DOLD MINISTART BL 9028 User manual

111.01.21 en / 335A
• According to IEC/EN 60947-4-2
• 2-phase motor control
• For motors up to 11 kW at 3 AC 400 V
• Separate settings for start and brake time, as well as
starting and braking torque
• No braking contactor necessary
• Function test of brake circuit before softstart
• With automatic standstill detection
• Current monitoring
- to protect the power semiconductors
- for device protection at stalled motor
• Maintenance- and wearfree
• Auxiliary DC 24 V
• Monitors undervoltage and phase sequence
• With input to detect motor temperature via PTC (variant /_1_)
• 3 relay outputs for indicaiton of status and fault with LED-indication
• Width: 112.5 mm
0277233
• Motor with gear, belt or chain drive
• Fans, pumps, conveyor systems, compressors
• Woodworking machines, centrifuges
• Packing machines, door-drives
The devices slowly ramps up the current on two phases, therefore allowing
the motor torque to build up slowly. This reduces the mechanical stress on
the machine and prevents damage to conveyed material.
Start/Stop switch
When the motor is on full speed after the starting with start/stop switch
S the semiconductors are bridged with internal relay contacts to prevent
internal power losses and heat built up. When stopping the motor via start/
stop switch S braking is started.
The braking current flows until the motor standstill is detected but not longer
(max. 20 s) through the motor windings.
Monitoring relay 1 (contact 13-14)
The relay energizes at the end of the softstart ramp and de-energizes at the
beginning of the braking cycle. (operation with bridged semiconductors).
When a failure occurs the relay de-energizes when the semiconductors
switch off.
Monitoring relay 2 (contact 13-24)
This relay energises as soon as the unit is ready for operation after connecting
it to power. If any error occurs the monitoring relay 2 will be de-energized
immediately. The power output will be switched off.
Monitoring relay 4 (contact 43-44)
This relay is energized when motor standstill is detected. It will be reset
by starting the motor. The monitoring relay 4 is de-energized if an error
occurs.
Input P1/P2/P3 to monitor the motor temperature (variant /_1_)
To monitor overtemperature onnb the motor a bimetallic contact can
be connected to P2 / P3. When overtemperature is detected the power
semiconductors switch off and all relays de-energize.
On P1/P2 up to 6 PTC sensors can be connected. On detection of
overtemperature, short circuit or broken wire (in sensor circuit) the power
semiconductors switch off and all relays de-energise.
The fault is reset by disconnecting the power supply temporarily after the
temperature on the motor is down again.
Power Electronics
MINISTART
Softstarter with braking function
BL 9028
Approvals and Marking
Applications
Function
Softstarters are electronic devices designed to enable 1-phase or 3-phase
induction motors to start smoothly. By means of internal current monitoring
we realise different protective functions, when stalling the motor or during
heavy duty starting. The semiconductors are bridged after softstart by relay
contacts. This reduces power dissipation and heating. The device parameters
are adjusted using potentiometers. LEDs indicate the status of the device.
Product Description
Function diagram
M10208_b
t0: start
t4: stillstand detection
t0-t1: brake function test
t1-t2: ramp up time
t
3
-t
4
: braking time
t
t1t1 t0t2t3t4t0
L1/L2/L3
T1
43-44
13-14
A1/A2
X1(+)
/ X2
MMot
n
13-24
T2/T3
Translation
of the original instructions
All technical data in this list relate to the state at the moment of edition. We reserve the right
for technical improvements and changes at any time.

211.01.21 en / 335A
- If standstill is not detected, the braking cycle is interrupted after 20 s.
- The brake current switches off after 0.5 sec standstill detection.
- After activation of the start input mains frequency, phase sequence and
presence of all 3 phases is checked.
- Internal temperature monitoring protects the thyristors. By switching on
or off of the power supply this fault can be reset after the temperature
has dropped.
- To protect the power circuit the current is monitored in L1-T1. If the fixed
settings are exceeded, the device switches off and a failure indication is
displayed by a red LED.
- Monitoring of phases and phase shift protects the motor or the
system. After removing the fault this error can be reset by switching
the power supply on and off.
- External bimetallic switches or PTC-thermo sensors are used to
monitor motors on thermal overload. (variant /_1_). Overload results in
disconnection of the motor and failure indication via the red error LED.
After a cooling down period for the motor, the failure can be reset reset
switching the power supply OFF and ON again.
Variation of speed is not possible with this device. Without load a softstart
cannot be achieved. It is recommended that the softstart is protected by
superfast semiconductor fuses rated as per the current rating of the softstart
or motor. However, standard line and motor protection is acceptable, but
for high starting frequencies motor winding temperature monitoring is
recommended. The softstarter must not be operated with capacitive load
e.g. power factor compensation on the output.
In respect to safety of persons and plant only qualified staff is allowed to
work on this device.
Green LED: perm. on: - When auxiliary supply connected or
bypass relay energized
flasher light: - While starting and breaking
Monitoring relay 1
Yellow LED: perm. on: - When contact 13-14 switched on
Monitoring relay 2
Yellow LED: perm. on: - When contact 13-24 switched on
Monitoring relay 4
Yellow LED: perm. on: - When contact 43-44 switched on
Red LED: steady
flashing: - Motor current is > 3 x device current
Red LED: flasher light :- Error
1*): - Overtemperature on thyristor (internal)
2*): - Overtemperature on motor or broken wire in
sensor circuit P1 / P2or bi-metal contact
at sensor circuit P2 / P3has tripped (ooen)
3*): - Short circuit on sensor circuit P1 / P2
4*): - Phase failure
5*): - Incorrect phase sequence,
exchange connections on L1 and L2
6*): - Incorrect frequency
7*): - Incorrect brake circuit
9*): - Incorrect internal temperature sensor
10*): - Incorrect RAM
13*): - Overcurrent
14*): - Brake current to high
15*): - Overcurrent at end of ramp up
16*): - Internal communication error
17*): - Overcurrent on bridging relay
1-17*)= Number of flashing pulses in short sequence
Monitoring Features
Notes
IndicatorsBlock Diagram
Circuit Diagram
Terminal designation Signal description
X1, X2 Start-/Stop-Signal
13, 14 Monitoring relay 1 bridging operation
13, 24 Monitoring relay 2 Ready
43, 44 Monitoring relay4 Standstill
A1(+) , A2 Auxiliary voltage DC 24 V
L1, L2, L3 Phase voltage
T1, T2, T3 Motor connection
P1, P2 , P3 PTC thermal sensor, bi-metal contact
Terminal Connection
M10200_b
13
A1+ X1+
24
A2
X2
L1
T1
L3
T3
14P3
P2
P1
43 44
L2
T2
L2
43
44 A2 T2
L3 L1
T3 T1
A1 X1 P1 P2 P3
X2
13
2414
Variante /_1_
L1 L2 L3
T1 T2 T3
M10206_b
Mon ton IBr
14 43
13 4424
IU
U
U
U
P1 variant
/_1_
P2
P3
micro control
A1+ A2 X1+ X2

311.01.21 en / 335A
Phase / motor
voltage L1/L2/L3: 3 AC 200 V -10 % ... 480 V + 10 %
Nominal frequency: 50 / 60 Hz
Nominal motor power PN
at 400 V: 11 kW
Switching frequency
at 3 x IN, 5 s, ϑU= 45°C: 20 / h
max. permissable braking current: 50 A eff.
Min. motor power: 0.1 PN
Start torque: 20 ... 80 %
Ramp time: 1 ... 20 s
Braking time: Max. 20 s
Braking delay: 750 ms
Braking voltage: DC 10 ... 90 V
Start delay: 250 ms
Auxiliary voltage UH
model DC 24 V: A1/A2, DC 24 V, + 10 %, - 15 %
Power consumption: 2 W
Residual ripple max.: 5 %
Max. semiconductor fuse: 6600 A2 s
Inputs
Control input X1, X2: DC 24 V / 2.5 mA / edge triggered
Input P2 / P3 for bi-metal contact
Switching current: DC 1 mA
Switch voltage: DC 5 V
Input P1 / P2 for PTC-sensor
Thermal sensor: According to DIN 44081
Number of sensors: 1 ... 6 in series
Response value: 3 kΩ
Measuring voltage: Max. DC 5V
Monitoring Output
Contacts: 3 x 1 NO contacts
Thermal continous current Ith:4 A
Switching capacity
to AC 15
NO contact: 3 A / 230 V IEC/EN 60947-5-1
Electrical life:
to AC 15 at 3 A,
AC 230 V: 2 x 105switch. cycl. IEC/EN 60947-5-1
Short circuit strength
max. fuse rating: 4 A gG / gL IEC/EN 60947-5-1
General Data
Temperature range
Operation: 0 ... + 45 °C
Storage: - 25 ... + 75 °C
Altitude: < 2000 m
Clearance and creepage
distances
Rated impulse voltage /
pollution degree
Control voltage to auxiliary
voltage, motor voltage: 4 kV / 2 IEC 60664-1
Auxiliary voltage to
motor voltage: 4 kV / 2 IEC 60664-1
motor voltage to heat sink: 6 kV / 2 IEC 60664-1
EMC
Electrostatic discharge: 8 kV (air) IEC/EN 61000-4-2
HF-irradiation
80 MHz ... 1 GHz: 10 V / m IEC/EN 61000-4-3
1 GHz ... 2,5 GHz: 3 V / m IEC/EN 61000-4-3
2,5 GHz ... 6 GHz: 1 V / m IEC/EN 61000-4-3
Fast transients: 2 kV IEC/EN 61000-4-4
Surge voltages
between
wire for power supply: 1 kV IEC/EN 61000-4-5
between wire and ground: 2 kV IEC/EN 61000-4-5
HF wire guided: 10 V IEC/EN 61000-4-6
BL 9028.03 3 AC 200 ... 480 V 50/60 Hz UHDC 24 V 11 kW
Article number: 0068352
•Nominal motor power
at 3 AC 400 V: 11 kW
•Control input X1, X2: DC 24 V
•Width: 112.5 mm
Technical Data Technical Data
Standard Type
Interference emission
Wire guided: Limit value class A IEC/EN 60947-4-2
Radio irradiation: Limit value class A IEC/EN 60947-4-2
The device is designed for the usage
under industrial conditions (Class A,
EN 55011). When connected to a
low voltage public system (Class B,
EN 55011) radio interference can be
generated. To avoid this, appropriate
measures have to be taken.
Degree of protection:
Housing: IP 40 IEC/EN 60529
Terminals: IP 20 IEC/EN 60529
Vibration resistance IEC/EN 60068-2-6
Frequency range: 10 ... 100 Hz
Amplitude: 0.35mm peak to peak up to 54 Hz
Acceleration: Above 54 Hz constant acceleration 4 g
Climate resistance: 0 / 045 / 04 IEC/EN 60068-1
Wire connection
Load terminals: 1 x 10 mm2solid
1 x 6 mm2stranded ferruled
Control terminals: 1 x 4 mm2solid or
1 x 2.5 mm2stranded ferruled (isolated) or
2 x 1.5 mm2stranded ferruled (isolated)
DIN 46228-1/-2/-3/-4 or
2 x 2.5 mm2stranded ferruled
DIN 46228-1/-2/-3
Stripping length: 10 mm
Wire fixing
Load terminals: Plus-minus terminal screws M4
box terminals with wire protection
Fixing torque: 1.2 Nm
Control terminals: Plus-minus terminal screws M3.5
box terminals with wire protection
Fixing torque: 0.8 Nm
Mounting: DIN rail mounting IEC/EN 60715
Weight: 1135 g
Dimensions
Width x height x depth: 112.5 x 85 x 121 mm
BL 9028. 03/_ _ _ 3 AC 200...480 V 50/60 Hz UHDC 24 V 11 kW
Nom. motor power
at 3 AC 400 V
Aux./Control voltage
Nom. frequency
Phase / motor voltage
Variant
0 = Standard
0 = Standard
1 = Input P1/P2/P3
for motor temp.
monitoring
0 = With standstill
detection
Contacts
Type
Ordering Example
Variant
BL 9028.03/_1_: Motor protection with bi-metal contact or
PTC thermal sensor

411.01.21 en / 335A
Connection Examples
L1
L2
L3
DC 24V
0V
L1 L2 L3 43X1(+)A1(+)
T1 T2 T3 44
UVW
X2A2
S
M
3~
Q1
BL9028.03
M10201_b
I> I> I>
13
14 24
L1
L2
L3
DC 24V
0V
L1 L2 L3 43X1(+)A1(+)
44
X2A2
S
Q1
BL9028.03/010
M12005
I> I> I>
13
14 24
T1
T1
T2
T2
T3
T3
P2
P2
P3
P3
U
U
V
V
W
W
M
3~
M 3~
T1 T2 T3
P1
P1 P2 P3
UVW
M 3~
without
temperature
monitoring
temperature
monitoring by
bimetallic contact
temperature
monitoring by
1...6 PTC-sensor
With BL 9028 softstart begins by closing switch S and braking starts when
opening switch S. When closing S during braking, softstart begins again.
A new start can only be made, after the braking cycle is completed. The
control input is triggered with rising edge.
Softstart:
1. Start the motor via control input X1/X2 and turn potentiometer „Mon“
up until the motor starts to turn without excessive humming.
2. Adjust potentiometer „ton“ to give desired ramp time.
3. On correct setting the motor should accelerate up to nominal speed.
If the start takes too long fuses may blow, especially on motors with
high inertia.
- Attention: If the ramp-up time is adjusted to short, the internal
bridging contact closes before the motor is on full speed.
This leads to interruption of the softstart and to fault
message 15.
Braking:
Press stop button and adjust with potentiometer „IBr“ the braking current to
the desired value. Please adjust the braking current high enough so that
the brake time is shorter than 20 sec.The brake current should be limited to
1.8 ... 2 x INof the motor. If the brake function at 1.8 ... 2 times of rated
current has not finshed within 20 sec the load is too high. The next larger
motor shoud be used. To avoid an overload of the device and the motor,
the brake current should be measured with a moving coil instrument in the
motor connecting line T1.
Function test of brake circuit:
Before starting the motor the function of the braking circuit is tested by a
short braking attempt. If no current flows during the test the device goes
into failure mode. By disconnecting and reconnecting of the auxiliary
voltage the fault can be reset.
Temperature monitoring:
BL 9028 features overtemperature monitoring of its internal power semicon-
ductors. The unit is therefore protected against overheating during the set
up procedure. BL 9028 can be reset after the semiconductors have cooled
down by momentarily removing the auxiliary supply voltage.
Monitoring of the power circuit:
To protect the power circuit against overcurrent the current is monitored in
L1-T1. To high starting current, braking current or current at stalled motor
result in disconnecting the motor current and failure indication by flashing
code (see Indicators).
Potentiometer Description Initial setting
Mon
ton
IBr
Starting voltage
Ramp-up time
Braking current
fully anti-clockwise
fully clockwise
fully anti-clockwise
Control input X1, X2
Adjustment Facilities
Set-up Procedure
- Never clear a fault when the device is switched on.
- The user must ensure that the device and the necessary
components are mounted and connected according to the locally
applicable regulations and technical standards.
- Adjustments may only be carried out by qualified specialist staff and
the applicable safety rules must be observed.
Safety Notes

511.01.21 en / 335A
During normal operation failure messages may occur. The messages are
indicated by a flashing sequence of the „Error“ LED.
Fault Indication by Flashing Code
Flashes Fault Reason Failure
recovery
1 x
Overtemperature
on
power unit
Permitted
duty cycle ex-
ceeded
Reduce
duty-cycle
Wait till heat sink
cools down
2 x
Overtemperature
on motor or
broken wire in
thermistor circuit
High duty-cycle
on motor or
broken wire
Decrease
duty-cycle.
Repair wiring
of temperature
sensor
3 x Short circuit in
thermistor circuit
Squeeze conduit,
defective
soldering point
Check
connection wire,
repair
4 x Phase failure
Defective fuse Change fuse
Check
voltage range
5 x Decrease
phase sequence
Connection
L1, L2, L3
incorrect
Correct connetion
sequence see
application
6 x
Mains frequency
is out of
tolerance
Wrong mains
frequency
Device
not suitable for
the frequency.
Contact
manufacturer.
7 x Broken ciruit
Cable break Check wiring
Defective
braking relay
The unit has to
repaired
9 x
Incorrect
internal
temperature
sensor
Defective
component or
temperature
out of range
Check
temp. range
The unit has to
repaired
10 x RAM defective Defective
component
The unit has to
repaired
13 x
Overcurrent
on power
semiconductors
Gravitational
start
Prolonging ramp
up time. Set
starting torque
lower. Use
unit with higher
ranges
Motor blocked Remove blockage
14 x Brake current
to high
Braking current
adjusted over
permitted value
Back off
potentiometer IBr
15 x Overcurrent on
ramp
Gravitational
start, ramp time
to short or
starting torque
to high
Prolonging ramp
up time. Set
starting torque
lower. Use
unit with higher
ranges
16 x
Communication
error
internal
Defective
component
The unit has to
repaired
17 x Overcurrent on
bridging relay Motor blockage Remove blocking

611.01.21 en / 335A
E. Dold & Söhne GmbH & Co. KG • D-78120 Furtwangen
dold-relays @dold.com • www.dold.com
• Bregstraße 18 • Phone [phone] • Fax [phone]