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CD Automation srl

STE Soft Starter

User’s Manual

20

5.4

Diagram of connection for Size 9 without Bypass

Warning:

Before connecting or disconnecting the unit check that power and control cables

are isolated from voltage sources.

Terminal

Description

1

Voltage Supply for Electronic Boards (see par. 6.2)

2

Voltage Supply for Electronic Boards (see par. 6.2)

3

Not connected

4

Isolated 12Vdc MAX 20mA

5

GND for Digital Input

6

10Vdc MAX 5mA

7

GND for Analogue Input

8

(+)Analogue Input 1: Configurable (see par. 6.3)

9

(+)Analogue Input 2: PTC probes (see par. 6.3)

10

Analogue Output 1: Configurable (see par. 6.4)

11

RS485 A

12

RS485 B

13

Output relay 2: Run (Max 500mA, 125Vac)

14

Common of the contact relay Output 1

15

NPN Output 3: Configurable (12Vdc max 20mA)

16

NPN Output 4: Configurable (12Vdc max 20mA)

17

Digital Input 1: Stop

18

Digital Input 2: Start

19

Digital Input 3: Configurable

20

Digital Input 4: Configurable

(See par. 6)

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Summary of Contents for STE Series

Page 1: ...USER S MANUAL Rev 01 2007 STE Enhanced Soft Starter ...

Page 2: ......

Page 3: ...s service no Bypass Power Connections 18 5 3 Bypass Power Connections 19 5 4 Diagram of connection for Size 9 without Bypass 20 5 5 Diagram of connection for Size 9 with Bypass 22 5 6 Diagram of connection for Size 11 13 14 without Bypass 24 5 7 Diagram of connection for Size 11 13 14 with Bypass 26 6 Connection description 28 6 1 Access to the Electronic boards 28 6 2 Supply the Electronic Board ...

Page 4: ...starting curves in Current Ramp 48 11 Maintenance 49 11 1 Cooling Fans 49 11 2 Maintenance 49 11 3 Repairing procedure 49 11 4 Warranty condition 49 12 RS485 Serial Port 50 12 1 MODBUS communication 51 12 2 MODBUS RTU Protocol 51 12 3 Message Format 51 12 4 Read Holding Registers 53 12 5 Preset Multiple Registers 53 12 6 Error and exception responses 54 12 7 Address Configuration 54 ...

Page 5: ...st the possibility of restarts example cut off the power This starter must be installed and set up in accordance with both international and national standards Bringing the device into conformity is the responsibility of the systems integrator who must observe the EMC directive among others within the European Union The specifications contained in this document must be applied in order to comply w...

Page 6: ... frequency power Alarm and shutdown operation Size S9 with Bypass Size S11 S13 S14 with Bypass The electronic control of STE is Full Digital with an high performance 16 bit embebbed microprocessor in connection with an 4 Digit Data Entry for display and programming parameter s application The RS485 Communication with MODBUS protocol enables the soft starter to perform full control and supervision ...

Page 7: ...from INTITIAL VOLTAGE to RATED VOLTAGE or nominal torque with current limit Current ramp Kickstart or voltage pulse of 80 UN without current limit intended for start high friction load requiring high starting torque for a short time Deceleration the motor by different methods Voltage ramp Free wheel by shut down of contactor ...

Page 8: ... L3 M1 M2 M3 U1 V1 W1 U2 V2 W2 IS IM Delta Connections 3 wires 3 L M I I L S I I L M V V IL Line current IS Soft Starter current IM Motor current Winding VL Line voltage VM Motor voltage IL L1 L2 L3 M1 M2 M3 U1 V1 W1 U2 V2 W2 IS IM Open Delta Connections 6 wires 3 L S M I I I L M V V IL Line current IS Soft Starter current IM Motor current Winding VL Line voltage VM Motor voltage IL L1 L2 L3 M1 M2...

Page 9: ...l Verify that there isn t a short circuit on the load see par 5 5 Now you are ready for Supply the Electronic boards see par 6 2 6 If not specified in the Order Code Set the Full Load Current In of AC motor in the parameter P017 Set the Limit Current in the parameter P018 3 Refer to the Typical Applications par 10 see par 8 7 Apply Start command If the motor doesn t begin to turn stop the unit inc...

Page 10: ...e product has a fault please contact the dealer from which you purchased the product The identification s label give all the information regarding the factory settings of the SOFT START unit this label is on the unit like represented in figure Check that the starter reference printed on the label is the same as that on delivery notes corresponding to the purchased order see par 4 2 ...

Page 11: ...12A 100A 87A 138A 121A 104A 90A 225A 190A 164A 156A 260A 242A 208A 190A 285A 260A 225A 208A 398A 346A 294A 260A 779A 779A 779A 779A 865A 865A 865A 865A 2 Start Current 3 In 3 5 In 4 In 4 5 In 3 Supply Voltage Specify this value to configure the unit in CD Automation 4 Voltage supply for the Electronic boards 110V From 100 to 130Vac 230V From 210 to 265Vac 5 Wiring 3W 3 wire connection 6W 6 wire co...

Page 12: ... pass closed is minimal i e 40 watt Without by pass heat dissipation is about 3 xIn watt During soft start the heat dissipation increase in the range 10 20 xIn watt depending from start current If the motor is frequently started the cabinet should be designed for the higher heat dissipation with for instance additional ventilation 4 3 1 Environment Ambient temperature 0 C to 45 C Storage temperatu...

Page 13: ... Fixing holes 316mm 187mm 116mm SIZE 9 Weight 5kg 290mm 96mm 104mm 5mm 7mm 440mm 270mm 137mm SIZE 11 Weight 10 5kg 97mm 410mm 97mm 7mm 12mm 440mm 270mm 262mm SIZE 13 Weight 18kg 410mm 222mm 222mm 7mm 12mm 460mm 270mm 262mm SIZE 14 Weight 22 5kg 222mm 222mm 490mm 7mm 12mm ...

Page 14: ...SIZE 9 150A 140A 120A 110A 165A 150A 130A 120A SIZE 11 230A 200A 170A 150A SIZE 13 450A 450A 450A 450A 500A 500A 500A 500A SIZE 14 6 wire connection Nominal Current 3 In pick Nominal Current 3 5 In pick Nominal Current 4 In pick Nominal Current 4 5 In pick STE Size 38A 33A 28A 24A 59A 52A 45A 42A 76A 66A 57A 52A 130A 112A 100A 87A 138A 121A 104A 90A 225A 190A 164A 156A SIZE 9 260A 242A 208A 190A 2...

Page 15: ...A 130A 120A 188000 3 230A 200A 170A 150A 245000 3 450A 450A 450A 450A 1050000 3 500A 500A 500A 500A 1050000 3 For 6 wire connection the Soft Start current is the same of winding current to have the line current multiply by 1 73 Caution The Fuses must have I t 20 less than thyristor s I t Caution High speed fuses are used only for the thyristor protection and can not be used to protect the installa...

Page 16: ...ving the cover SIZE 9 Remove the screw if present Open the unit Screw Open SIZE 11 Remove the screw if present Remove the plastic cover Open the unit Screw Screw Open SIZE 13 14 Remove the screw Remove the plastic cover Open the unit Screw Screw Screw Screw Open ...

Page 17: ...h M8 screw 505 57 0 2 350 UL Listed ZMVV Copper Tube Crimp Lug SIZE 13 Bus Bar with M10 screw 505 57 0 1 600 UL Listed ZMVV Copper Tube Crimp Lug SIZE 14 Bus Bar with M10 screw 505 57 0 Bus Bar 30x6mm Bus Bar 60x6mm 5 1 2 Power cable dimensions suggested Current Power Supply Cable Motor Cable Output Starter Bypass with Bypass Earth mm AWG mm AWG mm AWG mm AWG 14A 45A 10 8 10 8 10 8 6 10 50A 76A 35...

Page 18: ...or disconnecting the unit check that power and control cables are isolated from voltage sources Terminal Description L1 Line Input Phase 1 L2 Line Input Phase 2 L3 Line Input Phase 3 M1 Motor Output Phase U M2 Motor Output Phase V M3 Motor Output Phase W SIZE 9 L1 L2 L3 M1 M2 M3 SIZE 11 L1 L2 L3 SIZE 13 L1 L2 L3 SIZE 14 L2 L1 L3 ...

Page 19: ... Terminal Description L1 Line Input Phase 1 L2 Line Input Phase 2 L3 Line Input Phase 3 M1 Motor Output Phase U M2 Motor Output Phase V M3 Motor Output Phase W B1 Bypass Output Phase U not available for size 9 B2 Bypass Output Phase V not available for size 9 B3 Bypass Output Phase W not available for size 9 SIZE 9 L1 L2 L3 M1 M2 M3 SIZE 11 L1 L2 L3 B1 B2 B3 SIZE 13 L1 L2 L3 B1 B2 B3 SIZE 14 L2 L1...

Page 20: ...onnected 4 Isolated output 12Vdc MAX 20mA 5 GND for Digital Input 6 Output 10Vdc MAX 5mA 7 GND for Analogue Input 8 Analogue Input 1 Configurable see par 6 3 9 Analogue Input 2 PTC probes see par 6 3 10 Analogue Output 1 Configurable see par 6 4 11 RS485 A 12 RS485 B 13 Output relay 2 Run Max 500mA 125Vac 14 Common of the contact relay Output 1 15 NPN Output 3 Configurable 12Vdc max 20mA 16 NPN Ou...

Page 21: ... 2 A B RS485 4 5 17 18 19 20 15 16 9 8 10 7 Input 2 Input 1 12Vdc 10Vdc M1 M2 M3 Run 13 14 6 4 R1 3 NOTE The user installation must be protecting by circuit breaker or by fused switch Opening the disconnecting switch whitout STOP operating signal trip fault Undervoltage Use an appropriate external transformer based on the voltage supply of the electronic board see the identification label The coil...

Page 22: ...nnected 4 Isolated output 12Vdc MAX 20mA 5 GND for Digital Input 6 Output 10Vdc MAX 5mA 7 GND for Analogue Input 8 Analogue Input 1 Configurable see par 6 3 9 Analogue Input 2 PTC probes see par 6 3 10 Analogue Output 1 Configurable see par 6 4 11 RS485 A 12 RS485 B 13 Output relay 2 Run Max 500mA 125Vac 14 Common of the contact relay Output 1 15 NPN Output 3 Configurable 12Vdc max 20mA 16 NPN Out...

Page 23: ...1 2 A B RS485 4 5 17 18 19 20 15 16 9 8 10 7 Input 2 Input 1 12Vdc 10Vdc M1 M2 M3 Run 13 14 6 4 R1 3TA Module PL1 3 NOTE The user installation must be protecting by circuit breaker or by fused switch Opening the disconnecting switch whitout STOP operating signal trip fault Undervoltage Use an appropriate external transformer based on the voltage supply of the electronic board see the identificatio...

Page 24: ...par 6 2 3 Not connected 4 Isolated output 12Vdc MAX 20mA 5 GND for Digital Input 6 Output 10Vdc MAX 5mA 7 GND for Analogue Input 8 Analogue Input 1 Configurable see par 6 3 9 Analogue Input 2 PTC probes see par 6 3 10 Analogue Output 1 Configurable see par 6 4 11 Output relay 1 Bypass Max 500mA 125Vac 12 Common of the contact relay Output 4 13 Output relay 2 Run Max 500mA 125Vac 14 Common of the c...

Page 25: ...A B RS485 4 5 17 18 19 20 15 16 9 8 10 7 11 12 Input 2 Input 1 12Vdc 10Vdc M1 M2 M3 Run 13 14 6 4 4 NOTE The user installation must be protecting by circuit breaker or by fused switch Opening the disconnecting switch whitout STOP operating signal trip fault Undervoltage Use an appropriate external transformer based on the voltage supply of the electronic board see the identification label The coil...

Page 26: ...ar 6 2 3 Not connected 4 Isolated output 12Vdc MAX 20mA 5 GND for Digital Input 6 Output 10Vdc MAX 5mA 7 GND for Analogue Input 8 Analogue Input 1 Configurable see par 6 3 9 Analogue Input 2 PTC probes see par 6 3 10 Analogue Output 1 Configurable see par 6 4 11 Output relay 1 Bypass Max 500mA 125Vac 12 Common of the contact relay Output 4 13 Output relay 2 Run Max 500mA 125Vac 14 Common of the co...

Page 27: ...L1 L2 L3 1 2 A B RS485 4 5 17 18 19 20 15 16 9 8 10 7 11 12 Input 2 Input 1 12Vdc 10Vdc M1 M2 M3 Run 13 14 6 4 4 NOTE The user installation must be protecting by circuit breaker or by fused switch Opening the disconnecting switch whitout STOP operating signal trip fault Undervoltage Use an appropriate external transformer based on the voltage supply of the electronic board see the identification l...

Page 28: ...k requires a voltage supply for the electronic boards This voltage is used also to supply the internal fans The consumption is 20VA max at this you must add the consumption of the internal fans see par 11 1 The voltage supply for the electronic boards is configured in line with customer requirements that are defined in the Order Code The Order Code is written on the identification label Warning Be...

Page 29: ...is used with the option Control to set voltage at the end of start The Analogue Input 1 for default is already configured for 0 10Vdc input signal however if you wish to change the Analogue Input 1 ex from 0 10V to 4 20mA proceed as follows Caution this procedure must be performed only by qualified persons Control board Size 9 Control board Size 11 13 14 JP6 Type Input features Jumper 0 10V defaul...

Page 30: ...processed and used in two ways activate an alarm if the signal is active This alarm can be displayed in the parameter P004 or on a configurable logic output stop the STE Soft Starter if the signal is active Critical alarm The parameter P027 set the Motor PTC Probe as the critical alarm PTC probe protection does not deactivate the motor thermal protection Both types of protection can operate in par...

Page 31: ...nfigured for 0 10Vdc output signal however if you wish to change the Analogue Output ex from 0 10V to 4 20mA proceed as follows Caution this procedure must be performed only by qualified persons Control board Size 9 Control board Size 11 13 14 JP2 C B A Type Output features P100 Jumper 0 10V default 20mA Max 0 A B 0 20mA 500Ω Max 0 B C 4 20mA 500Ω Max 1 B C JP21 C B A Setting the Output Value The ...

Page 32: ... 5 17 18 Stop Start Alternative Start Stop Control Otherwise you can use only one logic input to control Run and Stop On power up or a manual fault reset the motor will restart if the START STOP command is present state 1 This is a typical use with a PLC 4 12Vdc 5 17 18 Start Stop 6 5 2 Configurable Input 3 Terminal 19 This digital input is configured by the parameter P088 and could perform differ...

Page 33: ...E Soft Starter has 2 digital output 1 for Size 9 with relay contact Max 500mA 125Vac and 2 digital output with logic NPN 12Vdc 20ma Max 6 6 1 Digital Output 1 By pass Relay Terminals 11 and 12 This digital output is used to control the by pass contactor at the end of the starting process this output is active and the contact is closed Before the stopping process the contact will be reopened This o...

Page 34: ...TUS DESCRIPTION The Auxiliary power supply is not connected or fault on the electronic board Fault on the electronic board Aux Electronic board is OK No Alarm Alarm active Alm Critical Alarm active No By pass By pass active BP Thermal Protection ready Thermal Fault Overload TH Thermal Protection active OFF ON Flashing ...

Page 35: ...he threshold value set in the parameter P044 00 for a time set in the parameter P045 00 see par 9 For restart the STE Soft Starter check the line voltage on the power terminals L1 L2 L3 or change the threshold value When the problem is solved before to restart is necessary Reset the Alarm see par 6 5 7 2 4 Overvoltage This critical alarm is active when the Line voltage is over the threshold value ...

Page 36: ... the control circuit powered The starter thermal control prevents the motor from restarting if the temperature rise is too high 7 2 8 Unbalanced This critical alarm is active when one of the three motor current read on the terminals M1 M2 M3 differs from the others more than the threshold value set in the parameter P040 0C for a time set in the parameter P041 0C see par 9 The unbalanced alarm coul...

Page 37: ...f these alarms see par 9 7 3 1 Motor PTC Probe If a special motor is used flameproof submersible etc thermal protection should be provided by PTC probes in stator windings of AC motor The PTC probes can be connected to the command Terminals analog input 2 on terminal 9 The PTC probe value can be processed and used in two ways activate an alarm if the signal is active This alarm can be displayed in...

Page 38: ...ers in the menu and to change data The ENTER key is used to edit the parameters and to save the modified values The Control Panel have three menu and to enter in one of them you must set correctly the parameter P000 Operator Menu P000 0 This menù contains a reading parameters that give information on the state of the unit Hardware Menu P000 5 This menu contains all the configuration parameters for...

Page 39: ...CD Automation srl STE Soft Starter User s Manual 39 Menù Operatore Menù Hardware Menù Setup 0 C 1 3 C 3 CC 1 C 3 1 1 0 1 0C 0C 00 00 0 0 C 0 3 ...

Page 40: ...re 40 Heat sink over temperature Note If more alarms occur the value will be equal at the sum of the two alarms example Overvoltage Phase Inversion 10 02 12 P002 H02 Code of Critical alarm group 2 Motor group R Function This parameter read only gives information on the following alarms that they stop the STE Soft Starter Value 00 No Alarm 01 Thermal Overload 02 Unbalance 04 Start Failure 10 Extern...

Page 41: ...will be equal at the sum of the two Digital Inputs example Digital Input 4 Digital Input 2 20 02 22 P065 H41 Digital Output Display R Function This parameter read only shows the status of the digital Output Value 00 Digital Outputs not active 01 Digital Output 1 active not for size S9 02 Digital Output 2 active 10 Digital Output 3 active 20 Digital Output 4 active Note If more Digital Outputs occu...

Page 42: ...iguration terminal 16 R W Function This parameter selects the function of the digital output 4 Value 0 Current Limit active 1 Critical Alarm active 2 Motor PTC Probe 3 Thermal Overload 4 Bypass active Default 4 P098 H62 3 CC AC motor Connection Type R W Function This parameter selects the type of the motor connection Value 0 star 3wire 1 delta 3wire 2 Open delta 6wire Default 0 if not specified in...

Page 43: ... of the Analog Output Value 0 Average Power 1 Average Current of all Phases Default 1 P102 H66 1 Baud Rate R W Function This parameter selects the Baud rate on the serial port RS485 Value 0 4800 1 9600 2 19200 Default 2 P103 H67 Address R W Function This parameter select the Address of STE Soft Starter on the serial port RS485 Min Max 1 127 Default 1 ...

Page 44: ...e correct rescaling inside the unit For this reason it s very important specify this value in the order code P018 H12 3 Current Limit value R W Function This parameter contains the Current Limit value set in of FL_A Min Max 150 500 Default 300 P019 H13 3 Power Factor Cosφ R W Function This parameter contains the Power factor value Min Max 0 10 1 80 Default 0 83 P020 H14 1 Acceleration Ramp Sec R W...

Page 45: ...when the Kickstart function is active Min Max 0 20 10msec ogni step Default 10 100msec P032 H20 Deceleration Ramp Sec R W Function This parameter set the time for motor deceleration Min Max 0 60 seconds Default 10 Note used only with Deceleration Ramp stop mode P033 H21 Stop Type R W Function This parameter selects the motor Stop Type Value 0 Freewheel stop mode 1 Deceleration Ramp stop mode Defau...

Page 46: ...ion This parameter contains Threshold voltage value set in of Voltage supply for the Overvoltage protection Min Max 125 0 150 0 Default 125 0 P047 H2F 0 Overvoltage Alarm Delay Sec R W Function This parameter set the time for delay the Overvoltage protection Min Max 0 10 0 seconds Default 1 0 P072 H48 Thermal Overload Threshold R W Function This parameter contains Threshold current value set in of...

Page 47: ...MPACT DEBARKER DRYER DUST COLLECTOR EDGER ELEVATOR FAN AXIAL CLAMPED FAN AXIAL UNCLAMPED FAN CENTRIFUGAL CLAMPED FAN CENTRIFUGAL UNDAMPED FAN HIGH PRESSURE GRINDER HYDRAULIC POWER PACK LOADED PISTON COMPRESSOR MILL MILL BALL MILL HAMMER MILL ROLLER MIXER MONORAILS PALLETISER PLANER POSITIVE DISPLACEMENT PUMP PRESS PUMPS BORE REPULPER ROLLER CONVEYOR ROTARY TABLE SANDER SCREW COMPRESSOR SCREW CONVE...

Page 48: ...CD Automation srl STE Soft Starter User s Manual 48 10 1 Example of starting curves in Voltage Ramp 10 2 Example of starting curves in Current Ramp ...

Page 49: ...4 500A Four Fans 120x120 68W No fans 11 2 Maintenance For maintain a correct cooling the consumer must clean the heat sink and the protective grate of the fans The frequency of these operations depends on the atmospheric local pollution Check also that the screw of the power terminals and earth terminals are shut correctly see Diagram of connection 11 3 Repairing procedure Phone to CD Automation E...

Page 50: ...and Terminals and on the 9pin DIN male connector On this port may be done a network up to 127 STE Soft Starter Terminal Description 11 RS485 B 12 RS485 A Terminal Description 1 Internal use 2 Internal use 3 RS485 A 4 RS485 B Pin Description 1 PMS5 5V 2 GND 0V 3 GND 0V 4 Reserved Rxd0 5 GND 0V 6 RS485 A 7 RS485 B 8 nc 9 Reserved Txd0 ...

Page 51: ... after a said time of time out equal at 3 5 time of a character transmission where there are not transitions on the transmission line The first Byte of each message is always the address of the unit that is a value from 1 to 127 or 0 for the broadcast messages the second is always the function number and the rest of the message depends of the function demand When a Slave receive an message the uni...

Page 52: ...agram show how to organize the CRC 16 bit C Language CRC 16 Example static short CRC16 unsigned char p_first unsigned char p_last unsigned int crc 0xffff short j for p_first p_last p_first crc p_first for j 8 j 0 j if crc 0x0001 crc crc 1 crc 0xA001 else crc crc 1 return crc ...

Page 53: ...C Address Unit Function N of Byte First Parameter Value Last parameter value CRC 16 3 3Hex HI LO HI LO LO HI 12 5 Preset Multiple Registers This function could write only a parameter for each message The message is composed by 11 Byte one Byte for the address one for the function 10 Hex two Byte for first parameter to write two Bytes for the N of parameters fixed to 1 0001 Hex one Byte with the nu...

Page 54: ...code could be one of the followings Error Code Name Cause 1 ILLEGAL FUNCTION Function not supported 2 ILLEGAL DATA ADDRESS Address out of range 3 ILLEGAL DATA VALUE Attempt to write invalid or action not carried out NOTE If you write a parameter s value equal at his actual value this is a valid transaction and don t cause an error 12 7 Address Configuration The STE Soft Starter is assigned a uniqu...

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