00 0 Default 0 00 00 0 hours minutes seconds Range 0 00 00 0 9 59 59 9 Logic 2 4 622 624 Refer to the descriptions for Logic 1 For default values see Menu List in Appendix 1 108 Functionality CG Drives amp Automation 01 5980 01r0 8 6 3 Timers 630 The timer function can be used as a delay timer as an interval timer with separate on and off times alternate mode or as a way to prolong a signal on time mode The selected trigger signal starts the timer function and the signal is converted according to the mode settings resulting in the timer output signal T1Q T4Q In Delay mode the activation of the timer output signal will be delayed in comparison to the trigger signal The timer output signal is activated high when the set delay time has expired See Fig 61 The timer output signal will however follow the trigger signal when this is deactivated low again Timer1 Trig T1Q ee ee SE ar Timer 1 Delay Fig 61 Delay timer mode In Alternate mode
55. Resolution 0 1 Nm Read only 714 Torque Stp Unit Resolution 1 Shaft power 715 716 This menu displays the actual shaft power expressed with different units in the two menus 715 Shaft Power Read only Stp W Unit W Resolution 1W 716 Shaft Power Read only Stp Unit Resolution 1 114 Functionality CG Drives amp Automation 01 5980 01r0 Electrical Power 717 This menu displays the actual electrical output power 717 El Power Read only Stp kW Unit kw Resolution 1W RMS Current 718 This menu displays the RMS value of the output current 718 RMS Current Read only Stp A Unit A Resolution 0 1 A Line Main Voltage 719 This menu displays the RMS value of the mains voltage 719 L Main Volt Read only Stp vV Unit V Resolution 1V Heatsink Temperature 71A This menu displays the actual measured heatsink temperature Read only 71A Heatsink Tmp Stp c Unit He Resolution 0 1 C PT100B1 123 71B This menu displays the actual PT 100 temperature for the first PT 100 option board B1 corresponding to input 1 2 and 3 See menu PT 100 Inputs 2323 page 64 PT100B2 123 71C This menu displays the actual PT100 temperature for the second PT 100 option board B2 corresponding to input 4 5 and 6 See menu PT100 Inputs 2
56. SI standards WARNING When the Units setting is changed this will also affect the factory settings of the motor 8 2 3 Motor Data 220 In this menu you enter the motor data to adapt the softstarter to the connected motor This will increase the control accuracy as well as different read outs and analogue output signals Some of the default motor data is derived from the setting in menu 21C Motor M1 is selected as default and motor data entered will be valid for motor M1 If you have more than one motor you need to select the correct motor in menu 212 before entering motor data 8 NOTE 1 The parameters for motor data cannot be changed during operation marked with a lock symbol here NOTE 2 The default factory settings are for a standard 4 pole motor according to the nominal current and power of the softstarter The softstarter will run even if motor data is not adapted to the actual motor but the performance will not be optimal NOTE 3 Parameter sets cannot be changed during operation if they are set for different motors NOTE 4 Motor Data in the different sets M1 to M4 can be reverted to default setting in menu 243 Default gt Set WARNING Enter the correct motor data to prevent dangerous situations and assure correct control 60 Functionality CG Drives amp Automation 01 5980 01r0 For more information about handling of motor data and paramete
57. WARNING The same external supply voltage level max 24 VDC or max 250 VAC must be used for all three output relays terminals 21 33 Do not mi x AC and DC voltage Make sure to use the same voltage level within this terminal section otherwise the softstarter may be damaged 144 Technical data CG Drives amp Automation 01 5980 01r0 Index A Comparator ENG1800 5 1 ENEE 6 Don tt toa 7 Analogu epes 101 Enable iii 34 51 94 Aggressive environment conditions 26 Digital cita estan Guarini 104 Energy consumption 119 Al aie at tores ect ae ee ang 45 Hysteresis type 101 102 104 ENTER key oe eseseeseteeteneenes 34 Action 45 49 63 65 84 89 90 Status sa seara retrata rara 118 Environmental conditions 142 o e hat pad A 50 Window type 101 102 104 EtherCAT wo cecceceseeseeeeees 123 ATE SCE Ennio at artes renda 48 87 Comparators e 100 EXOR operator 105 A ai g4 EE 24 Expression lite asadas 105 Eternal gange Eege h 88 CONNECTIONS vac sessssscisvevtovsescvocsasesisvers 11 External Control Panel 137 Indication inte 45 Mains supply metilo 29 F Load monitor ta an ads 84 Motor earth esessesessessesessesesseeees 29 Mans ion rali tea 89 Motor output een 29 eX DEE 20 E Mana Do deal pactos Ud 84 87 Safety earth EEN 29 an RAT Minimuma EEN 86 87 Virtual esla 99 Fieldbus RS po 73 123 137 Motor teta stands
58. amp Automation 01 5980 01r0 CG Drives amp Automation Sweden AB M rsaregatan 12 Box 222 25 SE 250 24 Helsingborg Sweden T 46 42 169900 F 46 42 16 99 49 www emotron com www cgglobal com e KW 1D o h E 9 q g 2 a 2 o O 19 A d g 2 5 E 2 3 E E Ka oO E a o CO
59. available signals and control functions can be used to create your own specific functions In these menus you find functions to enable eight internal connections of comparators timers SR flip flops counters and digital signals without occupying physical digital inputs or relay outputs CG Drives amp Automation 01 5980 01r0 Functionality 99 Example Start delay The motor will start in forward direction 10 seconds after Diglnl is activated high DigIn1 has a time delay of 10 s Menu Parameter Setting 521 Digln1 Timer 1 561 VIO 1 Dest Run FWD 562 VIO 1 Source T1Q 6311 Timer1 Trig Digln 1 6312 Timer1 Mode Delay 6313 Timer1 Delay 0 00 10 NOTE When a digital input and a virtual destination are set to the same function this function will act as an OR logic function Virtual Connection 1 Destination 561 With this function the destination of the virtual connection is established When a function can be controlled by several sources e g VIO Destination or Digital Input the function will be controlled in conformity with OR logic See section 8 5 2 page 94 Digital Input for descriptions of the different selections 561 VIO 1 Dest Stp FN Off Default off Same selections as in menu Digital Input 1 Selection 521 page 94 Virtual Connection 1 Source 562 With this function the source of the virtual connection
60. be entered 226 Motor Poles 8 Stp AMl 4 Default 4 Range 2 144 Nominal Motor Cos y 227 Set the nominal Motor cosphi power factor 227 Motor Coso 8 Stp EMI Cose Cos 0 86 Default see Note 2 page 60 Range 0 50 1 00 Motor Ventilation 228 Parameter for setting the type of motor ventilation This affects the characteristics of the I7t motor protection by lowering the actual overload current B 228 Motor Vent Sr Di Self Default Self None O Limited I2t overload curve Self Normal t overload curve Forced 2 Expanded I t overload curve When the motor has no cooling fan select None For a motor with a shaft mounted fan select Self When the motor has an external cooling fan select Forced 8 2 4 Motor protection 230 This function protects the motor against overload based on the standard IEC 60947 4 2 For general information on different alarm settings see section 7 3 page 45 Predictive tr function Based on how much the used thermal capacity It has increased during the most recent starts a prediction of the next start is made If there is no room for another start the start will be delayed until a start attempt results in a successful start WARNING If level control is used i e Level selection in menu 21A the motor will automatically continue to make a new start attempt
61. cause of the trip and what time it 8115 715 Shaft Power W occurred based on the actual time in 740 The display is showing actual trip message and alternates between showing Raio eo Shaft rower date and time when the trip occured 8117 717 El Power See a list of the possible trip messages in Table 32 page 117 8118 718 RMS Current When a trip occurs the operation and status menus 710 and 720 are copied to the trip message log There are nine trip 8119 719 L Main Volt message logs 810 890 When the tenth trip occurs the 811A TA Heatsink Temp oldest trip message will be erased 811B 71B PT100B1 123 NOTE After the reset of a trip the trip message will be 811C 71C PT100B2 123 removed and menu 100 will appear 811D 71D Current 11 811E 71E Current 12 8x0 Trip Message 811F 71F Current 13 Trp hh mm ss 811G 71G L12 Voltage Unit hh mm ss hours minutes seconds 811H 71H L13 Voltage Alternating YYYY MM DD year month day 8111 711 L23 Voltage Example 811 71 Phase Seq 811K 71K Used Thermal Cap The display is showing actual trip message and alternates between showing date and time when the trip occurred 830 Locked Rotor Trp 09 12 14 830 Locked Rotor Trp 2013 04 17 For fieldbus integer value of trip message see Table 32 page 117 menu 722 8 7 2 Status 720 8121 721 TSA Status 8122 723 Digital input status 8123 724 Relay status 8124 725 Analogue input status 8125 72
62. default The Max Pre Alarm Action 4122 is set to Warning and the Max Alarm Action 4111 is set to Hard Trip Then the Max Alarm Delay 4113 is set to 3 seconds and the Max Pre Alarm Delay 4123 to 0 seconds to get an instant warning when the load is increased Menu 4171 Max Alarm Margin is set to 10 and menu 4172 Max Pre Alarm Margin is set to 5 to indicate that an overload condition is close The motor is started and the actual shaft power is viewed to the left in menu 4175 Autoset Alarm When the process has stabilised this indicates that the normal load conditions take place at 60 of the nominal motor power 223 The autoset of the alarms is done by selecting Yes followed by pressing ENTER Autoset OK is displayed The motor is now fully protected with a maximum alarm set to 70 Normal Load Max Alarm Margin 60 10 and a pre alarm at 65 Normal Load Max Pre Alarm Margin 60 5 The Normal Load value is viewed in menu 4176 along with the actual shaft power value The following events are noted see Fig 35 A The load monitor function is activated when the set start delay time 30 seconds has expired B A maximum pre alarm condition is triggered and immediately results in a warning message Mon MaxPreAl as there is no alarm delay in this case C A maximum alarm condition is triggered D When the set maximum alarm delay time 3 seconds has passed t
63. exceeds this voltage level for a time period equal to the delay time set in menu 4313 a voltage unbalance alarm will occur and the action selected in menu 4311 will be executed 4312 UnbalLevel Stp FA 10 Default 10 of the nominal motor voltage 221 Range 2 25 of the nominal motor voltage 221 Voltage Unbalance Alarm Delay 4313 In this menu the response delay for the voltage unbalance alarm as set in 4311 and 4312 is selected 4313 VoltUnbDel Stp A 1s Default 1s Range 1 90s CG Drives amp Automation 01 5980 01r0 Functionality 89 Over Voltage Alarm 432 Under this menu the settings for an overvoltage alarm are selected Over Voltage Alarm Action 4321 In this menu the alarm action for an overvoltage alarm is selected The following alarm actions are available 4321 OverVolt AA Under Voltage Alarm 433 In this menu group the settings for an undervoltage alarm are selected Under Voltage Alarm Action 4331 In this menu the alarm action for the undervoltage alarm is selected The following alarm actions are available 4331 UnderVolt AA stp H No Action Stp fA No Action Default No Action Default No Action No Action O No Action O Hard Trip 1 Hard Trip 1 For a definition see Table 21 page 45 For a definition see Table 21 page 45 Soft Trip 3 Soft Trip 3 Warning 4 Warning 4
64. from below positive edge the The reference signal passes the Level LO comparator CA1 does not change output 1 value from below signal inside Window stays low band the comparator CA1 output is set high The reference signal passes the Level HI The reference signal passes the Level LO 2 value from below positive edge the value from above signal outside Window comparator CA1 output is set high 2 band the comparator CA1 is reset output is set low The reference signal passes the Level HI 3 value from above negative edge the comparator CA1 does not change output The reference signal passes the Level HI stays high 3 value from above signal inside Window j band the comparator CA1 output is set high The reference signal passes the Level LO 4 value from above negative edge the The reference signal passes the Level LO comparator CA1 is reset output is set low 4 value from above signal outside Window band the comparator CA1 is reset output is The reference signal passes the Level LO set low 5 value from below positive edge the E CA1 does not change output gt The reference signal passes the Level LO 5 value from below signal inside Window i band the comparator CA1 output is set high j The reference signal passes the Level HI 6 value from below positive edge the 1 comparator CA1 output is set high The reference signal passes the Level HI 6 value from below signal outside Window The reference signal
65. in menu 264 7 3 3 Alarm indications Depending on which alarm condition that is active the following indications are given Warning The Trip LED indicator red triangle on the control panel is flashing with 2 Hz see Table 15 page 34 e One of the status indications is displayed area D of the display e The accompanying warning message is displayed area F See a list of possible warning messages in Table 32 page 117 The most recent warning message is also displayed in menu 722 Warning The Warning relay or output is active if selected Hard Trip The softstarter is in a tripped condition and the motor coasts down to a standstill The Trip LED indicator red triangle is lit e The TRP status indication is displayed area D of the display e The accompanying trip message is displayed The Trip relay or output is active if selected Soft Trip The softstarter is in a tripped condition and the motor stops according to the set stop method for normal operation The softstarter is making a controlled stop During the stopping The accompanying trip message is displayed including an additional soft trip indicator S in area E of the display The Trip LED indicator red triangle is flashing with 2 Hz The Warning relay or output is active if selected After standstill is reached The Trip LED indicator red triangle is lit e The TRP status indica
66. level or it can be set indirectly by performing an Autoset 4122 MaxPreAlLev Run FA Pshatt 108 Default 108 Range O 200 of nominal motor power 223 Maximum Pre Alarm Delay 4123 When the load level exceeds the alarm level for a continuous period longer than the set Max Pre Alarm Delay time the selected Maximum Pre Alarm Action in menu 4121 is Minimum Pre Alarm Level 4132 The value of the minimum pre alarm level is given as a percentage of the nominal motor power 223 When the actual shaft power shown within brackets in the display falls to a value below this level the Minimum Pre Alarm Delay timer menu 4133 will start counting down When the delay time has elapsed an alarm will be generated according to the selected Minimum Pre Alarm Action in menu 4131 This menu can be set manually to the required alarm level or it can be set indirectly by performing an Autoset 4132 MinPreAlLev Run EN Pshart 92 Default 92 Range O 200 of nominal motor power 223 Example The Min Pre Alarm Level is set to 40 This means that when the shaft power falls to a value below 40 of the nominal motor power the alarm delay timer starts counting activated dow SE SC SE S Minimum Pre Alarm Delay 4133 t P a When the load level falls below the alarm level for a Default 05s con
67. level sensor with current signal 4 20 mA is connected to the analogue input See table below When the signal on Anln goes above 60 the CA output signal is activated high and when the signal on Anln goes below 40 the CA output signal is deactivated low again The output of CA1 is used as a virtual connection source that controls the virtual connection destination Run FWD Menu Function Setting 511 Anin Function Process value 512 Anln Setup 4 20 mA Fig 56 Analogue comparator type Window 6111 CA1 Value Anin 1 6112 CA1 Level HI 60 12 mA 20 mA x 100 6113 CA1 Level LO 40 8 mA 20 mA x 100 6114 CA1 Type Hysteresis 561 VIO1 Dest Run FWD 562 VIO 1 Source CA1 2151 Run Stp Ctrl Remote CG Drives amp Automation 01 5980 01r0 Functionality 101 Reference signal Anln mA t 20 CA1 Level HI CA1 Level LO Analogue Comparator 1 Level High 6112 Sets the analogue comparator high level with range according to the selected value in menu 6111 6112 CAL LevelHI Stp 30 0 Default 30 0 Es 1 1 W 0 1 A 0 1 V 1 0 1 C 1 kWh 1h se or 0 001 in 322 Example This example describes both for hysteresis and window type comparators the normal use of the constant level high and low The function is used for temperature control Follow the C
68. loop 1 Go to the menu you want to add to the loop 2 Press the Toggle key and keep it pressed while also press o ing the key 3 Check that a fi is shown to the right of the menu number area B CG Drives amp Automation 01 5980 01r0 Operation via the control panel 35 Delete a menu from the toggle loop 1 Goto the menu you want to delete using the toggle key 2 Press the Toggle key and keep it pressed while pressing the key 3 Check that there is no longer a fj symbol to the right of the menu number Delete all menus from the toggle loop 1 Press the Toggle key and keep it pressed while pressing the ESC key 2 Confirm with ENTER Default toggle loop Fig 24 shows the default toggle loop This loop contains the necessary menus that need to be set before starting the softstarter the first time Press the Toggle key to enter e g menu 211 then use the NEXT key to go to the submenus 212 and so forth and enter the parameters When you press the Toggle key again the next toggle menu is displayed Toggle loop To submenus Gz p Fig 24 Default toggle loop Indication of menus in toggle loop Menus included in the toggle loop are indicated with a in area B of the display 6 5 2 Loc Rem function With the Loc Rem function you can change between local and remote control of the softstarter from the control panel The Loc Rem function of the ke
69. many different applications with their challenges and a possible solution within the functions of the Emotron TSA Description and use of the table Application This column gives the various applications If the machine or application is not found in this list try to identify a similar machine or application If in doubt please contact your supplier Challenge This column describes possible challenges that are familiar for this kind of application Emotron TSA Solution This column gives the possible solution for the challenge using one of the functions of the Emotron TSA Menu Chapter This column guides you to the menu menu group or manual section where you find a description of the settings for the function For instance 331 Sqr Torq Ctr means set parameter 331 to Sqr Torg Ctr Example Hammer mill e Linear torque control menu 331 selection L n Torq Ctr will give the best results Torque boost to overcome high breakaway torque menu 337 submenus 3371 and 3372 Overload alarm function for jamming protection menu 410 Load Monitor with submenus for maximum alarm Stop function reverse current brake set Stop Method 341 to Brake and menu 344 to Rev Curr Brk It is possible to set a Reversed Current Braking Delay in menu 346 CG Drives amp Automation 01 5924 01r0 Application guidelines 23 Table 13
70. of the selected parameter set 211 Language 217 Key Functionality 218 Lock Code and 260 Serial Communication These parameter settings are global i e valid throughout the menu system NOTE Actual timer values are common for all sets When a set is changed the timer functionality will change according to the new set but the timer value will stay unchanged The menus for parameter set handling are found in section 8 2 5 page 66 starting with menu 240 The active parameter set is shown in the display to the lower left and can also be viewed in menu 721 TSA Status The detailed configuration for each set can be recorded in the menu list that can be found in the end of this manual alternatively be downloaded from the web at www cgglobal com or www emotron com 7 2 1 Control of parameter sets The parameter sets can be changed via the control panel via digital inputs or via serial communication This is decided in menu 241 Select Set All digital and virtual inputs can be configured to select parameter sets Fig 29 shows the way the parameter sets could be activated via digital input where for instance DigIn 3 523 is set to Set Ctrl 1 and DigIn 4 524 is set to Set Ctrl 2 Parameter Set A Run Stop B Jog Control D Braking Method Motor Protection Load Monitor 24V S E e E DI4 Set Ctrl2
71. page 45 Warning NOTE Menu 2151 or 2152 must be set to COM to activate the communication fault function supervision Communication Fault Time 2642 Defines the delay time for the trip warning 2642 ComFlt Time Stp Al 0 5s Default 0 5s Range 0 1 15 s 74 Functionality CG Drives amp Automation 01 5980 01r0 Ethernet 265 Settings for Ethernet module Modbus TCP Profinet IO For further information see the Fieldbus option manual NOTE The Ethernet module must be re booted to activate the below settings for example by toggling parameter 261 from fieldbus to RS232 and back Non initialised settings are indicated by a flashing display text IP Address 2651 2651 IP Address 0 0 0 O Default 0 0 0 0 MAC Address 2652 2652 MAC Address Stp FN 000000000000 Default A unique number for the Ethernet module Subnet Mask 2653 2653 Subnet Mask 0 0 0 O Default 0 0 0 0 Gateway 2654 2654 Gateway 0 O 0 O Default 0 0 0 0 DHCP 2655 2655 DHCP stp A Off Default Off Selection On Off Fieldbus Signals 266 Defines modbus mapping for additional process values For further information see the Fieldbus option manual FB Signal 1 16 2661 266G Used to create a block of parameters which are read written via communication 1 to 8
72. passes the Level HI band the comparator CA is reset output is 7 value from above negative edge the set low comparator CA1 does not change output Seen stays high The reference signal passes the Level HI 7 value from above signal inside Window The reference signal passes the Level LO band the comparator CA1 output is set high 8 value from above negative edge the comparator CA1 is reset output is set low The reference signal passes the Level LO 8 value from above signal outside Window set low CG Drives amp Automation 01 5980 01r0 Functionality 103 Analogue Comparator 1 Level Low 6113 Sets the analogue comparator low level with unit and range according to the selected value in menu 6111 Analogue Comparator 1 Reset Delay 6117 The reset of the output signal for the analogue comparator 1 is delayed with the set time in this menu See Fig 59 6113 CA1 LevelLO 6117 CA1 Res Dly Stp IN 20 0 Stp IN 0 00 00 0 Default 20 0 Default 0 00 00 0 hours minutes seconds Range See 6112 Range 0 00 00 0 9 59 59 9 Analogue Comparator 1 Type 6114 Selects the analogue comparator type i e hysteresis or window type See Fig 55 and Fig 56 page 101 6114 CA1 Type Analogue Comparator 1 Timer Value 6118 The actual timer value for analogue comparator 1 is viewed in this menu Stp A Hysteresis
73. the 3 phase mains supply voltage and control supply voltage e Select language menu 211 section 8 2 1 page 57 e Set the motor data menu 220 227 section 8 2 3 page 60 e Set real time clock menu 740 section 8 7 4 page 119 e Select keyboard control menu 2151 section 7 1 1 page 39 e Perform a test run from the control panel 5 2 Mains and motor connection Connect the softstarter between the 3 phase mains supply and the motor For the respective connections see the table below Dimension the mains and motor cables according to local regulations The cables must be able to carry the softstarter load current see Technical data on page 139 Table 14 Mains and motor connection L1 L2 L3 Mains supply 3 phase PE Protective earth T1 T2 T3 Motor output 3 phase Motor earth WARNING In order to work safely the mains earth must be connected to PE and the motor earth to al 5 2 1 Connect the mains cables The connection of the mains cables is shown in section 3 1 page 12 As standard the Emotron TSA softstarter has a built in RFI mains filter that complies with category C1 which is suited for environment B 5 2 2 Connect the motor cables The connection of the motor cables is shown in section 3 1 page 12 5 2 3 Connect the control supply voltage The control supply voltage is connected to the terminals marked N and L on the power board Fig 19
74. together It is possible e g in a pump station with two or more pumps to use one Emotron FDU AC drive on one pump and softstarters on each of the other pumps The flow of the pumps is then controlled by the pump control function in the Emotron FDU 4 4 4 Starting with counter clockwise reverse rotating loads It is possible to start a motor clockwise forward direction even if the load and motor are rotating counterclockwise reverse direction e g fans Depending on the speed and the load in the wrong direction Pleas note that the current can be quite high 4 4 5 Running motors connected in parallel When starting and running motors connected in parallel the total amount of the motor current must be equal or lower than the rating of the connected softstarter Please note that it is not possible to use the internal thermal motor protection or use other individual settings for each motor For instance the start ramp can only be set for an average starting ramp for all the connected motors This means that the start time may differ from motor to motor Similarly the load monitor alarm levels margins are applied for the average shaft power value of the connected motors In order to work around this kind of problem it could be necessary to deactivate a number of functions and alarms For motors connected in parallel torque control is not recommended because of the risk of oscillation between the motors Voltage contr
75. 0 50 50 63 63 Power loss at rated motor power 20 20 20 20 20 20 bypass mode W Average power loss if 10 starts hour W 22 24 22 26 23 27 Power consumption control supply VA 20 20 20 20 20 20 Dimensions H1 H2 x W x D mm 4 246 296 x 126 x 188 246 296 x 126 x 188 246 296 x 126 x 188 M ounting position Vertical Vertical Vertical Weight kg 5 5 5 5 5 5 Busbar connection mm 15 x 4 Cu M6 15 x 4 Cu M6 15 x 4 Cu M6 Cooling system Convection Convection Convection Protection class IP20 IP20 IP20 1 Normal duty Start current 3 x Lag Heavy duty Start current 5 x 1 soft 2 Fuse data for Semi conductor fuses see Table 41 3 H1 Height of enclosure H2 Total height Start time 15 s Size 1 or 30 s Size 2 6 10 starts hour Start time 15 s Size 1 or 30 s Size 2 6 10 starts hour CG Drives amp Automation 01 5980 01r0 Technical data 139 Table 39 Emotron TSA Size 2 model TSA52 070 TSA52 085 TSA52 100 Duty Normal Heavy Normal Heavy Normal Heavy Rated current In soft A 70 42 85 51 100 60 Motor size Py mot 400 V kW 37 22 45 22 55 30 Motor size Ph mot 460 V hp 50 30 60 40 75 40 Recommended load fuses A 80 80 80 80 100 100 Gre motor power 25 25 25 25 25 25 Average power loss if 10 starts hour W 33 44 37 51 38 55 Power consumption control supply VA 25 25 25 25 25 25 Dimensions H1 H2 x W
76. 01 as set in 322 EE CT CS ui 5 2Ala2alal2lalala CG Drives amp Automation 01 5980 01r0 153 COCINE CCT fame oe EE AA iros June iz ora rwv o0 0000 Joes um amar Jure o E e S Do o fes fumimoasfum DT 613 CA3 Setup Page 104 faia GEE em aim herons sms ae E E EC E CE E eras osa seroy ee Joe umiem je TT Doo ia Daach DI fis fomos im DEES SE ir um Dio o fis fumos um eeoa foo fase umam fume E SERGE AA 20 ui os June O Ee a EE fem EEN ew Ee EI im norocoasa Dio o usaras um rr ares by eeng Im Um um DP oo ui um Doo po fist fumimoas um enea foo 2608 ums um TT PD To o fumisim a DI fia fomos fim Sale Beate Im qu Jl Ur DDT Esses feiss ooires by ee Jm Dun O DP issu feiss corra eeng Jee fuman um A a Ju Ce Je D Jl vd ajalalalalala 154 CG Drives amp Automation 01 5980 01r0 A Modbus Inst Menu Parameters Default settings DemiceNe na ES Pasa fun tem fumo E o esa fomos foe Os umisim um Sie be Bs qm mo o Slam focos Jee fuman um E is oarespy om Je fuman fume SSS Do oo fis CT um a a ir im O feisi ooa ben Je Dr Jl Seilen eeng fasas Dach SSS a a a TAN IS DI Ts ui aos um iss opa mes oy een Ion Jumi i fume DI oo fimo 57 im 1 DI fia fomos um issue eeng Jee fuman um SSCS Doo fi ir um DI fi fomos fim INN o 198 A E T em reg exi iee UH ew qm mo i CSCS
77. 1 See Fig 63 6314 Timerl T1 Stp Al 0 00 00 0 Default 0 00 00 0 hours minutes seconds Range 0 00 00 0 9 59 59 9 Timer 1 T2 6315 In this menu the off time in the Alternate mode is set 6315 Timerl T2 Stp A 0 00 00 0 Default 0 00 00 0 hours minutes seconds Range 0 00 00 0 9 59 59 9 Timer 1 Value 6316 This menu shows the actual value of the timer 6316 Timerl Val Read onl i stp F 0 00 00 0 Default 0 00 00 0 hours minutes seconds Range 0 00 00 0 9 59 59 9 Timer 2 4 632 634 Refer to the descriptions for Timer 1 8 6 4 SR Flip flops 640 The flip flop function is a memory circuit that can be used to store data concerning state The output from a flip flop is dependent not only on its current input but also on its state at the moment this is received hence previous input status also matters The set reset flip flop circuit has two input signals SET and RESET that control the state of an output signal OUT The flip flop will only change output value when the input signal is at a positive edge When none of the input signals are active i e both are 0 the output signal is consequently inactive 0 In this case the flip flop will keep its current value When only one of the input signals is active 1 this will directly decide the status of the output signal Consequently if SET 1 active and RESET 0 inact
78. 1 0 5 0 n ng 0 0 5 1 Vin g Current 7 6 5 4 3 A ES 2 1 0 n ns 0 0 5 1 Tin 25 Torque N 1 5 0 5 o n ns 0 0 5 Ving Current 0 n ng 0 0 5 Fig 80 Sofi starting voltage ramp with current limit Once again the figure illustrates that the resulting performance depends on the combination of motor and load characteristics In the example above the motor torque is close to the load torque at about half speed This means for some other applications with different load characteristics for example a linear torque speed correlation this particular motor would need more than three times the nominal current to start The most sophisticated electronic softstarters use torque control which results in an almost constant acceleration during the start A low starting current is also achieved However this start method also uses reduced motor voltage and the quadratic correlation between current and torque described in the first section of this chapter is still valid This means the lowest possible starting current is determined by the combination of motor and load characteristics Fig 81 Soft starting torque control For optimal starting performance correct setting of the softstarter s parameters such as initial torque and end torque at start and start time is important The choice of parameters is explained in detail in section 8 3 3 page 78 10 3 Other star
79. 1 Control supply voltage connection PE N L power board WARNING For safety reasons the protective earth PE for the control supply must be connected 2 Earthing plate with slots for tie wraps for fixation and securing of control signal cables and option board cables This plate is connected to earth for earthing of shielded cables 3 S1 jumper for U I selection of analogue input 4 Option board ribbon cable connector 5 Communication module option 6 LED indicators visible through perforation Red and blue for communication signals Green indicating power on 7 Clock battery type CR 2032 3 V 8 Terminals for DigIn AnIn AnOut signals control board 9 Terminals for relay output signals and PTC connection power board 10 RS232 using 9 pin female D sub connector For temporary connection of a personal computer or connection of external control panel option Table9 Control signal cable dimension and stripping lenght Max Cable Recommended TSA size E dimension stripping length hla 2 1 2 Flexible 1 5 mm Era Solid 2 5 mm When using Ferrules suitable Ferrule length is 10 12 mm 14 Connections CG Drives amp Automation 01 5980 01r0 3 3 Control signal connections WARNING The same external supply voltage level max 24 VDC or max 250 VAC must be used for all three output relays terminals 21 33 Do not mix AC and DC voltage Make sure to use the s
80. 1A Example 1 Standard type of start wiring e Connect Protective Earth PE to earth bar marked PE and Motor earth the earth bar marked see chapter 3 1 page 12 Connect the softstarter between the 3 phase mains supply L1 L2 and L3 and the motor T1 T2 and T3 e Connect the control supply voltage 100 240 VAC to terminals N and L and the protective earth wire to terminal PE e Connect start and stop control to DigIn 1 and 2 terminals 11 and 12 with 24 V supplied from terminal 18 e Connect relay R1 terminals 21 and 22 to the contactor the softstarter then controls the mains contactor for factory configuration of R1 100 240V 10 L1 L2 L3 PE L N PE LA e LA e e e e l N 000 I WA CO Relay 1 O Jet L2 L3 PE 22 Relay 2 Relay 3 PTC R1 Digln1 Digln 2 11 12 O O 10V 13 O Anin 24V AnOut 24V 18 19 20 O O O GND 15 O Digln 3 16 O Digln 4 17 O 14 O Run FWD Stop E lt IF Fig 12 Standard wiring example NOTE If local regulations state that a mains contactor should be used relay R1 can control this Always use standard commercial slow blow fuses e g gl or gG types to protect the wiring and prevent short circuiting To protect the thyristors against short circuit currents ultrafast semiconductor fuses can be used if preferred The norm
81. 24 VDC 8A resistive 250 VAC 3A inductive See 33 NC and opening contact on 32 to 33 Warning 69 70 PTC Thermistor input Alarm level 2 4 kQ Switch back level 2 2 kQ Table 43 Control board connections Terminal Function Electrical characteristics 11 Digital input 1 Factory setting is Run FWD 0 4 V gt 0 8 27 V gt 1 Max 37 V for 10 sec 12 Digital input 2 Factory setting is Stop Impedance lt 3 3 VDC 4 7 kQ gt 3 3 VDC 3 6 kQ 13 Control signal supply voltage to analogue input 10 Dee Max A CADEIA 8 EE 8 8 put Short circuit proof and overload proof 14 Analogue input 0 10 V 2 10 V 0 20 mA and Impedance to terminal 15 O VDC voltage signal 4 20 mA digital input S1 jumper for U I selection 20 KQ current signal 250 Q 15 GND common O VDC signal ground 16 Digital input 3 Factory setting is Set Ctrl 1 0 4 V gt 0 8 27 V gt 1 Max 37 V for 10 sec 17 Digital input 4 Factory setting is Reset Impedance lt 3 3 VDC 4 7 KQO gt 3 3 VDC 3 6 kQ A a 24 VDC 5 Max current from 24 VDC 50 mA 18 Control signal supply 1 voltage to digital input Short circuit proof and overload proof Analogue output contact 19 Analogue output Factory setting is Current 0 10 V 2 10 V min load impedance 700 Q 0 20 mA and 4 20 mA max load impedance 500 Q Ee 24 VDC 5 Max current from 24 VDC 50 ma 20 Control signal supply 2 voltage to digital input Short circuit proof and overload proof
82. 323 page 64 71C PT100B2 123 Read only o Stp Cc Unit C Resolution 1 C Current 11 13 71D 71F This menu displays the actual output current in the three phases 71D Current I1 Read only Stp A Unit A Resolution 0 1 A L12 L13 and L23 Voltage 71G 711 This menu displays the actual voltage Read only 71G L12 Voltage Stp vV Unit V Resolution 1V Phase Sequence 71 This menu displays the phase sequence of the mains voltage Read only Ee EEN L123 Range L 0 Can not be detected L123 1 L321 2 Used Thermal Capacity 71K Read only 71B PT100B1 123 E This menu displays the used thermal capacity Stp C Unit C Read only 71K Used Th Cap Resolution 1 C Stp Unit Resolution 1 CG Drives amp Automation 01 5980 01r0 Functionality 115 8 7 2 Status 720 TSA Status 721 This menu indicates the overall status of the softstarter Read only 721 TSA Status Stp 1 222 333 Fig 66 Sofistarter status Display Example A Key This means A Parameter Set A is active ooo Operation is stopped Key Run Stop command source is both internal and external keyboard in this example bit 7 5 gt 1 Integer interpretation for A Key is 0 0 1 In bit format this is presented as Bit no 7 6 5 4 3 2 1 OLSB
83. 413 Fareset fo essa Jum Jum o jeaia Fasetoy oo0000 asss umim Jum TT Doo use fumicim fue po Doo o fue fumimoasfum jeais Fires by ooo mess Inte o DT o To ss e Jane Do o fuso DES 6416 Fatmrvel 000000 26 Jumiih fume O Do To o e Je Po SEENEN SECHER jeaai remode Reset passer om DI jeaza rast Jor mes E 6423 F2 reset Jor essa um Jum TT saza PSD 000000 Ier We Doo rss ar fun po Do o fes umas fum Po 6425 Fares Dy oo0000 asr umaim Jum OT Doo fs fumam fue po Doo o fuso E jeaz6 Fatmrvar onoooo most umain Jum o SEENEN E O fa ma aro June 158 CG Drives amp Automation 01 5980 01r0 de O PO eee CEA C e a C Ce Jor assi um um TT easajsseroy ren asss Jum um TT PD ooo ia a DI ui aos im os Fares by ee Jeer Jum um Do ooo ir um DI o iros a Selm een Jeer fuman fume SSS O it um O AA no in as June feaai Fa mode JE SD D mo 0 safras re Jum um SSCS lge fon Je um Jum TT feaaa Faserdy 000600 Je Um im um TT PD oo ui a DI ui aos im Oss Fares oy een asss Jum um O Do ooo ir um Dio o fi fumam os FaTmrvar een Jeer Dohier E IN III INSI LEAN E TAN INN Dio Do fi mimos June EREECHEN esr fom OS O SSS soma ow Je qm mo IN esferes fom Je Jum Jum festa cipal fo isso Uma um SSCS festa civeue eoo uma fume SSCS Slam el safen Jm BS qu mo IS fesza canes Jor iss Um um SSCS fosza ca tiovar Jo Je Di E safey faro ma Jun
84. 6 Analogue output status 8126 727 I O status option board B1 8127 728 I O status option board B2 8129 72A Analogue comparator 1 4 812A 72B Digital comparator 1 4 812B 72C Logic function status 1 4 812C 72D Timer status 1 4 812D 72E Flip flop status 1 4 812E 72F Counter status 1 2 120 Functionality CG Drives amp Automation 01 5980 01r0 Table 33 Stored trip message parameters 8 8 2 Same information as for menu 810 8 8 3 Trip menu Copied from Description 812F 72G Time to next start 8 7 3 Stored Values 730 8131 731 Run time 8132 732 Mains time Trip Messages 820 890 Reset Trip Log 8A0 This menu resets the content of the 10 trip memories 8A0 Reset Trip L Stp No Default No No 0 Yes 1 NOTE After the reset the setting goes automatically back to NO The message OK is displayed for 2 sec 8 9 System Data 900 Main menu for viewing all the softstarter system data 8 9 1 TSA Data 920 TSA Type 921 This menu shows the Emotron TSA type according to the type code The options are indicated on the product label of the softstarter See section 1 4 page 5 921 Stp TSA TSA52 016 Fig 72 Type number example Example TSA series suited for 525 V mains supply and a rated output current of 16 A NOTE If the control board is not configured then type shown is TSA52 XXX Software 922
85. 62 Control keys eine nmesemrisenairea 34 Flip flop Over voltage cate nt aca e 90 Control Panel MEMOTY Letianasniaiieives 67 Status iii 118 Die ie tie count 91 Control signals Flip flops E 110 rumm O 63 Edge controlled coccion 60 Function Keys as td 58 Pi Gd tn ee 64 A A 60 Function yaoi 34 EE EE 50 CCONV VOR eier seen eege 24 Fuses and power losses un 141 Te a O aa de SCONE rising as 9 10 G Under voltage ween 90 Counter clockwise rotary field 94 General electrical specifications 141 Ambient temperature below 0xC 26 Counters eessen 112 Analogue comparators memes 100 Status ias iii 118 H Analogue input ssssessssssessssseesseseees ent GUI gana ia 115 Hammer mill oooncnninnncninnnnenm 25 Configuration occiso 9 Duren ees ac 79 Heatsink temperature 115 EEN 117 p Hole pattern iniae a 10 Analogue opt 7 Ee y SS SE E e ZE 82 UD ope NIE cases eae ERR 105 Declaration of Conformity 6 WO Board acia ii 137 da E sick lection 21 Default iniciar 67 IO board status coccoconccncconconncinonnnn 118 pplications and functions selection S i E EE 52 69 Definitions A ca ade eh AS cometas de 7 2t protection Altos 48 86 87 Das Ee 63 SE Altitude cascades 143 Industrial Ethernet cc0ee 123 B Temperature merida 142 Input Background theory commons 127 Derating at higher temperature 142 LO pie ries its 107 108 Banda tte O A KEE E o ja o oa RR traten 127 Insulati
86. 730 The shown values are the actual values built up over time Values are stored at power down and updated again at power up Run Time 731 This menu displays the total time that the softstarter has been in the run mode 731 Run Time Read only Stp h mm ss Unit h mm ss hours minutes seconds Range 00 00 00 262143 59 59 Reset Run Time 7311 This menu resets the run time counter The stored information will be erased and a new registration period will start 7311 Reset RunTm Stp FN No Default No No 0 Yes 1 NOTE After reset the setting automatically reverts to No Mains time 732 This menu displays the total time that the softstarter has been connected to the mains supply This timer cannot be reset 732 Mains Time Read only Stp hh mm ss Unit hh mm ss hours minutes seconds Range 00 00 00 262143 59 59 Energy 733 This menu displays the total energy consumption since the last energy reset 7331 took place Read only 733 Energy Stp kWh Unit Wh shows Wh kWh MWh or GWh Range O Wh 999 999 GWh Reset Energy 7331 This menu resets the energy counter The stored information will be erased and a new registration period will start 7331 Rst Energy Stp FN No Default No Selection No Yes 8 7 4 Realtime clock settings 740 This menu group displays information on
87. 980 01r0 11 Troubleshooting Diagnoses and Maintenance For a description of the different alarm states see Alarm indications on page 45 11 1 Trip conditions causes and remedial action The table later on in this section must be seen as a basic aid to find the cause of a system failure and how to solve any problems that arise Although the softstarter gives a certain trip message it is not always easy to find the right cause of the failure Good knowledge of the complete system is therefore necessary Contact your supplier if you have any questions The softstarter is designed in such a way that it tries to avoid trips by limiting torque overvoltage etc Failures occurring during commissioning or shortly after commissioning are most likely to be caused by incorrect settings or even bad connections Failures or problems occurring after a reasonable period of failure free operation can be caused by changes in the system or in its environment e g wear Failures that occur regularly for no obvious reasons are generally caused by electromagnetic interference Be sure that the installation fulfils the demands for installation stipulated in the EMC directives See section 1 5 1 page 6 Sometimes the so called Trial and error method is a quicker way to determine the cause of the failure This can be done at any level from changing settings and functions to disconnecting single control cables or replacing entire units
88. A 0 Normal full current scale configuration of 0 20mA 1 the input that controls the full range for the input signal See Fig 50 The scale of the current controlled input that controls the full range for the input signal Can be defined by the advanced Anln Min and Anln Max menus User mA 2 Normal full voltage scale configuration of 0 10V 4 the input that controls the full range for the input signal See Fig 50 The voltage input has a fixed threshold 2 10V 5 Live Zero of 2 V and controls the full range for the input signal See Fig 51 The scale of the voltage controlled input sary 6 that controls the full range for the input signal Can be defined by the advanced Anln Min and Anln Max menus NOTE Always check the needed set up when the setting of S1 is changed selection will not adapt automatically 0 10V 0 20 mA gt 0 10V 20 mA Reference input signal Fig 50 Normal full scale configuration 100 eee 2 10V 4 20 mA 10V 20mA Reference input signal 0 2V 4mA Fig 51 2 10 V 4 20 mA Live Zero Analogue Input Advanced 513 NOTE The different menus will automatically be set to either mA or V based on the selection in Anin Setup 512 513 AnIn Advan Stp A Anin Min 5131 Parameter to set the minimum value of the external reference signal Only visible if 512 Use
89. A1 i See step by step explanation in Table 27 and Table 28 i tis Menu Function Setting Mode l 1 i RUN 1 A i l 325 Process Max Temperature 100 C 6111 CA1 Value PT100 1 C STOP i t s 6112 CA1 Level HI 50 C to 2 3 4 6113 CA1 Level LO 40 C Fig 57 6114 CA1 Type Window 561 VC1 Dest Timer 1 No Description 562 VC1 Source CA1 The reference signal passes the Level LO value from 1 below positive edge the comparator CA1 output stays Fig 58 low mode RUN 4 Max The reference signal passes the Level HI value from Temp 2 below positive edge the comparator CA1 output is set SS high mode RUN f mit cd S 50 C gt i CA1 Level HI The reference signal passes the Level HI value from GE SC TS Tiysteresis l 3 above negative edge the comparator CA1 output stays eet Ge band high mode RUN The reference signal passes the Level LO value from 4 above negative edge the comparator CA1 output STOP CA1 Level LO High Low High Low t Is 102 Functionality CG Drives amp Automation 01 5980 01r0 Table 27 Comments to Fig 58 regarding Hysteresis Table 28 Comments to Fig 58 regarding Window band the comparator CA1 is reset output is selection selection No Description Hysteresis No Description Window The reference signal passes the Level LO 1 value
90. Alarm Margin is set to 16 The actual shaft power at the moment of performing autoset is 45 The new maximum alarm will be set to 61 which means that the Maximum Alarm Delay timer in menu 4113 will start counting down when the actual shaft power exceeds 61 equal to 61 of the nominal motor power 223 When the alarm delay time has elapsed a maximum alarm could be generated depending on the setting in menu 4111 Max Alarm Action Maximum Pre Alarm Margin 4172 This autoset menu sets the band above the Normal Load 4176 that does not generate a maximum pre alarm The set Max Pre Alarm Margin percentage is added on to the percentage of the Normal Load The resulting percentage is where the maximum pre alarm level is put related to nominal motor power 223 4172 MaxPreAlMar Stp fA 8 Default 8 Range O of nominal motor power 223 4173 MinPreAlMar Stp Al 8 Default 8 Range O 100 of nominal motor power 223 Example The Min Pre Alarm Margin is set to 10 In the above example with a Normal Load of 45 this will result in a minimum pre alarm level at 35 of the nominal motor power The Minimum Pre Alarm Delay in menu 4133 will start as soon as the actual shaft power has dropped to below 35 of the nominal motor power 223 and the action set in menu 4131 Min Pre Alarm Action will be executed when the delay time has elapsed Minimum Alar
91. Application Functions List Application Challenge Emotron TSA Solution Menu Chapter 331 Sgr Torq Ctr Non linear ramps Square torque control for square loads 341 Sqr Torq Ctr Water hammer Square torque control 340 PUMP High current and peaks during starts Square torque control 330 Pump is going in wrong direction Phase reversal alarm 444 Dry running Use load monitor minimum alarm 410 High load due to dirt in pump Use load monitor maximum alarm 410 Mechanical shock for compressor motor and Linear torque control 330 transmissions Smali fis sahd law c rrentavailabie Linear torque control and current limit 331 Lin Torq Ctr at start 335 COMPRESSOR Screw compressor going in wrong direction Phase reversal alarm 444 Damaged compressor If liquid ammonia Use load monitor maximum alarm 410 enters the compressor screw Energy consumption due to compressor Use load monitor minimum alarm 410 running unloaded Torque control ensures smooth starts Mechanical shock for blower motor and dt mona iCal stress BLOWER transmissions High start current requires RREO 3 331 Lin Torq Ctr Start current is minimised by torque large cables and fuses controlled start Mechanical shocks for transmissions and Linear torque control 330 transported goods loading orunl ading convevors Slow speed and accurate position 350 8 8 y control 600 Conveyor jammed Us
92. As standard the Emotron TSA is equipped with coated boards in order to reduce the risk for corrosion For specification see section 13 3 page 142 4 4 11 IT earthing system Distribution systems may be equipped with an IT isolated earthing system which allows for one earth fault to occur without interruption of operation For use in these systems the Emotron TSA should be ordered with IT net option If you have a softstarter without IT net option the softstarter can be rebuilt Contact your local CG Drives amp Automation service partner 26 Application guidelines CG Drives amp Automation 01 5924 01r0 4 4 12 Earth fault relay It is possible to use an earth fault relay to protect motor and cables not for human safety To avoid undesired tripping due to filter capacitor charging currents choose a short time delayed residual current device rated for 30 mA leakage current 4 4 13 Other control voltage The power board must be connected to 100 240 VAC single phase control supply If this is not available a transformer must be used This transformer should be connected as in Fig 17 The transformer should be capable of supplying a power of 50 VA or more This item is not included in the range of CG options Transformer 100 240 VAC 380 500 VAC Sc ZE Ee 2 ER OO OOOO 50 Emotron TSA 7 Fig 17 Example of wiring when using transformer for 380 500 VAC
93. DC brake The speed is expressed as a percentage of the nominal motor speed 349 SwitchToDCB Stp FA 30 Default 30 Range O 100 of nominal motor speed 225 8 3 5 Jog 350 For setting of the jog function see section 7 1 3 page 40 The jog function can be activated by a start via the keyboard digital input Remote or communication option menu 2152 Jog Control page 58 For the Remote activation of the jog command the digital input must be set to Jog FWD and or Jog REV in menu 520 For information about the jog keys on the control panel see section 6 4 2 page 35 The Jog function will automatically generate a run command as long as the Jog function is active This is independent of Di the settings in menu 2151 Run Stop Control NOTE For the jog function to be available the rotation direction must be allowed in 219 n rpm Jog speed Jog command t s Fig 48 Jog command Jog Speed Forward 351 351 JogSpd FWD Stp Al 10 Default 10 Range Off 1 30 of nominal motor speed 225 Jog Speed Reverse 352 352 JogSpd REV Stp A 10 Default 10 Range Off 1 30 of nominal motor speed 225 CG Drives amp Automation 01 5980 01r0 Functionality 83 8 4 Load Monitor and Process Protection 400 8 4 1 Load Monitor 410 The functions in this menu enable th
94. Delay time the selected Minimum Alarm Action in menu 4141 is activated 4143 MinAlarmDel Stp KN 0 5s Default 0 5s Range 0 1 90s Start Delay 416 This setting can be used to e g override an alarm during the start up procedure The selected time will delay the activation of the load monitor alarms after the run command 416 Start Delay Stp A 10s Default 10s Range 1 999s Autoset 417 This is an alternative procedure to set up the alarm levels automatically which is based on the shaft power level at the moment of the Autoset NOTE If you have manually configured the alarm levels in menus 4112 4122 4132 and 4142 you do not need to do any settings in this menu or its sub menus When autoset is performed the actual value of the shaft power is stored to menu 4176 Normal Load The alarm levels are then recalculated as follows Table 24 Load monitor alarm levels Alarm Level Calculation 4176 Normal Load 4112 MaxAlarmLev 4171 MaxAlarmMar Overload 4176 Normal Load 4122 MaxPreAlLev 144721 MaxPreAlMar 4176 Normal Load 4132 MinPreAlLev 1473 MinPreAlMar Underload 4176 Normal Load 4142 MinAlarmLev 4174 MinAlarmMar NOTE Changing any alarm margin without performing Autoset will NOT affect the alarm levels After performing autoset you can view the actual alarm
95. E If more than one digital input is configured for the same external alarm signal activating high any of these inputs will generate an alarm if this is enabled in the corresponding menu for the external alarm External Alarm 1 Alarm Action 4211 The following alarm actions are available for external alarm 4211 ExtAlarmlAA Stp fA No Action Default Hard Trip No Action O Hard Trip 1 For a definition see Table 21 page 45 Soft Trip 3 Warning 4 External Alarm 2 Alarm Action 4212 4212 ExtAlarm2AA stp fA No Action Default Hard Trip No Action O HardTrip 1 For a definition see Table 21 page 45 Soft Trip 3 Warning 4 Rotor Locked 422 This alarm is used to avoid high motor current due to a mechanically locked rotor If the operation has been interrupted due to a locked rotor alarm the operation must be reset to restart the motor An autoreset command can be set for the locked rotor alarm See menu 2524 88 Functionality CG Drives amp Automation 01 5980 01r0 Locked Rotor Alarm Action 4221 4221 LockRot AA Stp No Action Default No Action No Action O Hard Trip 1 For a definition see Table 21 page 45 Soft Trip 3 Warning 4 Locked Rotor Time 4222 In this menu the time delay for detection of a locked rotor is set If the motor current exceeds its upper limit menu 4223 f
96. EI 7 Abbreviations and symbols 7 RS allge 7 MOUNTING indias 9 Installation in a cabinet 9 COOlIN E econo 9 Mechanical specifications and drawings 10 COMEN 11 Mains and motor connections 12 Board layout and COnnectors sssesessesererrerrerrsrens 14 Control signal Connections s ssseseseseesersreereerseens 15 Wiring examples a 16 Application guidelines ssscsccccere 21 Softstarter dimensioning according to AC 53b 21 Applications rating 21 The Application Functions List esseeseeeeneeeeeeneae 23 Special conditions ANEREN An 26 Small motor or low load seis 26 Ambient temperature below 0 C 26 Pump control with softstarter and AC drive togelher grina passe ata post rt pes sara a 26 Starting with counter clockwise reverse rotating Running motors connected in parallel 26 Running motors linked together 26 Heat dissipation in Cabinete ee 26 Insulation test on motor o 26 Operation above 1 000 mM 26 Aggressive environment conditions 26 IT earthing system 26 Earth fault relaying 27 Other control voltage nono 27 Getting started 29 Checklist n SEA 29 Mains and motor connection 29 Connect the mains cables ANEN 29 Connect the motor cables 29 Connect the con
97. ET key on the control panel is activated by selecting one of the keyboard alternatives enabled as default If controlled by digital input 520 or by virtual I O 560 this is set by selecting Reset signal An output signal can be set by a relay 550 to ManRst Trip which is defined as any active trip condition that needs a manual reset WARNING If the Run input signal is active high and level controlled start mode is selected the motor will start at the reset command Note that level control is not fulfilling the Machine directive Autoreset For several alarms it is possible to automatically generate a reset command to overcome the fault condition Providing that all other conditions are normal the softstarter will then attempt to restart the operation Only when the failure keeps on coming back recurring at a defined number of times and therefore cannot be solved by the softstarter will the unit give an alarm to inform the operator that attention is required The autoreset configuration can be done in menu group 250 Autoreset with submenus for Motor Protection Autoreset 252 Communication Error Autoreset 253 Process Protection Autoreset 254 Softstarter Protection Autoreset 255 and Mains Failure Autoreset 256 To enable the Autoreset function Reset is selected on one of 520 Digital Inputs The reset input must be constantly activated To activate the autorese
98. In this menu the delay time for an autoreset of a current limit alarm is set As a current limit fault condition cannot be detected in stopped state the delay time starts counting immediately after the alarm action has been executed When the delay time has elapsed the alarm will be reset and a restart attempt will automatically be made 2525 Curr Lim Stp FA Off Default Off Off 0 Off 1 3600 1 3600 1 3 600 s Communication Error autoreset 253 The delay counter starts counting as soon as communication is reestablished 253 ComErrArst Stp FA Off Default off Off 0 Off 1 3600 1 3600 1 3 600 s NOTE An autoreset is delayed by the remaining ramp time Process Protection Autoreset 254 When the load monitor function is used menu group 410 the following settings for autoreset can be done Load Monitor Max Alarm autoreset 2541 The delay counter starts counting immediately 2541 MaxAlarm Stp FA Off Default off off 0 Off 1 3600 1 3600 1 3 600 s 70 Functionality CG Drives amp Automation 01 5980 01r0 Load Monitor Max Pre Alarm autoreset 2542 The delay counter starts counting immediately External Alarm 2 autoreset 254A The delay counter starts counting as soon as the relevant external alarm input is inactive 254A Ext Alarm 2 2542 MaxPAlarm Stp FA Off Defaul
99. Long 1 ESE arinevab o 550 fume fue 0 520 Demos 0 A sor ema rn In que mo TT 522 n2 sop pa um um TT 525 owns Suomi usas Jum Jum TT 5 Duna bet Ju Um um SSS li Jor psa um um SSCS sor ermen om isso um um SSCS leng om usos um Jum TT 520 520gni Jor isso um um SSCS leng Jee D um SSCS clm Jee Jum JI 530 moms O e st monre er JD D mo TT 532 MOuSewp _ 420ma fass Jum Jum fC 533 anoutawven SSS 5331 anoutwin fama us ung iO fent 5332 anout max 2m D st Jill AnOutVaMin E 43545 aa ee Cpo a E E fo asses Nits EE 550 Jrs o 0 er s1 Rat operation n fom jum TT 552 e2 Jor n fun ime iP CCS ss reas tip en Dr CAN SSCS sa errea for Jan Dr que O ss ere Jo Jaen Dr CTN S 556 erres for en Dr fume SSCS Selena fon Jeu fume fume P SSCS Relay Advan 152 CG Drives amp Automation 01 5980 01r0 DeviceNet no format format eo fumo 0 ir vow oe jor s un Jorn 566 vo 8 Source for fasz unt um o 500 uogicatimers a RR ei Comparators o o TT alas CUTE 1W 0 1Hz 0 1A 0 1V 1rpm 1 0 1 C dE ea E ERR eee EB to EE ma a E E es ext sero oom James me Jum reen ees Je Junin Jum COC Joes fumam ue DP oo ZO CE um INN no 1 see 1W 0 1Hz 0 1A 0 1V 1rpm 1 0 1 C ari aaa SE ia Notes 1kwh 1h or 0 001 as set in 322 6123 CA2 LevelLO a 43413 Long Esse Notes 1W 0 1Hz 0 1A 0 1V 1rpm 1 0 1 C 1kWh 1h or 0 0
100. Min Value Process Value Process Min 324 Process Max 325 Shaft Power 0 Motor Power 223 Current OA Motor Current 224 El Power OW Motor Power 223 Output Voltage O V Motor Voltage 221 Torque 0 250 Anin Anln Function Min Anln Function Max 96 Functionality CG Drives amp Automation 01 5980 01r0 Example Set the AnOut function for Motor Current to 0 A set AnOut Function Min 5334 to User defined and AnOut Function Value Min 5335 0 0 This results in an analogue output signal from 0 4 mA to 20mA from 0 A to the value for Motor Current that is set in menu 224 This principle is valid for all Min to Max settings AnOut Function Value Minimum 5335 With AnOutVaMin you define a user defined value for the signal Only visible when User defined is selected in menu 5334 5335 AnOutVaMin 8 5 4 Relays 550 Submenu with all the settings for the relay outputs The relay mode selection makes it possible to establish a fail safe relay operation by using the normal closed contact to function as the normal open contact NOTE Additional relays will become available when I O option boards are connected Maximum 2 boards with 3 relays each Relay 1 551 Sets the function for the relay output 1 551 Relay 1 Stp KN Stp FA 0 000 Default 0 000 Range 10 000 000 10 000 000
101. O gt D Emotron TSA Softstarter Instruction manual English Software version 1 0X Emotron TSA softstarter INSTRUCTION MANUAL ENGLISH Software version 1 0X Document number 01 5980 01 Edition RO Date of release 13 05 2013 O Copyright CG Drives amp Automation Sweden AB 2013 CG Drives amp Automation Sweden AB retains the right to change specifications and illustrations in the text without prior notification The contents of this document may not be copied without the explicit permission of CG Drives amp Automation Sweden AB Safety instructions Congratulations for choosing a product from CG Drives amp Automation Before you begin with the installation commissioning or powering up the unit for the first time it is very important that you carefully study this instruction manual The following symbols can appear in this manual or on the product itself Always read these first before continuing NOTE Additional information as an aid to avoid problems CAUTION Failure to follow these instructions can result in malfunction or damage to the softstarter WARNING Failure to follow these instructions can result in serious injury to the user in addition to serious damage to the softstarter Safety The softstarter should be installed in a cabinet or in an electrical control room The device must be installed by trained personnel e Disconnect all power sources before servicing
102. Perform this the same way as for Remote I O operation on page 30 Follow the steps 1 10 Then press until you return to menu 100 Preferred View Select manual control 1 Press to display menu 200 Main Setup 2 Press to display menu 210 Operation 3 Press until you get to menu 215 Action Control then press E to go to submenu 2151 Run Stop Control 4 Select Int keyb using the key E Press to confirm Test run from control panel Press the key on the control panel to run the motor forward NOTE When the internal bypass contactor is activated three distinct clicks are heard Test run with external start command Now the installation is finished press the external start button contact closed to start the motor To stop the motor press the 9 key on the control panel RESET NOTE When the internal bypass contactor is activated three distinct clicks are heard NOTE For selection of other stop method than the default Coast see section 7 1 2 page 35 and menu 341 To stop the motor disconnect the start command contact open NOTE For selection of other stop method than the default Coast see section 7 1 2 page 35 and menu 341 CG Drives amp Automation 01 5980 01r0 Getting started 31 32 Getting started CG Drives amp Automation 01 5980 01r0 6 Operation via the control panel The co
103. Requires that menu 2151 Com Run Stop Control is set to Modbus DeviceNet Function Instance number 42901 Reset Run active together with either 42902 Run FWD or Run REV to perform start 42903 Run FWD 42904 Run REV 124 Serial communication CG Drives amp Automation 0 5980 01r0 9 6 Description of the Elnt formats A parameter with Eint format can be represented in two different formats F either as a 15 bit unsigned integer format F 0 or a Emotron floating point format F 1 The most significant bit B15 indicates the format used See detailed description below All parameters written to a register may be rounded to the number of significant digits used in the internal system The matrix below describes the contents of the 16 bit word for the two different Elnt formats B15 B14 B13 B12 B11 B10 B9 B8 B7 B6 B5 B4 B3 B2 Bl BO F 1 e3 ei el e0 ml0 m9 m8 m7 m6 m5 m4 m3 m2 ml m0 F 0 B14 B13 B12 B11 B10 B9 B8 B7 B6 BS B4 B3 B2 Bl BO If the format bit B15 is 0 then all bits may be treated as a standard unsigned integer UInt If the format bit is 1 then the number is interpreted as Value M 104E where M m10 m0 represents a two complement signed mantissa and E e3 e0 represents a two complement signed exponent NOTE Parameters with Elnt format may return values both as 15 bit unsigned integer F 0 or in Emotron floating point F 1 Value Binary 8
104. Run REV Fig 15 Connection for start forward reverse The configuration of the relays depends on the requirements of the application For applications which do not use the reverse current brake functionality the following settings may be used Menu Description Setting 551 Relay 1 terminals 21 and 22 Operation FWD 552 Relay 2 terminals 23 and 24 Operation REV The functionality for both applications with or without reverse current functionality is as follows If Digln 1 RunFWD is closed and DigIn 3 RunREV is open the mains contactor K1 for running in forward direction will be activated by relay R1 and the motor will start in forward direction Digln 1 RunFWD can be opened during forward running without any effect If DigIn 2 Stop is opened the stop settings in menu group 340 CG Drives amp Automation 01 5980 01r0 Connections 19 will be performed When the stop is finished the mains contactor for running forward K1 will be deactivated by relay R1 If both Digln 1 Stop and DigIn 3 RunREV are closed while DigIn 1 RunFWD is open the mains contactor for running in reverse direction K2 will be activated by relay R2 and the motor will start in reverse direction DigIn 3 RunREV can be opened during reverse running without any effect If DigIn 2 Stop is opened a stop according to the stop settings in menu group 340 will be
105. RunSignalFWD has been deactivated the relay configured for RevCurrBrake will not be activated until after the set time delay 346 RevC Brk Dly Stp FA 0 5s Default 0 5 Ss Range O 120s Dynamic Vector Brake Strength 347 The strength of the dynamic vector brake is set in this menu The value is expressed as a percentage of the available vector braking power dependent on motor characteristics RevCurrBrk 1 Reverse Current Brake NOTE If several softstarters are supplied from the same power line and the braking functionality is used the softstarters should be connected with different phase sequences i e L1 L2 L3 on the first unit L2 L3 L1 on the next and so on In addition to the braking methods described here there is also a spinbrake functionality available as a digital input See Spinbrake page 39 344 Brake Method 347 Brk Strength Stp Al DynVectBrk stp FA 75 Default 0 DynVectBrk Default 75 DynVectBrk O Dynamic Vector Brake Range O 100 DC Braking Strength 348 The strength of the DC brake is set here the value expressed as a percentage of the maximum available DC braking power 348 DCB Strength Stp FA 15 Default 15 Range O 100 82 Functionality CG Drives amp Automation 01 5980 01r0 Switch to DC Brake 349 Here you set the speed at which the braking method should be switched to
106. Stop Setting 340 Stopping is always initiated by triggering of the thyristors to take over the current when the bypass contact is opened When the current is correctly flowing through the thyristors the selected stop method is executed Stop Method 341 The available stop methods are Linear or Square Torque Control A torque controlled stop could be used when a sudden stop of the motor could harm the application The motor torque is controlled according to either a linear or a square ramp from the actual torque value to the set End Torque at Stop in menu 342 See Fig 46 below 80 Functionality CG Drives amp Automation 01 5980 01r0 Torque 1 Linear 2 Square Nominal torque Th I l End torque i Stop time Time Fig 46 Torque control at stop Voltage Control If a linear voltage ramp is preferred for the stop voltage control is selected First the voltage is reduced to the set Step Down Voltage at Stop 343 Then a linear ramp will be followed until the minimum allowed switch on period is reached the duration decided by Stop Time 345 See Fig 47 page 81 Coast The voltage is switched off and the motor is allowed to coast to a stop Brake Braking may be used in applications where the motor needs to be stopped quickly When this selection is made the braking method Dynamic Vector Brake or Reverse Current Brake can be activated i
107. YYY MM DD CG Drives amp Automation 01 5980 01r0 Functionality 113 Clock 1 Weekday 6615 Weekdays when the clock function is active Having entered the editing mode select or unselect the desired weekdays with the cursor using the PREV and NEXT keys on the control panel Confirm by pressing ENTER Exit the editing mode and the activated weekdays will be viewed in the menu display The deactivated weekdays are replaced by a dash mark e g MT WTF 6615 ClklWeekday Stp A MTWTFSS Default MTWTFSS all activated Monday Tuesday Wednesday Thursday Range Friday Saturday Sunday NOTE Please make sure that the correct time and date settings are done for the real time clock menu group 740 Clock Clock 2 662 Refer to the description for Clock 1 661 8 7 Operation Status 700 Menu with parameters for viewing all actual operational data such as speed torque power etc 8 7 1 Operation values 710 Process Value 711 This menu displays the actual value of the active process signal i e the same value as in menu 310 711 Process Val Read only Stp Unit Depends on selected process unit 322 Speed 1 rpm 4 digits Resolution Other units 3 digits Torque 713 714 This menu displays the actual shaft torque expressed with different units in the two menus Read only 713 Torque Stp O ONm Unit Nm
108. actions All the alarms and pre alarms can be independently configured to affect operation by applying an alarm action e g a trip or a warning See section 7 3 1 page 45 The alarm or pre alarm status is available on one of the programmable relays if so configured see menu 550 for more information The alarm actions for both the autoset alarm margins and the manually set alarm levels are configured in menu 4111 4121 4131 and 4141 The corresponding Alarm Delays which will affect the alarm response time are set in menu 4113 4123 4133 and 4143 Load monitor during start up To avoid faulty alarms due to initial over or underload situations at start a Start Delay time can be applied for the load monitor See menu 416 page 86 NOTE The load monitor alarms are disabled during jogging braking and stop ramp Example 1 Configuring alarm levels manually Assume that the load monitor is intended to be blocked during the start up procedure A start delay of 30 seconds is therefore selected in menu 416 in order to allow the process to settle before the load monitoring becomes active In this case a pump must be protected from both overload and underload e g cavitation conditions but no pre alarms are needed The alarm action for the pre alarms 4121 and 4131 is therefore set to No action Furthermore the alarm actions for Max alarm 4111 and Min alarm 4141 are set to
109. actor for heavy loads Application Challenge Emotron TSA Solution Menu Chapter High inertia Linear torque control gives linear 330 acceleration and low starting current Heavy load when starting with material Torque boost 337 Kees EE if a diesel powered generator is Current limit at start 335 Wrong material in crusher Use load monitor maximum alarm 410 341 Brake Vibrations during stop Dynamic vector brake without contactor 344 Dyn Vect Brk 347 High inertia load with high demands on Linear torque ramp gives linear 330 torque and current control acceleration and low starting current Dynamic vector brake without contactor AS 344 Dyn Vect Brk Need to stop quickly Tor medio as 347 BANDSAW Reverse current brake with external 341 Brake contactor for heavy loads 344 RevCurr Brk High speed lines Conveyor speed set from bandsaw 530 shaft power analogue output Worn out saw blade Use load monitor maximum alarm 410 Broken coupling saw blade or belt Use load monitor minimum alarm 410 High inertia load Linear torque control gives linear 330 acceleration and low starting current Too high load or unbalanced centrifuge Use load monitor maximum alarm 410 Dynamic vector brake without contactor Sale CENTRIFUGE for medium loads 24 Dyn Vect Brk Controlled stop 347 Reverse current brake with external 341 Brake contactor for heavy loads 344 Rev Curr Brk Need to open centrifuge in a certain position Braking down to Slow Speed angithen 340 350 positio
110. actual time and date The menus are quickly accessed from the default toggle loop See Fig 24 page 36 Time 741 Actual time displayed as HH MM SS Adjustable setting 741 Time Stp 00 00 00 Unit hh mm ss hours minutes seconds Date 742 Actual date displayed as YYYY MM DD Adjustable setting 742 Date Stp Unit YYYY MM DD year month day Weekday 743 Display of actual weekday 743 Weekday Read onl 4 Stp Monday CG Drives amp Automation 01 5980 01r0 Functionality 119 8 8 View Trip Log 800 Main menu with parameters for viewing all the logged trip data In total the softstarter saves the last 9 trips in the trip memory The trip memory refreshes on the FIFO principle First In First Out Every trip in the memory is logged on the time of the Run Time 731 counter At every trip the actual values of several parameters are stored and available for troubleshooting See section 7 3 1 page 45 for an explanation of the different Trip message 8111 8133 The information from the status menus are copied to the trip message log when a trip occurs Table 27 Stored trip message parameters Trip menu Copied from Description 8 7 1 Operation values 710 alarm types 8111 711 Process Value 8113 713 Torque Nm 8 8 1 Trip Message Log 810 8114 714 Torque The trip log displays the
111. al Motor Power 223 240 132 1489 lene 1180 The range for P mor depends on the nominal softstarter 300 160 1 490 250 1 790 power P of It must be set within the range 25 400 of 360 200 1 490 300 1 790 the softstarter powerP soft See nominal data for CG motors in Table 23 450 250 1 490 350 1 790 560 315 1 490 450 1 790 630 355 1 490 500 1 790 710 400 1 490 600 1 790 820 450 1 490 700 1 790 1 000 560 1 490 800 1 790 1 400 800 1 490 1 000 1 790 1 800 1 000 1 490 1 500 1 790 CG Drives amp Automation 01 5980 01r0 Functionality 61 Nominal Motor Current 224 Set the nominal motor current If parallel motors set the value as sum of motors current 224 Motor Curr 8 Stp FAM1 S In_mot A Ih mot In soft see Note 2 page 60 and Default Table 23 above 25 200 X In soft A depending on Range Emotron TSA model NOTE The default settings are for a standard 4 pole motor according to the nominal power of the softstarter In soft is the nominal softstarter current value according to Table 23 Nominal Motor Speed 225 Set the nominal full load asynchronous motor speed 225 Motor Speed 8 Stp EMI nn mot rpm Default Do mot see Note 2 page 60 and Table 23 Range 500 3 600 rpm Resolution 1 rpm 4 sign digits Nominal Motor Poles 226 This menu appears only when the nominal speed of the motor is lt 500 rpm Here the actual number of poles can
112. al guarantee is valid even if ultrafast semiconductor fuses are not used All signal inputs and outputs are galvanically insulated from the mains supply 16 Connections CG Drives amp Automation 01 5980 01r0 Example 2 Extended wiring Fig 13 gives a wiring example with the following functions e Analogue start stop via process value see description on page 91 Analogue output see section 8 5 3 page 95 Motor PTC input see description of Thermal motor protection in section 8 2 4 page 62 Menu Description Setting 521 Digital input 1 terminal 11 Run FWD default 522 Digital input 2 terminal 12 Stop default 524 Digital input 4 terminal 17 Reset default Analogue input function 511 terminal 14 Process Val default Analogue output function 531 terminal 19 Current default PTC alarm action terminal 69 p 2331 and 70 Hard trip Soft trip 100 240V 10 N PE Relay 3 10V 13 O Digln 1 11 O Digln 2 12 O 2 Digln3 Digln4 16 17 O O 24 V 18 O AnOut 19 O 24V 20 O Run FWD Stop Process value Measuring Fig 13 Extended wiring example using digital and analogue inputs and outputs CG Drives amp Automation 01 5980 01r0 Connections 17 Example 3 Reverse current brake wiring operation the first contac
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114. ame type of information For example parameter 43123 in parameter set A contains the same type of information as 44123 in parameter set B CG Drives amp Automation 01 5980 01r0 Serial communication 123 9 3 Motor data Communication information for the different motors 9 5 Process value It is also possible to send the Process value feedback signal over a bus e g from a process or temperature sensor Modbus profibus EtherCAT Set menu Process Source 321 to F Bus Use following DeviceNet Profinet IO Motor Slot f index parameter data for the process value Instance index Index hex number Default 0 168 200 M1 43041 to 19425 Abel 4be8 Range 16384 to 16384 43048 168 207 19432 Corresponding to 100 to 100 process value 44041 172 180 20425 M2 44048 to 20432 4fc9 4fdO 174 187 Communication information 45041 EEN 21425 z M3 to 53b1 53b8 Modbus DeviceNet Instance number 42906 45048 21432 176 167 Profibus slot Index 168 65 Profinet IO index 19290 46041 189 140 22425 p M4 to 5799 57a0 Fieldbus format Int 46048 22432 180 147 Modbus format Int M1 contains parameters 43041 to 43048 The M2 M3 and M contain the same type of information For example parameter 43043 in motor M1 contains the same type of information as 44043 in M2 9 4 Start and stop commands Set start and stop commands via serial communication
115. ame voltage level within this terminal section otherwise the softstarter may be damaged Fig 10 Control board and power board connections Table 10 Power board connections Terminal Function Electrical characteristics PE Protective Earth Protective grounding N L Control supply voltage 100 240 VAC 10 21 No oe del t Factory setting is o 1 pole closing contact NO 250 VAC 8 A or 24 VDC 8 A 22 C E HESE closing contacton terminals 21 to resistive 250 VAC 3 A inductive See Warning 23 NO Programmable relay 2 Factory setting is Off with 1 pole closing contact NO 250 VAC 8 A or 24 VDC 8 A 24 C indication by closing contact on terminals 23 to 24 resistive 250 VAC 3 A inductive See Warning 31 NO ing is Trip SL ne oO e Mo Stags Tee changeover conta NO NO 250 AC shor 24 i y 8 VDC 8A resistive 250 VAC 3A inductive See Warning 33 NC and opening contact on 32 to 33 69 70 PTC Thermistor input Alarm level 2 4 KQ Switch back level 2 2 KQ Table 11 Control board connections Terminal Function Electrical characteristics 11 Digital input 1 Factory setting is Run FWD 0 4 V gt 0 8 27 V gt 1 Max 37 V for 10 sec 12 Digital input 2 Factory setting is Stop Impedance lt 3 3 VDC 4 7 kQ gt 3 3 VDC 3 6 kQ 13 Control signal supply voltage to analogue input t10 VDC 5 Max Current iOm 19 VDC TU MA 8
116. amp Optl 2 2332 PTC Inputs Stp Bu PB PTC Default PB PTC PB PTC 0 On board power board PTC used for protection PB PTC 1 PB PTC and PTC input on option B1 used amp Opt1 for protection PB PTC 2 PB PTC and PTC input on options B1 and amp Opt1 2 B2 used for protection Start Limitation 234 The start limitation is used to protect the sofistarter by limiting the numbers of starts per hour or securing a minimum time delay between starts A start limitation alarm is reset when the alarm condition is gone and a new start signal is given The actual time left until the next start is allowed is shown in the status menu 72G Time to Next Start Start Limitation Alarm Action 2341 Start limitation is enabled in this menu by choosing a proper alarm action used as thermal protection for the softstarter Autoreset is available for all start limitation alarms menu 2552 2341 StartLim AA Stp FA No action Default No action No action 0 Hard Trip 1 Fora definition see Table 21 page 45 Warning 4 64 Functionality CG Drives amp Automation 01 5980 01r0 Number of starts per hour 2342 In this menu the allowed number of starts per hour can be set If this number is exceeded an alarm occurs and the action chosen in menu 2341 is performed The alarm is active until the hour has expired and a new start is allowed The first hour is counted di
117. aracter in the menu number 3rd level The third character in the menu number 4th level The fourth character in the menu number This structure is consequently independent of the number of menus per level For instance a menu can have two selectable menus Jog 350 or it can have 12 selectable menus Motor Data 220 NOTE If there are more than 9 menus within one level the numbering continues with alphabetic characters A B C PREV 200 700 Main Menu nam z a PREV NEXT NEXT m E 4x0 dl l Kei PREV 3rd level 411 YJLN3 be NEXT Fig 25 Menu structure 6 6 1 The main menu This section gives you a short description of the functions in the main menu For a more detailed description of the contents under each main menu see chapter 8 page 55 100 Preferred View Displayed at power up this menu shows two actual process signals electrical power and current as default The menu is programmable for many other read outs 200 Main Setup Here you find the main settings to get the softstarter operable the motor data settings being the most important The menu group also contains protection and communication settings 300 Process This menu contains settings more relevant to the application such as start stop and jog mode settings 400 Process Protection To protect the machine and process from damage a number of protection settings such as the load monitor can be configured un
118. are the same as for Relay 1 551 Default settings are Off NOTE Visible only if optional board is detected or if any input output is activated Relay Advanced 55D This function makes it possible to ensure that the relay will be closed also when the softstarter is malfunctioning or powered down 55D Relay Advan Stp Al Relay 1 Mode 55D1 55D1 Relayl Mode Stp FN N O Default N O The normal open contact of the relay will N O o be activated when the function is active NOTE The definitions described here are valid for the The normally closed contact of the relay active output condition will act as a normal open contact The N C 1 contact will be opened when function is not active and closed when function is This menu sets the function for the relay output 2 active 552 Relay 2 Stp A Operation Default Off Same selection as in menu Relay 1 551 Selection election page 97 Relay 3 553 This menu sets the function for the relay output 3 553 Relay 3 Stp FA Off Default Trip Same selection as in menu Relay 1 551 lection Selection page 97 Relay Modes 55D2 to 55DC Same function as for Relay 1 Mode 55D1 Default settings are N O 8 5 5 Virtual I Os 560 Virtual connections are used for wireless connection of a digital output function to a digital input function The
119. ase be longer than the set start time Voltage ramp with current limit The voltage period is increased linearly during the set start time from a value corresponding to the minimum allowed voltage period plus the value set as start voltage to full mains voltage The current limit regulator is activated when the current is reaching the chosen value in 335 to be switched off when full output voltage is reached or the start time has expired 336 Should the current fall to a value below the set current limit the current controller will be deactivated and the voltage ramp reactivated When the current controller is deactivated below current limit the voltage ramp slope will increase above the original slope to accomplish a start within the set start time See Fig 43 Current Limit period Start time Fig 43 Voltage ramp with current limit period DOL with current limit This could also be called pure current limit start The switch on period is increased linearly during the set start time from a value corresponding to the minimum allowed switch on period plus the value set as start voltage to full voltage The ramp time for the voltage ramp is 6 seconds The current limit regulator is activated when the current is approaching the chosen value to be switched off when full output voltage is reached or the start time has expired 336 Current limit FLC LG tis Start time ls
120. bient temperature of Check the functionality of the built in fans The fans must Guevien Hard tri the softstarter switch on automatically if the heatsink temperature gets p p Insufficient cooling too high At power up the fans are briefly switched on Too high current Check softstarter and motor rating Blocked or stuffed fans Clean fans No action Ss E Hard trip Too high 3 phase mains supply SHEER thes phase WEE E Over voltage 4321 Remove the interference cause or use other main supply Soft trip voltage f a lines Warning No action Hard trip Single phase loss Check fuses and mains supply ES Soft trip 233 Fuse broken Check that terminal screws are tightened Warning No action Phase rev Hard trip 4341 icones phase SEA UCR cento Swap L2 and L3 input phases Soft trip phase main supply Warning Motor PT100 elements exceeds Check on mechanical overload on the motor or the No action 7 e Hard tri maximum level machinery bearings gearboxes chains belts etc PT100 Soft tri H 2321 Check the motor cooling system E NOTE Only valid if option board Self cooled motor at low speed too high load Set alarm 8 PTC PT100 is used action to Off If motor overheated wait for it to cool down Check on No action mechanical overload on the motor or the machinery Hard trip Motor thermistor PTC exceeds bearings gearboxes chains belts etc PTC o 2331 J Soft trip maximum level Check the motor cooling system Wa
121. ceed A non running motor or an unfinished start delay generates a Failed message 4175 AutoSet Alrm Run EX Pshart No Default No No 0 Yes ab Normal Load 4176 This menu is read only If the menu shows Off the Autoset settings are deactivated and the manually set alarm levels in menu 4112 4122 4132 and 4142 are applied If the menu shows a number this is equal to the load level shaft power at the time of performing the autoset The alarm levels have also been calculated based on this level the autoset margins 4176 Normal Load Read only Stp IA Off Default Off Rang Off Autoset deactivated ge O 200 of nominal motor power 223 Example The menu shows 78 This means that an autoset command was last performed at a load level of 78 of the nominal motor power 223 and the corresponding alarm levels have been setup according to the margins set in menus 4171 4174 8 4 2 Process protection 420 External Alarm 421 The external alarm functionality is used to generate an alarm depending on the state of an external alarm signal Each of the digital inputs can be configured for Ext Alarm 1 or Ext Alarm 2 If any digital input is configured for an external alarm signal activating high this input will cause an external alarm to occur if the external alarm is enabled in the corresponding menu 4211 or 4212 NOT
122. clean the dust filters of the cabinets regularly Check external wiring connections and control signals Tighten terminal screws if necessary For more information on maintenance please contact your CG Drives amp Automation service partner Precautions to take with a connected motor If work must be carried out on a connected motor or on the driven machine the mains voltage must always first be disconnected from the softstarter CG Drives amp Automation 01 5980 01r0 Troubleshooting Diagnoses and Maintenance 133 11 3 Troubleshooting list Table 36 Alarms with possible causes and remedies Trip warning Alarm Action message S SC Possible cause Remedy SN Menu and indicator Bypass closed Hard trip Bypass contactor is permanently Service needed Contact your local Emotron TSA supplier shortcircuited Bypass open Hard trip Bypass contactor orits controls Service needed Contact your local Emotron TSA supplier malfunctioning No action Check cables and connection of the serial communication Hard trip Error on serial communication Check all settings with regard to the communication Comm error i 2641 f A Soft trip Fieldbus option Restart the equipment including the softstarter For Warning details see Fieldbus Manual Control panel is locked for Unlock control panel in menu 218 Enter unlock code CP locked a S settings 291 CtrlSupFaul
123. d B2 Note that the supervised inputs must be selected in a sequence without gaps i e if you like to have only one input supervised selection PT100 1 you must use input 1 on board one B1 If you wish to have four PT100 inputs supervised selection PT 100 1 4 you must use input 1 3 on option board one corresponding to input 1 3 and the first input of board 2 corresponding to input 4 All PT100 inputs are displayed in operation menu 71B PT 100 B1 1 2 3 and 71C PT100 B2 1 2 3 regardless of the menu selection 2323 PT100Inputs Stp FAM1 PT100 1 3 Default PT100 1 3 PT100 1 0 Channel 1 used for PT100 protection PT100 1 2 1 Channel 1 2 used for PT100 protection PT100 1 3 2 Channel 1 3 used for PT100 protection PT100 1 4 3 Channel 1 4 used for PT100 protection PT100 1 5 4 Channel 1 5 used for PT100 protection PT100 1 6 5 Channel 1 6 used for PT100 protection PTC Alarm 233 The PTC alarm menus are always shown as there is an integrated PTC input on the power board PB PTC as standard PTC Alarm Action 2331 2331 PTC AA StpfWM1 No action Default No action No action O Hard Trip 1 For a definition see Table 21 page 45 Soft Trip 3 Warning 4 PTC Inputs 2332 Two additional PTC option inputs can be handled The settings are therefore PB PTC for the on board PTC PB PTC8Opt1 and PB PTC
124. d Write 2633 Select Read Write to control the softstarter over a fieldbus network For further information see the Fieldbus option manual 2633 Read Write Stp Al RW Default RW RW 0 Read amp Write Read 1 Read only Valid for process data Select Read read only for logging process without writing process data Select RW in normal cases to control inverter Additional Process Values 2634 Define the number of additional process values sent in cyclic messages 2634 AddPrValues Stp FA 0 Default 0 Range 0 8 Communication Fault 264 Main menu for communication fault warning settings For further details please see the Fieldbus option manual Communication Fault Alarm Action 2641 Selects action if a communication fault is detected The following applies If RS232 485 is selected the softstarter will execute the selected action if there is no communication for the time set in parameter 2642 ComFlt Time If Fieldbus is selected the softstarter will execute the selected action if 1 the internal communication between the control board and fieldbus option is lost for the time set in menu 2642 ComFlt Time 2 a serious network error has occurred 2641 ComFlt AA Stp A No action Default No action No action No communication supervision 0 Hard Trip 1 Soft Trip 3 4 For a definition see Table 21
125. d in menu 218 6 5 Toggle and Loc Rem Key This key has two functions toggling between selected menus and switching between local and remote operation control If the key is programmed for Toggle default in menu 2171 it will only have the toggle function If the key is programmed for Loc Rem in menu 2171 it can only be used to switch between local and remote control of the softstarter If the key is programmed for Combined in menu 2171 the key can be used for both functions in the following manner Press one second to use the toggle function e Press and hold the toggle key for more than five seconds to enable the choice between Local or Remote function see section Loc Rem function on page 36 When editing parameter values the toggle key can be used to change the sign of the value 6 5 1 Toggle function Using the toggle function makes it possible to easily step through selected menus in a loop The toggle loop can contain a maximum of ten menus As default the toggle loop contains the menus needed for Getting Started You can also use the toggle loop to create a quick menu for the parameters that are most important to your specific application NOTE Do not keep the Toggle key pressed for more than five seconds without pressing either the or ESC key as this may activate the Loc Rem function of this key instead See menu 2171 Add a menu to the toggle
126. der this menu 500 Lie and Virtual Connections Settings for inputs and outputs are entered here 600 Logical Functions and Timers A set of freely programmable blocks are available in this section 700 View Operation and Status In this menu you can view operational data power torque current etc and get status information about e g inputs and outputs 800 View Trip Log Here you can see the last 9 trips in the trip memory 900 System Data This menu contains information on softstarter model and software version CG Drives amp Automation 01 5980 01r0 Operation via the control panel 37 38 Operation via the control panel CG Drives amp Automation 01 5980 01r0 7 Main features This chapter contains descriptions of the main features of the Emotron TSA softstarter 7 1 Setting Start Stop and Run functions 7 1 1 Start and stop control The start and stop control signals can be given from the control panel using the control keys via remote control i e programmable I O or via serial communication The start commands from the respective control sources depend on which motor rotation direction that has been selected for the motor see Fig 26 Follow the procedure in Fig 27 for setting of the start and stop signals g A FWD right a REV left Fig 26 Rotation direction Select Rotation Direction Default FWD Select Run Stop Control 2151 External control Control pan
127. digits Table 22 Default O e 3 Digit Resolution O 0 01 9 99 0 01 10 0 99 9 0 1 1 Parameter cannot be changed during operation 100 999 1 2 Parameter only for viewing 1 000 9 990 10 3 Menu information as displayed on control panel l 10 000 99 900 100 For explanation of display text and symbols see section 6 1 page 33 4 Factory setting of parameter also showed on display 5 Available settings for the menu listed selections 6 Communication integer value for the selection For use with communication bus interface only if selection type parameters 7 Description of selection alternative or range min max 8 1 Preferred View 100 This menu is displayed at every power up During operation the menu 100 will automatically be displayed when the keyboard is not operated for 5 minutes The automatic return function will be switched off when the Toggle and STOP RESET keys are pressed simultaneously for 5 seconds As default the electrical power and current values are displayed example in the figure below Fig 39 Default initial display 100 OkW SC 0 0A Menu 100 Preferred View displays the settings made in menu 110 Ist Line and 120 2nd Line value Example 2175 REV key Stp E off Default off Off 0 REV key deactivated REV 1 REV key activated Menu 2175 REV key has two available selections Off and
128. ding to instructions in this instruction manual Duration of warranty is as per contract Faults that arise due to faulty installation or operation are not covered by the warranty 1 4 Type code number Fig 1 gives an example of the type code numbering used for the Emotron TSA softstarter This identification will be required for type specific information when mounting and installing The code number is located on the product label on the right side of the unit when viewed from the front TSA52 016 23 N N N A A Position number 1 2 3 4 5 6 7 8 9 10 11 e installation engineers e maintenance engineers Fig 1 Type code number e operators S Table 1 e service engineers Position Configuration Description Motors 1 Type TSA The softstarter is suitable for use with E Aue SS Rs 52 Max 525 V mains asynchronous motors Contact your supplier for details ain supply voltag 69 Max 690 V mains 016 16A 1 1 Delivery and unpacking 3 Current rating ao E 3 1K8 1800 A Check for any visible signs of damage Inform your supplier immediately of any damage found Do not install the 4 Control voltage 23 230 V softstarter if damaged N No option Check that all items are present and that the type number is 5 Option position 1 P PTC PT100 cortect I 1 O board N No option A 6 Option position 2 P PTC PT100 1 2 Using of the instruction I 1 0 board manual N No
129. ding to the AC 53b norm a softstarter can have several current ratings The Applications Rating List in Table 12 page 22 shows which rating that is recommended for the application The Emotron T SA model is selected depending on its model size and on the duty cycle of the application AC 53b ratings for Emotron TSA size 1 e AC 53b 3 0 15 345 normal duty with bypass e AC 53b 5 0 15 345 heavy duty with bypass AC 53b ratings for Emotron TSA size 2 6 e AC 53b 3 0 30 330 normal duty with bypass e AC 53b 5 0 30 330 heavy duty with bypass NOTE To select softstarter size it is important to ensure that not only FLC Full Load Current is checked but also the starting requirements Example In the previous example in which the Emotron TSA 52 056 is used for a pump application the recommended rating is normal duty according to the Applications Rating List CG Drives amp Automation 01 5924 01r0 Application guidelines 21 Applications Rating List This list gives the typical rating type for the machine or application divided in normal duty and heavy duty applications both with bypass If the machine or application is not in this list try to identify a similar machine or application Ifin doubt please contact your Emotron TSA supplier Example rated differently according to the Applications Rating List Due to high starting current a roller mill is considered a heavy duty application which p
130. during ramping or full speed operation or during jogging slow speed at stop Exceptions are the external alarm and the communications alarm which are always active For most alarms different alarm actions can be chosen Common for all alarm actions is that the alarm condition is shown in the display via serial communication and at any relay programmed for the appropriate alarm functionality An alarm condition is indicated on the LEDs as appropriate see Chapter 6 2 page 34 The alarm actions are Table 21 Alarm actions No action The alarm condition is ignored A warning message is shown Operation continues as usual if no further measures are taken Warning Softstarter is tripped Operation is interrupted and restart is inhibited if the softstarter is inactive Activation will not be allowed if the softstarter is in operation The motor coasts to a stop Hard Trip Softstarter is tripped A stop is executed in the same way as for normal operation i e using the same stop method Restart is inhibited Soft Trip 7 3 2 Alarm settings To protect the motor use the alarm settings and operation limitations in menu 230 Motor Protection with submenus See section 8 2 4 page 62 For protection of process mains and other external devices you find load monitor functions and alarm settings in menu group 400 See section 8 3 page 76 Alarm actions for communication faults are set
131. e following picture a typical starting characteristic is shown The x axis represents the speed relative to the synchronous speed while the y axis shows the torque and the current respectively with those quantities normalised to their nominal values The dashed line indicates the nominal values Torque T Tn 2 5 2 1 5 A 0 5 0 n ns 0 0 5 1 Fig 74 Typical torque characteristics for the DOL start Current Vl 8 0 n ns 0 0 5 1 Fig 75 Typical current characteristics for the DOL start For many industrial applications direct on line starting is not convenient as the supply in this case has to be dimensioned to deliver the unnecessarily high starting current Moreover most applications do not gain anything from the high starting torque Instead there is a risk of mechanical wear or even damage because of the resulting jerk at speedup The acceleration torque is determined by the difference between motor and load torque The figure below shows some typical torque characteristics for constant speed applications For comparative purposes the induction motors torque characteristic is added to the diagram Wn 25 Torque 2 1 5 0 5 0 n ns 0 0 5 1 Fig 76 Typical load torque characteristics CG Drives amp Automation 01 5980 01r0 Softstarter theory 127 Typical applications with constant load are elevators cranes and conveyors Linear load characteristics are typical for cal
132. e the value 20 equals 4 mA I O Board Status B1 B2 727 728 This menu indicates the status for the additional I O on option boards 1 B1 and 2 B2 Read only 728 IO StatusB2 Stp RE 000 DI100 Fig 71 1 0 board status example Analogue comparator status 1 4 72A This menu indicates the active analogue comparators CAI CA4 72A CA1 4 Stp 0000 Digital comparator status 1 4 72B This menu indicates the active digital comparators CD1 CD4 72B CD1 4 Stp 0000 Logic function status 1 4 72C This menu indicates the active logic outputs L1 L4 72C Logic 1 4 Stp 0000 Read only Read only Read only Timer status 1 4 72D This menu indicates the active timers T1Q T4Q 72D Timer 1 4 Read only Stp 0000 SR Flip flop status 1 4 72E This menu indicates the active flip flops F1 F4 72E FlipFlopl 4 Read only Stp 0000 Counter status 1 2 72F This menu indicates the active counters CTR1 CTR2 Read only 72F Counter 1 2 Stp Time to next start 72G This menu indicates the time left to the next allowed start if at least one of the choices under menu 235 Start Limitation is activated i e number of starts per hour or minimum time between starts 72G TtoNxtStart Read only f Stp OMin 118 Functionality CG Drives amp Automation 01 5980 01r0 8 7 3 Stored Values
133. e control panel Copy the settings from the internal control board of TSA unit 1 to the control panel menu 244 Switch off power for both TSA units and dismount the front covers with built in control panel Disconnect the control panel cable connections from the control board sockets Connect the control panel cable of front cover 1 to TSA unit 2 using the socket for the internal control panel Switch on TSA unit 2 and load the desired settings from control panel 1 to the internal control board of TSA unit 2 using menu 245 244 WARNING Switch off all power connections before opening the front cover CG Drives amp Automation 01 5980 01r0 Main features 43 Copy via external control panel Ifan external control panel is available option page 137 there is no need to dismount the front covers when copying and loading data between two or more Emotron TSA units see Fig 31 The external control panel is usually mounted on the cabinet door NOTE Loading from and copying to the softstarter is only possible when the softstarter is in stop mode 1 Using the external control panel copy the settings from the softstarter control board to the external control panel menu 244 2 Detach the external control panel from the cabinet of the source softstarter and attach it to the cabinet with the target softstarter 3 Using the external control panel load the settings from thi
134. e cooling fins to prevent damage to the thyristors free circulation of air WARNING Never operate the softstarter with the front cover removed The Emotron TSA softstarters are delivered as enclosed versions with front access cover The units have top and bottom entry for cables etc see Chapter 3 page 11 2 1 1 Cooling Table5 Minimum free space TSA Minimum free space mm Frame size above below atside L 5 100 100 0 Above Cabinet roof to softstarter or softstarter to softstarter CG Drives amp Automation 01 5980 01r0 Mounting 2 1 2 Mechanical specifications and drawings Table 6 Connection TSA Dimensions Mounting position Weight puspals and PE Cooling Protection Frame size H1 H2 xW x D mm Vertical kg pressnut screw system class Horizontal g dimension mm 1 5 5 Convection 246 296 x 126 x 188 Vertical 15 x 4 Cu M6 M5 IP20 2 5 7 Fan H1 Height of enclosure H2 Total height M ou nti n g SC h emes Emotron TSA Size 1 2 o pl ef Sells 1 a NY 7 S IN Ss N 11 H1 H2 N S NI N S Y ia z j e ca eo L T 126 L 188 Fig 2 Dimensions for Emotron TSA frame size 1 and 2 N N Ww f D LA 00 e e e 00 l Y F
135. e load monitor maximum alarm 410 CONVEYOR Sean Conveyor belt or chain is off but the motor is S ae Use load monitor minimum alarm 410 still running Starting after screw conveyor has stopped JOG in reverse direction and then 71 p 39 due to overload starting in forward SS Conveyor blocked when starting Locked rotor function 422 High starting current in end of ramps Square torque control for square load 330 Slivering belts characteristics Catching the motor and stopping FAN Fan is going in wrong direction when starting smoothly to zero speed and then 331 Sqr Torq Ctr starting in right direction Belt or coupling broken Au Use load monitor minimum alarm 410 Blocked filter or closed damper High inertia load with high demands on Linear torque control gives linear 330 torque and current control acceleration and low starting current Dynamic vector brake without contactor GTE Brk Need to stop quickly both for emergency and for medium loads 347 y roduction efficiency reasons PLANER g y Reverse current brake with external 341 Brake contactor for heavy loads 344 Rev Curr Brk High speed lines Conveyor speed set from planer shaft 530 power analogue output Worn out tool Use load monitor maximum alarm 410 Broken coupling Use load monitor minimum alarm 410 24 Application guidelines CG Drives amp Automation 01 5924 01r0 Table 13 Application Functions List cont
136. e of shield NOTE For the Emotron TSA softstarter it is not mandatory to use shielded cables to fulfil the EMC regulations Section 1 5 page 6 The only exception is when connecting option board cables for which there is an earthing plate that serves as an attachment for the shielded control cables see Fig 9 on page 14 NOTE For UL approval use 75 C copper wire only CG Drives amp Automation 01 5980 01r0 Connections 11 3 1 Mains and motor connections Fig 5 Mains and motor connections for Emotron TSA Size 1 2 Emotron TSA frame size 1 2 1 3 phase mains supply connection L1 L2 L3 2 Protective earth PE connection for mains supply 3 Motor power supply connection T1 T2 T3 4 Motor earth L connection WARNING Leakage current may occur from the thyristors when a 3 phase mains supply is connected Full voltage can be detected if no motor is connected Table 7 Tightening torque for bolts Nm 100 240 VAC L1L2L3PE LN PE Tightening torque for bolts Nm TSA Frame size Motor or mains PE cable cables 1 8 5 2 8 5 Fig 6 Mains motor and control supply voltage connection 12 Connections CG Drives amp Automation 01 5980 01r0 W3 W2 WI o el Fig 2 Busbar distances Emotron TSA Size 1 and 2 Table 8 Busbar distances TSA Dist W1 Dist W2 Dist W3 frame size m
137. e softstarter to be used as a load monitor See explanation in section 7 3 4 page 46 The alarm actions for alarms and pre alarms can be chosen independently of each other in menus 4111 4121 4131 and 4141 The corresponding alarm delays are set in menus 4113 4123 4133 and 4143 Manual settings of the Alarm Levels are done in menus 4112 4122 4132 and 4142 e Settings of the Autoset Alarm Margins are done in menus 4171 4174 and the Autoset Alarm is activated in menu 4175 when running at what is considered to be the Normal Load All alarm levels are calculated and expressed as a percentage that refers to the nominal motor power menu 223 i e 100 equals the nominal motor power It is possible to choose whether the load monitor shall be active or not during start using the start delay function in menu 416 See detailed explanation of the load monitor function including examples in section 7 3 4 page 46 For more information regarding alarms trips and warning See section 8 2 4 page 62 Maximum Alarm 411 These menus contain the settings for the load monitor maximum alarm Maximum Alarm Action 4111 Setting of the wanted alarm behaviour when a Maximum Alarm has been detected 4111 MaxAlarmAct stp fA No Action Default No Action No Action O Hard Trip 1 For a definition see Table 21 page 45 Soft Trip 3 Warning 4
138. ect on the characteristics designed for your device The manufacturer is not liable for damage arising as a result of using non original parts and accessories Emergency You can switch the device off at any time with the mains switch connected before the softstarter both motor and control supply voltage must be switched off General warnings WARNING Make sure that all safety measures have been taken before starting the motor in order to avoid personal injury WARNING Never operate the softstarter with the front cover removed WARNING Make sure that all safety measures have been taken before switching on the power supply gt Alarms Never disregard an alarm Always check and remedy the cause of an alarm CG Drives amp Automation 01 5980 01r0 CG Drives amp Automation 01 5980 01r0 Contents 1 1 1 2 1 3 1 4 1 5 1 5 1 1 6 1 6 1 1 7 1 7 1 1 7 2 21 2 1 1 2 1 2 3 1 3 2 3 3 3 4 41 4 2 4 3 44 44 1 44 2 4 4 3 4 4 4 4 4 5 4 4 6 4 4 7 4 4 8 4 4 9 4 4 10 44 11 4 4 12 4 4 13 5 1 5 2 5 2 1 5 2 2 5 2 3 Safety instructions seser 1 Cote dia nai anni 3 Introducton 5 Delivery and unpacking 5 Using of the instruction manual 5 Warranty iia 5 Type code nu Deriva ads 5 E A contin A 6 Product standard for EMC 6 Dismantling and scrapping 6 Disposal of old electrical and electronic et ein 6
139. ed unit User defined Unit 323 This menu is only displayed if User is selected in menu 322 The function enables the user to define a unit with six symbols Use the PREV and NEXT keys to move the cursor to the required position Then use the and keys to scroll down the character list Confirm the character by moving the cursor to the next position by pressing the NEXT key E No for serial Character No for serial comm comm Space 0 m 58 0 9 1 10 n 59 A 11 60 B 12 O 61 C 13 62 D 14 63 E 15 p 64 F 16 q 65 G 17 r 66 H 18 s 67 19 t 68 J 20 u 69 K 21 70 L 22 v 71 M 23 w 72 N 24 x 73 76 Functionality CG Drives amp Automation 01 5980 01r0 Se y 74 i 26 z 75 Q 27 4 76 28 77 2 23 78 1 30 79 y 80 l 32 81 y 33 82 e 34 83 x 35 amp 84 Y 36 85 37 86 38 87 A 39 38 0 40 89 a 41 30 42 E 91 b 43 92 S 44 93 E 45 94 E 46 95 47 lt 96 48 97 49 gt 98 d cae 99 8 51 100 32 101 no E 102 f 54 S 103 j 55 2 104 56 3 105 57 Example Create a user unit named kPa 1 When in the menu 323 press to show the cursor 2 Press El to move the cursor to the rightmost position 3 Press until the character a is displayed 4
140. eeseeeseeeees 41 66 SR Flip flops munici 110 Wiring examples eceseecseeeeeeeees 16 Configuration cecccessecseeesseeens 42 Standards eiii idas 6 144 e EE 43 Start limitation comme 64 Gg SET NgS dE 67 Start right left functionality 19 Default values cccccccccccceccceeeee 67 Start Settings EE 78 Dieli is 95 Starting with counter clockwise Load settings ssss s siisssssesiriiir1ss 68 rotating loads eseese 26 Moor re ann 42 60 AAA 116 PCB Terminals en 15 144 Status indications 0 0 0 33 Phase compensation capacitor 1 Step up transformer for high Phase loss ti G5 voltage motor sss ssevvsssessresnssosnsssonssionss 26 Phase reveisal lt 2 c cccniianiecentes 91 Stop command 94 Phase sequence scsssecssesseseseeees 91 115 Stop settings creierii siesistenniiier 80 Planer narnia it 94 STOPIRESET key siet 34 Power and signal connectors 144 146 CG Drives amp Automation 01 5980 01r0 Appendix 1 Menu List This is a list of the Emotron TSA menu parameters and their Complete lists with communication data and parameter set factory settings along with communication settings for the information could be downloaded from www cgglobal com most important bus formats or www emotron com 2151 Ruso cu Remote mos mo mo E 2152 jogo Reme 49008 fum um fC 217 Key Func 2273 Functonkey oee om mo mo TT arra rocr Keyboard 49040 um um fC ESCHER ERRECHEN 218 tokco fo
141. egarding specific applications refer to The Application Functions List on page 23 If the load monitor function 410 is activated page 46 it could be necessary to apply a load monitor start delay time 417 in order to avoid faulty alarms during start up due to the high start current Spinbrake Spinbrake can be selected as a digital input 520 see section 8 5 2 page 94 Braking is then initiated from an inactive or active state when running by activating input This means the softstarter can catch a freewheeling motor and brake it down to standstill CG Drives amp Automation 01 5980 01r0 Main features 39 7 1 3 Jog functions The jog slow speed function can be activated independently from a start or stop via the control panel using the jog keys via remote I O control or via serial communication To select the method to activate the jog function follow the procedure described in Fig 28 Select Rotation Direction 197 Default FWD A Select Jog Speed 22l Default 10 352 Select Jog Control 2152 Default Remote R ss e VK External Control panel control for softstarter Remote Int keyboard Com Ext keyboard Virtual I O Lock keyboard Code 291 Finished le Finished Fig 28 Jog decision tree It is necessary that the rotation direction settings for all parameters involved in the jog function correlate to each other See Table 18 below Table 18 Jog settings depe
142. el for softstarter Remote Virtual I O Int keyboard Com Ext keyboard Level Edge control y E 21A Default Edge Activate start keys 2174 Default FWD y y Fig 27 Run Stop decision tree For configuration of programmable I O see the description for the respective input output For a list of the different possibilities see section 7 4 page 51 Local and remote control mode An additional possibility for start and stop control is given with the LOC REM function of the toggle key setting LOC REM in Function Key menu 2171 It is up to the user to define the REMOTE and LOCAL functions in the menus for Run Stop Control 2151 and Local Run Control 2173 In that respect the LOC REM key becomes a tool not just to alternate between the control panel and I O control but actually to quickly change between any two start and stop control locations See description in section 6 5 2 page 36 7 1 2 Start and stop methods The methods for starting and stopping the motor can be configured in the menus 330 Start Setting and 340 Stop Setting See descriptions in section 8 3 3 page 78 It is also possible to apply a Start Limitation 235 as part of the actions used for protecting the softstarter The functions for doing this are mainly related to time settings e g limiting the numbers of starts per hour or securing a minimum time delay between starts For guidelines r
143. ements and specific test methods EMC Directive Declaration of Conformity and CE marking All EN IEC 60947 4 2 Contactors and motor starters 2007 Safety requirements Electrical thermal and energy Low Voltage Directive Declaration of Conformity and CE marking IEC 60721 3 3 Classification of environmental conditions Air quality chemical vapours unit in operation Chemical gases 3C3 Solid particles 3S1 UL508C UL Safety standard for Power Conversion Equipment Pending USA UL 840 UL Safety standard for Power Conversion Equipment Pending 1 6 Dismantling and scrapping The enclosures of the Emotron TSA softstarters are made 1 6 1 Disposal of old electrical and electronic equipment from recyclable material such as aluminium iron and plastic Each softstarter contains a number of components demanding special treatment The circuit boards contain small amounts of tin and lead Any local or national regulations in force for the disposal and recycling of these materials must be complied with This symbol on the product or on its packaging indicates that this product shall be taken to the applicable collection point for the recycling of electrical and electronic equipment By ensuring this product is disposed of correctly you will help prevent potentially negative consequences for the environment and human health which could otherwise be caused by inappropriate waste handling of this product The recycling of materials will
144. ender rollers and various smoothing machines whereas quadratic correlation between speed and torque is typical for pumps and fans Some applications like conveyors or screws may need an initial torque boost However for many applications it can be seen that the torque needed is much lower than the torque delivered by the induction motor in a DOL start A common method to reduce both starting torque and current is to decrease the motor voltage during starting The following figure shows how the motor s torque and current characteristics are changed when the supply voltage is reduced Torque T Tn 2 5 2 15 Un 1 Uo lt U 0 5 TA NS 0 n ns 0 0 5 1 Current Vn g Un 7 6 5 4 3 2 1 n n ns Fig 77 Reduced voltage start A general rule of thumb is that the torque at each operating point is roughly proportional to the square of the current This means when the motor current is decreased by a factor of two by means of reducing the supply voltage the torque delivered by the motor will be decreased by a factor of four approximately T 12 lv 1 2 Ibo gt Try 1 4 Toot lv 1 3 loo gt Ty 1 9 Toot LV low voltage DOL Direct on line This relationship is the base for any starting method using reduced voltage It can be seen that the possibility of reducing the starting current depends on the correlation between the motor and the load s torque characteristic For the combination of an application wi
145. equency regulation Thus such a motor can be started with a quite simple frequency inverter with voltage frequency regulation This solution is also valid for all other applications which for some reason high load torque compared to motor torque etc cannot be started by a softstarter CG Drives amp Automation 01 5980 01r0 Softstarter theory 131 10 4 Use of softstarters with torque control To determine if a specific application benefits from using a softstarter at all the correlation between the motor s torque characteristic during the start and the load s requirements has to be evaluated As it can be seen from the examples above the application will only benefit from using a softstarter if the load torque during the start is clearly below the motor s starting capacity However loads with a high initial release torque may also benefit from a softstarter In this case an initial torque boost can be used thereafter the start ramp is continued reducing the starting current considerably The benefit can be maximised when using a softstarter with torque control To be able to configure the torque control parameters for optimal performance the load characteristics linear square or constant load need of initial release torque must be known In this case a proper torque control method linear or square can be chosen and torque boost can be enabled if needed 132 Softstarter theory CG Drives amp Automation 01 5
146. et Ctrl Stp Al Remote Keyb Default Remote Keyb Remote 0 Reset command via digital input do a Reset command via internal or external y control panel RESET key Reset command via serial Com 2 nee communication Remote Reset command via digital input or 3 E keyb control panel internal or external Reset command via serial Com keyb 4 communication or control panel internal or external Rem keyb Reset command via digital input control tom 5 panel internal or external or serial communication Key functionality 217 Menu group that sets the functions of the keys on the control panel See section 6 4 page 34 Function Key 2171 The Toggle key on the keyboard see section 6 5 page 35 has two functions that can be activated in this menu As default the key is set to operate as a toggle key that moves you easily through the selected menus in the toggle loop The Loc Rem function of the key allows you to easily switch between local and normal operation mode see page 36 If set to Off the function is disabled The Loc Rem function can also be changed via digital input See menu 520 Reset Control 216 When the softstarter is in alarm condition a reset command is required to make it possible to restart the softstarter Use this function to select the source of the reset signal The keyboard alternatives in this menu enable both external and internal control panels to be u
147. ge autoreset 2563 In this menu the delay time for an autoreset of an overvoltage alarm 442 is set The delay time starts counting when the fault is removed Usually the mains voltage will not be available to the softstarter in a stopped state as the mains contactor is deactivated In this case an overvoltage failure cannot be detected in stopped state and the delay time starts counting immediately after the alarm action has been executed When the delay time has elapsed the alarm will be reset and a restart attempt will automatically be made 2563 Overvolt Stp FA Off Default Off Off 0 Off 1 3600 1 3600 1 3 600 s Undervoltage autoreset 2564 In this menu the delay time for an autoreset of an undervoltage alarm 443 is set The delay time starts counting when the fault is removed Usually the mains voltage will not be available to the softstarter in a stopped state as the mains contactor is deactivated In this case an undervoltage failure cannot be detected in a stopped state and the delay time starts counting immediately after the alarm action has been executed When the delay time has elapsed the alarm will be reset and a restart attempt will automatically be made 2564 Undervolt Stp FA Off Default off off 0 Off 1 3600 1 3600 1 3 600 s 72 Functionality CG Drives amp Automation 01 5980 01r0 8 2 7 Serial Communication 260 In this menu we c
148. give a new reset command from one of the sources for reset control selected in menu 216 e The autoreset counter is now zeroed WARNING If the Run input signal is active high and level controlled start mode is selected the motor will start at the reset command Note that level control is not fulfilling the Machine directive Number of Allowed Autoreset attempts 2511 2511 AllowedArst Stp FA Off Default Off no autoreset Range 0 10 attempts Number of Actual Autoreset attempts 2512 In this menu the status of the internal autoreset counter is shown If no new trips occur the autoreset counter is decreased with one count for every tenth minute 2512 ActualArst Read onl 7 Stp FA 0 Default 0 NOTE An autoreset is delayed by the remaining ramp time Motor Protection Autoreset 252 Menu group for automatic reset of motor protection alarms Motor Dr protection autoreset 2521 The delay counter starts counting when the 1 t value is low enough to allow for a new start This means that first the internal thermal motor model will require time for cooling down to a thermal capacity of95 ifinternal thermal motor protection is enabled Then the delay time set in this menu is added on to this time When the delay time has elapsed the alarm will be reset and a restart attempt will automatically be made 2521 Motor 1 stp hy Off
149. gured The benefit of this feature is that occasional trips that do not affect the process will be automatically reset See also section 7 6 3 page 52 Autoreset Attempts 251 Any number set above 0 activates the autoreset This means that after a trip the softstarter will restart the operation automatically according to the number of attempts selected No restart attempts will take place unless all conditions are normal If the counter for Actual Autoreset Attempts 2512 contains more trips than the allowed number of attempts selected in menu 2511 the autoreset cycle will be interrupted No autoreset will then take place For every 10 minutes that have passed without any new trip the autoreset counter is counting down one count If the maximum number of trips has been reached the trip message time is marked with an A 830 OVERVOLT Trp A 345 45 12 The example above shows the 3rd trip memory menu 830 An overvoltage trip took place after running for 345 hours 45 minutes and 12 seconds at which time the allowed number of autoreset attempts was exceeded If the autoreset counter has reached the set maximum the softstarter must be reset by a normal reset See example below Number of allowed autoreset attempts 2511 5 e Within 10 minutes 6 trips occur At the 6th trip there is no autoreset because the autoreset counter allows only 5 attempts to autoreset a trip e To reset the autoreset counter
150. hanged during operation However if the sets are using different motors M1 to M4 the set will be changed only when the motor is stopped 241 Select Set stp ty Default A A 0 B 1 Fixed selection of one of the 4 parameter c o sets A B C or D D 3 Parameter set is selected via a digital Digln 4 input Define which digital input in menu 520 Digital Inputs Parameter set is selected via serial Com 5 are communication The parameter set is set via an option Option 6 Only available if the option can control the selection NOTE The parameter set cannot be changed 8 during run if the parameter set includes change of the motor set M 1 M 4 66 Functionality CG Drives amp Automation 01 5980 01r0 Copy Set 242 This function copies the content ofa parameter set into another parameter set e g A gt B means that the content of parameter set is copied into parameter set B NOTE The actual value of menus for viewing will not be 242 Copy Set Stp FA Default A gt B A gt B 0 Copy set A to set B A gt C kb Copy set Ato set C A gt D 2 Copy set Ato set D B gt A 3 Copy set B to set A B gt C 4 Copy set B to set C B gt D 5 Copy set B to set D C gt A 6 Copy set Cto set A C gt B 7 Copy set C to set B C gt D 8 Copy set Cto set D D gt A 9 Copy set D to set A D gt B 10 Copy set D to set B D gt C 11 Copy set D
151. he actual menu parameter Also shows S to indicate soft trip and A if max number of autoreset attempts is exceeded Shows the setting or selection in the active Area F menu empty at 1st level and 2nd level menus Shows warnings and alarm messages CG Drives amp Automation 01 5980 01r0 Operation via the control panel 33 6 2 LED indicators The three light emitting diodes below the display indicate the operation status of the softstarter and motor machine see Fig 23 Depending on the operating mode the TRIP and RUN indicators will also flash to alert the user about a coming event or action A description of the different LED signals is given in Table 15 below Table 15 LED indication RUN TRIP POWER green red green Fig 23 LED indicators Status LED symbol ON NORMAL FLASHING 2 Hz SLOW FLASHING 1 Hz OFF POWER Mains supply o Power off green power on TRIP Awaiti t toftri red Softstarter tripped Warning waiting autoreset of trip No trip simultaneously flashing RUN green Running at full speed Start and stop ramp RUN and TRIP LEDs Softstarter not active Frequency 1 Hz 1 flash per second 2 Hz 2 flashes per second 6 3 Control keys The control keys are used to give the START STOP or RESET commands directly As default the START and STOP keys are disabled and the commands are set remotely from digital input T
152. he set maximum alarm action a hard trip is executed CG Drives amp Automation 01 5980 01r0 Main features 49 O gt Time Fig 35 Example 2 Autoset load monitor function 7 3 5 Reset and autoreset When the softstarter is tripped due to a failure a reset command is required to make it possible to restart the softstarter The reset command can come from any of the selected sources in menu 216 Reset Control or it can be automatically generated through settings in menu group 250 Autoreset For the following explanations it is important to distinguish between reset and restart Reset means that the softstarter no longer is in a tripped condition as confirmed by a removal of the alarm message in the display If the operation has been interrupted due to a tripped condition the softstarter is prepared for a restart If an alarm occurs whose alarm action is configured for Warning see description of alarm actions in Table 21 page 45 the indication will automatically be removed as soon as the warning condition disappears i e no reset command is needed If the operation has been interrupted due to a trip a reset signal and a new start signal may be needed to restart the motor However some alarms can be automatically reset when a new start signal is given Manual reset The control source for the reset signal is selected in 216 Reset Control The RES
153. help to conserve natural resources For more detailed information about recycling this product please contact the local distributor of the product 6 Introduction CG Drives amp Automation 01 5980 01r0 1 7 Glossary 1 7 1 Abbreviations and symbols In this manual the following abbreviations are used 1 7 2 Definitions In this manual the following definitions are used Table 4 Definitions Name Description Unit Table 3 Abbreviations In soft Nominal softstarter current Arms mio Description In mot Nominal motor current Arms Pr soft Nominal softstarter power kW or hp cp Control panel the programming and Pn mot Nominal motor power kW or hp presentation unit on the softstarter Th Nominal motor torque Nm or Ib ft CB Control board E Do mot Nominal speed of motor rom 12 The amount of energy losses heating up the motor Cos Nominal motor power factor dimensionless Positive Temperature Coefficient U 3 phase mains supply voltage Vims PTC temperature sensor also known as i thermistor Un mot Nominal motor voltage V RETO Power board PIC Input Calculation of nominal motor torque RMS Root Mean Square value 9550 x P kW FLC Full Load Current T Nm 2330 x Pa morlkW An wel pm DOL Direct On Line Elnt Communication format 5252x P hp Ulnt Communication format Unsigned Integer ZER na morlrp m Int Communica
154. iate interruption of operation if it occurs during start jog or stop If for start and jog the lost phase should reappear within 2 seconds an automatic restart is performed For other functions the alarm action on single phase loss can be set in menu 235 This will take place if the phase loss lasts for more than 2 seconds NOTE Single phase loss is only detected for incoming phases L1 L2 and L3 and not for phases feeding the motor Restart The automatic restart is usually performed as for normal operation and according the set start method menu 331 Torque boost 337 is executed if enabled however the jog function at start 350 is not executed in this case Any automatic restart within 2 seconds is not counted for in a start limitation protection 234 For phase loss situations exceeding 2 seconds an automatic restart can be accomplished by using autoreset 2561 A phase loss alarm is reset when the alarm condition is gone and a new start signal is given Single Phase Loss Alarm Action 235 The action on a single phase loss is set in this menu The relevant action is performed when any phase is lost for more than 2 seconds 235 SnglPhLossAA Stp fA Hard Trip Default Hard Trip No action 0 Hard Trip al For a definition see Table 21 page 45 Soft Trip 3 Warning 4 CG Drives amp Automation 01 5980 01r0 Functionality 65 Current Limit Alarm Action 236 Thi
155. ig 4 Hole pattern for Emotron TSA frame size 1 and 2 Fig 3 Dimensions for Emotron TSA frame size 1 and 2 bottom view On our websites www cgglobal com and www emotron com it is possible to download a full size template for positioning of the fixing holes 10 Mounting CG Drives amp Automation 01 5980 01r0 3 Connections The installation description in this chapter follows the EMC standards and the Machinery Directive If the softstarter is temporarily stored before being connected please check the technical data for environmental conditions section 13 3 page 142 If the softstarter is moved from a cold storage room to the location where it is to be installed condensation could appear on the unit Allow the softstarter to become fully acclimatised and wait until any visible condensation has evaporated before connecting any supply voltages Cables Dimension the mains and motor cables according to local regulations and the nominal current of the motor It is not necessary to use shielded motor cables together with the Emotron TSA softstarter This is due to its very low radiated emissions Neither is it necessary to use shielded mains supply cables for the Emotron TSA softstarter For the control connections it is not necessary to use shielded control cables however with the exception of the option board connections see section 3 2 page 14 for which it is recommended to use flexible wire with a braided typ
156. ill no longer be adequate for the purpose The derating 1 100 m is calculated for the altitude above the rated 2 100 1 000 1 100 meters above rated altitude that gives 1 100 m 100 m x 1 11 Hence the nominal current must be derated by 11 The next higher rated model TSA52 056 rated for 56 A nominal current will be derated to 56 A 11 x 56 A 49 8 A which is well above the required 42 A and therefore TSA52 056 could be selected in this case CG Drives amp Automation 01 5980 01r0 Technical data 143 13 4 Control power and I O signal connectors Table 42 Power board connections Terminal Function Electrical characteristics PE Protective Earth Protective grounding N L Control supply voltage 100 240 VAC 10 21 NO ee ee See naa is 1 pole closing contact NO 250 VAC 8 A or 24 VDC 22 C peration with Indication by ciosing enlace an 8 A resistive 250 VAC 3 A inductive See Warning terminals 21 to 22 23 NO Programmable relay 2 Factory setting is Off with 1 pole closing contact NO 250 VAC 8 A or 24 VDC 24 C indication by closing contact on terminals 23 to 24 8 A resistive 250 VAC 3 A inductive See Warning 31 NO Programmable relay 3 Factory setting is Trip 1 pole change over contact NO NC 250 VAC 8A or 32 C Indication by closing contact on terminals 31 to 33
157. imum starting current The Applications Rating List With this list the Emotron TSA softstarter rating type can be selected depending on the type of application uses see Table 12 page 22 The Applications Function List This table gives an overview of the most common applications and their challenges For each application Emotron TSA softstarter settings are proposed with references to the menus used See Table 13 page 24 4 1 Softstarter dimensioning according to AC 53b The EN IEC 60947 4 2 2007 standard defines AC 53b as a norm for dimensioning of softstarters for continuous running with a bypass contactor This is the norm for which the Emotron TSA is designed AC 53b rating example Explanation of the rating designation see also Fig 16 56 A AC 53b 3 0 30 330 O Rated current FLC of softstarter Ampere Classification AC 53b for all Emotron TSA models Start current expressed as a multiple of FLC Start time seconds wee 4 Bypass time seconds The example concerns Emotron TSA model 52 056 used for a pump application The rating designation indicates a current rating of 56 A with a start current ratio of 3 0 x FLC 168 A for 30 seconds and with a 330 seconds 5 5 minutes interval between starts current via bypass contactors Current HA Start current Time gt ls Start Bypass operation Fig 16 Duty cycle 4 2 Applications rating Accor
158. ion is Reset and autoreset Programmable I O Logical functions sssssssesesseesesreseerersreerreisrsreernrn Remote control functions Default settings of the Run Stop Reset TUNCLIONS ee 51 Enable and Stop functions s ssessessesnsseernonnenneneenee 52 Reset and Autoreset operation 52 Functonalty 55 Preferred View 100 eee 56 IstiLine 110 essas saio ivan Geesen e 57 2nd Line 120 taaan 57 Main Setup 200 setas 57 Operation setup 210 57 Remote signal Level Edge DIAl 60 Motor Data 220 Motor protection 230 Parameter set handling 240 66 Autoreset 250 CG Drives amp Automation 01 5980 01r0 8 2 7 8 3 8 3 1 8 3 2 8 3 3 8 3 4 8 3 5 8 4 8 4 1 8 4 2 8 4 3 8 5 8 5 1 8 5 2 8 5 3 8 5 4 8 5 5 8 6 8 6 1 8 6 2 8 6 3 8 6 4 8 6 5 8 6 6 8 7 8 7 1 8 7 2 8 7 3 8 7 4 8 8 8 8 1 8 8 2 8 8 3 8 9 8 9 1 9 4 9 2 9 3 9 4 9 5 9 6 10 10 1 10 2 10 3 10 4 11 11 1 11 1 1 11 1 2 11 2 11 3 Serial Communication 260 ennnen 73 Process SOO miii za 76 View Process Value D1O0l 76 Process Settings 3201 76 Start Setting 330 Eeer EE 78 Stop Setting 340 80 JOSS DO A AA Shes 83 Load Monitor and Process Protection 400 84 Load Monitor IO 84 Process protection 420 88 Mains Protection 430
159. is defined See Relays 550 page 97 for description of the different selections 562 VIO 1 Source Stp FA Off Default off Same selection as in menu Relay 1 551 Selection page 97 Virtual Connections 2 8 563 to 56G Same function as Virtual Connection 1 561 and 562 Default settings are Off 8 6 Logical Functions and Timers 600 In the Logic amp Timers menu 600 you access comparators logic functions SR flip flops timers and counters enabling conditional signals to be programmed for control or signalling features This gives you the ability to compare different signals and values in order to generate monitoring controlling features All these functions are updated in 8 milliseconds intervals 8 6 1 Comparators 610 The comparator function makes it possible to monitor different internal signals and values and to visualise via digital relay outputs when a specific value or status is reached or established The output signals of the comparators can be logically tied together to yield a logical output signal All the output signals can be programmed to the digital or relay outputs or used as a source for the virtual connections 560 For each digital and analogue comparator it is possible to apply a Set Delay a Reset Delay and a Timer Value functions that could be used to extend or delay the output signal Analogue Comparator Setup 611
160. ive the SET command is given to the output signal OUT This will result in a signal change from inactive to active 1 if not already in an active state Conversely if SET 0 inactive and RESET 1 active the RESET command is given to the output signal OUT causing this to be deactivated 0 Flip flop priority mode When both input signals are in an active state simultaneously i e SET 1 and RESET 1 a priority function decides which signal will influence the output signal There are three different priority settings available for the flip flop function selected in the menu for Flip flop Mode Examples of the different priority settings are presented in Fig 64 Reset priority RESET OUT Set priority SET RESET OUT Edge controlled without priority SET RESET OUT Fig 64 Programmable flip flop modes 110 Functionality CG Drives amp Automation 01 5980 01r0 Reset priority Reset priority means that if both input signals are active it will be the RESET command that is obeyed causing the output signal to become inactive 0 See Table 29 Table 29 Truth table for Reset priority Flip flop 1 641 Functions for SR flip flop 1 Flip flop 1 Mode 6411 Priori
161. laces greater demands on the softstarter The technical data page 139 indicates that the TSA 52 056 is downrated to 33 A FLC for heavy duty applications If an FLC current of about 56 A is required for the roller mill it would be recommended to choose TSA model 52 100 for which the rated heavy duty current is 60 A If the Emotron TSA 52 056 from the previous example is used in e g a roller mill application instead it would be Table 12 Applications Rating List Applications rating for Emotron TSA softstarter Industry Normal duty cycle AC53b 3 0 Heavy duty cycle AC53b 5 0 General amp Water Centrifugal pump Submersible pump Compressor screw Conveyor Mixer Agitator Compressor reciprocating Fan Blower Dust collector Belt conveyor Grinder Hammer mill Rock crusher Roller conveyor Roller mill Tumbler Wire draw machine Metals amp Mining Bottle washer Centrifuge Slicer Dryer Mill Palletiser Food processing Repulper Pulp amp Paper Shredder Trolley Bandsaw Chipper Circular saw Debarker Planer Sander Lumber amp Wood Ball mill Centrifuge Extruder Screw conveyor Petrochemical Ball mill Grinder Material conveyor Palletiser Transport amp Machine Press Roller mill Rotary table Trolley Escalator 22 Application guidelines CG Drives amp Automation 01 5924 01r0 4 3 The Application Functions List This list gives an overview of
162. level settings in menus 4112 4122 4132 and 4142 NOTE A manual change of any alarm level will override the last performed autoset and menu 4176 Normal Load will be set to Off The alarm actions for all load monitor alarms both manual and autoset are configured in menus 4111 4121 4131 and 4141 and the corresponding alarm delays are set in menus 4113 4123 4133 and 4143 Autoset is also available via digital input 520 86 Functionality CG Drives amp Automation 01 5980 01r0 Maximum Alarm Margin 4171 This autoset menu sets the band above the Normal Load 4176 that does not generate a maximum alarm The set Max Alarm Margin percentage is added on to the percentage of the Normal Load The resulting percentage is where the maximum alarm level is put related to nominal motor power 223 Minimum Pre Alarm Margin 4173 This autoset menu sets the band below the Normal Load 4176 that does not generate a minimum pre alarm The set Min Pre Alarm Margin percentage is subtracted from the percentage of the Normal Load The resulting percentage is where the minimum pre alarm level is put related to nominal motor power 223 NOTE Changing any margin without performing autoset will NOT affect the alarm levels 4171 MaxAlarmMar Stp FA 16 Default 16 Range 0 100 of nominal motor power 223 Example The Maximum
163. loss multiple phase loss E 724 RelayStatus 21 Under voltag undervoltage Stp RE 100 22 Mot termOpen motor terminal open 23 Current Unbal current unbalance Fig 68 Relay status example 24 CtrlSupFault control voltage supply fault Analogue Input Status 725 25 Spare25 reserved for future use This menu indicates the status of the analogue input 26 Int error internal error 1 27 Phase rev phase reversal Read only 725 AnalogueIn 28 Spare28 reserved for future use Stp 65 29 Int error2 internal error 2 30 Over voltag overvoltage Fig 69 Analogue input status example 31 Volt Unbal voltage unbalance The status of the input is shown in so the example in Fig 69 indicates that AnIn is active and has a 65 input value NOTE The shown percentage is an absolute value based on the maximum value of the in or output so related to either to 10 Vor 20 mA CG Drives amp Automation 01 5980 01r0 Functionality 117 Analogue Output Status 726 This menu indicates the status of the analogue output Fig 70 726 AnalogueOut Read only Stp 65 Fig 70 Analogue output status example The status of the output is shown in so the example in Fig 70 indicates that AnOut is active and has a 65 output value NOTE The shown percentage is an absolute value based on the maximum value of the in or output so related to either to 10 Vor 20 mA If 4 20 mA output is used for exampl
164. m mm mm 1 23 40 40 2 23 40 40 When the Mains and motor cables are connected mount the cable covers according to Fig 8 Fig 8 Mount the cable covers CG Drives amp Automation 01 5980 01r0 Connections 13 3 2 Board layout and connectors This section contains general information about the power board and control board for each Emotron TSA size For additional information about special conditions refer to section 4 4 page 26 For a description of the available options go to chapter 12 page 137 Isolation The control board in the Emotron TSA product is a Separated Extra Low Voltage SELV circuit This means that this board is safely separated from other circuits that carry higher voltages and is isolated from earth and protective earth conductors of other circuits The PTC circuit on the power board is separated from the control board SELV circuit with a separation rated for Double insulation when used in softstarters rated up to 525 VAC e Basic insulation when used in softstarters rated up to 690 VAC It is recommended that the PTC PT 100 sensors are always separated from live parts with at least basic insulation for the relevant voltage WARNING J For softstarters rated higher than 525 VAC it is mandatory to have at least basic insulation from the temperature sensor towards live voltage Fig 9 Board layout for Emotron TSA Size 1 2 Emotron TSA Size 1 2
165. m Margin 4174 This autoset menu sets the band below the Normal Load 4176 that does not generate a minimum alarm The set Min Alarm Margin percentage is subtracted from the percentage of the Normal Load The resulting percentage is where the minimum alarm level is put related to nominal motor power 223 4174 MinAlarmMar Stp IA 16 Default 16 Range O of nominal motor power 223 Autoset Alarm 4175 When autoset is performed the actual value of the shaft power will be used as a basis when setting the alarm levels Autoset is performed by choosing Yes and confirming by pressing ENTER The message Autoset OK is displayed alternatively Failed ifthe command does not succeed To return to the menu display press any key When autoset is performed the actual shaft power shown to the left in the menu display is stored to menu 4176 Normal Load and the alarm levels are recalculated according to the description for menu 417 Autoset A new autoset command will overwrite previously used alarm levels Autoset can also be triggered by a remote signal setting the function of any digital input to Autoset Note that this signal is edge triggered CG Drives amp Automation 01 5980 01r0 Functionality 87 When performing an autoset the motor must be running with the load that needs to be recorded NOTE The motor must be running for the Autoset procedure to suc
166. me o dT S SC TCS Bojo o o RE 400 Montoro RR Max Alarm 4112 MaxAlarmact no action 49775 mo mo O EREECHEN EECHER 150 CG Drives amp Automation 01 5980 01r0 Menu Parameters Default settings Pocius inst Fieldbus Modbus 9 DeviceNet no format format 412 MaxPreAlarm MaxPreAlLev 108 43778 Long 1 1 MaxPreAlDel 0 5s 43331 Long 1 0 1s E N LA NENEN w N N WIN Min Alarm MinAlarmLev 84 43744 414 416 417 4171 4172 Dem No D um um iP Nomaitoad o iss omea JO 420 Provsspot A e T NET NN EE E EC PSS CAC ases Jum um O 422 Rotortoked SSCS 4221 LockRot AA _ Noadton asse um um SSCS 4222 LockRotTine 50 E ETA TEE fut IS EIERE CA S O e T ist fotu o E fasi2 Unbatever fio Jee Del asia vernos fis Jg Du Jum TT E o ES Es Ed E Al ALATA Al AP A NI NI NIN BY ARITA O of Afw Wil MIR UnderVolt asa rsrs 22 assi Phaserena Noadion wares Um mo O 4342 Alowedsequ fs Je fi TT 00 yes daw 510 aminas 0 fes CS it anto een In que mo TT 512 minseup Ant Je Jum um TT CG Drives amp Automation 01 5980 01r0 151 553 Tarima Sist aninMin ama oo rangos en 5132 AninMac foma fasaa tong t o0afem Anln VaMin E o Long 1 see 1 0 001 1rpm 1 1 C 0 001 nee TE Notes as set in 322 D o 5137 Anin VaMax 43551 Long 1 see Elnt 1 0 001 1rpm 1 1 C 0 001 Notes as set in 322
167. meter sets This is useful if you have two different motors that are not intended to run at the same time One motor must stop before changing to another motor 1 Select parameter set A in menu 241 Select motor M1 in menu 212 Enter motor data and settings for other parameters Select parameter set B in menu 241 Select M2 in menu 212 RO ES eee abe Enter motor data and settings for other parameters 7 2 4 Using the control panel memory The control panel memory could come in handy when more than one Emotron TSA unit is used The copy load functions allows for transfer of data between the internal control board of the softstarter and the control panel offering a quick solution for copying parameter sets and motor data to other softstarter units The control panel can also be used for temporary storage or back up copy of settings For description of the menu selections and the copy load function see menus 244 and 245 page 67 In order to enable transfer of data between Emotron TSA units there are two different set ups NOTE The two softstarters must have the same software version Check software version in menu 922 42 Main features CG Drives amp Automation 01 5980 01r0 Copy by moving control panel between units To transfer data from one TSA unit to a second TSA unit via the standard TSA control panel see Fig 30 1 Fig 30 Copy and load parameters between two Emotron TSA units via th
168. mp Automation 01 5980 01r0 Functionality 107 Logic 1 Operator 2 6215 In this menu the second operator for the Logic 1 function is Logic 1 Input 4 6218 In this menu the fourth input for the Logic 1 function is selected selected 6215 L1 Op 2 6218 L1 Input 4 Stp A Stp Al CA4 Default amp Default CA4 When dot is selected the Logic 1 Selection Same selection as in menu Logic 1 Input 1 0 expression is finished when two or 6212 page 107 three expressions are tied together amp 1 amp AND e Logic 1 Set Delay 6219 J S E The activation of the output signal for the Logic 1 function A 3 A EXOR is delayed with the set value in this menu Compare to Fig Logic 1 Input 3 6216 In this menu the third input for the Logic 1 function is 59 page 104 6219 L1 Set Dly Stp A 0 00 00 0 Default 0 00 00 0 hours minutes seconds Range 0 00 00 0 9 59 59 9 selected 6216 L1 Input 3 Stp A CA3 Default CA3 Selection Same selection as in menu Logic 1 Input 1 6212 page 107 Logic 1 Operator 3 6217 In this menu the third operator for the Logic 1 function is selected 6217 L1 Op 3 Stp amp Default amp When dot is selected the Logic 1 0 expression is finished when two or three expressions are tied together amp 1 amp AND 2 0R ge 3 A EXOR Logic 1
169. mp 0 which is equal to 1 106 Functionality CG Drives amp Automation 01 5980 01r0 Logic 1 Input 1 6212 T2Q 26 Logic timer 2 output In this menu the first input for the Logic 1 function is IT2Q 27 Inverted logic timer 2 output selected The same selections are valid for 6214 L1 Input 2 7 Ia E 6216 L1 Input 3 and 6218 L1 Input 4 Q ogie timer output This table is also valid for the input signals in logic functions IT3Q 29 Inverted logic timer 3 output 2 622 3 623 and 4 624 however default values vary TAQ 30 Logic timer 4 output See Menu List in Appendix 1 RR Note that a logic function can not directly use itselfas an ITAQ 31 Inverted logic timer 4 output input signal e g for the L1 Input it will not be possible to F1 32 Flip flop output 1 choose komt IFA 33 Flip flop output 1 inverted F2 34 Flip flop output 2 6212 L1 Input 1 i E y Stp A CA1 IF2 35 Flip flop output 2 inverted F3 36 Flip flop output 3 Default CA1 IF3 37 Flip flop output 3 inverted CA1 0 Analogue comparator 1 output FA 38 Flip fiop output 4 1A1 Jl Analogue comp 1 inverted output IFA 39 Flipfiop output 4 inverted CA2 2 Analogue comparator 2 output g p p CTR1 40 Counter output 1 1A2 3 Analogue comp 2 inverted outp
170. n 8 2 7 page 73 menu group 260 7 5 Logical functions To enable logic signals to be programmed for different controlling or signalling functions using AND OR EXOR operators there are a number of functions available e 4 analogue comparators and 4 digital comparators 610 e 4 logic functions 620 e 4 timers 630 e 4 SR flip flops 640 e 2 counters 650 e 2 clocks 660 See how to configure the logical functions in Chapter 8 6 page 100 7 6 Remote control functions Operation of the Run Stop Enable Reset functions As default the run stop commands are programmed for remote operation via the inputs on the terminal strip on the control board Default for the reset control is both remote and keyboard With the parameter Run Stop Control 2151 and Reset Control 216 these functions can also be selected for keyboard or bus communication control NOTE The examples in this paragraph do not cover all possibilities Only the default settings factory and the most relevant combinations are given 7 6 1 Default settings of the Run Stop Reset functions The default settings are shown in Fig 36 In this example the softstarter is started with Digln 1 Run FWD and stopped with Digln 2 Stop A reset after trip can be given with Digln 4 The inputs are default set for edge control Run FWD pulse 11 12 13 14 15 16 17 18 1 Control board nO No o Fig 36 Default se
171. n menu 344 341 Stop Method Stp fA Coast Default 4 Coast The motor torque is controlled according Lin Torq Ctr 1 3 to a linear ramp The motor torque is controlled according Ti 2 Sqr Torq Ctr to a square ramp The motor voltage is controlled according Voltage Ctr 3 E to a linear voltage ramp Coast 4 The motor coasts to a stop Braking method as activated in menu Brake 5 344 End Torque at Stop 342 This menu sets the end torque value when one of the torque control functions is chosen in menu 341 342 EndTorqueStp Stp A 0 Default 0 Range O 100 of Th Step Down Voltage at Stop 343 This setting is available when voltage control is chosen in 341 The switch on period will step down to an intermediate value from where it will follow a linear voltage ramp down to the minimum allowed switch on period The duration of the ramp is set in Stop Time 345 343 StepDwnVolt Stp KN 100 Default 100 Range O 100 of Un mot 221 Voltage 343 Un_mot Stop time L gt Ti 345 ZS Fig 47 Step down voltage at stop Braking Method 344 This menu is available when Brake is chosen in 341 Dynamic Vector Brake With dynamic vector brake the braking torque applied to the motor will increase with decreasing speed Dynamic vector brake can be used for all loads not rotating too close to
172. nal current 224 reduced according to Motor ventilation 228 See Fig 8 2 4 ln mot 11 The output is used to control a reverse RevCurrBrake 12 c rrent Beste 5337 AnOutVaMax Max or min alarm condition active LoadMonAlarm 13 E trip or warning Max or min pre alarm condition active Pre Alarm 14 j trip or warning Stp FA 0 000 Default 0 000 Range 10 000 000 10 000 000 Max alarm condition active trip or Max Alarm 15 warning Max pre alarm condition active trip or Max PreAlarm 16 warning Min alarm condition active trip or Min Alarm 17 e warning CG Drives amp Automation 01 5980 01r0 Functionality 97 Min PreAlarm 18 ee condition active trip or CTR2 61 Counter output a ICTR2 62 Counter output 2 inverted Cad 19 Analogue comparator f output CLK1 63 Clock output 1 Clock logic 660 1A1 20 Analogue comp 1 inverted output UK 64 Clock output 1 inverted CA2 21 jAnaloguecomparator 2 output CLK2 ep Clock output 2 Clock logic 660 A2 22 Analogue comp 2 inverted output ICLK2 66 Clock output 2 inverted CA3 23 Analogue comparator 3 output Run command is active The signal IA3 24
173. nalogue comparator compares the selectable analogue value in menu 6111 with the constant Level HI in menu 6112 and the constant Level LO in menu 6113 In menu Comparator Type 6114 Hysteresis or Window can be selected For the hysteresis function when the value exceeds the upper limit level high the output signal CAI is set high and A1 low See Fig 55 When the value decreases below the lower limit the output signal CAI is set low and A1 high CA1 Value 6111 CA1 CA1 Level HI 6112 CA1 Level LO 6113 4 Fig 55 Analogue comparator type Hysteresis For the window type comparator when the value is between the lower and upper levels the output signal value CA1 is set high and A1 low See Fig 56 When the value is outside the band of lower and upper levels the output CA1 is set low and LAT high CA1 Level HI 6112 CAL CA1 Level LO 6113 CA1 Value 6111 ER E The output signal can be programmed as a virtual connection source and to the relay outputs 6111 CA1 Value Stp FN Current Default Current Process Val O Torque 1 Shaft Power 2 kW El Power 3 kW Current 4 A Heatsink Tmp 5 C PT100_1 6 C PT100_2 7 C PT100_3 8 C Energy 9 kWh Run Time 10 h Mains Time 11 h Anin 12 PT100_4 13 C PT100 5 14 C PT100_6 15 C Example An analogue
174. nance 135 Observation Fault indication Cause Solution The display is not illuminated None No control supply voltage Switch on the control supply voltage Softstarter does not react to start command Start command comes perhaps from incorrect control source l e start from control panel when remote control is selected Give start command from correct control source as configured in menu 2151 and 2152 The motor jerks etc When starting motor reaches full speed but it jerks or vibrates If Torque control is selected it is necessary to input motor data into the system Start time too short If voltage control is used as start method the initial voltage at start may be too low Starting voltage incorrectly set Configure nominal motor data in menu group 220 Select the proper torque control alternative in menu 331 linear or square according to the load characteristic Select a correct initial and end torque at start in menus 332 and 333 Increase start time 336 Adjust initial voltage at start 334 Motor too small in relation to rated current of softstarter Motor too large in relation to load of softstarter Use a smaller model of the softstarter Use larger model of softstarter Starting voltage not set correctly Readjust the start ramp Select the current limit function Starting or stopping time too long
175. nd General start condition to run the softstarter If made low during running the output of the softstarter is cut off immediately causing the motor to coast Enable 3 to zero speed NOTE If none of the digital inputs are programmed to Enable the internal enable signal is set active NOTE Activated according to AND logic Run forward command positive speed Run FWD 4 The output of the softstarter will be a clockwise rotary field Run reverse command negative speed The output of the softstarter will be a counter clockwise rotary field External contactors required Run REV 5 Activates the Jog forward function Gives a run command with set Jog speed and Jog FWD 6 direction menu 350 NOTE Always level controlled even though edge control may be chosen in menu 214 Activates the Jog reverse function Gives a run command with set Jog speed and Jog REV 7 direction menu 350 NOTE Always level controlled even though edge control may be chosen in menu 214 Activates other parameter set See Table SE 8 25 for selection possibilities Activates other parameter set See Table SetCtrl2 9 25 for selection possibilities Loc Rem 10 Activates local mode defined in 2173 94 Functionality CG Drives amp Automation 01 5980 01r0 Anln Select 11 Activates deactivates analogue input defined in 513A Autoset 12 Activates autoset
176. nding on rotation direction Menu Forward Reverse Forward and Jog Jog reverse jog 219 FWD REV FWD REV 351 10 H off 10 1 352 Off 10 1 10 Y 1 Default value that can be changed in the respec tive menu NOTE To jog with the control panel jog keys press and hold 7 1 4 Start Stop signal priority A jog command has lower priority than a normal start command meaning that if the softstarter is already running the jog command is ignored If the softstarter is in jog mode a normal start command will override this and start the motor to full speed An Enable command setting via Digin 520 has the highest priority and overrides both a normal start stop command and a jog command If Enable is inactive it will not be possible to execute a normal start or a jog start The total priority order is listed in Table 19 below Table 19 Signal priority for digital inputs Priority Digital Input selection 1 Enable 2 Spinbrake 3 Stop 4 Run FWD and Run REV 5 Jog FWD and Jog REV 7 1 5 Setting motor data For optimal performance the Emotron TSA softstarter should be configured according to the motor s rating plate The menus for this are found in section 8 2 3 page 60 menu group 220 The motor data is handled as a parameter set one of four M1 M4 Motor M1 is selected as default and the motor data entered will be valid for motor M1 If different motors are used
177. ning control 600 650 Ditterent material Linear torque control gives linear 330 acceleration and low starting current MIXER Need to control material viscosity Shaft power analogue output 530 Broken or damaged blades Use load monitor maximum alarm 410 Use load monitor minimum alarm 410 l Linear torque control gives linear 331 Lin Torq Ctr Heavy load with high breakaway torque acceleration and low starting current Torque boost in beginning of ramp 337 HAMMER MILL Jamming Use load monitor maximum alarm 410 Reverse current brake with reversing 341 Brake Fast stop 344 Rev Curr Brk Motor blocked Locked rotor function 422 CG Drives amp Automation 01 5924 01r0 Application guidelines 25 4 4 Special conditions 4 4 1 Small motor or low load The minimum load current for the Emotron TSA softstarter is 10 of the rated current for the softstarter An exception is the TSA52 016 for which the minimum load current is 2A Example TSA52 056 with rated current of 56 A has a minimum current of 5 6 A Please note that this is minimum load current and not minimum rated motor current 4 4 2 Ambient temperature below 0 C For ambient temperatures below 0 C an electric heater or similar must be installed in the cabinet The softstarter can be mounted remotely from the motor since the distance between the motor and the softstarter is not critical 4 4 3 Pump control with softstarter and AC drive
178. ns that an input is activated by a low to high transition or vice versa NOTE Edge controlled inputs comply with the Machine Directive see Chapter 1 5 1 page 6 if the inputs are directly used for starting and stopping the machine The Enable and Stop inputs must be closed continuously in order to accept any run forward or run reverse command The last edge RunFWD or RunREV is valid If an edge controlled start is activated it is also necessary to use an input for the stop command according to Fig 36 page 51 Fig 37 gives an example of a possible sequence Edge control 21A INPUTS Enable Stop fF e Run FWD Run REV MOTOR OPERATION Forward rotation Reversed rotation Standstill LIT LS Fig 37 Input and output status for edge control 52 Main features CG Drives amp Automation 01 5980 01r0 Level controlled Run inputs Ifthe Run inputs remain in their position the softstarter will start immediately after the Reset command is given Autoreset is enabled if the Reset input is continuously active The autoreset functions are programmed in menu Autoreset 240 NOTE If the control commands are programmed for keyboard control or serial communication control autoreset is not possible Menu 21A Start signal Level Edge must be set to Level to activate level control This means that an inp
179. ntrol panel displays the status of the softstarter and is used to set all the parameters It is also possible to control the motor directly from the control panel SOFTSTARTER a LCD display a LEDS O A f B Ei td lt aq Control keys 4 Toggle key E E 4 PREV NEXT ESC vos lt gt CD Jos D gt ENTER CG 2 Fig 21 Control panel Function keys 6 1 Display The display is back lit and consists of 2 rows each with space for 16 characters The display is divided into six areas The different areas in the display are described below A B 221 hy Motor Volt Stp EJMi 400V D E F Fig 22 LC display Area A Shows the actual menu number 3 or 4 digits Shows if the menu is in the Toggle loop page 35 indicated with ES and or if the soft Area B i sa starter is set for Local operation page 36 indicated with fi Shows the abbreviated name of the active menu Area C e g parameter or description of the contents Shows the status of the softstarter 3 charac Area D ters The following status indications are possible Acc Motor starting Dec Motor stopping 12t Active It motor protection Run Motor runs at full speed Jog Motor runs at jog speed Trp Tripped Stp Motor is stopped Shows active parameter set D 3 or and if it is a motor parameter M1 M2 M3 or M4 Area E Shows a flashing cursor when a change is being done to t
180. nu Relay 1 551 page Selection 97 SET RESET OUT 0 0 O reset A 0 1 1 set 0 1 A 0 reset 21 a No change Flip flop 1 Set Delay 6414 The SET input signal for flip flop 1 is delayed with the set value in this menu 6414 F1 Set Dly Stp Fl 0 00 00 0 Default 0 00 00 0 hours minutes seconds Range 0 00 00 0 9 59 59 9 CG Drives amp Automation 01 5980 01r0 Functionality 111 Flip flop 1 Reset Delay 6415 The RESET input signal for Flip flop 1 is delayed with the set value in this menu 6415 F1 Res Dly Stp A 0 00 00 0 Default 0 00 00 0 hours minutes seconds Range 0 00 00 0 9 59 59 9 Flip flop 1 Timer Value 6416 This menu shows the actual value of the flip flop 1 timer 6416 F1 Tmr Val Read only Stp A 0 00 00 0 Default 0 00 00 0 hours minutes seconds Range 0 00 00 0 9 59 59 9 Flip flop 2 4 642 644 Refer to the descriptions for flip flop 1 Default for 6421 F2 Mode is Reset For 6431 F3 Mode the default is Set and for 6441 F4 Mode the default is Edge 8 6 5 Counters 650 The counter function counts pulses and can signal on a selected output when the counter reaches a specified level The counter counts up on the positive edges of the trigger signal and it is zeroed when the reset signal is active When the counter value equals the trip val
181. nu display settings 8 1 Operation setup 210 Basic settings for language key functionality control source 8 2 1 Motor data 220 Setting of electrical data for the used motor 8 2 3 Motor protection 230 Motor and softstarter thermal protections 8 2 4 Parameter set handling 240 Selection and configuration of parameter sets 8 2 5 Autoreset 250 Automatic reset of active alarms and restart of the softstarter 8 2 6 Serial communication 260 Serial communication settings for the data transfer 8 2 7 Process settings 300 Process value settings for analogue signal start stop functions 8 3 Process protection 400 Rim e the process and mains 84 1 O settings 500 Input and output settings for control and monitoring 8 5 Analogue input 510 8 5 1 Digital inputs 520 8 5 2 Analogue output 530 8 5 3 Relays 550 8 5 4 Virtual I Os 560 8 5 5 Logic and timers 600 Settings for logical functions and timers 8 6 Operation status 700 Viewing of operation parameter values 8 7 Trip log 800 Viewing of trip messages and trip data 8 8 System data 900 Emotron TSA model software and hardware version Service 8 9 CG Drives amp Automation 01 5980 01r0 Functionality 55 Description of menu table layout 8 D 332 Init Torque Read only Stp T9 Resolution of settings The resolution for all range settings described in this chapter is 3 significant digits unless stated otherwise Table 22 shows the resolutions for 3 significant
182. o enable START commands reverse and forward run from the control keys go to the description in section 7 1 1 page 39 menu 2151 The RESET key is activated by default It will remain active as long as one of the keyboard alternatives is selected in menu 216 If the Enable function is programmed on one of the digital inputs this input must be active to allow START STOP 6 4 Function keys The function keys operate the menus and are also used for programming and read outs of all the menu settings Table 17 Function key commands Step to lower menu level ENTER Confirm a changed setting ENTER Step to higher menu level ESCAPE Ignore a changed setting with ESC out confirming SU Step to previous menu within commands from the control panel q PREVIOUS the same level PREV Move cursor one position to the Table 16 Control key commands left Start with reversed Step to next menu within the left rotation gt same level START REVERSE RUN Requires reversing NEXT HES Move cursor one position to the contactor right Stop motor MINUS Decrease a value STOP RESET Reset softstarter after r Change a selection a trip Or E ios Y CSR Start reverse jog function START START FORWARD RUN Start with forward PLUS Increase a value right rotation Change a selection FWD gt de Fwo O KD Joc D gt di Start forward jog function NOTE It is n
183. of load monitor alarm levels according to menu group 417 NOTE Always level controlled even though edge control may be chosen in menu 214 Spinbrake 13 See description Spinbrake page 39 Can be activated either from inactive state softstarter stopped but motor rotating or active state when running Ext Alarm 1 14 16 Reserved for future use Be aware that if there is nothing connected to the input the softstarter will trip at External Alarm 1 immediately NOTE The External Trip is active low NOTE Activated according to AND logic See menu 2549 Ext Alarm 2 17 Be aware that if there is nothing connected to the input the softstarter will trip at External Alarm 2 immediately NOTE The External Alarm 2 is active low See menu 254A Timer 1 18 Timer 1 Delay 6343 will be activated on the rising edge of this signal Timer 2 19 Timer 1 Delay 6313 will be activated on the rising edge of this signal Timer 3 20 Timer 2 Delay 6323 will be activated on the rising edge of this signal Timer 4 Table 25 21 Timer 1 Delay 6333 will be activated on the rising edge of this signal Parameter Set Set Ctrl 1 Set Ctrl 2 Digital Input 2 522 to Digital Input 4 524 Same function as Digln 1 521 Default setting for DigIn 2 522 is Stop For DigIn 3 523 the default is Set Ctrl 1 and for DigIn
184. ol with or without current limit is recommended instead The use of the braking functionality is not recommended for motors connected in parallel 4 4 6 Running motors linked together When starting and running motors mechanically linked together but with one softstarter connected to each motor there are two kinds of operations available The first is to start the motors at the same time using voltage control with or without current limit The second is to start one motor first with torque or voltage control and after the motor has reached full speed the voltage to the other motors is ramped up using voltage control 4 4 7 Heat dissipation in cabinets For guidelines regarding calculation of heat dissipation in cabinets please contact your cabinet supplier The required data is found in Technical Data Chapter 13 page 139 4 4 8 Insulation test on motor When testing the motor with high voltage e g insulation test the softstarter must be disconnected from the motor This is due to the fact that the softstarter will be seriously damaged by the high test voltage 4 4 9 Operation above 1 000 m All ratings are stated for operation at maximum 1 000 m over sea level If the softstarter is operated at 3 000 m for example it must be derated and it is likely that a higher rated model than normal is required to fulfil the task See further information in section 13 3 2 page 143 4 4 10 Aggressive environment conditions
185. ome applications the star delta starter cannot be used as the resulting torque in a star connection is too low to start rotating the load On the other hand for low load applications further savings of starting current are impossible even though a big torque reserve is available Moreover the resulting abrupt rise of torque first at start and later when changing from star to delta connection may contribute to mechanical wear The high transient currents during start delta transition create unnecessary excess heat in the motor Better performance is achieved with a voltage ramp start which a simple electronic softstarter can provide The voltage is increased linearly from an initial value to the full supply voltage by means of phase angle control The resulting torque and current characteristics are shown in the following figure VT 25 Torque IW 1 5 0 5 o n ns 0 0 5 Vi 8 Current 0 nns 0 0 5 Fig 79 Soft starting voltage ramp Obviously a much smoother start is realised compared to the star delta start and the starting current is decreased A softstarter is often used to keep the starting current below a desired level For the example above setting a current limit of three times the nominal current may be desirable The following figure shows the resulting torque and current characteristics CG Drives amp Automation 01 5980 01r0 Softstarter theory 129 Tih 95 Torque 2 1 5
186. on and one serial communication option with RS485 interface which has galvanic isolation These options are described in a separate manual CG Drives amp Automation 01 5980 01r00 Options 137 138 Options CG Drives amp Automation 01 5980 01r00 13 Technical data Table 37 Emotron TSA Size 1 model TSA52 016 TSA52 022 TSA52 030 Duty Normal Heavy Normal Heavy Normal Heavy Rated current In soft A 16 10 22 12 30 18 Motor size Py mot 400 V kW 7 5 4 11 5 5 15 7 5 Motor size Py mot 460 V hp 10 5 15 7 5 20 10 Recommended load fuses A 20 20 25 25 35 35 Ra motor power 20 20 20 20 20 20 Average power loss if 10 starts hour W 20 21 21 22 21 23 Power consumption control supply VA 20 20 20 20 20 20 Dimensions H1 H2 x W x D mm 4 246 296 x 126 x 188 246 296 x 126 x 188 246 296 x 126 x 188 Mounting position Vertical Vertical Vertical Weight kg 5 5 5 5 5 5 Busbar connection mm 15 x 4 Cu M6 15 x 4 Cu M6 15 x 4 Cu M6 Cooling system Convection Convection Convection Protection class IP20 IP20 IP20 Table 38 Emotron TSA Size 1 model TSA52 036 TSA52 042 TSA52 056 Duty Normal Heavy Normal Heavy Normal Heavy Rated current In soft A 36 21 42 25 56 33 Motor size Ph mot 400 V kW 18 5 7 5 22 11 30 15 Motor size Ph mot 460 V hp 25 15 30 20 40 25 Recommended load fuses A 40 4
187. on test on motor 26 Bda tea tes 74 Digital comparators 100 IT earthing system 26 Blower nenian 24 Digital inputs J Brake is 81 Additional corista 95 DER tench Meet Teta 82 Board Relay renan ge Ja a e seeds ADB ES Dynamic vector sccessssseecsessseeses 81 Did 94 JOG FWD key un 34 EE te 81 Digla OA 95 JOG REV key en 34 Bee ee 95 Dimensions ococnononnnnnnoninnonnnininnnnonos 10 K Brake chopper 137 Direct on line DOL sn 78 KES Gopra a desea ers 34 Braking ici ster 81 Dismantling and scrapping 6 Busbar LEE 13 Display noroi riae 33 L DO Essas e 78 LANGUAGE cassiane assobios arauto 57 c Dynamic vector brake 81 82 LCD diepla ois tii 34 Cabinet mounting essa 9 E Level control ooocoononninnccnconannnon 53 60 CE marking unan nas 6 Load default 67 Centrifuge ceu seres adiada sesta resinas 25 Earth fault relay rice e GE E S TA 46 84 Checker 29 ER e a A 137 LOC REM key eat ae oak a 35 Clock logic monica 113 Edge control RE Sd ig 52 60 Local control cecccccccccscceccsecceceeesceceeeee 59 Clock settings conocio 119 Electrical specifications 139 E A RR 100 105 Clockwise rotary field 94 Emergency emcmocoonocnonannnnonincnncnananinnananos 1 caen tere aos 118 Coast s deceit EET Bi ENG A is 6 Low Voltage Directive 6 Com Type imita 73 ENG61800 3 eseeseneeeeees 6 CG
188. onfigure parameters for the serial communication options The RS485 and USB option com type setting USB RS485 in menu 261 uses the standard Modbus RTU protocol with a selectable baudrate in menu 2621 and Modbus address 2622 In addition to this there are also a number of fieldbus options available e g Profibus DeviceNet ModbusTCP Profinet IO etc When using a fieldbus option menu 261 Com Type must be set to Fieldbus The detailed fieldbus configuration is contained in menu 263 Fieldbus and its Submenus The com type RS232 is reserved for future RS232 options but is also used to perform a soft reset of the Fieldbus module which is required after e g node address configuration in many cases network dependant For more information see Chapter 9 page 123 and respective option manual There is also the onboard CB RS232 which is always active with fixed baudrate 9600 and fixed address 1 see Chapter 3 2 page 14 Communication Type 261 Valid communication option slot 261 Com Type Modbus RTU 262 Set up the parameters for Modbus RTU communication 262 Modbus RTU Stp Baudrate 2621 Set the baud rate for the communication NOTE This baud rate is valid only for communication via the RS485 and USB options 2621 Baudrate Stp FA 9600 Default 9600 2400 4800 9600 19200 38400 57600 115200 Selected baudrate O aj A W N R O
189. ontinuously e For bigger changes you can also directly select a digit with the cursor using the PREV and NEXT keys and change this with the or keys e Press the Toggle key to change the sign of the entered value only valid for certain parameters The sign of the value will also change when zero is passed Press ENTER to confirm the value The cursor to the left will stop flashing e Press ESC to leave the edit mode Entering lock code The lock code in menu 218 is inserted from the right to the left the position indicated with a cursor The digit is set by scrolling with the keys and the cursor is moved with the PREV key to the left in order to enter the next symbol Then the NEXT key can be used to go to the right and change something if needed When finished this is confirmed with ENTER NOTE When the control panel is locked the only menu in which it still is possible to use the A keys is 218 Lock Code This method is also used for new entries in e g User Unit or Unit Name Digits or characters are added from right to left in the same way as described above 6 4 2 Jog key function The and keys can be programmed for jogging enabling a manual jog start to be done from the control panel by pressing and holding the key To activate the jog key function see instructions in Jog functions on page 40 To deactivate the jog key function unlock the keyboar
190. ontrol signal outputs Output relays contact Analogue output voltage current 8 A 250 VAC or 24 VDC resistive load 3 A 250 VAC inductive load 0 10 V 2 10 V 0 20 mA 4 20 mA Analogue output load impedance Voltage signal min load 700 Q current signal max load 500 Q Control signal supply 24 VDC 24 VDC 5 Max current 50 mA Short circuit and overload proof 13 2 Semi conductor fuses Always use standard commercial fuses to protect the wiring and prevent short circuiting To protect the thyristors against short circuit currents superfast semiconductor fuses can be used if preferred Use fuses with It values lower or equal to Table 41 Table 41 Semi conductor fuse TSA model 2 A It fuse at 700 V 016 50 1 500 022 70 2 800 030 100 3 600 036 125 6 900 042 150 11 000 056 175 14 000 070 250 42 000 085 300 55 000 100 400 99 000 CG Drives amp Automation 01 5980 01r0 Technical data 141 13 3 Environmental conditions Normal operation Ambient temperature oo Max 55 C by derating 2 C in excess of 40 C see 13 3 1 Atmospheric pressure 86 106 kPa Relative humidity Max 95 non condensing Altitude Max 1 090 ti Max 4 000 m by derating 1 100 m in excess of 1 000 m with I O board max 2 000 m see 13 3 2 E According to IEC 60721 3 3 Vibrations Mechanical conditions class 3M4 2 9 Hz
191. option Profi IO 1 Check that the software version number on the first page of a ee 10 Sn this manual matches the software version in the softstarter Ge DeDeviceN t See chapter 8 9 1 page 121 option M Modbus TCP With help of the index and the table of contents it is easy to P Profibus track individual functions and find out how to use and set R RS485 them U USB The Quick Start Guide can be put in a cabinet so that it is 8 IT net option aa Je always easy to access in case of an emergency 9 Brand label A Standard 10 Software A Standard software 11 Standard CE approved CG Drives amp Automation 01 5980 01r0 Introduction 5 1 5 Standards The softstarters described in this instruction manual comply with the standards listed in Table 2 For the declarations of conformity and manufacturers certificate contact your supplier for more information or visit www emotron com or 1 5 1 Product standard for EMC The Emotron TSA softstarter complies with the product standard EN IEC 60947 4 2 2007 The standard Emotron TSA softstarter is designed to meet the EMC requirements according to category C1 www cgglobal com Table 2 Standards Market Standard Description EMC Directive 2004 108 EC European Low Voltage Directive 2006 95 EC WEEE Directive 2002 96 EC EN 60204 1 Safety of machinery Electrical equipment of machines Part 1 General requirements Contactors and motor starters Seat Part 3 EMC requir
192. or longer than the set Locked Rotor Time this will cause an alarm and the action selected in menu 4221 will be executed 8 4 3 Mains Protection 430 The Emotron TSA continuously monitors the mains voltage This means the motor can easily be protected from over and undervoltage as well as from voltage unbalance conditions A phase reversal alarm is also available Voltage Unbalance Alarm 431 Under this menu the settings for a voltage unbalance alarm are selected Voltage Unbalance Alarm Action 4311 In this menu the alarm action for a voltage unbalance alarm is selected The following alarm actions are available 4311 VoltUnbal AA stp fl No Action Default No Action Locked Rotor Current 4223 The current limit is normally 4 8 times the nominal motor current menu 224 but can be changed here 4223 LockRotCurr Stp FMI 480 Default 480 4 8 x In mot Range 100 1000 1 0 x Ih mot 10 0 X In met No Action O 4222 LockRotTime Hard Trip 1 stp Du 5s Soft Trip 3 For a definition see Table 21 page 45 Default 5s Warning 4 Range 0 1 10s Voltage Unbalance Level 4312 This menu is available if the voltage unbalance alarm is enabled in menu 4311 Here the maximum allowed voltage unbalance level is entered expressed as a percentage of the nominal motor voltage As soon as the difference between any two line voltages
193. ot possible to simultaneously activate the Run Stop commands from the keyboard and remotely from the terminal strip Exception is the J og function which can give a start command see Jog functions on page 40 34 Operation via the control panel CG Drives amp Automation 01 5980 01r0 6 4 1 key function To manually change a value or a selection or to enter a new value the and active the keyboard must be unlocked as it is by default menu 218 keys are used For this function to be Changing parameter selection o o nm To change selection in a menu press the or keys to scroll between the available alternatives The cursor to the left area E is flashing while doing so To confirm a selection press ENTER and the cursor will stop flashing Editing parameter values Most of the parameters can be changed during operation without stopping the sofistarter The parameters that can not be changed during operation are in this manual marked with a lock symbol NOTE If you try to change a function during operation that only can be changed when the motor is stopped the message Stop First is displayed o e e To change a parameter value press the or keys The cursor to the left is flashing while the value is increased or decreased If you keep the or keys pressed the value will increase or decrease c
194. ou have to use one of the communication option boards RS485 or USB NOTE This RS232 port is not galvanically isolated WARNING Correct and safe use of a RS232 connection depends on the ground pins of both ports having the same potential Problems can occur when connecting two ports of e g machinery and computers where both ground pins have not the same potential This may cause hazardous ground loops that can destroy the RS232 ports The on board RS232 connection is not galvanically isolated The RS485 and USB option boards from CG Drives amp Automation are galvanically isolated Note that the on board RS232 connection can safely be used in combination with commercially available isolated USB to RS232 converters 9 2 Parameter sets Communication information for the different parameter sets The different parameter sets in the softstarter have the following DeviceNet instance numbers Profibus slot index numbers Profinet IO index and EtherCAT index numbers Modbus Param DeviceNet Profibus Profinet IO EH index set Instance Slot Index index hex number 43001 168 160 to 19385 A 43899 172 38 20283 appease 44001 172 140 to 20385 p 44899 176 18 21283 See 45001 176 120 to 21385 E 45899 179 253 22283 339979706 46001 180 100 to 22385 B 46899 183 233 23283 Rear Parameter set A contains parameters 43001 to 43899 The parameter sets B C and D contain the s
195. output signal will be active when the maximum number of restarts is reached and the softstarter stays in fault condition Example Autoreset for undervoltage In an application it is known that the main supply voltage sometimes disappears for a very short time a so called dip That will cause the softstarter to trip an Undervoltage alarm Using the Autoreset function this trip will be reset automatically Enable the Autoreset function by making the reset input continuously high e Activate the Autoreset function in menu 2511 Allowed Autoreset Attempts The autoreset for the undervoltage alarm is activated in menu 2564 The set delay time starts counting when the fault is gone If the softstarter is stopped an undervoltage cannot be detected and the delay time starts counting immediately after the alarm action has been executed 7 4 Programmable I O There are a number of selectable signals for analogue and digital inputs and outputs gathered under section 8 5 page 91 1 analogue input 510 1 analogue output 530 e 4 digital inputs 520 with the possibility for up to 6 extra digital inputs if extended I O option boards max 2 are fitted No digital outputs are available e 3 relay outputs 550 with the possibility for up to 6 extra relays if extended I O option boards max 2 are fitted e There are also 8 virtual I Os 560 Parameters for serial communication are described in sectio
196. overload has Mon Maxalarm Soft trip been reached 4112 Warning No action Hard trip Max pre alarm level overload has Mon MaxP reAl Soft trip been reached 4122 Warning Check the load condition of the machine No action Check the monitor setting in section 8 4 page 84 e Hard trip Min alarm level underload has Mon MinAlarm Soft trip been reached 4142 Warning No action e Hard trip Min pre alarm level underload MON MINETEAI Soft trip has been reached 4132 Warning Motor Dr GE 1 t value is exceeded Check for mechanical overload on the motor or the Area D 12t Soft tri H 2311 Overload on the motor according machinery bearings gearboxes chains belts etc 1 ane to the prog rammed it settings Change the Motor 12t Current setting in menu 2312 134 Troubleshooting Diagnoses and Maintenance CG Drives amp Automation 01 5980 01r0 Table 36 Alarms with possible causes and remedies Trip warning rm Action message Ala CHo Possible cause Remedy eh Menu and indicator Motor term Check wiring between softstarter and motor N Open motor contact cable or SCH open motor Hard trip E Initiate a restart If the alarm appears again contact your i motor winding 3 terminal open local Emotron TSA supplier i i Mul phase loss Sor POSES supply Check fuses and mains supply voltage Heatsink temperature too high Check the cooling of the softstarter cabinet Too high am
197. performed When the stop is finished the mains contactor for reverse running K2 will be deactivated by relay R2 If both Digln 1 RunFWD and Digln 3 RunREV are closed at the same time a stop is performed according to the stop settings in menu group 340 In this case no start will be allowed A motor can switch from forward to reverse direction as follows Open DigIn 1 RunFWD while the motor is running in forward direction Then close DigIn 3 RunREV As a result the voltage to the motor is switched off and the mains contactor for forward running K1 is deactivated by relay R1 After a time delay of 100 milliseconds the mains contactor for reverse running K2 will be activated by relay R2 and a start in reverse direction will be performed The motor can switch from reverse to forward running in the same way by opening Digln 3 RunREV while running in reversed direction and then closing DigIn 1 RunF WD 20 Connections CG Drives amp Automation 01 5980 01r0 4 Application guidelines This chapter is a guide to selecting the correct sofistarter rating and softstarter functionality for different applications To make the right choice the following tools are used The AC 53 norms The AC 53 norms are defined in the EN IEC 60947 4 2 2007 standard for electronic softstarters The purpose of these norms is to aid in selecting a softstarter with regards to duty cycle starts per hour and max
198. ploglist6 Communication data in Appendix 2 Bro oes __ 880 roes EE Boo me Bro reseno o e poe Um rage o E 900 system Data ee OSOS mo seme mt To To jo om Netsevice o o o o o 912 semet o o o o o 820 rsabata 0 o A A AA om iam peo mis fumo o E 822 software aos fm fumo o E Do Too fuso mo fm o 9225 Butane faros fumo fumo o Oo a a Do fo E mo CTI IN Do To fuso mo fm To 162 CG Drives amp Automation 01 5980 01r0 31044 E Do o fis E RR DO fas E 42308 Int Modbus Inst Fieldbus Modbus DI oo fes fm fun OD DI o fes fm fim OD 2 um um O 924 Hardware CG Drives amp Automation 01 5980 01r0 163 Appendix 2 Trip message communication data Trip log list 31101 31154 810 31201 31254 820 31301 31354 830 Modbus Instance no 31401 31454 840 DeviceNet no 31501 31554 850 31601 31654 860 31701 31754 870 31801 31854 880 31901 31954 890 Trip log list 121 245 122 43 810 122 90 122 143 820 122 190 122 243 830 123 35 123 88 840 Profibus slot index 123 135 123 188 850 123 235 124 33 860 124 80 124 133 870 124 180 124 233 880 125 25 125 78 890 Trip log list 1101 1154 810 1201 1254 820 1301 1354 830 i 1401 1454 840 Profinet IO index 1501 1554 850 1601 1654 860 1701 1754 870 1801 1854 880 1901 1954 890 Fieldbus format Modbus format See respective parameter 164 CG Drives
199. pted to mA or V according to the selection in AnOut Setup 532 533 AnOut Advan Stp Al Analogue Output Minimum 5331 This parameter is automatically displayed if User mA or User V is selected in menu AnOut Setup 532 The menu will automatically adapt to current or voltage setting according to the selected setup Only visible if 532 User mA V 5331 AnOut Min Stp FA 4 00mA Default 4 00 mA Range 0 00 20 00 mA O 10 00 V Analogue Output Maximum 5332 This parameter is automatically displayed if User mA or User V is selected in menu AnOut Setup 532 The menu will automatically adapt to current or voltage setting according to the selected setup Only visible if 532 User mA V 5332 AnOut Max Stp FA 20 00mA Default 20 00 mA Range 0 00 20 00 mA 0 10 00 V AnOut Function Minimum 5334 With AnOut Function Min the physical minimum value is scaled to selected presentation The default scaling is dependent of the selected function of AnOut 531 5334 AnOutFcMin Stp A Min Default Min Min 0 Min value Max 1 Max value User defined 2 Define user value in menu 5335 Table 26 page 96 shows corresponding values for the min and max selections depending on the function of the analogue output 531 Table 26 AnOut Function Max Value
200. quate for the purpose Derating 2 C is calculated for a temperature of 10 C above the rated 10 C x 2 20 Hence the nominal current must be derated by 20 To select a model that is adapted to the derating demands the next higher rated model is checked TSA52 085 rated for 85 A nominal current 85 A 20 x 85 A 68 A which is lower than the required 70 A An even higher rated model is checked TSA52 100 rated for 100 A nominal current 100 A 20 x 100 A 80 A which is well above the required 70 A and therefore TSA52 100 is the model to be selected in this case 142 Technical data CG Drives amp Automation 01 5980 01r0 13 3 2Derating at high altitude The Emotron TSA softstarter can operate at an altitude up to 1 000 m without derating Above 1 000 m the thinner air will have several negative effects on the performance of the softstarter therefore a derating is done For elevations in excess of 1 000 m the derating of the nominal current is 1 per 100 m The Emotron TSA softstarter can be operated up to 4 000 m in which case it can only be operated at 70 of the nominal current it was originally constructed for NOTE If the unit has an I O board the maximum altitude with derating is 2 000 m Example A motor with the following data is going to be used at 2 100 m altitude Voltage 400 V Current 42 A normal duty Power 22 kW Due to the high altitude the TSA model 52 042 w
201. r Ee 40 pO POU UBS Com Active 98 Fieldbus communication active ES A EE Overtemp 101 Softstarter overtemperature condition IL3 48 Logic output 3 inverted is active trip L4 49 Logic output 4 PTC Alarm 103 PTC alarm active trip or warning IL4 50 Logic output 4 inverted PT100 Alarm 104 PT100 alarm active trip or warning F1 51 Flip flop output 1 12t 105 Et alarm active trip or warning IFA 52 Flip flop output 1 inverted Ext Alarm 1 106 Output active F2 53 Flip flop output 2 Ext Alarm 2 107 Output active IF2 54 Flip flop output 2 inverted Option 112 GR occurred in built in option F3 55 Flip flop output 3 IF3 56 Flip flop output 3 inverted F4 57 Flip flop output 4 IF4 58 Flip flop output 4 inverted CTR1 59 Counter output 1 ICTR1 60 Counter output 1 inverted 98 Functionality CG Drives amp Automation 01 5980 01r0 Motor voltage Reverse current rake t t gt t s 0 15 i i tejo dj des Delay Starttime Full voltage Stop time Fig 54 Relay functions Relay 2 552 Board Relay 554 to 559 These additional relays are only visible ifan I O option board is fitted in slot 1 or 2 The outputs are named B1 Relay 1 B1 Relay 3 and B2 Relay 1 B2 Relay 3 B stands for board and 1 and 2 is the number of the board which is related to the position of the I O option board on the option mounting plate The functions and selections
202. r data serere bisey esy 40 42 60 Run commande 34 Torque eonprol 132 Motor poles union 62 EES tier Tipae a ao 34 45 Motor speed soosiana 62 Running motors connected in Trip Message log 120 Motor ventilation G2 parallel ea eo eke ae TSA Datta tient teure 121 Mounting motas hada 2 Running motors linked together 26 Type code number 5 Mounting schemes 10 S U N Safety caisson on en aero E 76 Nominal data eee 61 Semi conductor fuses anna ehe 144 Unit name sessssssessssesesesssrsrereseseeee 122 Normal Lodi 84 Service information ennan 121 Unlock Code cccconnononannornoonosnons 59 leegen string tate 88 Set reset delay ccccesccsessessessesceeeseens 104 y o E e eo n 62 Operation PRP E E 57 114 Gils ca mande ee 26 Virtual O cion ice hese 99 Operation above 1000 m 26 Sill amare 40 KE 115 Options visi 137 ui a er o load Bey oe 26 Voltage control sssssseseesseeseress 78 81 Brake chopper 137 ee A Voltage unbalance wees 89 External Control Panel ECP 137 Soft trip GE 45 HO Board 137 Softstarter rating esseseseseersresreress 21 W Software cid Dl ta N 1 45 116 OR operator emmccoccnnonncnnonannnranincnnenos 105 S 1 anng nes Over voltage es 90 Sead IRAN NV aaa AL Weekday en 119 Special conditions Aeren 26 Naight E spots cs shee aden 10 P Spinbrakes ss cussies dea an 39 95 Wireless connection oec 99 Parameter sets scces
203. r mA V 5131 AnIn Min Stp FA 0V 4 00mA Default Min O V 4 00 mA Ranee 0 00 20 00 mA ge 0 10 00 V Anln Max 5132 Parameter to set the maximum value of the external reference signal Only visible if 512 User mA V 5132 AnIn Max Stp 10 0V 20 00mA Default Max 10 00 V 20 00 mA Range 0 00 20 00 mA ge 0 10 00 V Special function Inverted signal If the AnIn minimum value is higher than the AnIn maximum value the input will act as an inverted input See Fig 52 92 Functionality CG Drives amp Automation 01 5980 01r0 n rpm 100 Inverted signal Anln Min gt Anln Max 0 10V 20 mA Input signal Fig 52 Inverted input Anin Function Min 5134 With AnIn Function Min the physical minimum value is scaled to selected process unit The default scaling is dependent of the selected function of Anln 511 5134 AnIn FcMin Stp FA Min Default Min Min 0 Min value Max 1 Max value User E defined Define user value in menu 5135 Anln Function Value Min 5135 With AnIn Function VaMin you define a user defined value for the signal Only visible when user defined is selected in menu 5134 5135 AnIn VaMin Stp FA 0 000 Default 0 000 Range 10 000 000 10 000 000 Anin Function Max 5136 With AnIn Function Max the physical maximum value is scaled to
204. r sets see section 7 2 3 page 42 223 Motor Power For explanation of the different abbreviations used in this 8 Stp DM Pn soft KW chapter see Chapter 1 7 2 page 7 E Ro Default Ph soft 25 400 x P default see Table 23 Nominal Motor Voltage 221 Range 7 Zen page 61 Set the nominal motor voltage Un mor SS Resolution 3 significant digits 221 Motor Volts Table 23 Nominal data for CG motors complying to IE2 class 8 stp FIM 400V of IEC 60034 30 Default 400 V for Sl units Default Default Default Default j 460 V for US units Softstarter nominal nominal nominal nominal nominal power speed power speed Range SEN current 400V 050Hz 0460V 60Hz Resolution 1V A Sl units Sl units US units US units kW rpm hp rpm NOTE The Motor Volts value will always be stored as a 3 16 7 5 1 440 10 1 730 digit value with a resolution of 1 V 22 11 1 460 15 1 750 30 15 1 460 20 1 750 Nominal Motor Frequency 222 36 185 1 465 25 1 760 Set the nominal motor frequency 22 22 1 465 30 1 760 56 30 1 465 40 1 760 222 Motor Freq 8 stp AML 50Hz 70 37 1 480 50 1 780 85 45 1 475 60 1 770 A 50 Hz for Sl units Default 60 Hz for US units 100 55 1 480 75 1 780 Range 50 Hz 60 Hz 140 75 1 480 100 1 780 e E 170 90 1 480 125 1 780 200 110 1 485 150 1 780 Nomin
205. re available OR operator 8c AND operator A EXOR operator Expressions according to the following truth table can be made see also the example below Input Result amp AND OR MEXOR plrlolo plolr o Gi ol ol o Gi bal bal o oO KB BK oO The output signal can be programmed to the relay outputs or used as a virtual connection source 560 The logic expression must be programmed by means of the menus 6211 to 621B and its actual appearance can be viewed in menu 621 with example below 621 Logic 1 Read only Stp 1 amp 2 amp 3 amp 4 CG Drives amp Automation 01 5980 01r0 Functionality 105 Logic 1 Expression 6211 Selection of execution order of the logic expression for the Logic 1 function 6211 L1 Expr Stp A 1 2 3 4 Default 1 2 3 4 1 2 3 4 0 Default execution order see explanation below 1 2 2 4 1 Alternative execution order see explanation below e Parentheses show the order in which the Logic 1 Inputs are combined according to 6211 1 2 3 and 4 represent the Logic 1 Input signals selected in menu 6212 6214 6216 and 6218 The dots stand for the Logic 1 Operators amp or whose values are selected in menus 6213 6215 and 6217 To build the Logic 1 expression using the default selection in menu 6211 the execution order is a
206. read 1 to 8 write parameters possible Modbus addresses are entered the actual numbers are found in the Fieldbus option manual 2661 FB Signal 1 Stp FA 0 Default 0 Range 0 65535 Fieldbus Status 269 Sub menus showing status of fieldbus parameters For detailed information please see the Fieldbus option manual 269 FB Status Read only stp CG Drives amp Automation 01 5980 01r0 Functionality 75 8 3 Process 300 These parameters are mainly adjusted to create a process signal used for analogue start stop The input signal is rescaled in order to be used for viewing or as a signal for the analogue comparators The read out actual value depends on the selected process source 321 8 3 1 View Process Value 310 This menu is only visible if a process source is selected in menu 321 Process Source i e by default the menu is not shown When selected the actual value of the active on line process signal is viewed here 310 ProcessValue Read only Stp Process Source 321 and Process Unit Dependent on 322 Min according to menu 324 max All modes according to menu 325 8 3 2 Process Settings 320 With these settings the softstarter process value can be set up to fit the application The process value in menus 110 120 310 and 711 all use the process unit selected in 322 for the application e g rpm bar or m3 h
207. rectly from the first start of the motor whereas the following hour is counted not directly but from the moment a new start is done i e no rolling hour 2342 Starts h Stp FAM1 z 10 Default 10 Range 1 99 Minimum time between starts 2343 In this menu a minimum time between consecutive starts can be set If a new start attempt is made before the minimum time is expired an alarm will occur and the action chosen in menu 2341 is performed The alarm remains active until the chosen minimum time has expired and a new start is allowed 2343 MinTBtwStrt Stp FAM1 Off Default off Range 1 60 min Time to next start 2344 In this menu the time to the next allowed start is shown Counts down from set value in menu 2343 2344 TimTNxtStrt Read only A Stp ami min Unit minutes Resolution 1 min Phase Loss Autoreset is available for single phase loss alarm menu 2561 Multiple and internal phase loss A multiple phase loss always results in a hard trip If there is an external phase loss mains supply this is not indicated before an alarm delay of 2 seconds If the phase loss is internal thyristor problem the trip is activated immediately in order to prevent faulty actions from damaging the softstarter and motor If the lost phases reappear within 2 seconds an automatic restart is performed Single phase loss A single phase loss results in an immed
208. ring data to one control panel the other control panel is temporarily disabled NOTE Start commands will be ignored during copying or loading NOTE If the on board RS 232 port is connected to a PC orto an external control panel this will be temporarily locked while copying or loading data to the internal control panel To copy settings from the control board to a control panel use the actual control panel and set 244 Copy to CP to Copy This will copy all user parameter settings stored in the control board and erase any corresponding settings previously stored in the control panel While the data is CG Drives amp Automation 01 5980 01r0 Functionality 67 transferred Copy is flashing on the control panel from which the command was activated while the other control panel will be temporarily inactive When finished Transfer OK is displayed and it will be possible to give a new command from any of the control panels 8 244 Copy to CP stp fq No Copy Default No Copy No Copy O Nothing will be copied Copy 1 Copy all settings NOTE The actual value of menus for viewing will not be copied into control panel memory set Load settings from control panel 245 This function can load single or multiple parameter sets and motor data from the actual control panel to the softstarter control board memory This is carried out much in the same way as abo
209. rning Self cooled motor at low speed too high load Set alarm action to No action No action Wait and start again Number of starts per hour e Hard trip dee Perhaps the number of starts per hour could be decreased Start limit 2341 exceeded min time between ee Soft trip starts n k Kept in menu 2342 or the min time between starts could be Warning pi increased menu 2343 During start stop and jog Stop first changing parameters is not Set parameters during standstill permitted Thyristor open Hard trip a EES Service needed Contact your local Emotron TSA supplier Thyristor short Hard trip Damaged thyristor Service needed Contact your local Emotron TSA supplier Tob low phase mainssubpi Make sure all three phases are properly connected and No action voltage H ppm that the terminal screws are tightened i EE k that the 3 ph i is within th Under voltage Hale trip 4331 Mains voltage dip due to starting eneg t ar the phase mains SUppIy voltage is within the Soft trip E i limits set in menu group 433 8 other major power consuming i Ed nto e Warning s Use other mains supply lines if dip is caused by other machines on the same line machinery No action Hard trip Check 3 phase mains supply Volt unbalance Soft trip 4311 Mains supply voltage unbalance Check settings in menu 4312 and 4313 Warning CG Drives amp Automation 01 5980 01r0 Troubleshooting Diagnoses and Mainte
210. rque boost parameter enables a high torque to be obtained by providing a high current for 0 1 2 seconds at start This enables a soft start of the motor even if the break away torque is high at the start An example is crushing mills applications etc A Torque boost current limit FLC tis Ex Torque boost time Fig 45 Torque boost principle Torque boost may be activated before the start ramp The current regulator is activated immediately and the current is controlled to be at the set Torque Boost Current Limit 3371 for the set Torque Boost Time 3372 See Fig 45 The switch on period remains at the value assigned during torque boost if the Start Method 331 is set to torque control linear or square or if a current limit is applied in menu 335 In this case the torque or the current regulator respectively will handle the transition from torque boost to ramping If voltage control is selected as start method with or without current limit the switch on period is set to the correct initial value for the voltage ramp If torque boost is used the total start time is prolonged with the Torque Boost Time 3372 Torque Boost Current Limit 3371 3371 TB CurrLim Stp FA Off Default Off Range Off 300 700 of In mot 224 Torque Boost Time 3372 3372 TB Time Stp A 1 0s Default 10s Range 0 1 2 0s 8 3 4
211. rward direction a REV command will be ignored To define reverse and forward rotation we assume that the motor is connected according to section 3 1 page 12 In this menu you set the allowed rotation for the motor 219 Rotation Stp FA FWD Default FWD Limited to forward right rotation FWD 1 REV key JOG REV key and reverse commands are disabled Limited to reverse left rotation FWD key JOG FWD key and forward REV 2 commands are disabled See note below FWD REV 3 Both rotation directions allowed See note below NOTE When reversed rotation is selected REV or FWD REV in menu 219 this requires phase reversal contactors See Fig 15 page 19 CG Drives amp Automation 01 5980 01r0 Functionality 59 8 2 2 Remote signal Level Edge 214 In this menu you select the type of control used for the input signals for RunFWD RunREV and RESET that are operated via the digital inputs on the terminal strip The input signals are default set for edge control and the input signals will be activated by the low to high or high to low transition of the input When level control is selected the input signals will be active as long as the input is kept high or low See section 7 6 page 51 US units The corresponding default values for US units will be e Power hp Torque Ib ft e Temperature F Nominal motor frequency will be preset to
212. s alarm is only active if there is a current limit coupled to the start method settings in 331 and 335 An alarm is activated if the current still is at the current limit when the start time has expired This means that the motor has not reached full speed If no action is programmed there will be a current peak at the end of the start ramp Autoreset is available for this function menu 2525 236 CurrLim AA stp fA Hard Trip Default Hard Trip No action O Hard Trip 1 For a definition see Table 21 page 45 Soft Trip 3 Warning 4 8 2 5 Parameter set handling 240 Parameter sets are used if an application requires different settings for different modes See detailed description in Working with parameter sets page 41 There are four available parameter sets that can be individually configured and stored in the control panel The selected motor M1 M4 212 decides the parameter settings for the motor data in menu group 220 See instructions in Handling motor data in parameter sets page 42 Select Set 241 Here you select the parameter set directly or from where the selection is going to be controlled Every menu included in the parameter sets is designated A B C or D depending on the active parameter set This is shown in the lower left area of the display i e with an Y as default The active set is also showed in 721 TSA Status The parameter sets can be c
213. s follows 1 Input 1 is combined with Input 2 using Operator 1 2 Input 3 is combined with the expression 1 2 using Operator 2 3 Input 4 is combined with the result of 1 2 3 using Operator 3 The alternative execution order leads to 1 Input 1 is combined with Input 2 using Operator 1 2 Input 3 is combined with Input 4 using Operator 3 3 Expression 1 2 is combined with expression 3 4 using Operator 2 Example Input 1 CA1 set in menu 6212 Input 2 F1 menu 6214 Input 3 T1Q menu 6216 Input 4 A2 menu 6218 Operator 1 amp AND set in menu 6213 Operator 2 OR menu 6215 Operator 3 amp AND menu 6217 The following expression is created using the menus above CA18F1 T1Q8 1A2 With the default setting for L1 Expression this is viewed in 621 as 621 Logic 1 Stp 182 3 amp 4 representing CA182F1 T1Q 8z142 Let s use the following values on the input signals as an example CA1 1 active high Fl 1 active high TIQ 1 active high 142 0 inactive low With the respective values inserted the resulting logic expression is 1 amp 1 1 amp 0 which is equal to 0 With the alternative execution order for the L1 Expression the expression is viewed in 621 as 621 Logic 1 Stp 1 amp 2 3 amp 4 representing CAI amp F1 T1 Q amp A2 With the above values inserted the resulting logic expression now becomes 1 amp 1 1 a
214. s menu counter 1 is set to a trip value When the counter value equals the trip value the counter 1 output signal CTR1 is activated high NOTE Value 0 means that counter output is always high 6513 Cl Trip Val Stp A 0 Default 0 Range O 10 000 Counter 1 Value 6514 This menu shows the actual value of counter 1 NOTE Counter 1 value is common for all parameter sets NOTE The value is lost at power down 6514 Cl Value Read only Stp A 0 Default 0 Range O 10 000 Counter 2 652 Refer to description for Counter 1 651 Clock 1 Time On 6011 Time when the clock is activated 6611 Clk1TimeOn Stp IA 0 00 00 0 Default 0 00 00 0 hours minutes seconds Range 0 00 00 0 9 59 59 9 Clock 1 Time Off 6612 Time when the clock is deactivated 6612 Clk1TimeOff stp E 0 00 00 0 Default 0 00 00 0 hours minutes seconds 0 00 00 0 9 59 59 9 Range Clock 1 Date On 6613 Date when the clock is activated 6613 Clk1DateOn Stp FA 2013 01 01 Default 2013 01 01 Range YYYY MM DD year month day Clock 1 Date Off 6614 Date when the clock is deactivated Note that if CIk1 DateOff is set to an earlier date than Clk1DateOn the result will be that the clock is not deactivated at the set date 6614 Clk1DateOff Stp FA 2013 01 01 Default 2013 01 01 Range Y
215. s to the internal control board of the target softstarter menu 245 TSA unit 2 Fig 31 Copy and load parameters between two Emotron TSA units using an external control panel optional NOTE Another solution for copying settings and data between different softstarter units is via PC using the EmoSoftCom PC tool option See section 12 2 page 137 44 Main features CG Drives amp Automation 01 5980 01r0 7 3 Applying limitations alarms and autoreset In order to protect the softstarter and the connected devices the principal operating variables are continuously monitored by the system If one of these variables exceeds the safety limit an error warning message is displayed In order to avoid any possibly dangerous situations the softstarter sets itself into a mode called Trip and the cause of the trip is shown in the display Trips will always stop the softstarter 7 3 1 Alarm types and actions Alarm Any faulty condition Trip Any action on a fault condition which leads to interruption of operation Trips can be divided into hard and soft trips see Table 21 Warning Any action on a fault condition which does not lead to interruption of operation In general an alarm may only be triggered when the softstarter is active e g
216. sed For autoreset SC Remote Default Remote Remote O Jog command via digital input Int Ext 1 Jog command via internal or external keyb control panel Com 2 Jog command via serial communication Spare 3 Reserved for future use Int keyb 5 Jog command via internal control panel Ext keyb 6 Jog command via external control panel 2171 Functionkey Stp FN Toggle Default Toggle Off O No function Toggle 1 Toggle function Loc Rem 2 Local Remote control mode function Both Toggle function and Combined 3 Local Remote control mode function See explanation in 6 5 1 58 Functionality CG Drives amp Automation 01 5980 01r0 Local Run Control 2173 The Local mode of the Loc Rem functionality is defined in this menu see also page 36 When the softstarter is in Local operation mode the display shows EB 2173 LocRunCtrl Stp FN Keyboard Default Keyboard Remote 1 Local start stop command via digital input Local start stop command via control Keyboard j2 panel internal or external Local start stop command via serial Com 3 EE Communication FWD key 2174 The START FWD key gives a start with forward right rotation if the function is activated in this menu The rotation direction must also be permitted in menu 219 Rotation 2174 FWD key Stp FN Default FWD Off
217. selected process unit The default scaling is dependent of the selected function of Anln 511 5136 AnIn FcMax Stp IN Max Default Max Min 0 Min value Max 1 Max value User defined 2 Define user value in menu 5137 Anin Function Value Max 5137 With AnIn Function VaMax you define a user defined value for the signal Only visible when user defined is selected in menu 5136 5137 AnIn VaMax Stp FA 0 000 Default 0 000 Range 10 000 000 10 000 000 NOTE With Anln Min Anin Max Anin Function Min and Anin Function Max settings loss of feedback signals e g voltage drop due to long sensor wiring can be compensated to ensure an accurate process signal Example Process sensor is a sensor with the following specification Range 0 3 bar Output 2 10 mA Analogue input should be set up according to 512 Anln Setup User mA 5131 Anln Min 2 mA 5132 AnIn Max 10 mA 5134 AnIn Function Min User defined 5135 AnIn VaMin 0 000 bar 5136 AnIn Function Max User defined 5137 AnIn VaMax 3 000 bar CG Drives amp Automation 01 5980 01r0 Functionality 93 Anin Filter 5139 If the input signal is unstable e g fluctuation reference value the filter can be used to stabilise the signal See Fig 53 This will result in a 63 change of the input signal within the set AnIn Filter time T After 5 times
218. splayed at start 1 Press to display menu 211 Language Select Language using the and keys Confirm with Sch 2 Press to display menu 221 Motor Volts and set nominal motor voltage Change the value using the and 3 keys Confirm with a Perform in a similar way the following settings Set motor frequency 222 Set motor power 223 Set motor current 224 Set motor speed 225 Set power factor cos p 227 Press to display menu 740 Clock setting Press to display menu 741 Time Change the time using the and keys To activate setting of hh mm ss respectively use the or El keys Confirm with A 10 Press to display menu 742 Date and set date Confirm with Be SS cl JON ht Ve 9 St 11 Switch off power supply 12 Connect digital and analogue inputs outputs as in Fig 19 13 Switch on power supply NOTE For selection of other start method than the default linear torque control see section 7 1 2 page 35 5 5 Control panel operation A manual test run can be executed via the control panel This example demonstrates the set up to carry out for a standard motor Switch on the voltage Once the 3 phase mains and control supply voltage is switched on the softstarter is started and the internal fan only in sizes 2 6 will run for 5 seconds Set the basic data Enter the basic data i e language time and motor data for the connected motor
219. t Off Off 0 Off 1 3600 1 3600 1 3 600 s Stp FA Off Default Off Off 0 Off 1 3600 1 3600 1 3 600 s Load Monitor Min Pre Alarm autoreset 2543 The delay counter starts counting immediately 2543 MinPAlarm Stp FA Off Default Off Off 0 Off 1 3600 1 3600 1 3 600 s Load Monitor Min Alarm autoreset 2544 The delay counter starts counting immediately 2544 MinAlarm Stp FN Off Default Off Off 0 Off 1 3600 1 3600 1 3 600 s External Alarm 1 autoreset 2549 The delay counter starts counting as soon as the relevant external alarm input is inactive 2549 Ext Alarm 1 Stp FA Off Default Off Off 0 Off 1 3600 1 3600 1 3 600 s Softstarter Protection autoreset 255 For alarms that are present to protect the softstarter the following settings for autoreset can be done Overtemperature autoreset 2551 In this menu the delay time for autoreset is set for a softstarter overheated alarm The delay time starts counting when the fault is removed This means the softstarter has to be cooled down When the delay time has elapsed the alarm will be reset and a restart attempt will automatically be made 2551 Overtemp Stp A Off Default Off Off 0 Off 1 3600 1 3600 1 3 600 s Start Limitation autoreset 2552 The delay counter starts counting when the time to next
220. t Hard trip Control voltage supply fault Check control supply voltage level No action Current limit parameters are i i d h Curr limit Hard trip 236 perhaps not matched to the load Increase the start time menu 336 and or the current Soft trip limit at start menu 335 f and motor Warning Curr Unbal Bypass or thyristor fault Service needed Contact your local Emotron TSA supplier No action quis Hard trip External tip connected to digital Check the equipment that initiates the external input Ext Alarm 1 E 4211 input active y A Soft trip t z Check the programming of the digital inputs menu 520 active low function on the input Warning EEN External trip connected to digital Hard trip H 8 Check the equipment that initiates the external input Ext Alarm 2 E 4212 input active ae Soft trip Check the programming of the digital inputs menu 520 e active low function on the input Warning Int phase loss Internal phase loss Service needed Contact your local Emotron TSA supplier Internal alarm Hard trip Service needed Contact your local Emotron TSA supplier Check for mechanical problems at the motor or the No action i Hard tri Torque limit at motor standstill machinery connected tothe motor Locked rotor Soft tri p 422 a blocking of the rotot Set 4221 Locked rotor alarm to No action Adjust Geen 8 Locked Rotor time 4222 and Locked Rotor Current 8 4223 No action Hard trip Max alarm level
221. t function via Virtual I O 560 Reset is selected in the destination menu for the internal connection In the menus for Relays 550 an output signal of the autoreset trip can be set AutoRst Trip Relay is activated when the maximum number of autoresets is reached See more about remote reset control in Reset and Autoreset operation on page 52 To activate the autoreset function Allowed Autoreset Attempts are set in 2511 Once the maximum number of autoresets is reached the softstarter will stay in fault condition indicating that external assistance is required The details of the autoreset counter can be found in Autoreset Attempts 251 on page 69 Example Autoreset for thermal overload A motor is protected by an internal protection for thermal overload When the protection is activated the softstarter should wait until the motor has cooled down enough before resuming normal operation In this case the estimated time for cooling down is 300 seconds When the problem has occurred three times in a short period of time a call for external assistance should be required To do this Enable the Autoreset function by making the reset input continuously high e Set maximum number of restarts to 3 in menu 2511 e Activate Motor Ur to be automatically reset set menu 50 Main features CG Drives amp Automation 01 5980 01r0 2521 to 300 s e Set relay 1 menu 551 to AutoRst Trip
222. t in em OOOO y MINI INN IESO LN TESTO O DID es fm O ape o is TES im iOS Pas Weekdey monday 2926 img im TT ma for e fusos un Jum S EC vemo E E E O SY 10 rip message TJ Di Jl operaron 00 0 S 811 Operation Long fetta Tome 505 ES fam Bis shattPower enos ETE UI em Rio faite shatowers feno umi i um SSS surfarm fenos hoerwjem O OO ooo i faite awS cure feno long t oaafem fai Leman vo AMIA eno long t oavfeme SSS n Lo 811A Heatsnk Tm 31114 Long Eint P 1 0 1 C usmon O ea iste Ce Pst fone tere fem CSCS te ine ee fee INS Patt E fem O Doo Lo fimo TES Slogan Il ESECA ourentis Jm Tan IS ESE 13 votege EELER EREECHEN alae lalallala et ler gt CG Drives amp Automation 01 5980 01r0 161 seres EE ESPA RECETA ens Di fume IAS 8124 araiogven 520 fumei fem SSS 8125 anaiogueout feo Jl ize OSEA is uni um SSS Bi iosause2 fens uma um E fsizafoara fna imate TT safon 5155 E um dP SSCS size tego za ens fumar um SSCS 120 timerta pens maa Jum EO ES sofor III um sr comers fens umae fum s mones fomo CCE O 826 Time owoo00 fena hostem em E INN ION E asim fem o lt Ee EEE a E E So Os foem Dj To fimo CPE Do o fosso finais 820 mogno Page 127 830 meia 840 Meia 850 Triploglist5 RR e as for menu group 810 Trip 860 Tri
223. tactor K1 will be activated For braking K1 will be opened and the second contactor K2 will be activated to change the phase sequence For security reasons it is possible to set a delay time between these two signals in menu 346 To activate the braking method Reverse Current Brake must also be selected in menu 344 The actual speed is detected and the reverse current brake is active until the speed is below a set limit For lower speeds the DC brake is activated DC brake at low speed At low speed the DC brake mode is activated until the stop time in 345 has elapsed In DC brake mode only two phases L2 and L3 are active The DC brake will automatically be deactivated when the motor has stopped or when the stop time has expired Optionally an external rotation sensor can be connected via digital input 520 using logical functions to end the DC braking See section 8 6 page 100 Stop Time 345 Stop Time is defined as the time during which a stop attempt is done This function is available for all stop methods except for Coast NOTE The stop time given in menu 345 is NOT the time during which a full stop is completed It is a time out function for a stop attempt 345 Stop Time Stp A 10s Default 10s Range O 120s Reverse Current Braking Delay 346 A delay time for the reverse current brake function can be set in this menu When the relay configured for
224. tent of the reset When working with several parameter sets it saves a lot of work if menu 242 Copy Set is used for copying sets e g A gt B C gt D etc This will copy the entire contents of a single parameter set to another parameter set and you only need to change the differences in the new set 7 2 3 Handling motor data in parameter sets Motor Data M1 M4 is a kind of parameter set in itself see section 7 1 5 page 40 The motor data settings are gathered under a designated motor and belong to this To change the parameter set to one that includes changes in motor data it is therefore necessary to also change motor in Select Motor 212 The following cases may exist One motor and one parameter set This is the most common case As default all entered data will be saved under parameter set A and the motor data under motor data M1 One motor and two parameter sets This case is useful if you want to alternate between for instance two control sources or two different starting or braking requirements Once default motor M1 is selected 1 Select parameter set A in menu 241 2 Enter motor data in menu 220 3 Enter the settings for other parameters in set A 4 If there are only minor differences between the parameter sets you can copy parameter set A to parameter set B menu 242 5 Enter or change the settings for parameters other than motor data in set B Two motors and two para
225. th very low starting load and a motor with very high starting torque the starting current may be reduced significantly by means of decreasing the voltage during start However for applications with high starting load it may depending on the actual motor not be possible to reduce the starting current at all 10 2 Reduced voltage starting This section describes different starting methods which are based on the reduced voltage principle explained above A pump and its quadratic torque characteristic are used as an example The star delta starter is the simplest example of a reduced voltage starter The motor phases are first star connected at about 75 of nominal speed the phase connection is then changed to delta To enable star delta start both ends of all three motor windings have to be available for connection Moreover the motor has to be dimensioned for the higher voltage in the delta connection The following figure shows the resulting torque and current characteristics 128 Softstarter theory CG Drives amp Automation 01 5980 01r0 VT 2 5 Torque 1 5 0 5 0 Dn 0 0 5 k Vl 8 Current 0 n ns 0 0 5 Fig 78 Star delta start The disadvantage of the star delta start is that it cannot be adapted to a special application Both the voltage in star and in delta connections are defined by the supply and the resulting starting performance depends on the motors DOL characteristic For s
226. the set time i e 5xT Anln will have reached 100 of the input change 5139 AnIn Filt Stp Al 0 100s Default 0 100 s Range 0 001 10 0s Anin change Original Anln signal 100 f Filtered Anln signal 63 peras Fig 53 Anin Enable 513A Parameter for enable disable analogue input selection via digital inputs DigIn set to function AnIn Select 513A AnIn Enabl Stp fA Default On On O Anln is always active IDigln 1 Anin is only active if the digital input is low Digln 2 Anin is only active if the digital input is high 8 5 2 Digital Inputs 520 Submenu with all the settings for the digital inputs NOTE Additional inputs will become available when the 1 O option boards are connected Digital Input 1 521 To select the function of the digital input On the standard control board there are four digital inputs Ifthe same function is programmed for more than one input that function will be activated according to OR logic if nothing else is stated 521 DigIn 1 Stp FA Run FWD Default Run FWD off O The input is not active Stop command according to the selected Stop mode in menu 340 Stop E NOTE The Stop command is active low NOTE Activated according to AND logic Reset 2 Reset command To reset a Trip condition and to enable the Autoreset function Enable comma
227. the timer output signal will switch automatically between high Timer T 1 and low Timer T2 according to set interval times See Fig 62 When the trigger signal is deactivated low again the timer output signal will also be deactivated low Timer1 Trig T1Q DD sie Timer T2 Timer Ti Timer T2 Timer T1 Fig 62 Alternate timer mode The function of the On time mode is to extend an activated high timer output signal in comparison to the trigger signal See Fig 63 Timer Trig T1Q o q Timer T1 Fig 63 On time timer mode The timer output signals T1Q T4Q can be programmed to the relay outputs used in logic functions 620 or be used as a virtual connection source 560 NOTE The actual timers are common for all parameter sets If the actual parameter set is changed the timer functionality will change according to the settings but the timer value will stay unchanged So initialisation of the timer might differ for a set change compared to normal triggering of a timer Timer 1 631 Parameter group for Timer 1 Timer 1 Trigger 6311 Selection of the trigger signal for the timer function 6311 Timer1 Trig Stp A off Default Off Same selections as in menu Relay 1 551 page Selection 97 Timer 1 Mode 6312 Selection of the conversion of the trigger signal according to the descriptions in Fig 61 Fig 63 6312 Timerl
228. ting methods In contrast to the preceding sections of this chapter which focused on squirrel cage motors slip ring motors are dealt with later on slip ring motor is equipped with a wound rotor one end of each rotor winding is available for external connection via slip rings These motors are often optimised for rotor resistance starting i e with short circuited rotor windings they develop a very low torque at an extremely high current For starting external resistances are connected to the rotor windings During the start the resistance value is decreased in several steps until the rotor windings are short circuited at nominal speed The following figure shows typical torque and current characteristics for a slip ring motor during the start with an external rotor resistance starter 130 Softstarter theory CG Drives amp Automation 01 5980 01r0 T T 25 n n 0 0 5 k Vin 8 Current 7 6 5 4 3 2 1 0 n ns 0 0 5 1 Fig 82 Rotor resistance starting Because of the low starting torque it is often not possible to short circuit the rotor windings and replace the rotor resistance starter with a softstarter However it is always possible to use a frequency inverter instead The following illustration shows how the torque and current characteristics are affected when the stator frequency is changed T Tn 25 n ns 0 0 5 1 Vin 8 Current 0 n ns 0 0 5 1 Fig 83 Voltage fr
229. tinuous period longer than the set Min Pre Alarm Delay time the selected Minimum Pre Alarm Action in Range 0 1 90 s menu 4131 is activated 4133 MinPreAlDel Stp IA 0 5s Default 0 5s Range 0 1 90 s Functionality 85 CG Drives amp Automation 01 5980 01r0 Minimum Alarm 414 These menus contain the settings for the load monitor minimum alarm Minimum Alarm Action 4141 Setting of the alarm behaviour when a Minimum Alarm has been detected 4141 MinAlarmAct stp A No Action Default No Action No Action O Hard Trip 1 For a definition see Table 21 page 45 Soft Trip 3 Warning 4 Minimum Alarm Level 4142 The value of the minimum alarm level is given as a percentage of the nominal motor power 223 When the actual shaft power shown within brackets in the display falls to a value below this level the Minimum Alarm Delay timer menu 4143 will start counting down When the delay time has elapsed an alarm will be generated according to the selected Minimum Alarm Action in menu 4141 This menu can be set manually to the required alarm level or it can be set indirectly by performing an Autoset 4142 MinAlarmLev Run FA Pshart5 84 Default 84 Range O 200 of nominal motor power 223 Minimum Alarm Delay 4143 When the load level falls below the alarm level for a continuous period longer than the set Min Alarm
230. tion format Integer Long Communication format Integer Long 8 The function cannot be changed in run model CG Drives amp Automation 01 5980 01r0 Introduction 7 Introduction CG Drives amp Automation 01 5980 01r0 2 Mounting This chapter describes how to mount the Emotron TSA softstarter Before mounting it is recommended that the installation is planned out Be sure that the softstarter suits the mounting location The mounting site must support the weight of the softstarter Will the softstarter continuously withstand vibrations and or shocks Consider using a vibration damper Check ambient conditions ratings required cooling air flow compatibility of the motor etc Do you know how the softstarter will be lifted and transported Make sure that the installation is performed in accordance with the local safety regulations and in accordance with DIN VDE 0100 for setting up power installations Care must be taken to ensure that personnel do not come into contact with live circuit components Zu Installation in a cabinet When installing the softstarter Ensure that the cabinet will be sufficiently ventilated after the installation Keep the minimum free space as listed in Table 5 Ensure that air can flow freely from the bottom to the top NOTE When installing the softstarter make sure it does not come into contact with live components The heat generated must be dispersed via th
231. tion is displayed area D of the display The Trip relay or output is active if selected CG Drives amp Automation 01 5980 01r0 Main features 45 Trip message The trip message can be viewed in the menu View Trip Log 800 in which the nine most recent trip messages are stored 810 to 890 For every logged trip the date and time from real time clock 740 is displayed along with the actual trip message according to the denotations in Table 32 page 117 The cause of the most recent or actual trip is indicated in menu 810 To facilitate troubleshooting data is copied from the operation and status menu groups 710 730 when a trip occurs See a list of the stored parameters in Table 33 page 120 The stored parameters and their values are shown under menus 8X1 Operation 8X2 Status and 8X3 Stored Values To view the value go down to menu level 4 i e 8XXX NOTE When the trip is reset the trip message will be removed from the control panel display but remains in the trip message log 800 7 3 4 Load monitor function The load monitor settings in menu 410 can be used to protect machines and processes against mechanical overload and underload such as a conveyor belt or screw conveyor jamming a belt failure on a fan or a pump running dry The load is determined by calculating the motor shaft power while running There are two overload alarms Max Alarm and
232. to set C copied into the other set Load Default Values Into Set 243 With this function different levels of factory settings can be selected for the four parameter sets When loading the default settings all changes made on the Emotron TSA softstarter are set to factory settings This function also includes selections for loading default settings to the four different motor data sets 243 Default gt Set Stp fA Default A A 0 B 1 Only the selected parameter set will revert C 2 toits default settings D 3 All four parameter sets will revert to the ABER s default settings All settings except 211 221 22D Factory 5 261 and 923 will revert to the default settings M1 6 M2 7 Only the selected motor set will revert to its M3 8 default settings M4 9 M1M2M3 10 All four motor sets will revert to default M4 settings Copy all settings to control panel 244 All the settings including the motor data can be copied between the control board memory and a control panel external or internal This can be useful when transferring settings to a second softstarter unit for instance To put the copy load function into practice see different setups in section 7 2 4 page 42 If two control panels are connected to the softstarter using an optional external control panel only one at a time can be used for copying or loading data While transfer
233. tor K1 will be activated Fig 14 The example in Fig 14 shows the wiring for a reverse page 18 For braking R1 will open and the second contactor current brake functionality For further settings see the K2 will be activated via R2 to change the phase sequence description for Dynamic Vector Brake on page 81 The contactors have to be controlled by the relay outputs of SE Description Setting the softstarter For relay settings see menu 550 and Fig 54 521 Digital input 1 terminal 11 Run FWD default page 99 The relay R1 for the first mains contactor K1 is 522 Digital input 2 terminal 12 Stop default set to RunSignalFWD in menu 551 and will control the 551 Relay 1 terminals 21 and 22 RunSignalFWD mains contactor K1 The second mains contactor K2 is yA E 552 Relay 2 terminals 23 and 24 RevCurrBrake controlled by another relay R2 that is set to RevCurrBrake in menu 552 During start and full voltage 100 240V 10 PE L N PE D e e e Relay 2 Relay 3 O L1 L2 L3 PE L N PE 24 V 18 O AnOut 19 O 24V 20 O Digln 2 12 O 10 V 13 O Anin 14 O GND 15 O Digln 3 16 O Digln 4 17 O Run FWD Stop Fig 14 Reverse current brake wiring example 18 Connections CG Drives amp Automation
234. trol supply voltage 29 5 3 5 4 5 5 6 1 6 2 6 3 6 4 6 4 1 6 4 2 6 5 6 5 1 6 5 2 6 6 6 6 1 7 1 7 1 1 7 1 2 7 1 3 7 1 4 7 1 5 7 1 6 7 2 7 2 1 7 2 2 7 2 3 7 2 4 7 3 7 3 1 7 3 2 7 3 3 7 3 4 7 3 5 7 4 7 5 7 6 7 6 1 7 6 2 7 6 3 8 1 8 1 1 8 1 2 8 2 8 2 1 8 2 2 8 2 3 8 2 4 8 2 5 8 2 6 Default toggle lOOP ietin 30 Remote I O operation 30 Control panel operation sita 31 Operation via the control panel 33 DISPO Rate te Control KEYS oia iia Function keys key function Jog key function 35 Toggle and Loc Rem Key 35 Toggle functlon sisisi e 35 Loc Rem fUNnCtON rias dd 36 The menu structure s sss ese sessisrareeaecassnneaso tra quenears 37 The main menus E 37 Main features 39 Setting Start Stop and Run functions ssse1enee 39 Start and stop Control 39 Start and stop methoden 39 JOBTUNCTIONS comics 40 Start Stop signal priority 40 Setting motor data 40 Process Information 40 Working with parameter sets 41 Control of parameter sets 41 Configuration of parameter seis 42 Handling motor data in parameter sets 42 Using the control panel memory 42 Applying limitations alarms and autoreset 45 Alarm types and actions Alarm SINES sana Alarm indications sssiisissisiniiaiininaanneniaoirea tatafi anaa Load monitor funct
235. tting Run Reset commands CG Drives amp Automation 01 5980 01r0 Main features 51 7 6 2 Enable and Stop functions Both functions can be used separately or simultaneously The choice of which function is to be used depends on the application and the control mode of the inputs Level Edge 21A NOTE In edge control mode at least one digital input must be programmed to Stop because the RunFWD and RunREV commands are only able to start the softstarter Enable The enable function is used as a start interlock This means that if any input is set to Enable this input must be set to active high to allow any run command When the input is low the motor will coast to stop CAUTION If the Enable function is not programmed to a digital input it is considered to be active internally Stop If the input is set low open the softstarter will stop according to the selected stop method in menu 341 7 6 3 Reset and Autoreset operation If the softstarter is in stop mode due to a trip condition the softstarter can be remotely reset by a pulse low to high transition on the Reset input on Digln 4 Depending on the selected control method a restart takes place as follows Edge controlled Run inputs After the Reset command is given a new Run command must be applied to start the softstarter again The inputs are set for edge control as default This mea
236. ty setting of input signals for flip flop 1 6411 F1 Mode SET RESET OUT 0 0 O reset 0 1 O reset 1 0 1 set 1 1 O reset Set priority For Set priority the determining input signal is SET should both input signals be active resulting in an activated 1 output signal See Table 30 Table 30 Truth table for Set priority Stp Al Reset Default Reset Reset 0 Reset priority Set 1 Set priority Edge 2 Edge controlled without priority Flip flop 1 Set 6412 Selection of SET input signal for flip flop 1 6412 Fl Set stp A Off SET RESET OUT 0 0 O reset 0 1 O reset 1 0 1 set 1 1 1 set Default Off Same selections as in menu Relay 1 551 page lection Selection 97 Edge controlled without priority The third setting is Edge controlled for which no input signal has priority over the other The output signal follows any of the two input signals still providing they are at a positive edge The most recent registered activity decides the output See Table 31 Should both inputs become activated simultaneously there will not be any change the output signal will just keep its earlier status Table 31 Truth table for Edge control without priority Flip flop 1 Reset 6413 Selection of RESET input signal for flip flop 1 6413 F1 Reset Stp FA Off Default Off Same selections as in me
237. uare End torque Nominal torque Initial torque 332 gt gt gt Start time Time Fig 40 Torque control at start Voltage Control Voltage control is selected when a linear voltage ramp is desired The thyristor switch on time will be ramped up linearly from Initial Voltage menu 334 up to full mains voltage See Fig 41 Voltage Un mot Start time Time Fig 41 Initial voltage and start time Direct on line DOL If this alternative is selected the motor can be accelerated as if it was connected directly to the mains resulting in a very fast ramp For this type of operation Check whether the motor can accelerate the required load DOL start This function can also be used with shorted thyristors 6 7 x In soft FLC Time 03 F115 2 Fig 42 DOL start 331 Start Method Stp f Lin Torq Ctr Default Lin Torq Ctr The motor torque is controlled according to a linear ramp set in menu 332 and 333 Lin Torq Ctr 1 The motor torque is controlled according to a square ramp set in menu 332 and 333 Sar Torq Ctr 2 The motor voltage is controlled according Voltage Ctr 3 toa linear voltage ramp menu 334 DOL 4 Direct online Initial Torque 332 Used with start method linear square torque control 332 Init Torque Stp A 10 Default 10 Range O 250 of Th
238. ue the counter output signal CTR1 or CTR2 is activated See Fig 65 CTR1 Counter 1 output signal 6511 Counter 1 Trigger 6512 Counter 1 Reset 6513 Counter 1 Trip Value 6519 Counter 1 Value Fig 65 Counters principle Counter 1 651 Counter 1 parameter group 651 Counter 1 Stp FA Counter 1 Trigger 6511 The selected signal is used as a trigger signal for counter 1 Counter 1 is incremented by 1 on every positive edge of the trigger signal NOTE Maximum counting frequency is 8 Hz 6511 C1 Trig Stp FA off Default Off Same selections as in menu Relay 1 551 lection Selection page 97 112 Functionality CG Drives amp Automation 01 5980 01r0 Counter 1 Reset 6512 The selected signal is used as a reset signal for counter 1 When the reset signal is activated high this will zero counter 1 and the counter will remain at zero as long as the reset signal is active high 8 6 6 Clock Logic 660 Clock 1 661 The actual value of clock 1 is viewed in this menu NOTE Reset input has top priority 6512 C1 Reset 661 Clock 1 Read only Stp Al 0 00 00 0 Range 0 00 00 0 hours minutes seconds Stp IA Off Default Off Selection Same selections as in menu Relay 1 551 page 97 Counter 1 Trip Value 6513 In thi
239. ut CTRL 2 Counter output i inverted A1 4 Anal tput S EE outp CTR2 42 Counter 2 output IA 5 Analogue comp 3 inverted output EZ 43 Counter output 2invertsd CA2 6 Analogue comparator 4 output 1A2 7 Analogue comp 4 inverted output Logic 1 Operator 1 6213 GDA 8 Digital comparator 1 output In this menu the first operator for the Logic 1 function is ID1 9 Digital comp 1 inverted output selected CD2 10 Digital comparator 2 output ID2 11 Digital comp 2 inverted output 6213 L1 Op 1 stp A CD3 12 Digital comparator 3 output ID3 13 Digital comp 3 inverted output Default amp CD4 14 Digital comparator 4 output When dot is selected the Logic 1 ma 0 expression is finished when two or d e e three expressions are tied together Logic output 1 E L1 16 Not used for Logic 1 amp 1 STAND 11 17 Logic output 1 inverted SR 2 TOR i Not used for Logic 1 3 EXOR 12 E ee EE Logic 1 Input 2 6214 ogic output 2 inverted 1L2 19 SC us d a Logic 2 In this menu the second input for the Logic 1 function is selected Logic output 3 ES SS Not used for Logic 3 IL3 21 Logic output 3 inverted 6204 Et Inp t 2 i Not used for Logic 3 Stp A AZ Logic output 4 Default IA2 EA ee Not used for Logic 4 Es Same selection as in menu Logic 1 Input 1 Logic output 4 inverted Selection 6212 page 107 IL4 23 D 4 Not used for Logic 4 T1Q 24 Logic timer 1 output 1110 25 Inverted logic timer 1 output CG Drives a
240. ut is activated by making the input continuously high This method should be applied ifa PLC is used to operate the softstarter for instance CAUTION Level controlled inputs DO NOT comply with the Machine Directive if the inputs are directly used to start and stop the machine The Enable input must be continuously active in order to accept any run forward or run reverse command If both RunFWD and RunREV inputs are active then the softstarter stops according to the selected stop method in menu 341 Fig 38 gives an example of a possible sequence Level control 21A INPUTS Enable Stop i Fig 38 Input and output status for level control CG Drives amp Automation 01 5980 01r0 Main features 53 54 Main features CG Drives amp Automation 01 5980 01r0 8 Functionality This chapter describes the menus and parameters in the software You will find a short description of each function and information about default values ranges etc A menu list with default values and the most important communication settings is found in Appendix 1 at the end of this manual At www emotron com or www cgglobal com in the download area you can also find a complete communication information list and a menu list with space for parameter set notes information Function Menu number Description See section Preferred view 100 Me
241. ve Level off 100 240V Start Stop Control board 000000000 ODODODOOD D Power board 11 12 13 14 15 16 17 18 19 20 PE 01 02 21 22 23 24 31 32 33 6970 Fig 19 Minimum wiring for remote controlled start using level control Switch on the voltage Once the 3 phase mains and control supply voltage is switched on the softstarter is started and the internal fan only in model sizes 2 6 will run for 5 seconds Set the basic data Default toggle loop In order to make it easier to setup the initial data there is a default toggle loop see Fig 18 This loop contains the necessary menus that need to be set before starting the softstarter the first time Press the Toggle key to enter e g menu 740 then use the next keys to go to the submenus 741 and so forth and enter the parameters When you press the Toggle key again the next toggle menu is displayed Toggle loop To submenus lt 4 741 740 224 223 Fig 20 Default toggle loop Enter the basic data i e language time and motor data for the connected motor The motor data is used in the calculation of complete operational data in the softstarter Change settings using the keys on the control panel For further information about the control panel and menu structure see Chapter 6 page 33 30 Getting started CG Drives amp Automation 01 5980 01r0 Menu 100 Preferred View is di
242. ve The selected parameter sets from the control panel are copied to the corresponding parameter sets in the softstarter control board i e A to A B to B M1 to M1 and so on The different choices are listed below If a second control panel is connected this will not be affected when loading from the first control panel 8 245 Load from CP Stp FA No Copy Default No Copy No Copy 0 Nothing will be loaded A de Data from parameter set A is loaded B 2 Data from parameter set B is loaded C 3 Data from parameter set C is loaded D 4 Data from parameter set D is loaded ABCD 5 Data from parameter sets A B C and D are loaded A Mot 6 Parameter set A and Motor data are loaded B Mot 7 Parameter set B and Motor data are loaded C Mot 8 Parameter set C and Motor data are loaded D Mot 9 Parameter set D and Motor data are loaded ABCD Mot 10 Parameter sets A B C D and Motor data are loaded M1 11 Data from motor 1 is loaded M2 12 Data from motor 2 is loaded M3 13 Data from motor 3 is loaded M4 14 Data from motor 4 is loaded oe 15 Data from motor 1 2 3 and 4 are loaded All 16 All data is loaded from the control panel NOTE Loading or copying will not affect the value in menus for viewing 68 Functionality CG Drives amp Automation 01 5980 01r0 8 2 6 Autoreset 250 With these menus an autoreset can be confi
243. warning messages Digital Input Status 723 Communication EE This menu indicates the status of the digital inputs See integer value p g g example in Fig 67 1 Digln 1 0 No Error 2 Digln 2 1 Motor Dt 3 DigIn 3 4 Digln 4 2 PTC The positions 1 4 on the display from left to right indicate 3 Locked rotor the status of the associated input Digln 1 Digln 4 4 Ext Alarm 1 1 High 0 Low 5 Ext Alarm 2 The example in Fig 67 indicates that DigIn 2 and Digln 4 6 Curr limit current limit are active at this moment 7 Start limit 8 Comm error communication error Read only 723 DigIn Status Stp 0101 9 Pt100 10 Bypass open Fig 67 Digital input status example 11 BypassClosed 12 Mon MaxAlarm load monitor max alarm Relay Status 724 13 se MaxPreAl load monitor max pre This menu indicates the status of the relays See Fig 68 alarm RE indicates the status of the relays on position 14 Mon MinPreAl load monitor min pre 1 Relay1 alarm 2 Relay2 15 Mon MinAlarm load monitor min alarm 3 Relay3 The status of the associated output is shown 16 Over temp over temperature 1 High Ig 17 Thyr open thyristor open 0 Low 18 Thyr short thyristor short The example in Fig 68 indicates that Relay 1 is active Relay 2 and Relay 3 are not active 19 Phase loss single phase loss Ph Itiple ph l 20 M Phase
244. x D mm Mounting position 246 296 x 126 x 188 Vertical Horizontal 246 296 x 126 x 188 Vertical Horizontal 246 296 x 126 x 188 Vertical Horizontal Weight kg 5 7 5 7 Dif Busbar connection mm 15 x 4 Cu M6 15 x 4 Cu M6 15 x 4 Cu M6 Cooling system Fan Fan Fan Protection class IP20 IP20 1 Normal duty Start current 3 x In soft gt Start time 15 s Size 1 or 30 s Size 2 6 10 starts hour Heavy duty Start current 5 x In soft gt Start time 15 s Size 1 or 30 s Size 2 6 10 starts hour 2 Fuse data for Semi conductor fuses see Table 41 3 H1 Height of enclosure H2 Total height IP20 140 Technical data CG Drives amp Automation 01 5980 01r0 13 1 General electrical specifications Table 40 Parameter Description General Mains supply voltage 200929 V 10 19 200 690 V 10 15 Mains and Control supply frequency 50 60 Hz 10 Number of fully controlled phases 3 Control supply voltage 100 240 V 10 15 Single phase Recommended fuse for control supply Max 10 A Control signal inputs Digital input voltage 0 4 V gt 0 8 27 V gt 1 Digital input impedance to GND O VDC lt 3 3 VDC 4 7 kQ gt 3 3 VDC 3 6 kQ Analogue input voltage current 0 10 V 2 10 V 0 20 mA 4 20 mA Analogue input impedance to GND 0 VDC Voltage signal 20 KQ Current signal 250 Q C
245. xed point number 72 It is within the range 0 32767 which means that the 15 bit fixed point format may be used The value will then be represented as B15 B14 B13 B12 B11 B10 B9 B8 B7 B6 B5 B4 B3 B2 Bl BO 0 0 0 0 0 0 0 00100 10 0 0 Where bit 15 indicates that we are using the fixed point format F 0 CG Drives amp Automation 01 5980 01r0 Serial communication 125 Programming example typedef struct int m 11 mantissa 1024 1023 int e 4 exponent 8 7 unsigned int f 1 format 1 gt special emoint format eint16 unsigned short int float_to_eint16 float value eintl6 etmp int dec 0 while floor value value amp amp dec lt 16 dec value 10 if value gt 0 amp amp value lt 32767 amp amp dec 0 short int amp etmp short int value else if value gt 1000 amp amp value lt 0 amp amp dec 0 etmp e 0 etmp f 1 etmp m short int value else etmp m 0 etmp f 1 etmp e dec if value gt 0 etmp m 1 Set sign else etmp m 1 Set sign value fabs value while value gt 1000 etmp e increase exponent value value 10 value 0 5 round etmp m etmp m value make signed return unsigned short int amp etmp float eint16_to_float unsigned short int value float f eint16 evalue evalue eintl6 value if evalue f if evalue e gt 0 f int evalue m powl10 evalue e
246. y AnIn Advanced settings in menu 513 511 AnIn Fc Stp Al Process Val Default Process Val Off O Input is not active The input value equals an actual process value and can be used as comparator input for creating a start signal It can also be used to display and view the actual process value w Process Val NOTE When Anin Fc is set to Off the connected signal will still be available for Comparators 610 Analogue Input Setup 512 The analogue input setup is used to configure the analogue input in accordance with the signal used that will be connected to the analogue input With this selection the input can be determined as current 4 20 mA or voltage 0 10 V controlled input Other selections are available for using a threshold live zero or a user defined input range Fig 49 Select voltage or current input with jumper S1 NOTE The selection of voltage or current input is done with S1 When the jumper is in voltage mode only the voltage menu items are selectable With the jumper in current mode only the current menu items are selectable CG Drives amp Automation 01 5980 01r0 Functionality 91 512 AnIn Setup 4 20mA Stp FA Default 4 20 mA Dependenton Setting of jumper S1 The current input has a fixed threshold Live Zero of 4 mA and controls the full range for the input signal See Fig 51 4 20m
247. y 95 Analogue Output Setup 532 Preset scaling and offset of the output configuration 532 AnOut Setup stp H 4 20mA Default 4 20mA The current output has a fixed threshold Live Zero of 4 mA and controls the full range for the output signal See Fig 51 4 20mA 0 Normal full current scale configuration of the output that controls the full range for the output signal See Fig 50 0 20mA 1 The scale of the current controlled output that controls the full range for the output signal Can be defined by the advanced AnOut Min and AnOut Max menus User mA 2 Normal full voltage scale configuration of the output that controls the full range for the output signal See Fig 50 O 10V 4 The voltage output has a fixed threshold Live Zero of 2 V and controls the full range for the output signal See Fig 51 2 10V 5 The scale of the voltage controlled output that controls the full range for the output signal Can be defined by the advanced AnOut Min and AnOut Max menus User V 6 NOTE When Anln is selected the setup of the AnOut 532 has to be set to 0 10 V or 0 20 mA When the AnOut Setup is set to e g 4 20 mA the mirroring is not working correctly Analogue Output Advanced 533 With the functions in the AnOut Advanced menu the output can be completely defined according to the application needs The menus will automatically be ada
248. y is disabled as default Enable the function in menu 2171 The function Loc Rem can also be changed via Digln see menu Digital inputs 520 Change control mode 1 Press the Loc Rem key for five seconds until Local or Remote is displayed 2 then confirm with ENTER 3 or cancel with ESC When using the LOC REM key it is important to define what LOCAL and REMOTE will mean Local mode The LOCAL function is set up in the menu Local Run Control 2173 for which the factory default selection is Keyboard The actual status of the softstarter will not change e g Run Stop conditions will remain exactly the same When the softstarter is set to Local operation the display will show H in area B of the display alternating with fq if it is also a toggle loop menu Remote mode The REMOTE function is defined in menu 2151 Run Stop Control where default is Remote To monitor the actual Local or Remote status of the softstarter control a Loc Rem signal is available for the Relays 550 When the softstarter is set to LOCAL the signal on the relay will be active high In REMOTE the signal will be inactive low 36 Operation via the control panel CG Drives amp Automation 01 5980 01r0 6 6 The menu structure The menu structure consists of 4 levels ne The first character in the menu number 2nd level The second ch

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