DOLD MINISTART BL 9228 User manual

111.01.21 en / 335A
Power Electronics
•According to IEC/EN 60947-4-2
•2-phase motor control
•For motors up to 15 kW bei 3 AC 400 V
•Separate settings for start and brake time, as well as starting
and braking torque
•No braking contactor necessary
•With automatic standstill detection
•Maintenance- and wearfree
•Auxiliary voltages AC 230 V, AC 400 V and DC 24 V
•Monitors undervoltage and phase sequence
•3 relay outputs for indicaiton of status and fault with LED-indication
•With input to detect motor temperature
•Function test of braking circuit when actuating the On-button
•Monitored braking current
- safe monitored start
- protection against unententional start-up
- safe disconnection of motor contactor after finished braking
•BL 9228 up to 7.5 kW: 90 mm width
BL 9228 up to 15 kW: 112.5 mm width
MINISTART
Softstarter With DC-Brake
BL 9228
0249781
Approvals and Marking
Applications
•Motor with gear, belt or chain drive
•Fans, pumps, conveyor systems, compressors
•Woodworking machines, centrifuges
•Packing machines, door-drives
Softstarters are electronic devices designed to enable 1-phase or
3-phase induction motors to start smoothly. 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.
These features allow cost saving constructions of mechanical gear. The
braking circuit is tested für correct function at start-up. A negative test
interrupts the starting and indicates a fault signal.
Start/Stop switch
When the motor is on full speed after the starting with start switch the
semiconductors are bridged with internal relay contacts to prevent internal
power losses and heat built up.
When stopping the motor via start switch braking is started. The braking
current flows until detection of the stillstand through the motor windings. If
the brake function takes longer than 10 sec, the monitoring relay 1 provides
a signal. After 15 sec the brake function will be finished and the motor will
be separated from the mains via contactor K1.
Monitoring relay 1 (contact 13-14)
Relay 1 is energized if the brake function takes longer than 10 sec. By
restarting of the device this relay is de-energized. However, if the brake
function has been longer than 10 sec for the third time, the device is set
into an error mode.The red LED flashes code 9.This fault can only be reset
by switching on and off the power supply.
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 3 (contact 33-34)
The relay is energized after activating the on-button and is de-energized
after indication of the motor standstill at the end of braking.
If standstill is not detected, the relay is de-energized after pushing the off-
button and elapse of a safety time.The relay is operating the motor contactor.
It is immediately de-energized by any fault indication.
Function
Block Diagram
BL 9228 up to 15 kW
BL 9228 up to 7,5 kW
L1 L2 L3 A1P1 P2 P3 A2 X1 X2
T1 T2 T3
M8463_c
Mon
Elektronik-
Versorgung
ton IBr
Microcontroller
Sicher-
heitsüber-
wachung
33 34
Tv
14 43
13 4424
IU
Circuit diagram
M8464_d
X2
P1 P2 P3
13
A1 A2 X1
24
34
33
L1
T1
L3
T3
14
43 44
L2
T2
L2
3343
3444 A1 T2
L3 L1
T3 T1
X1 X2 P1 P2
A2 P3
13
2414
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
Function Diagram Indication
- If the motor does not stand still within 10 sec during brake function
the monitoring relay 1 will indicate this. The brake function is stopped
latest after 15 sec if there is no standstill detection, and the motor
is separated from the mains.
A restart resets the monitoring relay 1. If this error occurs for the third
time the device changes into the error mode. The red LED will flash
code 9.
- The brake current switches off after 0.5 sec standstill detection.
- On power up the mains frequency, phase sequence and presence
of all 3 phases is checked.
- Internal temperature monitoring protects the thyristors. With the
function "motor overtemperature" a bimetall switch or PTCs are
monitored. By switching on or off of the power supply this fault can
be reset after the temperature has dropped.
- 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.
- After connecting the power supply or after braking until restart a
check will be done if L1, L2 or L3 of the device are separated
from the mains (to ensure that contactor K1 or relay 3 are not welded).
It is detected if 2 or 3 phases are connected in a wrong way.
- Monitored current to protect the power part and the relays at heavy duti
start or blocked motor.
Monitoring Features
Function
Monitoring relay 4 (contact 43-44)
This relay is energized when motor standstill is detected. It will be reset by
pushing the on-button.The contact can be used for example to lock a safety
gate. The monitoring relay 4 is de-energized if an error occurs.
Input P1/ P2/ P3to monitor the motor temperature
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-energise.
On P1/ P2up 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.
Indication
Green LED: Continous light: - When auxiliary supply connected
Flashing light: - While starting and breaking
Monitoring relay 1
Yellow LED: Continous light: - When contact 13-14 switched on
Monitoring relay 2
Yellow LED: Continous light: - When contact 13-24 switched on
Monitoring relay 3
Yellow LED: Continous light: - When contact 33-34 switched on
Monitoring relay 4 optional
Yellow LED: Continous light: - When contact 43-44 switched on
Red LED: Flashing light : - Error
1*): - Overtemperature on thyristor (internal)
2*): - Overtemperature on motor or broken
wire in sensor circuit P1/P2
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
8*): - Incorrect safety monitoring
9*): - Braking time 3 x higher than 10 s
10*): - Incorrect RAM
11*): - Incorrect RUN-input (start switch
welded)
12*): - Device not separated from mains (2 or
3 phases occur before start)
13*): - Overcurrent in semiconductors
14*): - Brake current to high
15*): - Overcurrent at end of ramp up
16*): - Communication error
17*): - Overcurrent on bridging relay
1-17*)= Number of flashing pulses in short sequence
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.
Notes
t
t1t1 t0t2t3t4t0
t0: start
t4: stillstand detection
t0-t1: test
t1-t2: ramp up time
t3-t4: braking time
L1/L2/L3
T1
43-44
33-34
A1/A2
X1
MMot
n
M5663
13-24
T2/T3

311.01.21 en / 335A
Technical Data
EMC
Electrostatic discharge: 8 kV (air) IEC/EN 61000-4-2
HF-irradiation: 10 V 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
Degree of protection
Housing: IP 40 IEC/EN 60529
Terminals: IP 20 IEC/EN 60529
Vibration resistance: Amplitude 0.35 mm
frequency 10 ... 55 Hz, IEC/EN 60068-2-6
Climate resistance: 0 / 055 / 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
Wire fixing
Load terminals: Plus-minus terminal screws M4
box terminals with wire protection
Control terminals: Plus-minus terminal screws M3.5
box terminals with wire protection
Mounting: DIN rail mounting IEC/EN 60715
Weight
Width 90 mm: 895 g
Width 112.5 mm: 1135 g
Dimensions
Width x height x depth
BL 9228 up to 7.5 kW: 90 x 85 x 121 mm
BL 9228 up to 15 kW: 112.5 x 85 x 121 mm
Width
90 mm 112.5 mm 112.5 mm
Nominal motor power PNat 400 V: 7.5 kW 11 kW 15 kW
Switching frequency
at 3 x IN, 5 s, ϑU= 45°C: 10 / h 45 / h 30 / h
permissable braking current: 35 A 50 A 65 A
Min. motor power: 1 kW
Start torque: 20 ... 80 %
Ramp time: 1 ... 20 s
Braking time: 1 ... 15 s
Braking delay: max. 2500 ms
Braking voltage: DC 10 ... 90 V
Start delay: 450 ms
Auxiliary voltage UH
Model DC 24 V: A1/A2, DC 24 V, + 10 %, - 10 %
Model AC 230 V: A1/A2, AC 230 V, + 10 %, - 15 %
Model AC 400 V: A1/A2, AC 400 V, + 10 %, - 15 %
Power consumption: 2 W
Residual ripple max.: 5 %
Max. semiconductor fuse
BL 9228 / 7.5 kW: 1800 A2 s
BL 9228 / 11 kW: 6600 A2 s
BL 9228 / 15 kW: 18050 A2 s
Inputs
Control input X1, X2
Voltage. DC 24 V
Input P2 / P3for
bimetallic contact
Current: Approx. 1 mA (= switch closed)
Voltage: Approx. 5 V (= switch open)
Input P1 / P2for PTC-sensor
Temperature sensor: PTC-sensor according to DIN 44081/082
Number of sensors: 1 ... 6 in series
Response value: 3.2 ... 3.8 kΩ
Reset value: 1.5 ... 1.8 kΩ
Load in measuring circuit: < 5 mW (at R = 1.5 kΩ)
Broken wire detection: > 3.1 kΩ
Measuring voltage: ≤2 V (at R = 1.5 kΩ)
Measuring current: ≤1 mA (at R = 1.5 kΩ)
Voltage, when broken
wire in sensor circuit: DC approx. 5 V
Current, when short
circuit in sensor circuit: DC approx. 0.5 mA
Monitoring Output
Contacts: 4 x 1 NO contacts
Thermal continous
current Ith:4 A
Switching capacity
to AC 15
NO contact: 3 A / 400 V IEC/EN 60947-5-1
Electrical life
to AC 15 at 3 A,
AC 400 V: 2 x 105switching cycles
IEC/EN 60947-5-1
Short circuit strength
max. fuse rating: 4 A gG / gL IEC/EN 60947-5-1
General Data
Temperature range: 0 ... + 45 °C
Storage temperature: - 25 ... + 75 °C
Clearance and creepage
distances
rated impuls 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
Technical Data
Phase / motor
voltage L1/L2/L3: 3 AC 200 V -10 % ... 480 V + 10 %
Nominal frequency: 50 / 60 Hz
Ordering example:
BL 9228. 03/_ _ _ 3 AC 200...480 V 50/60 Hz UHDC 24 V 15 kW
Auxiliary/control voltage
Nominal motor power
at AC 400 V
Nominal frequency
Phase/motor voltage
Variants, if required
0 = Standard
0 = Standard
1 = Input P1/P2/P3
for motor temperatur
monitoring
0 = With standstill
monitoring
1 = Without standstill
monitoring; braking
time adjustable on
potentiometer
Contacts
Type
Standard Type
BL 9228.03/010 3 AC 200 ... 480 V 50/60 Hz UHDC 24 V 15 kW
Article number: 0064256
•Nominal motor power
at AC 400 V: 15 kW
•Control input X1, X2
•Width: 112.5 mm

411.01.21 en / 335A
Safety Notes
- 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.
Set-up Procedure
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 10 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 10 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.
Temperature monitoring:
BI 9028 features overtemperature monitoring of its internal power
semiconductors.The unit is therefore protected against overheating during
the set up procedure. BI 9028 can be reset after the semiconductors have
cooled down by momentarily removing the auxiliary supply voltage.
With BL 9228 soft start begins by pressing the start button. By pressing
the stop button braking will start.
Control Input X1, X2
Adjustment Facilities
Potentiometer Description Initial setting
Mon Starting voltage fully anti-clockwise
ton Ramp-up time fully clockwise
IBr Braking current fully anti-clockwise
Set-up Procedure
Soft start:
1. Press start button.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 may damage the bridging contactor or bridging
relay.
Connection Examples
Auxiliary voltage UH= AC 400 V or AC 230 V Auxiliary voltage UH= DC 24 V
L1
L2
L3
L1 L2 L3 A1 A2
T1
T1
T2
T2
T3
T3
P2
P2
P3
P3
U
U
V
V
W
W
33
DC 24V
0V
control
voltage
43
3444
K1
M
3~
M3~
Q1
K1
1
246
53
BL9228/010
M9766_b
I> I> I>
T1 T2 T3
P1
P1 P2 P3
UVW
M3~
13
14 24
without
temperature
monitoring
temperature
monitoring by
bimetallic contact
temperature
monitoring by
PTC-sensor
X1 X2
S
L1
L2
L3
N
L1 L2 L3 A1 A2
T1
T1
T2
T2
T3
T3
without
temperature
monitoring
temperature
monitoring by
bimetallic contact
P2
P2
P3
P3
U
U
V
V
W
W
S
3343
3444
M
3~
M3~
Q1
K1
1
246
53
BL9228/010
M5668_b
I> I> I>
T1 T2 T3
P1
temperature
monitoring by
PTC-sensor
P1 P2 P3
UVW
M3~
13
14 24
K1
X1 X2

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
Braking delay
time 3 times
higher than 10 s
Brake current to
small
Setting brake
curren higher
Centrifugal mass
for max. brake
current to large
Use
brake unit with
higher ranges
10 x RAM defective Defective
component
The unit has to
repaired
Flashes Fault Reason Failure
recovery
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
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]