ZIEHL COSFI100V User manual

ZIEHL industrie –elektronik GmbH + Co KG
Daimlerstr.13, 74523 Schwäbisch Hall, Germany
+ 49 791 504-0, [e-mail], www.ziehl.de
Temperature Relays and MINIKA® Mains Monitoring Digital Panelmeters MINIPAN® Switching Relays and Controls Measuring Transducers Grid- and Plant Protection
Operating Manual COSFI100V
updated: 2018-09-07/Fu
from Firmware: 0-05
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- Motor load relay, current direction relay
New, Firmware 0-05:
Pr4 optimised for own consumption of energy / preventing from feeding-in of energy
for Display the firmware version press Set for >10s

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Table of contents
1Application and brief description.......................................................................................................... 3
2Summary of the functions ..................................................................................................................... 3
3Display and controls .............................................................................................................................. 4
4Detailed description ............................................................................................................................... 5
4.1 Description of the connections....................................................................................................... 5
4.2 Functional characteristics .............................................................................................................. 6
5Important notice ..................................................................................................................................... 6
6Mounting................................................................................................................................................. 7
7Connection diagram............................................................................................................................... 8
7.1 Motor, 3-phase ............................................................................................................................. 8
7.2 Motor, 1-phase .............................................................................................................................. 8
7.3 Current direction monitoring (generator) 3-phase........................................................................... 9
7.4 Feeding-in, limiting or preventing from, without current transformer............................................. 10
7.5 Feeding-in, limiting or preventing from, with current transformer.................................................. 10
7.6 Explanation of limiting of or preventing from feeding in................................................................ 11
7.7 Increasing of own consumption without current transformer ........................................................ 12
7.8 Increasing of own consumption with current transformer ............................................................. 12
8Commissioning..................................................................................................................................... 14
8.1 Program setup............................................................................................................................. 14
8.2 Pr1 / AL1 and AL2: cos  ............................................................................................................ 15
8.3 Pr2 / AL1 and AL 2: Active current (with current direction)........................................................... 16
8.4 Pr3 / AL1: cos and AL 2: Active current (with current direction) ................................................ 17
8.5 Pr4 / AL1 und AL 2: Active current (with current direction)........................................................... 18
8.6 Description of the parameters...................................................................................................... 19
8.7 Display mode............................................................................................................................... 20
8.8 Menu mode.................................................................................................................................. 20
8.9 Configuration mode ..................................................................................................................... 20
8.10 Alarm configuration...................................................................................................................... 21
8.11 Enable, Delay-Display and PTC configuration ............................................................................. 22
8.12 Simulation.................................................................................................................................... 23
8.13 Code block................................................................................................................................... 23
8.14 Possible indications in display...................................................................................................... 24
9Factory settings and software version ............................................................................................... 25
10 Maintenance and repair........................................................................................................................ 25
11 Troubleshooting and measures .......................................................................................................... 26
12 Technical data ...................................................................................................................................... 27
13 Mounting type V4.................................................................................................................................. 28

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1 Application and brief description
Motor load monitors monitor motors for overload and/ or underload. They are simply wired into the motor
supply line and evaluate the phase angle between the voltage and the motor current or, optionally, the
active current. That facilitates monitoring drive motors which enables, for instance, detecting a break in a
V-belt or the blockage of a filter or valve.
As current directional relays, they monitor the direction of the flow of current to generators and whether
current is being supplied or consumed.
The digital display and many adjustment facilities allow optimising the device for each task.
Cosfi application / Active current
•V-belt monitoring
•Fan monitoring
•Pump monitoring
•Conveying equipment (message if low is too low)
•Stirrers
•Wear monitoring
•Tool wear
•Load protection of motors, plants and drives
Current direction application
•Warning or shutdown if a generator is consuming instead of supplying current
•Optimizing of own consumption of energy in photovoltaic plants. Consumers can be switched on or off
depending on power available. By measuring current at the feed point it can be detected, wheather
there is enough power available to start heat pumps, cooling units or other consumers.
•Limiting feeding-in power or preventing from feeding-in at plants for own generation of electricity
2 Summary of the functions
In an alternating current motor (inductive load), the current follows phase angle . If the load is decreasing,
it increases so that the power factor (cosfi) decreases. This change of phase angle is a gauge of the
change of the load on the motor. The COSFI100V motor load monitor is suitable for sinusoidal alternating
current signals.
•Digital displays for the power factor (cosfi) and active current
•Inductive / capacitive load display
•2 limits / output relay
•Each adjustable for min, max, or min/max
•Monitoring of 2 x cosfi, 2 x active current or 1 x cosfi and 1 x active current
•Current display scalable (converter factor)
•Hysteresis and switching delay adjustable
•Auto-reset or locked shutdown
•Restarting attempts programmable 0…10
•Auto-enable via current (> 0.2A) or via start signal (open bridges E1 - E2)
•Power-on delay can be adjusted 0…99s
•Current input max. 10A through current transformer (sec. 5A) 500 A
•Wire break in current measurement circuit
•PTC thermistor input with short-circuit detection
•Distributor housing for panel mounting 4TE, front-to-back size 55mm
•Mounting on 35mm DIN EN 60715 standard rail or with screws (optional)

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3 Display and controls
1
LED Cap (yellow)
OFF
Inductive or resistive load
ON
Capacitive load
2
Last decimal point (red)
Off
Display mode
Illuminated
Configuration mode
Flashes
Menu mode
3
LEDs relay status (yellow)
OFF
Relay is released
ON
Relay operating
4
LED PTC (red)
OFF
PTC normal temperature
ON
PTC excess temperature
FLASHES
PTC ready for reset after excess temperature
FLASHES and 8Er28
PTC short circuit
5
LEDs active current limit value undercut / exceeded (red)
ON, 8A188 or 8A288
Limit value undercut / exceeded
FLASHES, 8A1L8 or 8A2L8
Ready for reset after undercutting / exceeding the limit value
FLASHES
Restart was attempted
OFF
Limit value not undercut / exceeded
6
LEDs cos limit value undercut / exceeded (red)
ON, 8A188 or 8A288
Limit value undercut / exceeded
FLASHES, 8A1L8 or 8A2L8
Ready for reset after undercutting / exceeding the limit value
FLASHES
Restart was attempted
OFF
Limit value not undercut / exceeded
7
Up / Down key (in display mode, normal state)
Press briefly
Change into the menu mode (see Point 8.5)
Press for > 2s:
Displays the MAX (Up) and MIN (Down) measurement, pressing the Set
key for ≥ 2s in addition deletes the saved value
8
Set/Reset key (in display mode, normal state)
Press briefly
Changes the limits in PR 1 and 2 (Easy Limit)
Press for > 2s:
Reset after locked alarm (manual restart)
Press for > 4s:
Displays the program, e.g. 8Pr18
Press for > 10s:
Displays the software version e.g. 800.08
9
4-digit digital display with sign LED (red)
Sign LED indicates the direction of current, illuminated = negative current direction
Depending on the program, display of the current cos and/or the active current
Displays the alarm messages e.g. 8A18, 8a2L8,…
Displays the errors with error code e.g. 8Er18, 8Er28, …
On as 1000 digit for adjust 8dal8and( 8dof8, only Pr4),
dAl( doF) = Value + 1000s

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4 Detailed description
4.1 Description of the connections
Connection
Function
A1 and A2
Control voltage Us, see 12. Technical data
11, 12, 14
Relay K1, Menu item 8AL1.8
21, 22, 24
Relay K2, Menu item 8AL2.8
E1 –E2
Enable input
(Pr1…3)
Floating break contact from motor contactor
Adjustable through menu item 8eN .8(8on8 ,8off8)
Contact closed = COSFI100V disabled, no evaluation, good state
open = COSFI100V enabled, evaluation after enable time active
Y1 –Y2
external reset
Floating normally open contact
Function same as pressing the Set/Reset key for >2s
T1 –T2
PTC input
PTC thermistor connection from motor / generator winding
Adjustable through menu item 8PtC. (8off8 ,8al18 ,al28)
Short-circuit monitored, coupled with LED PTC
L1l
Phase L1, load side
L1k
Phase L1, power plant side
L2
Phase L2 with 3-phase connection, neutral conductor with 1-phase
connection
L3
Phase L3 with 3-phase connection

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4.2 Functional characteristics
Functional characteristics
Explanation
Sign
Indicates the direction of current
Motor: positive = power consumption,
negative = power delivery
Generator: positive = power delivery,
negative = power consumption
Min. load current
(only Pr1…3)
To enable evaluation in program 1…3, the load current must be >
0.2A, below that the relay switches into good state (no alarm)
Automatic
reconnection attempts
(only Pr1…3)
If a locking relay function was selected for the relay, an adjustable
number of automatic reconnection attempts will be performed before
final switch-off of this relay.
An automatic reconnection attempt is started when a limit is undercut
or exceeded
The time until the next reconnection attempt is displayed or counted-
down in seconds
All reconnection attempts failed →
Locked shutdown
Reset through the Set key or by closing bridge Y1 –Y2, resets the
previous reconnection attempts
Enable time,
Start-up bypass time
(only Pr1…3)
No evaluation takes place during this time, respectively, the alarms are
suppressed; the alarms are detected only after this enable time has
expired
Enable input active (8En8) 8on8:
Enable time starts when Input E1 –E2 is opened
or
the enable input is deactivated (8En8) 8off8:
The enable time starts as soon as load current becomes > 0.2A
Enable time starts if an automatic reconnection attempt was
undertaken
Wire break L1
A wire break in the line from L1 can only be detected if the enable
input is being used
If the load current < 0.2 A and the enable input is open and the enable
time has expired, a wire break is detected →8Er18, relays switches
into alarm state
Current factor for current
transformer
To enable correct display of the measurement or the limit value, the
transmission ratio of the current transformer can be set in Programs 2
and 3.
5 Important notice
Inputs T1 –T2, Y1 –Y2, E1 –E2 are not potential isolated to
the measurement inputs L1l, L1k, L2, L3. Sufficient insulation of the
PTC thermistor is mandatory!
WARNING
Hazardous electrical voltage!
Can lead to electric shock and burns.
Before starting work, switch plant and device voltage-free.

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The flawless and safe operation of a device requires that it is shipped and stored appropriately,
professionally installed and put into operation and operated according to its intended use.
Only people who are familiar with the installation, commissioning and operation and who have qualifications
corresponding to their job are permitted to work on the device. They must comply with the contents of the
operating instructions, the notices attached to the device and the relevant safety regulations for constructing
and operating electrical plants.
The devices are built and certified in accordance with EN 50178 / EN 60 947 and leave the factory in a safe
and technically flawless condition. To maintain this state you must comply with the safety regulations
indicated with "Caution" in the operating instructions. Non-compliance with the safety regulations can lead
to death, bodily injury or property damage on the device itself and on other devices and equipment.
If the information in the operating instructions is insufficient at any time, please contact us directly
or contact the representation responsible for you.
Instead of the industrial norms and stipulations stated in the operating instructions and applicable in Europe,
you must comply with the valid and applicable regulations in the country of utilisation if the device is used
outside of the area of application
Caution! If the operating current execution is programmed for all relays,
a failure of the control voltage or the device will not be
detected. When using as a monitoring device, the operator
must ensure that this error is detected through periodic
performance tests. We recommend programming and correspondingly
evaluating at least one relay in closed-circuit current execution.
When connecting through a current transformer, use a current transformer with 5A secondary as otherwise
the measurement range is greatly reduced.
Set the transmission ratio of the current transformer under the current factor parameter.
Resolution active current = Current factor * 0.1 A
6 Mounting
The device can be mounted:
•Distribution board or switch cabinet on 35 mm rails according to EN 60715
•With M4 screws for wall installation (additional bar not included in the scope of delivery)
Connect in accordance with the connection diagram or the rating plate.
Comply with the maximum permissible temperature when installing in a switch cabinet.
Ensure sufficient clearance to other devices or heat sources. If cooling is inhibited, e.g.,
through close proximity to devices with increased surface temperature or interference with
the cooling-air current, the permissible ambient temperature is decreased.
Caution!
Before applying mains voltage to the device, make sure
that the control voltage Uscomplies with the mains voltage
connected to the device!

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7 Connection diagram
7.1 Motor, 3-phase
If load current < 10A, connection without a current transformer is possible.
7.2 Motor, 1-phase
If load current < 10A, connection without a current transformer is possible.

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7.3 Current direction monitoring (generator) 3-phase
If load current < 10A, connection without a current transformer is possible.

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7.4 Feeding-in, limiting or preventing from, without current transformer
7.5 Feeding-in, limiting or preventing from, with current transformer
1) Fuses only when line protection necessary