DOLD MINISTART GF 9016 User manual

108.05.23 en / 731A
Approvals and Markings
Applications
Product Description
The softstarter and softstop device GF 9016 is a electronic control unit for
the smooth starting and stopping of three-phase asynchronous machines.
The GF 9016 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.
When the motor is up to full speed the power semiconductors in GF 9016
are bridged to prevent internal power losses and heat build up. In addition
GF 9016 allows a softstop function prolonging the stop time of the motor,
preventing high counter torques from abruptly stopping the motor.
•Motors with gear, belt or chain drive
•Fans, pumps, conveyor systems, compresseors
•Packaging machines, door drives
•Start current limiting on 3 phase motors
M9816_a
1L1 3L2 5L3
2T1 4T2 6T3
Ustart
tt
X7
X5
X3
X2
X1+
X4
X8
X6
Bypass
Interference
Boost
Start
Supply
votlage
Electronic
Control
for
bridging
Trigger pulse
generator Ramp control
0254730
Power Electronics
MINISTART
Softstarter And Softstop Device
GF 9016
Terminal designation Signal description
L1, L2, L3 Phase voltage L1, L2, L3
T1, T2, T3 Motor voltage U, V, W
X1 Output + 24V
X1 Input + 24 V
at variant with wide voltage
X2 Start / Stop
X3 Kickstart 0,5 s
X4 0 V
X5, X6 Indicator output, fault
X7, X8 Indicator output, device bridged
Connection Terminals
Translation
of the original instructions
Block Diagram
Your Advantage
• For soft and shockfree start of your asynchronous motors
• Less wearing and longer life for your motors and components
• Space saving and easy fitting
• Reduce load from supply mains by reducing of starting current
Features
• According to IEC/EN 60947-4-2
• Softstart with softstop
• For motors up to 22 kW
• 2-phase control
• Adjustable start up and deceleration time als well as starting voltage,
optionally with kickstart
• Without auxiliary voltage
• W3 connection is possible
• Up to 15 kW: Width 45 mm
Up to 22 kW: Width 52.5 mm
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.

208.05.23 en / 731A
LED green: Indicates the ready-to-operate state of the control unit
LED yellow: Lights up after completion of start-up
flashes with rising or falling speed at softstart / softstop
flashes with same frequency at error (see table)
Failure codes
Fault LED yellow Operating state
1Yellow LED flashes 1 x times
with short space
Supply voltage error or
load too low
2Yellow LED flashes 2 x times
with short space
Device overloaded /
heat sink temperature to high
3Yellow LED flashes 3 x times
with short space Failure in electronics
4Yellow LED flashes 4 x times
with short space Firing error in phase 1
5Yellow LED flashes 5 x times
with short space Firing error in phase 3
6Yellow LED flashes 6 x times
with short space
Error in motor phase/ power
semicond. defective in phase 1
7Yellow LED flashes 7 x times
with short space
Error in motor phase/ power
semicond. defective in phase 3
8Yellow LED flashes 8 x times
with short space General synchronising error
Indication
Troubleshooting
In case of a fault, please proceed as follows:
Fault 1:
Electronics supply or motor too small (see technical data minimum motor
load). Send device to the producer to have it checked.
Fault 2:
Check the frequency of starts and the starting current and also observe
the max. ambient temperature. Give the device and/or the motor enough
time between starts to cool down. The heat dissipation can be improved
by forced cooling, e.g., by means of a fan mounted unterneath the device
or by using a motor with a separately driven fan.
Fault 3:
Defect in the internal control electronics. Send device to the producer to
have it checked.
Fault 4/5:
Mains supply is interrupted.Motor lead interrupted, power semiconductor(s)
defective, motor defective. Check motor and wiring. Send device to the
producer to have it inspected.
Fault 6/7:
Mains supply is interrupted. Power semiconductors do not trigger. Motor
rating is too small. Check as to whether the motor is suitable for the device
rating. Send device to the producer to have it checked.
Fault 8:
Mains or motor wiring is interrupted. Power semiconductor(s) defective.
Check wiring. Send device to producer to have it inspected
Motor load must always be connected as continuous operation of the
softstart with no load may cause overheating of the motor and softstart.
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.
Resetting of faults
The fault message can be reset by disconnecting and reconnecting the
supply voltage.
!
Warning:
At any rate, the cause of the fault has to be identified and remedied by
trained and qualified personnel. Only then must the device be put into
operation again.
Notes
!
Attention:
Please pay attention and consider for the operation of IE3-motors while
dimensioning of softstarters the resulting higher starting currents.
For the use of IE3-motors we highly recommend to dimension and design
the needed softstarters one size higher.
!
Warning:
- To avoid heat accumulation, keep a distance of at least 40 mm between
the cable duct and the unit.
- If the ramp-up time is set too short, the internal bypass contacts close
before the motor has reached the rated speed.This can cause damage
to the bypass relays.
- Make sure that the specified switching frequency is not exceeded! After
each start, the power semiconductors must be given sufficient time
to cool down. Starting processes in short succession can destroy the
power semiconductors! Operation in bridged state also allows the power
semiconductors to cool down!
Function Diagram
t
tttt
0123
X1 / X2
M
L1/L2/L3
T2
Mot
n
M9607_a
T1/T3
0,5s
Kickstart
:
:
:
t-t
32
t-t
10
t0Start
Ramp time
Stop time

308.05.23 en / 731A
GF 9016 3 AC 400 V 50/60 Hz 7.5 kW AC 230 V
Auxiliary supply
(only necessary > 500 V)
Nominal motor power
Nominal frequency
Nominal voltage
Type
GF 9016 3 AC 400 V 50/60 Hz 7.5 kW
•Nominal voltage: 3 AC 400 V
•Nominal motor power: 7.5 kW
•Width: 45 mm
Technical Data
Standard Type
Ordering Example
Technical Data
Nominal voltage: 3 AC 400 V ±15 %
(others on request)
Nominal frequency: 50 / 60 Hz
Rated current: 17 25 32 45 A
Nominal motor power
at PNat 400 V: 7.5 11 15 22 kW
Min. motor power: Approx. 0.2 PN
Start torque: 40 ... 80 %
Ramp time: 0.5 ... 10 s
Deceleration time: 0.25 ... 10 s
Recovery time: 200 ms
Switching frequency: 60 40 30 10 1/h
I2t-Power semiconduct. fuse: 4000 4000 9100 16200
Backup value for
coordination type 1: 35 50 50 63 A
nfo
Coordination type!
Coordination type 1 according to IEC 60947-4-1: The engine
control unit is defective following a short circuit and must be
replaced.
Usage category: 17A: AC-53b:3-5:55
25A: AC-53b:3-5:85
32A: AC-53b:3-5:115
45A: AC-53b:3-5:355
Rated insulation voltage: 600 V
Control inputs
Control voltage
Control input current:
10 ... 24 V DC
1 ... 2.4 mA
Indicator output
Contacts: 1 changeover contact
Switching capacity
to AC 15
NO contact: 3 A / AC 230 V IEC/EN 60947-5-1
NC contact: 1 A / AC 230 V IEC/EN 60947-5-1
Electrical life
to AC 15 at 3 A, AC 230 V: 2 x 105switching cycles
Permissible switching
frequency: Max. 1800 switching cycles / h
Short circuit strength
max. fuse rating: 4 A gG / gL IEC/EN 60947-5-1
Mechanical life: ≥108switching cycles
General Data
Temperature range
Operation: 0 ... + 45 °C
Storage: - 25 ... + 70 °C
Relative air humidity: < 95%, no condensation at 40 °C
Altitude: ≤2000 m
Power reduction
at > 45°C:
For instal. heights over 1000 m:
- 2 % up to max. 60 °C
- 2 % 100 m each
Overvoltage caregory /
polluiton degree: III / 2
Insulation class:
Main circuit:
Control and auxiliary circuit:
6 kV
2.5 kV
EMC
Interference resistance
Electrostatic discharge (ESD): 8 kV (air) IEC/EN 61000-4-2
HF-irradiation
80 MHz ... 1.0 GHz: 10 V / m IEC/EN 61000-4-3
1.0 GHz ... 2.5 GHz: 3 V / m IEC/EN 61000-4-3
2.5 GHz ... 2.7 GHz: 1 V / m IEC/EN 61000-4-3
Fast transients: 2 kV IEC/EN 61000-4-4
Surge voltage
between
wires 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
Voltage dips: IEC/EN 61000-4-11
Interference emission
Wire guided: Limit value class B IEC/EN 60947-4-2
Radio irradiation: Limit value class B IEC/EN 60947-4-2
Degree of Protection: IP 20
Wire connection
Load terminals: Plug in screw terminal
Stranded wire: 6 6 16 16 mm2
Control terminals: 1.5 mm2cage clamp terminals
Fixing torque: 1.2 ...
1.5
1.2 ...
1.5
1.5 ...
1.7
1.5 ...
1.7 Nm
Mounting: DIN-rail mounting IEC/EN 60715
Weight: 1.0 1.0 1.0 1.0 kg
Dimensions
Width x height x depth (incl. terminals)
7.5 / 11 / 15 kW:
22 kW:
45 x 173 x 158 mm
52.5 x 178 x 158 mm

408.05.23 en / 731A
Softstart with softstop
L1
L1 L2 L3 X1 X2 X3 X4
L2
L3
U1
U2
V1
V2
W1
W2
T1 T2 T3 X5 X6 X7 X8
GF9016
Q1
M8480
I> I> I>
M
3~
L1
L1 L2 L3 X1 X2 X3 X4
GND
External DC voltage
DC 10...24V
Start
Kickstart
L2
L3
UVW
T1 T2 T3 X5 X6 X7 X8
GF9016
Q1
M9609
I> I> I>
M
3~
Softstart in a √3-circuit up to 22 kW
Start only by connecting the mains voltage, terminals X1-X2 bridget
Application Examples
Safety Notes
Set-up Procedure
Connect conact to X1, X2 and select softstart (close contact) or softstop
(open contact). As option the unit can also be started by an external
control voltage of DC 10 ... 24 V. This has to be connected to terminals X2,
X3, X4 connecting means starting up,disconnection stopping. On terminal
X3 a kickstart function can be activated. This is useful on motors that have
a high starting load as e.g. mills, breakers, conveyors. Kickstart takes 0.5
sec at fully switched thyristors.
X5, X6: Error at phase failure, frequency variation, thyristor failure,
overtemperature of the unit, disconnected motor. Reset by
switching the unit off and on
X7, X8: Softstart finished, semiconductors bridged
Potentiometer Description Initial setting
Ustart Starting voltage Fully anti-clockwise
t Ramp-up time Fully clockwise
t Deceleration time Fully clockwise
Control Input
Adjustment Facilities
Indicator Outputs
Softstart:
1. Switch on the unit and motor and select start-up via control input X1/X2
(close). Turn trimmer "Man" clockwise until the motor starts immediately
after switching on.
2. Select the acceleration time briefly by turning "tan" counterclockwise to
keep the additional thermal load low.
-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.
Softstop:
- During the soft coasting phase, the unit must remain switched on at the
three-phase mains.
- Select the run-down via the control input X1/X2 (open).
- Adjust the tab trimmer until the desired run-down time is reached.
!
- Never clear a fault when the device is switched on
- Attention: This device can be started by potential-free contact, while
connected directly to the mains without contactor (see
application example). Please note, that even if the motor is
at rest, it is not physically separated from the mains.
Because of this the motor must be disconnected from the
mains via the corresponding manual motor starter.
- 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.
- These units are reset by switching the control supply voltage off and
on.
- The protective conductor connection to the motor must not be laid in
shielded motor cables, but separately with an appropriate cross-sec-
tion. The individual earthing systems, power earth, protective earth,
digital earth and analogue earth should be laid separately by suitable
neutral point wiring.
!
E. Dold & Söhne GmbH & Co. KG • D-78120 Furtwangen
dold-relays @dold.com•www.dold.com
• Bregstraße 18 • Phone +49 7723 654-0 • Fax +49 7723 654356