Kimo LEKTROMIK DS1 User manual

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Product Manual
(Short Description)
LEKTROMIK®DS1
Digital soft starter / braking unit
Version: 15DS1-11
Version: 02
Issued: 30.09.2020
Language: English

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Table of contents
About this document ............................................................................................4
1
1.1 Structure of the warnings ....................................................................................................................4
1.2 Signal words and colours....................................................................................................................4
1.3 Symbols...............................................................................................................................................4
1.3.1 Mandatory action symbols...................................................................................................................4
1.3.2 Warning symbols.................................................................................................................................5
1.3.3 Other symbols .....................................................................................................................................5
1.3.4 Representation of instructions.............................................................................................................5
1.4 Definition of key terms.........................................................................................................................5
Identification and information..............................................................................6
2
2.1Product data........................................................................................................................................6
2.2 Manufacturer .......................................................................................................................................6
2.3 Intended use........................................................................................................................................6
2.3.1 Area of application and service life of the product ..............................................................................6
2.4 Reasonably foreseeable misuse.........................................................................................................7
2.5 General information.............................................................................................................................7
2.5.1 Warranty and liability...........................................................................................................................7
2.6 Target groups for the operating instructions .......................................................................................7
2.6.1Target group matrix.............................................................................................................................8
2.6.2 Target group definition ........................................................................................................................8
Safety instructions................................................................................................8
3
3.1 General safety instructions..................................................................................................................8
3.1.1 Duties of the personnel .......................................................................................................................9
3.2 Additional instructions .........................................................................................................................9
Product description ............................................................................................10
4
4.1 Overall view.......................................................................................................................................10
4.2 Product features................................................................................................................................10
4.3 Block diagram....................................................................................................................................11
4.4 Construction and function of the product ..........................................................................................12
4.4.1 Description of the construction..........................................................................................................12
4.4.2 Functional description .......................................................................................................................13
4.5 Technical Data ..................................................................................................................................13
4.5.1 Product name plate with CE marking................................................................................................15
4.5.2 CE-conformity....................................................................................................................................15
4.6 Product dimensions...........................................................................................................................16
4.7 Connections.......................................................................................................................................17
4.8 Circuit recommendations...................................................................................................................18
4.9 Planning the installation ....................................................................................................................21
4.9.1 EMC - Electromagnetic compatibility ................................................................................................22
Menu structure ....................................................................................................23
5
5.1 Parameterization ...............................................................................................................................23
5.2 Initial setup menu ..............................................................................................................................23
5.3 Main menu.........................................................................................................................................24
5.4 Sub-menus........................................................................................................................................25
5.4.1 Messages sub-menu.........................................................................................................................25
5.4.2 Device info sub-menu........................................................................................................................26

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5.4.3 Display sub-menu..............................................................................................................................26
5.4.4 Settings sub-menu ............................................................................................................................27
5.4.5 Basic setting sub-menu.....................................................................................................................28
5.4.6 Soft start sub-menu...........................................................................................................................28
5.4.7 Soft stop sub-menu...........................................................................................................................30
5.4.8 Braking sub-menu.............................................................................................................................31
5.4.9 Control inputs sub-menu...................................................................................................................31
5.4.10 Control outputs sub-menu.................................................................................................................32
5.4.11 Parameter sets sub-menu.................................................................................................................33
5.4.12 Parameter list sub-menu...................................................................................................................34
Control................................................................................................................. 36
6
6.1 Control inputs ....................................................................................................................................36
6.2 Control outputs..................................................................................................................................37
6.3 Operating modes and conditions ......................................................................................................37
6.3.1 Switch on control voltage ..................................................................................................................37
6.3.2 Standby .............................................................................................................................................38
6.3.3 Soft start............................................................................................................................................38
6.3.4 End of ramp-up..................................................................................................................................39
6.3.5 Soft stop ............................................................................................................................................39
6.3.6 Braking ..............................................................................................................................................39
6.3.7 Cancellation.......................................................................................................................................40
6.3.8 Switching off (DC 24V)......................................................................................................................41
Appendix ............................................................................................................. 43
7
7.1 Lists...................................................................................................................................................43
7.1.1 List of figures.....................................................................................................................................43
7.1.2 List of tables ......................................................................................................................................44

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About this document
1
This chapter explains how information is presented in this document.
1.1 Structure of the warnings
The combination of a signal word in connection with a pictogram classifies the respective warning information.
The symbol can vary depending on the type of danger.
DANGER
The signal word (here: Danger) is followed by a description of the type and source of the
potential danger.
A description of consequences that will occur if no measures are taken to avert the danger follows next.
The warning is concluded with a description of the measure to be taken to avert the danger.
1.2 Signal words and colours
The following signal words are based on DIN ISO 3864-2 and are used in this documentation.
The safety colours have been taken from the standard ISO 3864-1. The design conforms with DIN EN 82079-1
and ANSI Z 535.4.
Signal word
Explanation
DANGER
Indicates a dangerous situation that will result in serious or fatal injury if ignored.
WARNING
Indicates a hazardous situation which, if not avoided, can result in fatal or serious injury.
CAUTION
Indicates a dangerous situation that can result in minor injury and property damage if ignored.
NOTE
Indicates ways to make operation easier, as well as cross-references.
Table 1: Signal words
1.3 Symbols
A number of the following specific safety symbols per DIN EN ISO 7010 are used in the corresponding text
passages of these operating instructions and require special attention depending on the combination of signal
word and symbol.
Please note the differentiation between
Mandatory action symbol –stipulates an action to be taken (e.g. wearing safety goggles).
Warning symbol –illustrates a hazard source and thus supplements the warning instructions.
1.3.1 Mandatory action symbols
Symbol
Explanation
Symbol
Explanation
Observe instruction
General mandatory action symbol
Table 2: Mandatory action symbols

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1.3.2 Warning symbols
Symbol
Explanation
Symbol
Eplanation
General warning signs
Warning of electrical energy
Warning of electrostatic discharge
Warning of non-ionising radiation
Table 3: Warning symbols
1.3.3 Other symbols
Symbol
Explanation
Symbol
Explanation
Dispose of packaging material in
accordance with regulations
Recycling
Table 4: Other signs
1.3.4 Representation of instructions
Action instructions guide the reader through actions step-by-step. The individual components of instructions are
the following:
The topic of instructions as headline
The objective of the instructions
Potentially needed tools or aids
1. A first action step
2. Further steps follow
The result concludes the action
1.4 Definition of key terms
NOTE
Disregard of definitions
Read the definitions carefully. In order to ensure safe handling of the product, the entire information
contained in these operating instructions must have been read and understood.
Term
Abbreviation
Definition
Authorised
personnel
Employees who are authorised to carry out specific jobs with and at the product
according to the target group matrix and definitions of this product manual.
Personal
protective
equipment
PPE
Equipment that is intended to be used and worn by the personnel to protect
themselves against hazards posed at their workplaces.
Other tasks
Are tasks that are to be carried out only by specialist personnel in accordance
with the target group definitions. This includes, for example, installation, initial
commissioning, etc.
Table 5: Definition of key terms

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Identification and information
2
This section contains information on the product and its identification. This section is aimed at all specified target
groups.
2.1 Product data
Designation:
LEKTROMIK®DS1
Type / Series:
Digital soft starter / d.c. injection brake 15DS1-11
Order number:
8110.322
Country of origin:
Germany
2.2 Manufacturer
KIMO Industrial Electronics GmbH
Am Weichselgarten 19
91058 Erlangen
Germany
E-Mail: [e-mail]
Tel: [phone]
Fax: [phone]
Web: www.kimo.de
2.3 Intended use
The product LEKTROMIK®DS1 is used for the soft starting/stopping or braking of three-phase induction motors.
The LEKTROMIK®DS1 is intended for mounting in a suitable housing (e.g. cabinet) as a part of a machine or
electrical system.
Any other use of the product is deemed not to be in the manner intended and thus improper. KIMO Industrial
Electronics GmbH accepts no liability for damage resulting from such improper use.
Intended use also includes:
following all instructions in these operating instructions
compliance with all safety and warning instructions
compliance with the maintenance regulations
2.3.1 Area of application and service life of the product
The intended area of application of the product is for commercial use.
The service life of the product is - among other things - dependent on the following factors:
application environment
intensity of use
compliance with the maintenance regulations specified by the manufacturer

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2.4 Reasonably foreseeable misuse
Reasonably foreseeable misuse that could result in hazards posed to the personnel, third parties or to the
product, for all operating modes, includes:
using the product contrary to its intended use
operating the product outside the physical application limits (see chapter 4.5 Technical Data from
page 13)
using the product contrary to the stipulations in the operating instructions
using the product with obvious faults or damage (e.g. broken connections, housing damage, etc.)
CAUTION
Unauthorised modifications to the product
Unauthorised modifications may result in the risk of sustaining injuries.
Never carry out unauthorised modifications to the product without prior consent by KIMO
Industrial Electronics GmbH.
2.5 General information
2.5.1 Warranty and liability
In principle the “Terms of Trade” of KIMO Industrial Electronics GmbH apply.
Warranty and liability claims in the event of personal injury or property damage will be excluded if the damage
results from one or more of the following causes:
improper use of the product
use of the product contrary to its intended use
disregard of the safety and warning instructions in the operating instructions
unauthorised structural modifications of the product
deficient performance of the specified maintenance measures
disaster situations with the effects of foreign objects or force majeure
The operating instructions must be read prior to handling the product. The operating instructions familiarise the
personnel with the handling of the product and inform them of the life phases of the product in detail.
Safety and warning instructions in these operating instructions must always be adhered to and observed. For
further questions that go beyond the scope of these operating instructions, please contact KIMO Industrial
Electronics GmbH at any time.
The guarantee period for the LEKTROMIK®DS1 is one year from the delivery date, in accordance with the
Terms of Trade. The guarantee applies only if the recommended product protection has been employed.
These operating instructions, including all safety and warning instructions, must be:
observed, read and understood by the personnel working with the product
easily accessible to everyone at all times
consulted in the case of even the slightest doubt
2.6 Target groups for the operating instructions
WARNING
Personnel lacking the proper qualification
Improper qualification of personnel causes a risk of serious injuries.
Observe the target group matrix and definition.
Only carry out the tasks you are authorised to.
Consult your superior if you have any questions.
The target group matrix and definitions are based on the European and German qualifications framework.

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2.6.1 Target group matrix
At different life cycles of the product, personnel with varied expertise come into contact with the product.
Tasks
Operating personnel
(DQR/EQR Level 1)
Specialist personnel
(DQR Level 3/EQR Level 4)
Operation
X
X
Other
X
Table 6: Target group matrix
NOTE
Observe Chapter 1.4 Definition of key terms on page 5.
2.6.2 Target group definition
2.6.2.1 Operating personnel
A person (physically/mentally capable adult) who has been instructed and trained by specialised technicians for
the work assigned (e.g. product start-up, shut-down and operation) and for potential hazards posed in the event
of improper conduct.
2.6.2.2 Specialised technicians
A person (physically/mentally capable adult) who has gained special skills and experience due to their
professional training. These persons must be familiar with applicable standards, able to evaluate work assigned
to them (e.g. instructing personnel, product start-up, shut-down and operation). Specialised technicians must be
able to identify mechanical and electrical dangers and potentially hazardous situations.
Safety instructions
3
This chapter includes general safety information and safety-related instructions for the product. This section is
aimed at all specified target groups.
CAUTION
Disregard of the operating instructions
Disregard of the operating instructions results in the risk of sustaining injuries.
Read and observe the operating instructions prior to starting work with the product.
The product has been constructed in accordance with state-of-the-art technology and generally accepted safety
rules. There is a risk of personnel injury or property damage in the event of improper use, incorrect installation or
incorrect operation. The company operating the product or the persons assigned by it is/are liable for injuries
and/or property damage resulting from non-compliance with the instructions provided in the operating instruct-
tions.
3.1 General safety instructions
DANGER
Electrical energy
Risk of injury or death due to electrical energy.
Have work on the electrical components carried out only by authorised personnel.
Check the electrical components in accordance with the maintenance instructions.
Switch the product on only if the check of the electrical components confirms that there are no faults.
If faults are discovered during the checking of the electrical components, inform your supervisor.

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Observe the five safety rules (EN 50110-1 Operation of electrical installations):
Disconnect
Secure against being switched on again
Ensure that product is in de-energised state
Earth and short-circuit the product
Cover or isolate neighbouring live parts
WARNING
Negligence with the product
Negligence in handling the product results in the risk of sustaining injuries.
Ensure that you comply with the instructions in these operating instructions when dealing
with the product.
NOTE
Electrostatic discharge
Electronic components are endangered by electrostatic discharge.
Take appropriate precautions when working with the product.
3.1.1 Duties of the personnel
The personnel working near the product have a shared responsibility to ensure safety and protect health at the
workplace. Apparent safety deficiencies must be reported to a superior without delay.
WARNING
Operation with faults or malfunctions
Operation with faults or malfunctions can present a risk of serious injury.
Check the product in accordance with the maintenance instructions.
3.2 Additional instructions
In addition, observe and follow the
applicable mandatory accident prevention regulations
generally accepted technical rules for safe and professional work
existing environmental protection regulations
other applicable regulations

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Product description
4
This section contains information pertaining to the installation and function of the product. This section is aimed
at all specified target groups.
4.1 Overall view
1Display
2Control knob
3Fault and status LED
4Interface / Service interface
5Connection points
6Connection points
7Connection points
8Housing screw
Figure 1: Front view
4.2 Product features
The LEKTROMIK®DS1 is an electronic motor control unit for soft starting, soft stopping and wear-free braking of
three-phase motors, in particular those in efficiency classes IE1 to IE3.
The features of the LEKTROMIK®DS1 are summarised below:
Three-phase controlled soft start - adjustable torque characteristic to protect the drive components in
comparison to direct starting or star-delta switchover
Current limit –reduction of the starting current during the start phase
Phase failure and rotary field monitoring
Integrated bypass relays –minimisation of the power losses through internal bridging of the power
semiconductors

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Soft stop –controlled ramp-down for loads with a large frictional component, preventing stopping too
abruptly
Ramp-up and ramp-down time separately adjustable
Integrated DC current brake, fully controlled, 2-phase, reliable electrical braking of the drive
Brake function fulfils the requirements for PL = b per DIN EN ISO 18349-1 (in preparation)
Integrated zero speed detection –detection of motor zero speed condition and monitoring of the zero
speed time
Increase of motor current by 70% possible when power section is connected in delta connection
Integrated monitoring of the motor winding temperature
Optional interfaces –modular extension with interfaces: CANopen, Ethernet, PROFINET, Modbus-TCP
(further optional interfaces are possible on request)
Plug-in/push-in control terminals —rapid installation of pre-assembled control cables when used in
serial manufacturing
Protection to IP20
Fault LED –immediate recognizability of a fault
Certification per DIN EN ISO 19085-1: 2018 optional –see technical data for additional standards
Microprocessor controlled
Simple operation via rotating encoder knob and two-line display
Pre-defined parameter sets for different applications.
Two memories for user parameter sets
4.3 Block diagram
Figure 2: Block diagram

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4.4 Construction and function of the product
4.4.1 Description of the construction
The processor module, the power module and the display module are integrated into the housing.
The processor module controls and monitors all functions of the device, processes the inputs and controls the
outputs. The processor module reads in the following variables:
Synchronisation signals (3-phase) from the power supply L1, L2 and L3
Motor voltage (3-phase) on T1, T2 and T3
Motor current (1-phase) in T3
Heat sink temperature.
Thyristors, relays and other power electronic components are gathered together in the power module. Three
bypass relays are directly controlled by the processor module. The actuation of the thyristor groups is
implemented via an optocoupler to ensure electrical isolation.
The LEKTROMIK®DS1 has a control and display unit on the front (display and control knob). Operating
parameters can be displayed and the configuration and parameters changed via this unit.
1Display
2Control knob
Figure 3: Display and control knob
Display
The LEKTROMIK®DS1 is equipped with a 2-line display on the front for displaying operating conditions and
configuration/parameters. The backlight has adjustable duration. The backlight switches on as soon as the rotary
encoder or button is actuated.
Figure 4: Two-line LCD display (example)
Control knob
The control knob is located on the right under the display on the front. It has the following functions:
Illustration
Function
Explanation
Turn
Navigation in the status displays
Navigation in the menus, selection and entering of values
Press
Confirmation of the input/selection
Menu item selection
Table 7: Control knob functions

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LED indicators
There are two LED indicators on the control board of the LEKTROMIK®DS1:
Illustration
LED
indicators
Explanation
Fault LED
MS
LED is off
No fault present
LED illuminates or flashes red.
Fault present
Operating LED
MB
LED is off
LEKTROMIK®DS1 is not ready for operation
LED illuminates
LEKTROMIK®DS1 is ready for operation
Table 8: LED indicator functions
4.4.2 Functional description
Three anti-parallel thyristor modules are used in a fully controlled circuit for the soft start/stop. The motor voltage
is provided by the three phase-controlled thyristors. In doing so, the supply frequency to the motor remains
identical to the mains frequency. The drive torque can be parameterised within a large range.
Separate thyristors are used for the braking in order to rectify the line voltage in a controlled manner. The DC
current created flows through two windings of the motor, creating a stationary magnetic field that works against
the rotational movement of the rotor. The control of the thyristors enables the adjustment of the braking torque
within a large range.
Due to a modified synchronization the power-unit may be operated in delta connection. Thus it is possible that
the device can be used with motors with 70% higher rated current. Precondition: All six, not connected winding
ends in the motors are available for connection and the motor is switched to delta.
4.5 Technical Data
General technical data
Voltage:
3 AC 200 bis 480 V, -15/+10 %
Frequency:
50 bis 60 Hz +/- 2%
Type of supply
only for use on TT/TN grids with earthed star point
Overvoltage category (EN 60664-1):
III
Rated insulation voltage to PE:
AC 300 V
Rated impulse withstand voltage:
4 kV
Protective class:
I (EN 61140), basic insulation und PE connection (protective earth).
The operating company is responsible for the proper connection of the
PE connection (protective earth).
IP protection:
IP20 (EN 60529), finger protection
Signal and control terminals:
The control circuit is separated from the power circuit by secure
separation.
Electromagnetic compatibility:
- interference
EN 60947-4-2, environment B (EN 55011, class B). While conti-
nuously operated the limit for the operation on the public grid in resi-
dential, commercial, industrial and light-industrial environments is met.
- immunity
EN60947-4-2, environment A. The product withstands the interference
level of industrial areas.
Table 9: Product technical data (general)

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Environmental conditions
Permissible temperatures
Normal operation:
Storage:
Transport (short-term):
0 to 40 °C
-25 to 55 °C
-25 to 70 °C
Climatic conditions:
Class 3K3 (EN 60721-3-3)
5 to 85% relative humidity, no condensation permitted
Max. installation altitude:
2000 m above sea level
≥ 1000 m: 1.5%/100 m power derating
Pollution:
Pollution degree 2:
(EN 60664-1), only dry, non-conducting contamination, infrequent light
condensation permitted whilst switched off
Table 10: Technical Data –Environmental conditions
Specific technical data
Designation:
LEKTROMIK®DS1
Type:
15DS1-11
Order number:
8110.322
Rated motor power:
Standard connection
Delta connection (soft start/stop only)
3AC
230 V
7,5 kW (up to 8,5 kW)
15 kW
400 V
15 kW
26 kW
480 V
18,5 kW
30 kW
Minimum motor power:
10% of the respective nominal power
Rated current:
30 A
Starting current:
max. 6-time rated current
Braking current:
max. 5-time rated current
Control voltage / current:
24 V DC +/- 20 %, max. 1 A
Control inputs:
Optocoupler, suitable for DC 24 V industrial logic (input load ≈ 5 mA)
Control outputs:
Switching voltage range:
Switching current:
Relay
AC 250 V, DC 24 V
max. 2 A
Device type (EN 60947-4-2):
Utilisation category / load cycle 1):
Device variant:
Bridged semiconductor controller
30A: AC53b: 6-6: 354
1 (soft start, full-load control, soft stop, braking)
Power losses in continuous operation:
ca. 20 W (after ramp-up)
Semiconductor fuses 2):
20,000 A2s, max. switch-off I²t –semiconductor fuse value
at 25 °C
Connection wire connecting capacity 3):
Mains and motor connection:
Control connection:
2,5 to 6 mm2X0
0,75 to 2,5 mm2X1.1 to X1.10
0,5 to 1,5 mm² X1.11 to X1.20
Cooling:
Convection, optional fan
Cooling clearance:
50/50/10/10 mm
Top/bottom/left/right
Additional heating due to neighboring devices/products/machines
must be prevented.
Permissible heat sink temperature:
Depending on current motor current:
up to 4-times of rated current of device: 85 °C
up to 6-times of rated current of device: dropping linearly to 65 °C

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Specific technical data (continuation)
Mass:
3 kg
Dimensioning of the product:
235 / 90 / 195 mm
height / width /depth
Table 11: Product technical data (specific)
1) Utilization category / load cycle e.g. 30 A: AC-53b: 6-6: 354, so:
●30 A: Rated current INdevice
●AC-53b: Soft start with bridging during operation with three-phase squirrel-cage motor
●6-6: Max. starting current is 6* INdevice for 6 s
●354: Min. waiting time [s] between last use and new start-up at max. starting current/time
2) Not included in the scope of supply
3) Cable cross section (fine wire with end ferrules)
4.5.1 Product name plate with CE marking
The product name plate is located on the right side of the product on the housing.
Figure 5: Name plate (example)
4.5.2 CE-conformity
Our units are matching the relevant EU-directives and regulations and do fulfill the CE-conformity. On demand
we may supply the CE- declaration of conformity. Any other certifications, e.g. like UL, are noted separately.

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4.6 Product dimensions
Illustration of the product specifying the space requirement (values in mm).
Figure 6: Front and side view of the product

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4.7 Connections
NOTE Ensure:
The line voltage present matches with the line voltage specified for operating the product,
The cross section of the PE connection (protective earth) and connection cables,
The connection data in chapter 4.5 Technical Data from page 13 and in the circuit diagram.
Figure 7: Arrangement of the connection terminals
Terminal
Designation
Signal/Function
Explanation
Power unit
X0: 1, 2, 3
L1, L2, L3
Supply connection
3 AC 200 to 480 V
X0: 6, 7, 8
T1, T2, T3
Motor connection
X0: 4, 5
PE
Protective earth
Control unit
X1: 1, 2
A1
ME Control output on
Relay contact (N0)
X1: 3, 4
A2
MB Control output
ready
Relay contact (N0)
X1: 5, 6
A3
M0 Control output zero
speed
Relay contact (N0)
X1: 7, 8
A4
MX Control output
parameterizable
Relay contact (N0)
X1: 9, 10
PTC
Motor temperature
monitoring connection
Motor PTC or temperature
switch
X1: 11, 12
M
Control voltage 0V
X1: 13, 14
P24
Control voltage + 24V
X1: 15, 16
E1
BF Enable command
Optocoupler, 15 -, 16 +
X1: 17, 18
E2
BH Ramp-up command
Optocoupler, 17 -, 18 +
X1: 19, 20
E3
BX command
parameterizable
Optocoupler, 19 -, 20 +
Interface
X2
Service interface
RJ10, RS232
Table 12: Explanation –Arrangement of the connection terminals

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4.8 Circuit recommendations
NOTE K1 has to be controlled bay A1/ME.
Figure 8: Connection recommendation –manual control
NOTE Input BF is parametrised to continually enabled (bridge permissible).

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Figure 9: Connection recommendation –External control with PLC

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Figure 10: Connection recommendation –power circuit in delta connection