EDS BL 9228 User manual

1BL 9228 / 06.12.07 e
Power Electronics
•According to IEC/EN 60 947-4-2, prEN 1870-1, GS-HO-01
•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
•Control input and relay output for emergency stop according to
safety category 1, EN 954-1
•No braking contactor necessary
•With automatic standstill detection
•This brake system fullfills the requirements of category 2
according to EN 954-1 of "Recommandation for Use"
(CNB/M/01.051IR/E), prEN 1870-1, GS-HO-01
•Safe separation of the motor from the mains after fault or
brakefunction via external contactor, category 1 according to
EN 954-1
•Maintenance- and wearfree
•Auxiliary voltages 230 V and 400 V
•Monitors undervoltage and phase sequence
•3 relay outputs for indicaiton of status and fault with LED-indication
•With input to detect motor temperature
•BL 9228 up to 7.5 kW: 90 mm width
BL 9228 up to 15 kW: 112.5 mm width
Softstarter with DC-Brake BL 9228
ministart
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.
A 0249781
Approvals and marking
Applications
•Motor with gear, belt or chain drive
•Fans, pumps, conveyor systems, compressors
•Woodworking machines, centrifuges
•Packing machines, door-drives
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
M5667
Mon
electronics
supply
ton IBr
micro control safety
monitoring
33 34
Tv
14 43
13 4424
IU
HBG
Circuit diagram
M8464_c
33 34
P1 P2 P3
13
A1 X1
24
A2 X2
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
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.
A special monitoring allows the application in systems of safety
category 2.
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 energised if the brake function takes longer than 10 sec. By
restarting of the device this relay is de-energised. 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-energised immediately. The power output will be switched off.
Monitoring relay 3 (contact 33-34)
The relay is energised after activating the on-button and is de-
energised after indication of the motor standstill at the end of braking.
If standstill is not detected, the relay is de-energised after pushing the
off-button and elapse of a safety time. The relay is operating the motor
contactor. It is immediately de-energised by any fault indication.
Function

2BL 9228 / 06.12.07 e
Function diagram
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
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.
- By turning the brake potentiometer during braking the standstill
monitoring is deactivated. In this case the motor brakes always with
the maximum motor braking time of 15 sec.
- 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 and
checked that the on-button is not welded or bridged.
Monitoring features
Function
Monitoring relay 4 (contact 43-44) optional
This relay is energised 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-energised 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)
1-12*)= 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

3BL 9228 / 06.12.07 e
Technical data
EMC
Electrostatic discharge: 8 kV (air) IEC/EN 61 000-4-2
HF-irradiation: 10 V IEC/EN 61 000-4-3
Fast transients: 2 kV IEC/EN 61 000-4-4
Surge voltages
between
wire for power supply: 1 kV IEC/EN 61 000-4-5
between wire and ground: 2 kV IEC/EN 61 000-4-5
Degree of protection
Housing: IP 40 IEC/EN 60 529
Terminals: IP 20 IEC/EN 60 529
Vibration resistance: Amplitude 0.35 mm
frequency 10 ... 55 Hz, IEC/EN 60 068-2-6
Climate resistance: 0 / 055 / 04 IEC/EN 60 068-1
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 46 228-1/-2/-3/-4 or
2 x 2,5 mm2stranded ferruled
DIN 46 228-1/-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 60 715
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: approx. 5.5 kW
Start torque: 20 ... 80 %
Ramp time: 1 ... 20 s
Braking time: 1 ... 15 s
Braking delay: 750 ms
Braking voltage: DC 10 ... 90 V
Start delay: 250 ms
Auxiliary voltage UH
model AC 24 V: A1/A2, AC 24 V, + 10 %, - 15 %
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: 6600 A2 s
Inputs
Control input X1
Voltage
depending on model
(reference for X1 is A2): AC 24 V, AC 230 V, AC 400 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:4A
Switching capacity
to AC 15
NO contact: 3 A / 400 V IEC/EN 60 947-5-1
Electrical life
to AC 15 at 3 A,
AC 400 V: 2 x 105switching cycles
IEC/EN 60 947-5-1
Short circuit strength
max. fuse rating: 4 A gL IEC/EN 60 947-5-1
General data
Temperature range: 0 ... + 45 °C
Storage temperature: - 25 ... + 75 °C
Clearance and creepage
distances
overvoltage category /
contamination level
Control voltage to auxiliary
voltage, motor voltage: 4 kV / 2 IEC 60 664-1
Auxiliary voltage to
motor voltage: 4 kV / 2 IEC 60 664-1
Technical data
Phase / motor
voltage L1/L2/L3: 3 AC 200 V -10 % ... 480 V + 10 %
Nominal frequency: 50 / 60 Hz
Ordering example:
BI 9228. 03/_ _ _ 3 AC 200...480 V 50/60 Hz UHAC 400 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
2 = with standstill
monitoring and
4-step switch to
adjust standstill
sensing
Contacts
Type
Standard type
BL 9228.03/010 3 AC 200 ... 480 V 50/60 Hz UHAC 230 V 15 kW
Article number: 0058140
•Nominal motor power
at AC 400 V: 15 kW
•Control input X1
•Width: 112.5 mm

4BL 9228 / 06.12.07 e
E. DOLD & SÖHNE KG • D-78114 Furtwangen
e-mail: dold-relays @dold.com • internet: http://www.dold.com
• PO Box 1251 • Telephone (+49) 77 23 / 654-0 • Telefax (+49) 77 23 / 654-356
Safety instructions
- 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. During the brake currrent adjustments the stand-
still monitor is deactivated so the brake function is always done within 15
sec. 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
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.
The hold on contact of the motor contactor should be connected at the
control input. (see connection example).
Control input X2
Connection examples
L1
L2
L3
N
L1 L2 L3 A1 A2 X1
K1
13
14
T1
T1
T2
T2
T3
T3
without
temperature
monitoring
temperature
monitoring by
bimetallic contact
P2
P2
P3
P3
U
U
V
V
W
W
X2
on
off
emergency
stop
3343
3444
M
3~
M3~
Q1
K1
1
246
53
BL9228/010
M5668
I> I> I>
T1 T2 T3
P1
temperature
monitoring by
PTC-sensor
P1 P2 P3
UVW
M3~
13
14 24
K1
L1
L2
L3
L1 L2 L3 A1 A2 X1
K1
13
14
T1
T1
T2
T2
T3
T3
P2
P2
P3
P3
U
U
V
V
W
W
X2 33
AC24V
AC24V
control voltage
43
3444
K1
M
3~
M3~
Q1
K1
1
246
53
BL9228/010
M9766
I> I> I>
T1 T2 T3
P1
P1 P2 P3
UVW
M3~
13
14 24
without
temperature
monitoring
temperature
monitoring by
bimetallic contact
on
off
emergency
stop
temperature
monitoring by
PTC-sensor
Auxiliary voltage UH= AC 400 V or AC 230 V Auxiliary voltage UH= AC 24 V