ClinkII Starter Control - User Manual (en)

TAKING CARE OF YOUR POWER

Clink II SCU ManagerManual

version 5.0

CLINK II SCU MANAGER

2version 5.0

REVISIONS CLINK II SCU MANUAL

Realisation in corporation with:

Geert van der Molen

Copyrights: ©2003 Eaton Electric N.V. All rights reserved.

Table 1: Versions Clink II SCU manual

Version Date Description

1.0e November 29th 2000 Initial version

2.0 February 18th 2000 Minor changes (author: E. Morskieft)

2.1 July 2nd 2001 Minor changes (author: R.M. Wetzels)

2.2 September 2003 Environmental conditions changed(author R.M. Wetzels)

3.0 October 2001 Changes regarding the use of LCU-4 (author R.M. Wetzels)

5.0 June 2003 Manual adapted with the use of LCU-5 and with the SCU protection functions Over / Under Voltage and Under current (author R.M. Wetzels).


Contents

1. INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .81.1 Audience SCU manual. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .81.2 Required knowledge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8

1.2.1 Commissioning and maintenance personnel . . . . . . . . . . . . . . . . . . . . . 81.2.2 System engineer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

1.3 How to use the Clink II manuals . . . . . . . . . . . . . . . . . . . . . . . . . . . .81.3.1 Using the SCU manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81.3.2 Using the System Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81.3.3 Using the LCU-5 Manual. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

1.4 Referenced documents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .91.4.1 Holec Holland documents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91.4.2 Documents from other sources. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

2. DESCRIPTION OF THE STARTER CONTROL UNIT. . . . . . . . . . . . . . . . .102.1 Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .102.2 Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .102.3 History . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .102.4 Design and layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10

3. SAFETY INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .113.1 Safety aspects Capitole 40 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .113.2 Safety instructions Clink II . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11

4. COMMISSIONING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .124.1 Placing an SCU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .124.2 Checking the jumper setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .124.3 Setting the power supply configuration . . . . . . . . . . . . . . . . . . . . . .124.4 Putting the SCU into operation . . . . . . . . . . . . . . . . . . . . . . . . . . . .13

5. FUNCTIONAL DESCRIPTION SCU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .155.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .155.2 Measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15

5.2.1 Mains voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155.2.2 Motor current. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165.2.3 Earth leakage current . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175.2.4 Motor temperature rise . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 185.2.5 Active power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 235.2.6 Power factor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 245.2.7 Energy. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

5.3 Inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .255.3.1 Digital inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

5.4 Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .265.4.1 Digital outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 265.4.2 Analog output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

5.5 Motor control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29

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5.5.1 Control levels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 305.5.2 Switching conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 315.5.3 Interlockings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

5.6 Starter logic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .325.6.1 Tray in Test state . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 325.6.2 Drive type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 325.6.3 Starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 335.6.4 Starter logic Direct on Line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 355.6.5 Starter logic Star-Delta . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 355.6.6 Starter logic Forward-Reverse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 365.6.7 Starter logic Dual-Speed. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 375.6.8 Stop/start commands . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 395.6.9 Command after communication failure . . . . . . . . . . . . . . . . . . . . . . . . . 40

5.7 Automatic restart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .405.7.1 Mains failure detection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 405.7.2 Contactor failure detection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 415.7.3 Restart time out. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 415.7.4 Immediate restart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 425.7.5 Delayed restart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 435.7.6 No restart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 445.7.7 Cancel automatic restart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 445.7.8 Automatic restart during starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 445.7.9 Automatic restart during powerdown . . . . . . . . . . . . . . . . . . . . . . . . . . 44

5.8 Protection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .445.8.1 Characteristics of protection functions . . . . . . . . . . . . . . . . . . . . . . . . . 455.8.2 Read-out of trip and warning signals . . . . . . . . . . . . . . . . . . . . . . . . . . 455.8.3 Acknowledge command . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 475.8.4 Motor stall . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 485.8.5 Motor overload . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 495.8.6 Phase unbalance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 505.8.7 Earth leakage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 515.8.8 Process underload . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 515.8.9 Process overload . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 525.8.10 External protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 535.8.11 Over Voltage Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 535.8.12 Under Voltage Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 535.8.13 Under Current Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

5.9 Monitoring of diagnostic and maintenance data . . . . . . . . . . . . . . .545.9.1 Number of operating hours . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 545.9.2 Number of contactor operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 555.9.3 Number of contactor operations during last hour . . . . . . . . . . . . . . . . . 555.9.4 Starting current . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 555.9.5 Starting time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 565.9.6 Trip current L1, L2, L3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 565.9.7 Time to trip . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 575.9.8 Time to reset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 575.9.9 Reset maintenance command . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57

6. TROUBLESHOOTING GUIDE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .586.1 How to use the trouble shooting guide. . . . . . . . . . . . . . . . . . . . . . .586.2 States of the SCU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .586.3 Status Module LED. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60

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6.4 Status Network LED. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .616.5 Fault messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .616.6 Corrective actions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .63

7. MAINTENANCE SCU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .667.1 Replacement of the main board. . . . . . . . . . . . . . . . . . . . . . . . . . . .667.2 Replacement of the interface board. . . . . . . . . . . . . . . . . . . . . . . . .667.3 Use of Hyper Terminal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .67

8. TECHNICAL SPECIFICATIONS SCU . . . . . . . . . . . . . . . . . . . . . . . . . . . . .688.1 Technical specifications main board and interface board . . . . . . . .688.2 SCU print . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .688.3 Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .68

8.3.1 Connectors on the front of the SCU . . . . . . . . . . . . . . . . . . . . . . . . . . . 688.3.2 Motor starter tray connections of the interface board . . . . . . . . . . . . . . 69

8.4 Inputs and outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .728.4.1 Digital inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 728.4.2 Analog inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 728.4.3 Digital outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 738.4.4 Analog output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74

9. ELECTRIC CIRCUIT DIAGRAMS SCU. . . . . . . . . . . . . . . . . . . . . . . . . . . .759.1 Single line and auxiliary circuit diagrams . . . . . . . . . . . . . . . . . . . . .75

9.1.1 Direct On Line starter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 759.1.2 Star-Delta starter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 779.1.3 Forward Reverse starter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 799.1.4 Dual Speed starter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81

9.2 Mains configurations SCU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .839.2.1 Single phase supply (L-N) I < 64A . . . . . . . . . . . . . . . . . . . . . . . . . . . . 839.2.2 Three phase supply without neutral. I < 64 A . . . . . . . . . . . . . . . . . . . . 849.2.3 Three phase supply without neutral. I > 64 A . . . . . . . . . . . . . . . . . . . . 859.2.4 Three phase supply with neutral. I < 64 A. . . . . . . . . . . . . . . . . . . . . . . 869.2.5 Three phase supply with neutral. I > 64 A. . . . . . . . . . . . . . . . . . . . . . . 87

10. GLOSSARY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .88

11. INDEX. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .89

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ABOUT THIS MANUAL

IntroductionThis manual describes the Starter Control Unit (SCU), a component of Clink II motor management system ofEaton Holec, part of Eaton Electric Europe.

This manual addresses:• the system engineer of a process control system that has to communicate with Clink II. • commissioning engineers and maintenance personnel.

NoteUse this manual with SCU embedded software version 4.x.

Use of symbols and conventionsThroughout this manual notes are given to alert you to possible injury to people or damage to equipment underspecific circumstances. See table 2.

WarningOnly personnel familiar with DeviceNet™ devices and associated machinery should plan orimplement the installation, start-up, configuration and subsequent maintenance of Clink IIcomponents. Failure to comply may result in personal injury and/or equipment damage.

WarningClink II modules contain ESD (Electrostatic Discharge) sensitive parts and assemblies. Static controlprecautions are required when installing, testing, servicing, or repairing these assemblies.Component damage (including degradation or malfunctioning of the performance) may result if ESDcontrol procedures are not followed.

NoteClink II is an innovated version of Clink. Although the principle of protection has not been changed, a numberof important alterations and additions have been effectuated. As a consequence Clink II and Clink parts are notexchangeable.

Trademarks• RSNetWorx™ for DeviceNet is a trademark of Rockwell Automation, Allen-Bradley.• Windows™ is a trademark of Microsoft Corporation.

Table 2: Warning symbols and conventions

Symbol or convention Name Description

Note - Identifies information that is especially important for successful application and understanding of the product

Warning Identifies information about practices or circumstances that can lead to personal injury or death, property damage, or economic loss. Warnings help you to:• Identify a hazard• Avoid the hazard• Recognize the consequences

Warning ESD Identifies information about practices or circumstances that can cause a transfer of electrostatic charge that might cause damage to Clink II components. See 3.2 on page 11.

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Protocol trademarks:• ModbusTM

• ProfibusTM

• ControlNetTM

• Data Highway PlusTM

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1 INTRODUCTION

1.1 Audience SCU manual

This manual of the Starter Control Unit (SCU) is designed to be used by three user categories:

1 System engineers who configure the process controller and design the communication between Clink II and DeviceNet. For the system engineer the interface requirement specifications of the SCU and FCU are included in the SCU/FCU manuals.

2 Commissioning engineers who install and configure the Clink II system.

3 Maintenance personnel.

1.2 Required knowledge

1.2.1 Commissioning and maintenance personnel

• Electrical engineer education on a medium level. Qualification according to local regulations.• Personnel should know how to employ the materials, equipment and procedures necessary to prevent

damage to components caused by Electrostatic Discharge.• Experience with Microsoft Windows™.

1.2.2 System engineer

• Knowledge and experience in the field of system design for industrial automation.• Knowledge of and experience with DeviceNet™ and RSNetWorx™.

1.3 How to use the Clink II manuals

1.3.1 Using the SCU manual

Refer to the SCU manual for information regarding:• Design and layout• Functions and parameter settings• Commands• Troubleshooting• Maintenance• Technical specifications• Electrical circuit diagrams• Interface requirements specification

1.3.2 Using the System Overview

See the Clink II System Overview manual for:• An introduction to Clink II• Information regarding DeviceNet cable connections and power supply connections• Technical specifications of Clink II components other than the FCU or SCU• An overview of power supply configurations• Diagrams of Measurement Interface Unit configurations

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NoteFor project specific information (e.g. technical specifications of a Central Interface Unit) see the projectdocumentation.

1.3.3 Using the LCU-5 Manual

See the Clink II LCU-5 Manual for:• An introduction to LCU-5• The parts LCU-5 consists of:

• Clink II System Manager• the SCU Manager,• the FCU Manager

1.4 Referenced documents

1.4.1 Holec Holland documents

1 Capitole 40 manual MBO 2991.901

2 Project documentation

1.4.2 Documents from other sources

1 DeviceNet PC Card Installation Instructions, Allen Bradley, publication 1784-5.29. Website Allen Bradley: http://www.ab.com/manuals

2 User Manual Allen-Bradley RSNetworx™ Software. Website Allen Bradley: http://www.ab.com/manuals

3 DeviceNet RS-232 interface module installation instructions, Allen Bradley, publication 1770-5.6. Website Allen Bradley: http://www.ab.com/manuals

4 DeviceNet Specifications Volume II, ODVA. Website ODVA: http:\\www.odva.org

5 European standard EN 100015-1 Protection of electrostatic sensitive devices, part 1 general require-ments.

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2 DESCRIPTION OF THE STARTER CONTROL UNIT

2.1 Location

The SCUs are accommodated in the vertical cable-entry compartment of the Capitole cubicle. In this way theyare fully separated from the primary motor starter circuits. Up to 16 Starter Control Units can be mounted, oneon top of the other, in a common withdrawable cassette. The pitch is identical to that of the adjacent switchgearcompartment so that each SCU is in line with its own motor starter tray.

2.2 Function

The SCU fully autonomously, monitors and protects the allocated motor. In addition, it controls the motor starterin accordance with the DCS commands and sends all actual motor data to the higher control system (forexample PLC). For a detailed description of SCU functions see chapter 5 on page 15.

2.3 History

In 2003 the FCU of the Clink II system is enhanced with new functions: the automatic restart function and theearth leakage function. For more details see the Clink II FCU Manual version 4.0 and higher. As a consequencefor the SCU the analog input channel is no longer present.The description of this analog input has beenremoved from this manual.

2.4 Design and layout

See figure 1 for the location of the main components.

Figure 1: Layout of the SCU main board

MODULE

NETWORK A

NETWORK B

RS 232

ELCO's

Jumper SCU/FCUSF

X1

LH

Jumper EarthLeakage Range

H = 0.3 - 6 A.L = 0.03 - 0.6 A

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3 SAFETY INSTRUCTIONS

3.1 Safety aspects Capitole 40

For each plant, a central housing is installed for the central components. The housing for the Starter andFeeder Control Units is located in the various vertical cable-entry compartments of the Capitole 40 switchboard.For commissioning and maintenance of Clink II it is not necessary to work in the immediate vicinity of highvoltage carrying parts. Therefore no special high voltage safety measures are required.

WarningAlways consult the Capitole 40 user manual when working in the vicinity of parts that may carry high voltages(bus bar systems, cables).

3.2 Safety instructions Clink II

WarningOnly personnel familiar with DeviceNet™ devices and associated machinery should plan orimplement the installation, start-up, configuration and subsequent maintenance of Clink IIcomponents. Failure to comply may result in personal injury and/or equipment damage.

WarningOne of the strong features of Clink II is the possibility to replace units while keeping the Clink II systemoperational. The replacement of Clink II parts should always be reported and executed according tolocal safety procedures.

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4 COMMISSIONING

4.1 Placing an SCU

All SCU’s are placed in the cassette at the factory.

NoteAll nodes are already commissioned in the factory according to project specifications.In case you want to add more than one SCU or other devices to an existing network, add one device at a timebefore commissioning nodes (see the System Overview manual). It’s not possible to commission more thanone node at a time.

4.2 Checking the jumper setting

When a unit (SCU) is placed in the cassette, the software checks the settings in the EEPROM. The settingsmust be right and fit the jumper setting (SCU or FCU) of the print. When the settings are right, the SCU programis started. The status of the Module LED is green, indicating normal operation (see also “Status Module LED”on page 60).

When the settings are wrong or do not fit the current jumper setting the print will be in stand-by mode and theModule LED flashes green. The SCU needs commissioning because of missing, incomplete or incorrectconfiguration. Commissioning consists of providing the SCU with a node number and adjust the correct baudrate for communicating on DeviceNet. See Use of Hyper Terminal‚ page 67.

4.3 Setting the power supply configuration

The network power supply configuration of each SCU must have been set in order to enable the SCU to testthe power supply and generate an error message ‘no power’ (Module LED ‘off’).

Network power supplyThe network power supply configuration is set via LCU-5. Select: SCU Manager - Unit - Properties - tab SystemConfiguration, see table 3.

General power supplyThe general power supply configuration (when applicable) is set via LCU-5. Select: SCU Manager - Unit -Properties - tab System Configuration, see table 4.

Table 3: Setpoint System Configuration

Name Description Parameter type

System configuration NPS ANPS B

Setpoint



System configuration GPS AGPS B

Setpoint

commissioning version 5.0 12


Local power supplyThe local power supply configuration is set via LCU-5. Select: SCU Manager - Unit - Properties - tab SystemConfiguration, see table 5.

4.4 Putting the SCU into operation

Power the Clink II system.The SCU can be in six different operational modes. See figure 2 for an overview of transitions, modes andcorresponding Module LED signals. See also Troubleshooting guide‚ page 58



System configuration LPS Setpoint

Nonexisting

Device Self Testing

Standby

Operational

Major Recoverable Fault Major Unrecoverable Fault

PowerApplied

Test Passed

Identity Object Reset Service

(from any state except

Maj. Unrec. Fault)

Power Loss

TestFailed

MajorRecoverable

Faults

MajorUnrecoverable

Faults

Deactivated Activated

MinorFault

FaultCorrected

MajorRecoverable

Faults

Led: Off

Led: Flashing Red/Green

Led: Flashing Green

Led: Solid Green

Led: Flashing Red Led: Solid Red



Figure 2: Operational modes SCU (Led = Module Led)



5 FUNCTIONAL DESCRIPTION SCU

5.1 Introduction

This chapter describes all functions of the SCU. The functions are grouped into:• measurement: see 5.2 on page 15• digital and inputs: see 5.3 on page 25• digital and analog outputs: see 5.4 on page 26• motor control: see 5.5 on page 29• motor protection: see 5.8 on page 44• monitoring of diagnostic and maintenance data: see 5.9 on page 54

5.2 Measurement

The Starter Control Unit measures a number of quantities which can be read-out by both LCU-5 and theprocess controller. These quantities are used internally as input signals for the various protective devices. Inthe following paragraphs the measuring method for each quantity is explained and it is indicated where themeasured quantities can be read-out. The accuracy of the measured values is stated and, if necessary, theconfiguration method for a measurement is given.

5.2.1 Mains voltage

The voltage measurement mode (phase/phase or phase/neutral) is set via LCU-5. Select: SCU Manager - Unit- Properties - tab Meas, see table 6.

CalculationThe mains voltage Lx is measured by the Measurement Interface Unit. The Starter Control Unit calculates theeffective value of the phase and the connected voltage using the following formula:

Table 6: Mains Voltage parameters

Name Range Unit Parameter type

Voltage Measurement Mode

LLLNL1NL2NL3N

NoteIn case of single phase select L1N, L2N or L3N.

- Setpoint

Mains voltage 0 - 862 V Actual

U 1T--- u2

0

T

∫ td=

functional description scu version 5.0 15


U = RMS value of the mains voltageu = Instantaneous value of the mains voltage

In order to calculate this value, 16 samples are taken so that up to and including the 8th harmonic is taken intoconsideration in the calculation.

Note• The accuracy of the measured value is ± 2%.• The displayed value of the mains voltage is the voltage measured between phases (phase-phase) except

in case of a single phase motor where the voltage between line and neutral is displayed.

5.2.2 Motor current

The motor current is measured by means of transformers which are placed in the Measurement Interface Unit.For application of the different types of Measurement Interface Units see Mains configurations SCU‚ page 83.

The nominal current and auxiliary current transformer ratio are set via LCU-5.Select: SCU Manager - Unit Properties - tab Meas, see table 7.

NoteThe auxiliary current transformer ratio is the ratio between the primary and secondary current of the auxiliarycurrent transformer. If no current transformer is applied, the ratio must be set to 1.

The Motor Current can be read-out via LCU-5. Select: SCU Manager - Module - Measurement. See table 8.

The measured values are representative for the phase currents and serve as input for the following protectionfunctions:• Thermal protection, stall: 5.8.4 on page 48• Thermal protection, motor overload: 5.8.5 on page 49• Phase unbalance: 5.8.6 on page 50• Process underload: 5.8.8 on page 51• Process overload: 5.8.9 on page 52

Table 7: Setpoints nominal current and auxiliary current transformer ratio


Nominal Current MIU 1 - 64 A Setpoint

Auxiliary CT Ratio 1 - 1200 - Setpoint

Table 8: Motor current parameter


Motor Current L1 0-10.00 I/In Actual



Motor Current L1 0-1,200.000 A Actual



CalculationThe Starter Control Unit calculates the effective value of the current using the following formula:

In order to calculate this value, 16 samples are taken so that up to and including the 8th harmonic is taken intoconsideration in the calculation. To attain the required accuracy, it must be synchronised with the mainsfrequency using a so-called Phase Locked Loop circuit, abbreviated to PLL

I = RMS value of the currenti = Instantaneous value of the current

NoteThe accuracy of the measured value is ± 2.5% of In

5.2.3 Earth leakage current

The purpose of this measurement is to detect an earth leakage current caused by a.o.:• Disruptive discharge between motor winding and earth• Deteriorated insulation between motor winding and earth• Short-circuit between one of the phases and earth.

The earth leakage current is measured with a so-called 'core balance' current transformer. The three phasesconductors are led through the hole of the transformer so that the transformer measures the vectorial sum ofthe 3 phase currents. Under normal operating conditions the vectorial sum is 0. If, due to a fault, the sum currentis no longer 0, this will be detected in the secondary winding.

Earth leakage current serves as input signal for the earth leakage protective function and can be read-out viaLCU-5. Select: SCU Manager - Module Measurement.

CalculationThe Starter Control Unit calculates the effective value of the earth leakage current using the following formula:

I = RMS value of the earth leakage currenti = Instantaneous value of the earth leakage current



Table 9: Earth leakage current parameter


Earth leakage current 0-6.0 A Actual

Table 8: Motor current parameter


I 1T--- i2 td

0

T

∫=



In order to calculate this value, 16 samples are taken so that up to and including the 8th harmonic is taken intoconsideration in the calculation.

NoteThe accuracy of the measured value is ± 2.5%.

5.2.4 Motor temperature rise

Motor temperature-rise is calculated in the Starter Control Unit by means of a thermal model of the motor andis used to protect the motor under all operating conditions against overload.

The model - see figure 3 on page 18 - determines the average temperature-rise of the copper winding (Tcu)and the stator iron packet ((Tfe) from the copper and iron loss.Tcu serves as input for the stall and motor overload protection and can be read-out via LCU-5. Select: SCUManager - Module Measurement.

Figure 3: Thermal model

In the model the following parameters or dependent variables can be distinguished (see table 10):

Table 10: Parameters and dependent variables in the thermal model

Para-meter Name

Pcu copper loss

Ccu thermal capacity of the copper

Rcufe thermal resistance between copper and iron

Pfe iron loss

I 1T--- i2 td

0

T

∫=

Rcufe

Rfeam

b_on

Rfeam

b_offPfePcuCcu1 Ccu2 Cfe1 Cfe2

S1 S2 S3

Pcufe Pfeamb

Pccu Pcfe



Principle of operationPcu represents the copper loss which varies proportionally to the square of the motor current.Pfe represents the iron loss which is constant when the mains voltage and the mains frequency are constant.Due to the heat flows caused by these loss sources, the thermal capacities are charged, resulting intemperature differences over the thermal resistances.

Via Rcufe the copper yields heat to the iron (Pcufe) and the iron yields heat to the environment (Pfeamb) viaRfeamb_on when the motor is running and via Rfeamb_off when the motor is off. These heat resistances togetherwith Cfe and CCU determine the heating-up respectively cooling-down time constant of the motor.

If the motor is running with a constant load, a thermal equilibrium will be reached after some time. This meansthat the thermal capacities are charged and that the copper and iron temperature-rise will remain constant.

The model is dimensioned in such a way that at nominal motor current and thermal equilibrium, the coppertemperature-rise will be equal to the value entered as maximum temperature-rise via LCU-5. Select: SCUManager - Module Protection - Settings - tab Motor.

Figure 4: Temperature rise of a 5.5 kW motor after cold start and nominal load

Cfe thermal capacity of the iron

Rfeamb_on thermal resistance between iron and environment when the motor is running

Rfeamb_off thermal resistance between iron and environment when the motor is off.

Tcu copper temperature-rise

Tfe iron temperature-rise

Table 10: Parameters and dependent variables in the thermal model

Para-meter Name

Tcu

Tfe

T_ambient t (min)

T_stall

T_nom

Temp. rise



Figure 5: Temperature rise of a 5.5 kW motor after cold start and switch-off due to overload

Cooling ratioIn order to simulate the motor temperature as accurately as possible, one switches, dependent on the operatingstatus of the motor, between Rfeamb_off (decisive for cooling time constant) and Rfeamb_on (decisive forwarming-up time constant). The ratio between the two time constants is called cooling ratio and is set via LCU-5. Select: SCU Manager - Module Protection - Settings - tab Motor.For motors with built-in ventilation the cooling ratio is standard set at 10. In case of external cooling the coolingratio value has to be determined for each separate case.

Initial temperature thermal modelEach time when the supply voltage of the system is switched on, the thermal model is set, for safety reasons,at the copper and iron temperature-rise (maximum temperature-rise) of a warmed-up motor and continues tocalculate on that basis. The value maximum temperature-rise can be set via LCU-5. Select: SCU Manager -Module Protection - Settings - tab Motor. Because of this, the motor can also be protected against short or longmains interruptions. After switching on the motor and irrespective of the load, the calculated temperature-riseand the real temperature-rise of the motor will correspond within the allowed deviation.

T_ambient t (min)

T_nom

Temp. rise

t

I motor

Inom0

I start

TcuTemp. rise interlock level

Time to reset



Read-out of the motor temperature

Model parametersThe model parameters are calculated by the SCU on the basis of the motor data. For the calculation, use ismade of the name-plate data of the motor which have to be entered via LCU-5. Select: SCU Manager - ModuleProtection - Settings - tab Motor. For lacking data, standard values are entered. An overview of the data to beentered as well as a short explanation is given via LCU-5. Select: SCU Manager - Module Protection - Settings -tab Motor, (see table 12).

While entering the parameters, the ranges are checked by LCU-5. The mutual ratios are checked by the SCU.In case of an invalid value a major recoverable fault will be generated. See Fault messages‚ page 61 for adescription.

Table 11: Motor temperature parameters


Motor Temperature Cu 0-190.0 K Actual

Motor Temperature Fe 0-190.0 K Actual

Table 12: Motor data parameters


Motor Weight 2-6,000 kg Setpoint

Stall Current1 2.50-10.00 I/In Setpoint

Stall Current2 2.50-10.00 I/In Setpoint

Stall Time 1 2.0-30.0 s Setpoint

Stall Time 2 2.0-30.0 s Setpoint

Stall Time Condition ColdHot

- Setpoint

Overload Current 0.80-1.15 I/In Setpoint

Trip Time At 1.5 In 4-720 s Setpoint

Maximum Temperature Rise 50-125 K Setpoint

Warning Temperature Rise 0-125 K Setpoint

Temperature Rise Interlock Level

0-130 K Setpoint

Cooling ratio 1.0-20.0 - Setpoint

Nominal Voltage 220-690 V Setpoint

Auxiliary CT ratio 1-1,200 - Setpoint

Nominal Power 1 0.09-600.00 kW Setpoint

Nominal Power 2 0.09-600.00 kW Setpoint



Explanation of the motor data settings• Motor weightThe motor weight is taken from the name-plate of the motor. If the weight is not available, 7.5 kg/kW is to beused. In case of motors < 1 kW the minimum weight to be used is 2 kg.

• Stall Current 1 and 2 (2 only applicable for dual speed)Stall current indicates the ratio between the current at blocked rotor (stall current) and the nominal motorcurrent. If not available, the value to be entered is 5 I/In.

• Stall Time 1 and 2 / Stall Time Condition 2 (only applicable for dual speed)The stall time is the maximum switching-on time of the motor at blocked rotor. Hereby it is important to knowwhether the indicated stall time applies to a cold or hot motor. Therefore, when entering the stall time, also thecondition (hot/cold) has to be stated.If the stall time is not known, the standard entry is 4.5 s for condition hot. The lower threshold of the I2t valueis limited to 103. This means that as the stall current factor decreases, the stall time to be entered will increase.

The stall time versus stall current factor should meet the condition of following formula:

When this condition is not met an error message is generated. See table 12 for ranges of the stall current factor.

• Overload CurrentOverload Current is the threshold value for the motor current. When this value is continuously exceeded, themotor will be switched-off. The switch-off time depends on the motor current and can be found in table 37 onpage 49. The Overload Current is given relatively to the nominal motor current. If not available, enter 1.05 In.

• Trip Time at 1.5 InThis is the trip time at 1.5 In in hot operation. The time to be entered depends on the motor temperature class,see table 37 on page 49.In case the temperature class is not known, the standard value entered is 60 s.

• Maximum Temperature RiseMaximum temperature rise is the nominal temperature-rise for a given motor insulation class. See table 13.

Nominal Current 1 0.10-1,200.00 A Setpoint

Nominal Current 2 0.10-1,200.00 A Setpoint

Nominal Cos Phi 1 0.30-1.00 - Setpoint

Nominal Cos Phi 2 0.30-1.00 - Setpoint

Table 12: Motor data parameters


StallTime 103StallCurrentFactor2-----------------------------------------------------≥



If not available, category B (80 K) is used.• Warning Temperature Rise

This is the temperature rise at which a warning is generated. The value to be entered depends on the insulation class of the motor. Rule of thumb: warning temperature rise = max. temperature rise + 5.

• Temperature Rise Interlock LevelTemperature Rise Interlock Level is the temperature rise at which the motor can be safely switched-on again after a trip due to motor overload or stall. This value is set via LCU-5. Select: SCU Manager - Module Protection - Settings - tab Motor. When no value is set, the default value is set to 0.7 * Maximum Tempera-ture Rise.

• Cooling RatioThe Cooling Ratio is the ratio between Rfeamb-off and Rfeamb-on. For motors with a built-in ventilator the standard setting value is 10. If cooling is realised otherwise, the value is determined for each case sepa-rately.

• Nominal VoltageThe Nominal Voltage is taken from the name plate of the motor.

• Auxiliary CT ratioThe auxiliary CT ratio is the ratio between the primary and secondary currents. If no current transformer is used, use setpoint = 1.

• Nominal Power 1 and 2The Nominal Power is taken from the name plate of the motor.

• Nominal Current 1 and 2The Nominal Current is taken from the name plate of the motor.

• Nominal Cos Phi 1 and 2The Nominal Cos Phi is taken from the name plate of the motor.

5.2.5 Active power

Active Power is calculated in the Starter Control Unit from the voltage and current of phase L1 in case of a 3phase system or from the connected phase in case of a 1 phase system. The calculated value serves as inputsignal for process underload and process overload respectively.

Active Power can be read-out via LCU-5. Select: SCU Manager - Module Measurement. See table 14.

Table 13: Insulation category and nominal temperature rise

Insulation category Nominal Temperature Rise

B 80 K

F 100 K

H 125 K

Table 14: Active Power parameter


Active Power -18,000,000..+18,000,000 W Actual

Active Power -12.50..+12.50 P/UnIn Actual



CalculationActive power is calculated using the following formula:

u = Instantaneous voltagei = Instantaneous currentP = Active powerIn case of DOL1 the factor 3 must be replaced by 1.

NoteThe accuracy of the measured value is ± 5%

5.2.6 Power factor

The Power Factor is calculated in the Starter Control Unit from the Active Power, Mains Voltage andMotorCurrent L1 in case of a 3 phase system or from the connected phase in case of a 1 phase system. Thepower factor can be read-out via LCU-5. Select: SCU Manager - Module Measurement.

CalculationPower factor is calculated according to the following formula:

P = Active PowerU = Mains VoltageI = Motor current L1Note: in case of DOL1 factor must be omitted.

NoteThe accuracy of the measured value is ± 5%.

5.2.7 Energy

The energy values are derived in the Starter Control Unit from the calculated powers (active power). The energy is calculated using the following formula:

Table 15: Power Factor parameter


Power Factor -1.00..+1.00 - Actual

P 3T--- u i⋅( )

0

T

∫× td=

PF P3 U I⋅ ⋅

----------------------=

3



E = Active energy import / exportP = Active power total

If energy is supplied by the mains, then this is referred to as energy import. If energy is supplied back into themains, then this is referred to as energy export.

The values of Active Energy Export and Import can be preset via LCU-5. Select: SCU Manager - ModuleMeasurement - Preset - window Preset Cumulative Values, see table 16.

The value of the energy can be read-out via LCU-5. Select: SCU Manager - Module Measurement, see table 17.

NoteThe accuracy of the measured value = ± 4%

5.3 Inputs

5.3.1 Digital inputs

The Starter Control Unit disposes of 8 digital inputs (DI_0 to DI_7). The functions of the first three inputs (DI_0to DI_2) are fixed and the functions of the other inputs (DI_4 to DI_7) are configurable. See table 18.

Configurable digital inputsThe digital inputs Di_3 to Di_7 can be assigned via LCU-5 to the functions listed in table 18. Select: SCUManager - Unit Properties - tab Dig. Input.

Table 16: Setpoints energy import and energy export (Application Energy Object)

Name Description Value Parameter type

Energy Value Import The Consumed Energy 0.999,999,999 Setpoint

Energy Value Export The Produced Energy 0.999,999,999 setpoint

Table 17: Read-out of energy


Active Energy Import 0..999,999,999 kWh Actual

Active Energy Export 0..999,999,999 kWh Actual

Table 18: Functions of digital inputs

Digital Input Function Parameter type

DI_0 Isolator

DI_1 Contactor K1

DI_2 Contactor K2

E P td0

T

∫=



Digital Input InvertIt is possible to invert a digital input via LCU-5. Select: SCU Manager - Unit Properties - tab Dig. Input.

5.4 Outputs

5.4.1 Digital outputs

The Starter Control Unit has 8 digital outputs (DO_0 to DO_7). The functions of the first three outputs (DO_0to DO_2) are fixed and the functions of the other outputs (DO_3 to DO_7) are configurable. See table 19.

Configurable digital outputsThe digital outputs DO_3 to DO_7 can be assigned via LCU-5 to the functions listed in table 20. Select: SCUManager - Unit Properties - tab Dig. Output.

DI_3 NoneIsolatorContactor K1Contactor K2Manual StopManual Start 1Manual Start 2Manual AcknowledgeExternal ProtectionTray In TestExternal Interlock

Setpoint

DI_4

DI_5

DI_6

DI_7

Table 19: Functions of digital outputs

Digital Output Function For information see

DO_0 Auxiliary Relay K10 5.6 on page 32



DO_3 See table 20

DO_4 See table 20

DO_5 See table 20

DO_6 See table 20

DO_7 See table 20

Table 18: Functions of digital inputs

Digital Input Function Parameter type



The functions listed in table 20 can be set via LCU-5, see table 21. Select: SCU Manager - Unit Properties - tabDig. Output.

Table 20: Possible functions of the configurable digital outputs

Function Description

Auxiliary Relay K10 See also “Starter logic” on page 32

Auxiliary Relay K11

Auxiliary Relay K12

Trip Signal • ‘low’ when there is no trip/warning• ‘toggle’ when there is at least one not

acknowledged trip/warning.• ‘high’ when there are only acknowl-

edged trips/warnings.

Warning Signal

Trip Or Warning Signal

Trip Status • ‘low’ when there is no trip/warning.• ‘high’ when there are only acknowl-

edged trips/warnings.Warning Status

Trip Or Warning Status

General Purpose Output 0

General Purpose Output 1



Digital Output InvertIt is possible to invert a digital output via LCU-5. Select: SCU Manager - Unit Properties - tab Dig. Output.

General Purpose Output StatusThe General Purpose Output Status can be read via LCU-5. Select: SCU Manager - Module Control - Settings -Function Digital Input x.

Note When a General Purpose Output is not used, the status of that output is 0.

Table 21: Digital Output Function x

Name Description Parameter Type

Digital Output Function x

Note:(x= number of the digital out-put 3 to 7)

NoneAuxiliary Relay K10Auxiliary Relay K11Auxiliary Relay K12Trip SignalWarning SignalTrip Or Warning SignalTrip StatusWarning StatusTrip Or Warning StatusMotor Overload Warning Phase Unbalance WarningEarth Leakage WarningProcess Overload WarningProcess Underload WarningExternal Protection WarningOver Voltage WarningUnder Voltage WarningUnder Current WarningMotor Stall TripMotor Overload TripPhase Unbalance TripEarth Leakage Trip Process Overload TripProcess Underload TripExternal Protection TripOver Voltage TripUnder Voltage TripUnder Current TripGeneral Purpose Output 0General Purpose Output 1General Purpose Output 2General Purpose Output 3General Purpose Output 4

Setpoint



5.4.2 Analog output

The SCU has 1 analog output that can be used as a 0-20 mA or 4-20 mA output. The analog output range canbe controlled via LCU-5. Select: SCU Manager - Unit Properties - tab An. Output. The analog output signal isdetermined by a parameter setting in LCU-5. See table 22.

NoteAn output signal leaving the motor starter tray must be isolated.

5.5 Motor control

The motor control function takes care of the motor control, using a number of preprogrammed starter logicprocedures:

• Direct-on-line• Star-delta• Forward-reverse• Dual-speed

Apart from these starter logic procedures, the automatic restart function ensures that the motors are restartedafter a mains interruption.

This paragraph describes the working of both the starter logic functions and the automatic restart function.

Table 22: Reading and setting the analog output function

Name Default Description Parameter type

Analog Output Source

X Analog Output Value(External)

0..100% =0..100%

Setpoint

Motor Current L1 0..100% = 0 .. 1.2 In



Earth Leakage Current 0..100% = 0 .. 6 A

Power Factor 0..100% =0..1 or 0..-1

Analog Output Range

X 0 - 20 mA Setpoint

4 -0 mA



5.5.1 Control levels

Figure 6: Control levels within a typical configuration

Within the Clink-system three control levels and ways of control are distinguished, see figure 6:1 Process control level: controlled via DeviceNet2 Switchgear level: controlled via Digital inputs3 Field level: controlled via hard wired circuits

DeviceNetAt the highest level, motor control takes place by means of a Distributed Control System (DCS), aProgrammable Logic Controller (PLC) or a Supervisory Control And Data Acquisition system (SCADA). In thismanual all controlling systems are indicated as process controller. From a process controller it is possible toswitch motors on and off.

Via LCU-5 it is possible to configure the starter logic operation (see 5.6 on page 32) and the automatic restartfunction (see 5.7 on page 40). In order to configure the automatic restart function select: SCU Manager - MotorControl - Settings - tab Restart.

Digital inputsAt the second level, motor control takes place by means of:• Operation buttons on the motor starter tray. With these buttons start1, start2 and stop commands can be

given which are processed by the Starter Control Unit.• Digital inputs, for the use of digital inputs see 5.3.1 on page 25.

LCU

Field level

RCU

Process control level

Switchgearlevel

Monitoring, maintenance &engineering

Mfeeder/incomer

DCS SCADA EWS

DeviceNet

CIU 1 CIU 2

SCU

SCU

SCU

FCU

FCU

FCU



Hard-wired circuitsAt the lowest level, motor control takes place with the Remote Control Unit. With this unit start and stopcommands can be given. However, these commands don't pass through the Clink system but interfere directlyin the auxiliary circuit.

Levels and control• Motor stop is possible via all control levels• Motor start 1 and motor start 2 is not possible via the hard wired control level• Motor start via the hard wired control level is only possible with a direct-on-line starter.

Manual control at the switchgear levelThe manual control generates commands in the Starter Control Unit as soon as the push-button on the motorstarter tray is pressed.

WarningPush buttons can not be used for interlocking purposes!

Auxiliary relaysTo energize a contactor in the main circuit, the auxiliary relays are (de)energized by a 200 ms pulse. In thenormal course of events, the auxiliary relay K10 is energized and K11 and K12 are not energized (see 9.1 onpage 75 for diagrams). This means that the motor stops running if the Starter Control Unit is no longerfunctioning.

5.5.2 Switching conditions

This paragraph describes how a motor can be switched on and off. First an overview is given of the switchingconditions for each starter logic procedure. Then it is shown which external factors can switch a motor on or off.

Switching conditions direct-on-line, star delta, forward reverse, dual speed• Start1 and start2 commands are only possible when the isolator is closed.• Start1 and start2 commands are only possible if there is no interlocking because of a protection proce-

dure.• A stop command is dominant over a start1 or start2 command, in other words a start action is interrupted

by a stop action.

Additional switching conditions forward-reverse• If during operation a stop command is given, a start command for the other sense of rotation will be

delayed until the set interlock time has passed.• Starting left is not possible during motor starting right.• Starting right is not possible during motor starting left.

The set points for the running down time (Interlock 1 Time and Interlock 2 Time, see table 23) can be set viaLCU-5. Select: SCU Manager - Module Control Settings - tab Transfer..

Table 23: Running down (Interlock) time settings

Name Range Default Unit Parameter type

Interlock 1 Time 0-100.00 5 s Setpoint

Interlock 2 Time 0-100.00 5 s Setpoint



5.5.3 Interlockings

Lock/unlock control is possible via:• Manual control: via digital inputs• Local control: via LCU-5. Select SCU Manager - Module Interlock • Process control: via DeviceNet. See table 24.

The External Interlock (Digital Input) (5.3.1 on page 25) can be used to lock the Manual control or Process andLocal control.

The interlock status can be read-out via LCU-5. Select: SCU Manager - Module Interlock.

5.6 Starter logic

This paragraph describes the starter logic by means of a number of time diagrams. For each starter type it isdescribed, for the various transition states, how switching from one operating state to the other takes place.

5.6.1 Tray in Test state

In normal operational state a contactor can only be switched when the isolator is closed. Purpose of the Trayin Test state is make the test possible of the auxiliary circuit and all messages without starting a motor. Toactivate the ‘Tray in test’ mode the push button / switch in the motor tray has to be closed. This can only bedone when the door of the motor starter tray is open and thus the isolator is in the off position.The contact ofthe ‘Tray in test’ push button / switch simulates a closed contact of the isolator and thus the contactor can becontrolled either manually or by Clink.

5.6.2 Drive type

The drive type can be set via LCU-5, see table 25. Select: SCU Manager - Unit Properties - tab Nominal.

Table 24: Setpoint lock/unlock (command object)


Lock manual controllocal controlprocess control

Setpoint

Unlock see lock Setpoint

Table 25: Setpoint Drive Type


Drive Type Direct-on-Line 1 phaseDirect-on-Line 3 phaseStar-DeltaForward-ReverseDual Speed

Setpoint



5.6.3 Starting

An engine is starting when the motor reaches a certain status (ON, STAR, DELTA, LEFT, RIGHT, LOW, HIGH)and one of the following conditions has not yet been met:• The motor current has dropped below the change-over current level• The change-over time has elapsed

In figure 7 the motor reaches a certain status at the moment t0. The motor current increases and will decreaseafter some time to, for instance, the nominal motor current. As soon as the motor current drops below thechange-over current level, starting has finished.

In figure 8, contrary to figure 7, the end of the starting is determined by the change-over time.

Figure 7: Determining starting by Change Over Current Level

Change Over Timet0

off starting running

Nominal Motor Current

Change Over Current level

mot

or c

urre

nt

t



Figure 8: Determining starting by Change Over Time Level

Both Change Over Current and Change Over Time can be set via LCU-5, see table 26. Select: SCU Manager -Module Control - Settings - tab Transfer.

The Starter Logic Status can be read-out via LCU-5, see table 27. Select: SCU Manager - Module Control. Thetime diagrams in paragraphs 5.6.4 to 5.6.7 show the moment when a specific status is high.

Table 26: Change over current and change over time setpoints


Change Over Current 0-10.00 1.50 I/In Setpoint

Change Over Time 0-100.00 10.00 s Setpoint

Table 27: Starter Logic Status parameter


Starter Logic Status Motor StoppedMotor Running 1Motor Running 2Motor Starting 1Motor Starting 2Motor Starting K1Motor Starting K2

Actual

Change Over Timet0

off starting running

Nominal Motor Current

Change Over Current levelm

otor

cur

rent

t



5.6.4 Starter logic Direct on Line

Figure 9: Time diagram direct-on-line: Motor Stopped to Motor Running1 and Motor Running 1 to Motor Stopped

MOTOR STOPPED TO MOTOR RUNNING 1See figure 9, left:• After a start1 command, K11 is energized causing K1 to energize.• When MotorStarting1 has finished, the end status is reached (MotorRunning1).

MOTOR RUNNING 1 TO MOTOR STOPPEDSee figure 9, right:• After a stop command K10 is energized causing K1 to de-energize.

5.6.5 Starter logic Star-Delta

Figure 10: Time diagram Motor Stopped to Motor Running 2 and Motor Running 2 to Motor Stopped

AuxiliaryRelayK10

AuxiliaryRelayK11

ContactorK1

MotorStopped MotorStarting1 MotorRunning1

Start1

MotorStopped

Stop

MotorRunning1

MotorStarting K1

AuxiliaryRelayK10

AuxiliaryRelayK11

ContactorK1

AuxiliaryRelayK12

ContactorK2

Start2

ContactorK3


Stop

MotorRunning2 MotorStoppedMotorStarting K1 MotorStartingK2



MOTOR STOPPED TO MOTOR RUNNING 2See figure 10, left:• After a start2 command, K11 is energized causing ContactorK1 and ContactorK3 to energize.• When MotorStarting K1 has finished, K11 and K12 are energized simultaneously, causing K1 to de-ener-

gize.• When the Interlock2Time has elapsed, K12 is energized causing K2 to energize.• When MotorStarting2 has finished, the end status is reached (MotorRunning2).

MOTOR RUNNING 2 TO MOTOR STOPPEDSee figure 10, right:• After a stop command K10 is energized causing K2 and K3 to de-energize.

5.6.6 Starter logic Forward-Reverse

Figure 11: Time diagrams Motor Stopped to Motor Running 1 and Motor Running 1 to Motor Stopped

MOTOR STOPPED TO MOTOR RUNNING 1See figure 11, left:• After a start1 command, K11 is energized causing K1 to energize.• When Motor Starting1 has finished, the end status is reached (Motor Running 1).


AuxiliaryRelayK10

AuxiliaryRelayK11

ContactorK1

AuxiliaryRelayK12

ContactorK2

MotorStopped

Start1

MotorStarting1 MotorRunning1

Stop

MotorRunning1 MotorStopped

MotorStartingK1




MOTOR STOPPED TO MOTOR STARTING 2See figure 12, left:• After a start2 command, K12 is energized causing K2 to energize.• When Motor Starting 2 has finished, the end status is reached (Motor Running 2).


5.6.7 Starter logic Dual-Speed


AuxiliaryRelayK10

AuxiliaryRelayK11

ContactorK1

AuxiliaryRelayK12

ContactorK2

MotorStopped

Start2


Stop


MotorStartingK2

ContactorK3

AuxiliaryRelayK10

AuxiliaryRelayK11

ContactorK1

AuxiliaryRelayK12

ContactorK2

MotorStopped

ContactorK3

Start2

MotorStarting2

MotorRunning2

Stop

MotorRunning2 MotorStoppedMotorStartingK1 MotorStartingK2



MOTOR STOPPED TO MOTOR RUNNING 2See figure 13, left:• After a start2 command, K11 is energized causing K1 and ContactorK3 to energize.• When MotorStartingK1 has finished, K11 and K12 are energized simultaneously, causing K1 to de-ener-

gize.• When the Interlock2Time has elapsed, K12 is energized causing K2 to energize.• When Motor Starting 2 has finished, the end status is reached (Motor Running 2).

MOTOR RUNNING 2 TO MOTOR STOPPEDSee figure 13, right:• After a stop command, K10 is energized causing K2 and K3 to de-energize.


MOTOR STOPPED TO MOTOR RUNNING 1See figure 14, left:• After a start1 command, K11 is energized causing K1 and K3 to energize.• When motor starting1 has finished, the end status is reached.

MOTOR RUNNING 1 TO MOTOR STOPPEDSee figure 14, right:• After a stop command K10 is energized causing K1 and K3 to de-energize.

AuxiliaryRelayK10

AuxiliaryRelayK11

ContactorK1

AuxiliaryRelayK12

ContactorK2

ContactorK3


Start1 Stop


MotorStartingK1



Figure 15: Time diagrams RUNNING 1 TO RUNNING 2 and RUNNING 2 TO RUNNING 1

MOTOR RUNNING 1 TO MOTOR RUNNING 2See figure 15, left:• After a start2 command, K11 and K12 are energized causing K1 to de-energize.• When the Interlock2Time has elapsed, K12 is energized causing K2 to energize.• When motor starting2 has finished, the end status is reached (MotorRunning2).

MOTOR RUNNING 2 TO MOTOR RUNNING 1See figure 15, right:• After a start1 command, K11 and K12 are energized causing K2 to de-energize.• When the Interlock1Time has elapsed, K11 is energized causing K1 to energize.• When motor starting1 has finished, the end status is reached (MotorRunning1).

Interlock1Time and Interlock2TimeThe setpoints Interlock1Time and Interlock2Time are set via LCU-5. Select SCU Manager - Module Control- Settings tab Transfer, see table 23 on page 31.

5.6.8 Stop/start commands

Stop and start control is possible via LCU-5, see table 28. Select: SCU Manager - Module Control.

AuxiliaryRelayK10

AuxiliaryRelayK11

ContactorK1

AuxiliaryRelayK12

ContactorK2

MotorRunning1

Start2


Start1

MotorRunning2 MotorStarting1 MotorRunning1

MotorStartingK1MotorStartingK2ContactorK2



5.6.9 Command after communication failure

Command After Communication Failure generates a command when the last master is not available anymore.At that moment also the LED Network A or Network B on the front of the Starter Control Unit will start flashing.The command is set via LCU-5, see table 29. Select: SCU Manager - Module Control - Settings - tab Com.

The output status of the General Purpose Outputs 0-4 will be set to zero after loss of communication. Thisstatus is fixed set and thus not adjustable by the user.

5.7 Automatic restart

The automatic restart function detects failures in the mains voltage and ensures, depending on the duration ofthe failure, a direct or delayed restart so that the continuity of the process is guaranteed.

5.7.1 Mains failure detection

The Starter Control Unit continuously monitors the condition of the mains. As soon as the mains voltage dropsbelow 65% of the nominal voltage there is a mains failure (see figure 16). As soon as the mains voltage returnsto a value > 90% of the nominal voltage, the mains voltage is considered healthy.

Table 28: Stop/start commands (command object)

Command

Trigger event if Drive Type is

Direct-on-Line 1 Phase

Direct-on-Line 3 Phase Star-Delta Forward-

ReverseDual Speed

Stop Stop Stop Stop Stop Stop

Start 1 Start Start Not Available Start For-ward

Start Low

Start 2 Not Available Not Available Start Start Reverse

Start High

Table 29: Setpoint Command after Communication Failure (parameter object)

Name Default Description Parameter type

Command After Communication Failure No Action No ActionStopStart1Start 2

Setpoint



Figure 16: Mains failure detection

5.7.2 Contactor failure detection

The starter logic records exactly in which state the contactors should be. Nevertheless the state of thecontactors may change as a result of:

• A start1, start2 or stop command generated by the Remote Control Unit.• A mains failure.

As soon as the starter logic sees a change of state as a result of one of the above-mentioned points, a restartrequest is made to the automatic restart procedure. To determine whether the contactor de-energized becauseof a mains failure, the time is measured between:

• The start of the mains failure (mains voltage failure message).• The moment the contactor de-energizes (restart request).

If this time is shorter than 200 ms it may be concluded that the contactor de-energized because of a mainsfailure and the automatic restart procedure is started.

5.7.3 Restart time out

By means of the setpoint Immediate Restart Time-out and Delayed Restart Time-out (see table 30 on page44), three time zones can be defined. See also figure 17:

90

65

0

Mains Voltage

[%]

100

mains interruption time

MainsVoltageFailure

MainsVoltageHealthy

t



• Immediate restart• Delayed restart• No restart.

Figure 17: Automatic restart phases

Under normal conditions one uses immediate, delayed and no restart. However it is possible to disable one ormore times zones:

• If the immediate restart timeout is 0, time zone 1 doesn't exist and there will be no immediate restart.• If the delayed restart timeout is 0, time zone 2 doesn't exist and there will be no delayed restart.• If the delayed restart timeout is infinite, time zone 3 doesn't exist and there will always be a restart.

5.7.4 Immediate restart

Immediate restart will take place, if the mains voltage returns before the Immediate Restart Time-out haselapsed (see figure 18). In that case the speed of the motor has only decreased so little that the electricmagnetic force of the machine and the mains voltage are more or less in phase, so that the start current surgewill be limited.

NoteThe maximum time for an immediate restart is 0,4 second. This is because the SCU can operate 0,4 secondon the energy stored in it’s elco’s. After the 0,4 seconds the SCU will shutdown and restart.

Immediate restart means that the de-energized contactors are immediately energized. This means that a star-delta starter will not start through STAR (Running 1) and that a dual speed starter that was in HIGH (Running2) will not start through LOW (Running 1).

NoteBecause the relays K10, K11 and K12 are energized by an external power supply this power must be availableif the mains voltage becomes healthy.

immediate restart delayed restart no restart

ImmediateRestartTimeout

DelayedRestartTimeout



Figure 18: Immediate restart

5.7.5 Delayed restart

If the mains voltage returns after the minimum restart timeout has elapsed, the motor speed will havedecreased so much that the electric magnetic force of the motor and the mains voltage are out of phase. Startof motors at that moment would result in an impermissible start current surge. For that reason the motor startis delayed. See figure 19.

Figure 19: Delayed restart

The delay time is set using the setpoint Restart Delay Time, see table 30 on page 44. The counting of delaytime is started as soon as the mains voltage exceeds 90% of the nominal voltage. The counting is temporarilyinterrupted as soon as the mains voltage drops to a level below 90% of the nominal voltage.

At delayed restart the motors are started following the normal starting procedures (see starter logic, 5.6 onpage 32).




contact status

MainsVoltageFailure




contact status

MainsVoltageFailure

MainsVoltageHealthy

restart delay time



5.7.6 No restart

As soon as the Delayed Restart Time-out has expired, the motor will no longer be started by the automaticrestart procedure because the process is too much disturbed. In that case the motor can only be restarted bya normal switching command.

If the Restart Time-out is infinite, the motor will always be restarted.

5.7.7 Cancel automatic restart

The automatic restart procedure is cancelled when a start1, start2 or stop command is given.

5.7.8 Automatic restart during starting

In the above description it is assumed that the mains failure takes place at a moment when the motor is in thestate RUNNING. However if there is a mains failure during Motor Starting (1 or 2), there will always be delayedrestart.

5.7.9 Automatic restart during powerdown

When the SCU loses power during a mains voltage failure the duration of that mains voltage failure is measuredby means of a hardware timer. This hardware timer is powered by it’s own powersource that has stored energyfor at least 5 minutes.When the power returns the value of the timer contains the total mains voltage failure time which is read andis used in the restart logic.

5.8 Protection

This paragraph describes the protection functions of the SCU. A short description of each protection is given,followed by the threshold values of the quantity to be observed, which are set via LCU-5 by selecting: SCUManager - Module Protection. See 5.2 on page 15 for information regarding the measurement quantities.

Protection procedures• Motor stall: see 5.8.4 on page 48• Motor overload: see 5.8.5 on page 49• Phase unbalance: see 5.8.6 on page 50• Earth leakage: see 5.8.7 on page 51• Process underload: see 5.8.8 on page 51• Process overload: see 5.8.9 on page 52• External protection: see 5.8.10 on page 53• Overvoltage protection: see 5.8.11 on page 53

Table 30: Setpoints automatic restart


Immediate Restart Time-out 0.00-0.40 0.20 s Setpoint

Delayed Restart Time-out 0.00-300.00 4.00 s Setpoint

301.00 = infinite s

Restart Delay Time 0.00-300.00 2.00 s Setpoint



• Under voltage protection: see 5.8.12 on page 53• Under current protection: see 5.8.13 on page 54

5.8.1 Characteristics of protection functions

• Each protection function has an input for a variable to be observed and inputs for setpoints which are set via LCU-5 by selecting: SCU Manager - Module Protection - Settings.

• After having been configured, each protection function is performed autonomously by the Starter Control Unit.

• Each protection function has the facility to generate a trip signal to switch off the motor in the event that one of the setpoints is exceeded.

• Each protection function (except motor stall) has the facility to generate a warning signal in the event that one of the setpoints is exceeded.

• Setpoints are used to define which trip and warning signals can be acknowledged via manual control or process control.

The status of a protection function can be read-out via LCU-5, by the process controller and on the motor startertray.

Protection states:• Fault not present.• Protection activated, message not yet confirmed by an acknowledge/reset command.• Message acknowledged but fault is still present.

5.8.2 Read-out of trip and warning signals

Via LCU-5 and the process controller the following statuses can be read-out (see also table 31):• Trip Status indicates which protection has been activated.• Trip Acknowledge Status indicates which protection has been activated and also has been confirmed by

means of an acknowledge command.• Warning Status indicates which protection gives a warning signal.• Warning Acknowledge Status indicates which protection gives a warning signal and also has been con-

firmed by means of an acknowledge command.

Table 31: Read-out of protection status registers


Trip Status Motor stallMotor OverloadPhase UnbalanceEarth LeakageProcess OverloadProcess UnderloadExternal ProtectionOver Voltage ProtectionUnder Voltage ProtectionUnder Current Protection

Actual

Trip Acknowledge Status See description Trip Status (above)

Actual



The two registers together represent the status for each protection, see table 32.

Trip and warning signalsThe lamp on the motor starter tray is connected to a digital output (DO_3, 4, 5, 6 or 7) of the SCU. See table32 for a description of generated trip and warning signals (for information regarding the digital outputs of theSCU see 5.4.1 on page 26).

Trip currentThe moment a protection function is activated, the motor current is measured and stored. This value is storeduntil the protection is confirmed by means of an acknowledge command. See table 33.

Warning Status ReservedMotor OverloadPhase UnbalanceEarth LeakageProcess OverloadProcess UnderloadExternal ProtectionOver Voltage ProtectionUnder Voltage ProtectionUnder Current Protection

Actual

Warning Acknowledge Status See description Warning Sta-tus (above)

Actual

Table 32: Meaning of protection status registers and trip/warning signals

Status (Trip or Warning)

Acknowledge Status (Trip or Warning) Status of the protection Trip/warning signal

0 0 no fault is present low

1 0 protection activated, mes-sage not yet confirmed by an acknowledge/reset command

flashing

0 1 not applicable not applicable

1 1 message acknowledged, but fault is still present

high

Table 33: Read-out of Trip Current by DeviceNet


Trip Current L1 0-10.00 I/In Actual



Trip Current L1 0-1200.000 A Actual

Table 31: Read-out of protection status registers




5.8.3 Acknowledge command

Configuring the acknowledge commandTo define which trip and warning signals can be acknowledged via manual control or process control, thesetpoints listed in table 34 are configured via LCU-5 by selecting: SCU Manager - Module Protection - Settings,tab Enable.

After a trip or warning, an acknowledge command has to be given to confirm the protection and/or statusmessage. This can be done from two levels:• Process control, via DeviceNet, see table 35.• By an acknowledge push-button on the motor starter tray.

NoteThe Acknowledge commands can only be set when the Interlock Status (see table 24 on page 32) of manual,local and process control are FALSE.



Table 34: Process Control Acknowledge setpoints


Process Control Acknowledge Trip Enable

Motor StallMotor OverloadPhase UnbalanceEarth LeakageProcess OverloadProcess UnderloadExternal Protection

Setpoint

Process Control Acknowledge Warning enable

See above. Setpoint

Manual Control Acknowledge Trip Enable

See above. Setpoint

Manual Control Acknowledge Warning Enable

See above. Setpoint

Table 35: Acknowledge commands via DeviceNet command object


Acknowledge Protection

0->1 = Acknowledge Protection Setpoint

Table 33: Read-out of Trip Current by DeviceNet




5.8.4 Motor stall

This function protects the motor when it is switched on with blocked rotor. The input signals are listed in table36.

If MotorStallTripLevel is exceeded the motor will immediately be switched off. This protection has no warningfunction.

See figure 20 for the copper temperature curve when the motor is switched on with blocked rotor from a hotcondition. When the stall trip temperature is exceeded, the motor will immediately be switched off.

Acknowledge Trip

bit 0: 0 -> 1 = Acknowledge Motor Stall Tripbit 1: 0 -> 1 = Acknowledge Motor Overload Tripbit 2: 0 -> 1 = Acknowledge Phase Unbalance Tripbit 3: 0 -> 1 = Acknowledge Earth Leakage Tripbit 4: 0 -> 1 = Acknowledge Process Overload Tripbit 5: 0 -> 1 = Acknowledge Process Underload Tripbit 6: 0 -> 1 = Acknowledge External Protection Tripbit 7: 0 -> 1 = Acknowledge Over Voltage Tripbit 8: 0 -> 1 = Acknowledge Under Voltage Tripbit 9: 0 -> 1 = Acknowledge Under Current Trip(bit 10 - 15: Reserved)

Setpoint

Acknowledge Warning

bit 0 = Reservedbit 1: 0 -> 1 = Acknowledge Motor Overload Warningbit 2: 0 -> 1 = Acknowledge Phase Unbalance Warningbit 3: 0 -> 1 = Acknowledge Earth Leakage Warningbit 4: 0 -> 1 = Acknowledge Process Overload Warningbit 5: 0 -> 1 = Acknowledge Process Underload Warningbit 6: 0 -> 1 = Acknowledge External Protection Warningbit 7: 0 -> 1 = Acknowledge Over Voltage Warningbit 8: 0 -> 1 = Acknowledge Under Voltage Warningbit 9: 0 -> 1 = Acknowledge Under Current Warning(bit 10 - 15: Reserved)

Setpoint

Table 36: Input signals motor stall


MotorStallTripEnable Trip Enable, bit 0 Setpoint

MotorStallTripLevel = Maximum Temperature Rise + 65 K Setpoint

MotorTemperatureCu Actual

MotorStallTripAcknowledgeCommand Command object

Table 35: Acknowledge commands via DeviceNet command object




Figure 20: Temperature curve after start with blocked rotor in hot condition

5.8.5 Motor overload

The motor overload protection uses the motor temperature calculated by the thermal model and the motorcurrent to protect the motor against overload.The motor is switched off if it is overloaded during a certain time. The length of this time depends on the sizeof the overload. The corresponding current/time characteristic complies with IEC 947-4-1 concerning motorstarters.IEC 947-4-1 distinguishes 4 temperature classes. In table 37, the trip time is stated as a function of the motorcurrent for each temperature class.

The times at 1.05 In and 7.2 In are from cold condition, the times at 1.2 In and 1.5 In are from hot condition. AtIn there is a thermal equilibrium.

Table 37: Trip times according to IEC 947-4-1

Class Trip time

1.05 In 1.2In 1.5In 7.2 In (stall)

10 A > 2 hours < 2 hours ²<= 2 min. 2 < t <= 10 s

10 > 2 hours < 2 hours <= 4 min. 4 < t <= 10 s



Tcu

T_ambient t (min)

T_stall

T_nom

Temp. rise

TfeTemp. rise interlock level

Time to reset



In figure 21 extreme values in the table are graphically represented. The curve relates to the hot characteristics.It is possible to set any value in between.

Figure 21: I/t curves according to IEC 947-4-1

The current/time characteristic is defined on the basis of setpoints in LCU-5:• For a relevant explanation of parameters see 5.2.4 on page 18. • For motor data settings see table 12 on page 21.

If the Trip Current is exceeded, the motor will be switched off after the Trip Time.If Warning Temperature-Rise is exceeded during 1 second there will only be a warning.

5.8.6 Phase unbalance

This protection calculates the phase unbalance from the 3 phase currents and switches the motor off when thetrip level is exceeded. At the indicated default setpoint, the protection complies with IEC 947-4-1 (clause7.2.1.5.2).

CalculationThe phase unbalance is calculated as follows:• Of each phase the deviation compared with the average value of the 3 phase currents (Iaverage) is deter-

mined, whereby the absolute value of the biggest deviation is considered equal to dImax.• Now the phase unbalance is calculated dependent on the average value of the 3 phase currents.• If Iaverage is higher than Inominal then: phase unbalance = (dImax / Iaverage).• If Iaverage is lower than Inominal then: phase unbalance = (dImax / Inominal).In formula:

• When Iav >= In then:

10000

1000

100Ti

me(

s)

10

11 2 5 10i/In

PhaseUnbalanceIx Iav–

Iav---------------------- 100%×=



• When Iav < In then:

Iav = Average motor currentIx = Motor current with the biggest deviation compared to IavIn = Nominal motor current

Trip and warning level are set relatively to Inominal. See table 38.

AccuracyThe accuracy of the measured value is ± 5%.

NoteIf DriveType = DL1 then Phase Unbalance = 0.

5.8.7 Earth leakage

The purpose of this protection is to switch off the motor in case of impermissible earth leakage currents.

• The usual setpoint for the trip level is 3% of the nominal motor current with a maximum of 6 A. • The warning level is usually set at 80% of the trip level.• If the trip level is exceeded, the motor will be switched off after the trip time.• If the warning level is exceeded during 1 second there will only be a warning.

5.8.8 Process underload

The purpose of this protection is to monitor the lower load limit determined by the process. For this the ActualPower is used to determine the actual load.

Trip and warning level are set relatively to the nominal motor capacity.

Table 38: Phase Unbalance Setpoints


Phase Unbalance Trip Time 0-100.00 10.00 s Setpoint

Phase Unbalance Trip Level 0-100 40 % Setpoint

Phase Unbalance Warning Level

0-100 20 % Setpoint

Table 39: Earth Leakage Setpoints


Earth Leakage Trip Time 0.05-100.00 0.50 s Setpoint

Earth Leakage Trip Level 0.3-6.0 1.0 A Setpoint

Earth Leakage Warning Level 0.3-6.0 0.8 A Setpoint

PhaseUnbalanceIx Iav–

In---------------------- 100%×=



To prevent that the process underload protection responds during motor starting, the Process UnderloadInterlock Time should be set as follows:

• At minimum 2* Stall Time (hot) + 1 s. or• At minimum Stall Time (cold) + 1 s.

• If in normal operation the actual load is less than the Process Underload Trip Level and Process Under-load Trip Enable is activated, the motor will be switched off after the Process Underload Trip Time has elapsed.

• If the actual load is less than the Process Underload Warning Level during 1 second there will only be a warning.

5.8.9 Process overload

The purpose of this protection is to monitor the upper load limit determined by the process. For this the ActivePower is used to determine the actual load.

Trip and warning level are set relatively in relation to the nominal motor capacity.

To prevent that the process overload protection responds during motor starting, the Process Overload InterlockTime should be set as follows:

• At minimum 2* Stall Time (hot) + 1 s. or• At minimum Stall Time (cold) + 1 s.

• If in normal operation the actual load is higher than the Process Overload Trip Level and Process Over-load Trip Enable is activated, the motor will be switched off after the Process Overload Trip Time has elapsed.

• If the Process Overload Warning Level is exceeded during 1 second there will only be a warning.

Table 40: Process Underload Setpoints


Process Underload Interlock Time 0-100.00 60.00 s Setpoint

Process Underload Trip Time 0-100.00 60.00 s Setpoint

Process Underload Trip Level 0-2.00 0.20 P/Pn Setpoint

Process Underload Warning Level 0-2.00 0.30 P/Pn Setpoint

Table 41: Process Overload Setpoints


Process Overload Interlock Time 0-100.00 60.00 s Setpoint

Process Overload Trip Time 0-100.00 60.00 s Setpoint

Process Overload Trip Level 0-2.00 1.50 P/Pn Setpoint

Process Overload Warning Level 0-2.00 1.20 P/Pn Setpoint



5.8.10 External protection

The Starter Control Unit has 8 digital inputs. The five free inputs (DI_3 to DI_7) can be used for the connectionof an external protection unit to switch the motor off when the unit responds or to generate only a warning.

Configuration digital inputsFor information regarding the configuration of Digital Input Functions see 5.3.1 on page 25.

The output of the protection unit must have a potential-free contact with the following specifications:• Insulation: 2.5 kV/50Hz/1 min. (between contact and other parts of the unit)• switching power: must be suitable for switching 10 mA at 24 Vdc.

ConnectionsThe potential-free contact of a protection unit is connected between the +24V and the respective digital inputof the Starter Control Unit.The input signal will only be effective when the input concerned has been configured as an External Protectionfunction and when the respective protection procedure has been activated.

Activation of the protective deviceActivation of the protective device is possible via LCU-5.When the protection unit responds, the motor will be switched off after 0.1 second if the trip function is enabled.When the warning function is enabled there will only be a warning after 0.1 second.

5.8.11 Over Voltage Protection

The purpose of this protection is to monitor the maximum voltage limit.

Trip and warning levels are set as a percentage of the nominal mains voltage.

5.8.12 Under Voltage Protection

The purpose of this protection is to monitor the minimum voltage limit.

Trip and warning levels are set as a percentage of the nominal mains voltage.

Table 42: Over Voltage Setpoints


Over Voltage Warning Level 0-130 130 % Setpoint

Over Voltage Trip Level 0-130 130 % Setpoint

Over Voltage Trip Time 0-100 10 s Setpoint

Over Voltage Interlock Time 0-100 5 s Setpoint

Table 43: Under Voltage Setpoints


Under Voltage Warning Level 0-100 0 % Setpoint



5.8.13 Under Current Protection

The purpose of this protection is to monitor the minimum value of the motor current.

Trip and warning levels are set as a percentage of the nominal motor current.

5.9 Monitoring of diagnostic and maintenance data

The diagnostic and maintenance data are described in this paragraph.

5.9.1 Number of operating hours

Number of operating hours is understood to mean the cumulative time that one of the contactors K1 or K2 wasactivated. The resolution with which the number of running hours is displayed is 0.1 hour. Internally a muchsmaller resolution (100 ms) is used, so that a motor that was 6 times 1 minute in status RUNNING, alsoincreases the number of running hours by 0.1.

The number of running hours is represented via LCU-5 (select SCU Manager - Module Maintenance) and isavailable to the process controller. See table 45.

The Number of Operating Hours can be reset via LCU-5. Select: SCU Manager - Module Maintenance.

Under Voltage Trip Level 0-100 0 % Setpoint

Under Voltage Trip Time 0-100 10 s Setpoint

Under Voltage Interlock Time 0-100 5 s Setpoint

Table 44: Under Current Setpoints


Under Current Warning Level 0-100 0 % Setpoint

Under Current Trip Level 0-100 0 % Setpoint

Under CurrentTrip Time 0-100 10 s Setpoint

Under Current Interlock Time 0-100 5 s Setpoint

Table 45: Number of Operating Hours


Number of Operating Hours 0-4,000,000 hours Actual

Table 43: Under Voltage Setpoints




5.9.2 Number of contactor operations

Number of contactor operations is understood as the number of times a contactor is switched from off to on.The number of contactor operations is represented via LCU-5 (select SCU Manager - Module Maintenance) andis available to the process controller. See table 46.

The Number of Contactor Operations can be reset via LCU-5 by selecting: SCU Manager - Module Maintenance- Reset - reset Number of Starts.

5.9.3 Number of contactor operations during last hour

Number of contactor operations during last hour is understood to mean the number of times a contactor wasswitched from off to on during the last hour.The number of contactor operations is represented via LCU-5 (select: SCU Manager - Module Maintenance) andis available to the process controller. See table 47.

It is not possible to reset The Number of Contactor Operations Last Hour.

5.9.4 Starting current

The Starting Kx Current is the maximum motor current measured during the period Motor Starting Kx is TRUE(5.6.3 on page 33) starting after 200 ms because of the inrush current.

The Starting Current is represented both related to ‘In’ and in ampere via LCU-5, see table 48. Select: SCUManager - Module Maintenance.

Table 46: Read-out of Number of Contactor Operations


Number of Contactor K1 Operations 0-4,000,000 - Actual

Number of Contactor K2 Operations 0-4,000,000 - Actual

Table 47: Read-out of Number of Contactor Operations Last Hour


Number of Contactor K1 Operations Last Hour

0 - 64 - Actual

Number of Contactor K2 Operations Last Hour

0 - 64 - Actual

Table 48: Read-out of Starting Current


Starting K1 Current 0-10.00 I/In Actual

Starting K2 Current 0-10.00 I/In Actual

Starting K1 Current 0-1,200.000 A Actual



The measured value for Starting Kx Current is refreshed each time Motor Starting Kx changes from TRUE toFALSE.

5.9.5 Starting time

The Starting Kx Time is the time during which Motor Starting Kx is TRUE with a minimum of 200 ms becauseof the inrush current. See also 5.6.3 on page 33.

Starting Time can be read-out via LCU-5. See table 49. Select: SCU Manager - Module Maintenance.

The measured value for Starting Kx Time is refreshed each time Motor Starting Kx changes from TRUE toFALSE.

5.9.6 Trip current L1, L2, L3

The trip current Lx is the measured value for motor current Lx at the moment when the Trip Status changesfrom FALSE to TRUE. The trip current can be read-out related to In and in Ampere via LCU-5. See table 50. Select SCU Manager -Module Maintenance

Trip current is refreshed each time a protection function is called.

Starting K2 Current 0-1,200.000 A Actual

Table 49: Read-out of Starting Time


Starting K1 Time 0-100.00 s Setpoint

Starting K2 Time 0-100.00 s Setpoint

Table 50: Read-out of Trip Current

Name Range Unit Access Rule




Trip Current L1 0-1,200.000 A Actual



Table 48: Read-out of Starting Current




5.9.7 Time to trip

Time To Trip is calculated only when there is a motor overload. Time To Trip can be read-out via LCU-5. Seetable 51. Select: SCU Manager - Module Protection.

Determining whether there is an overload, is done by calculating the theoretical end temperature Tcu of thecopper winding. When Tcu < Temperature Rise Interlock Level (see table 52), the Time To Trip is infinite. WhenTcu exceeds the Temperature Rise Interlock Level the Time To Trip is calculated as the sum of: 1 The time necessary according to the thermal model to reach Motor TemperatureCu = Motor Temperature-

Trip Level and2 the time necessary according to the MotorOverload model to reach Trip status according to the It-diagram.

5.9.8 Time to reset

Calculating Time To Reset only happens when the motor is not running (contactors K1 and K2 FALSE) and thetemperature of the copper windings (Tcu) exceeds the Temperature Rise Interlock Level. Time To Reset can be read-out via LCU-5. See table 53.Select: SCU Manager - Module Protection.

5.9.9 Reset maintenance command

The reset maintenance command is possible via local and process control. Via local command (LCU-5) select:SCU Manager - Module Maintenance - reset Operating Hours and reset Number of Starts.

Table 51: Read-out of Time To Trip

Name Range Description Unit Parameter type

Time To Trip 0-7200 s Actual

Table 52: Setpoint Temperature Rise Interlock Level


Temperature Rise Interlock level 0-130 65 K Setpoint

Table 53: Read-out of Time To Reset

Name Range Description Unit Access Rule

Time To Reset 0-3600 s Actual



6 TROUBLESHOOTING GUIDE

6.1 How to use the trouble shooting guide

Within the Clink II system, error messages can be generated at several levels. This chapter describes possibleerror messages and shows what action should be taken to eliminate their cause.

For information regarding:• States of the SCU see 6.2 on page 58• Status Module LED see 6.3 on page 60• Status Network LED see 6.4 on page 61• Fault messages see 6.5 on page 61• Corrective actions see 6.6 on page 63

6.2 States of the SCU

The behaviour of the SCU is illustrated in the State Transition Diagram (STD) in figure 22.This STD associates the state of the device with the status reported by the status Module LED (see 6.3).

NoteThe LED mentioned in figure 22 is the Module LED.

troubleshooting guide version 5.0 58


Figure 22: State Transition Diagram (STD, note: LED = Module Led)

The State Transition Diagram contains the following states (see table 54):

Table 54: Description of operational modes

State Description

Nonexisting The device is without power.

Device Self Testing The device is executing its selftest.

Standby The device needs commissioning due to an out-of-box configuration.

Operational The device is operating in a fashion that is normal for the device.

Nonexisting

Device Self Testing

Standby

Operational

Major Recoverable Fault Major Unrecoverable Fault

PowerApplied

Test Passed

Identity Object Reset Service

(from any state except

Maj. Unrec. Fault)

Power Loss

TestFailed

MajorRecoverable

Faults

MajorUnrecoverable

Faults

Deactivated Activated

MinorFault

FaultCorrected

MajorRecoverable

Faults

Led: Off

Led: Flashing Red/Green

Led: Flashing Green

Led: Solid Green

Led: Flashing Red Led: Solid Red



The State Transition Diagram contains the following transitions (see table 55):

NoteThe digital outputs are active in the Operational state only. In all the other operational states they are low.

6.3 Status Module LED

The bi-color (green/red) Module LED provides information regarding the SCU status. It indicates whether ornot the SCU has power and is operating properly, see table 56. For an overview of operational modes andtransitions see figure 22 on page 59.

Major Recoverable Fault The device has experienced a major fault that is believed to berecoverable (see 6.5).

Major Unrecoverable Fault The device has experienced a major fault that is believed to beunrecoverable (see 6.5).

Table 55: Overview of transitions

Transition Trigger

Power Applied The device is powered up (> 21.8 V).

Power Loss The device is powered down (< 19.8 V).

Test Passed The device has successfully passed all self tests.

Test Failed The device has detected a fault during the self test.

Activated The device has been successfully configured.

Deactivated The device has received new parameters.

Minor Fault A fault classified as either Minor Unrecoverable Fault or Minor Recoverable Fault has occurred (see 6.5).

Major Recoverable Fault A fault classified as Major Recoverable Fault has occurred (see 6.5).

Major Unrecoverable Fault A fault classified as Major Unrecoverable Fault has occurred (see 6.5).

Fault Corrected The device has received new parameters that are believed to be correct.

Table 56: States of the Module LED

LED is State Indication

Off Nonexisting There is no power applied to the device.

Solid Green Operational The device is operating normally.

Flashing green Standby The device needs commissioning. Download all parame-ters.

Table 54: Description of operational modes

State Description



6.4 Status Network LED

The bi-color (green/red) LED NETWORK A and NETWORK B indicate the status of the communication link.See table 57 for a description of the LED states.

6.5 Fault messages

The SCU is able to report a number of fault messages which are classified into four fault types (see table 58).See table 59 for an overview of SCU fault messages.

Solid Red Major Unrecovera-ble Fault

The device has experienced a major fault that is believed to be unrecoverable (see 6.5).

Flashing Red Major Recoverable Fault

The device has experienced a major fault that is believed to be recoverable (see 6.5).

Flashing Red/Green Device Self Testing The device is in selftest.

Table 57: States of the Network LEDs

Network A or B LED is State Indication

Off Not powered/not on-line SCU is not on-line:• the SCU has not completed the Dup_MAC-ID test yet.• the SCU may not be powered, look at the status Module

LED.

Flashing green

On-line, not connected SCU is on-line but has no connections in the established state:• the SCU has passed the Dup_MAC_ID test, is on-line, but

has no established connections to other nodes• the SCU has no established connections.

Solid green Link OK, on-line, con-nected

The SCU is on-line and has connections in the established state.• the SCU has one or more established connections.

Flashing Red Connection time-out One or more I/O connections are in the timed-out state.

Red Critical link failure Failed communication. The SCU has detected an error that has rendered it incapable of communicating on the network (duplicated MAC ID or Bus-off).

Flashing Red/Green

Communication faulted and received an identify comm fault request - long protocol

A specific communication failure. The SCU has detected a Network access error and is in the communication faulted state. The SCU has subsequently received and accepted an Identify Communication Faulted Request - Long Protocol message.

Table 56: States of the Module LED

LED is State Indication



Table 58: Fault type classification

Fault type Description

Minor Recoverable fault The device detected a problem with itself, which is thought to be recovera-ble. The problem does not cause the device to go into one of the faulted states. See 6.2.

Minor Unrecoverable Fault The device detected a problem with itself, which is thought to be unrecov-erable. The problem does not cause the device to go into one of the faulted states. See 6.2.

Major Recoverable Fault The device detected a problem with itself, which caused the device to go into the “Major Recoverable Fault” state. See 6.2.

Major Unrecoverable Fault The device detected a problem with itself, which caused the device to go into the “Major Unrecoverable Fault” state. See 6.2.

Table 59: SCU fault messages

Name Range DescriptionParameter type

Major Recoverable Fault 0 - 10 0 = No Fault Actual

1 = Duplicate Digital Input Function

2 = Duplicate Digital Output Function

3 = Invalid Current Configuration

4 = Invalid Nominal Current

=

=

5 = Invalid Nominal Power

6 = Invalid Motor Weight

7 = Invalid Stall Time

8 = Invalid Trip Time At 1.5 In

9 = Invalid Warning Temperature Rise

10 = General Configuration Failure



6.6 Corrective actions

Major Unrecoverable Fault

0 - 13 0 = No Fault Actual

1 = Software Failure

2 = Clock Read Failure

3 = Clock Write Failure

4 = Reserved

5 = Safety Circuit Failure

6 = EEPROM Read Failure

7 = EEPROM Write Failure

8 = RAM Failure

9 = FLASH Failure

10 = Crystal Failure

11 = Invalid Serial Number

12 = EEPROM CRC Failure

13 = Thermal Input Failure

Minor Recoverable Fault 0 - 2 0 = No Fault Actual

1 = General Power Supply Error

2 = Network Power Supply Error

Minor Unrecoverable Fault

0 - 2 0 = No Fault Actual

1 = General Power Supply Error

2 = Network Power Supply Error

Table 60: Corrective actions after a failure

Fault indication Description Corrective action

Minor Fault

• general power supply error• network power supply error

The power supply configuration does not match the actual power supply.

Select the appropriate config-uration via LCU-5 by select-ing SCU Manager - Unit Properties - tab System Con-figuration.

Major recoverable fault

Table 59: SCU fault messages

Name Range DescriptionParameter type



• duplicate digital input func-tion

A specific digital input function isassigned to more than one digital input.

See 5.3.1 on page 25.

• duplicate digital output func-tion

A specific digital output function is assigned to more than one digital out-put.

See 5.4.1 on page 26.

• invalid current configuration The selected nominal current MIU is not valid.

Correct setpoint.

• invalid nominal power The set nominal power does not match the other setpoints.

See 5.2.4 on page 18 and table 12 on page 21.

• invalid motor weight The set motor weight does not match the other setpoints.


• invalid stall time The set stall time does not match the other setpoints.


• invalid trip time at 1.5 In The set trip time at 1.5 In does not match the other setpoints.


• invalid warning temperature rise

The set warning temperature rise does not match the other setpoints.


• general configuration failure. The SCU does not function with the current thermal and motor data set-points.


Major unrecoverable fault

• Software fault Software failure in SCU. Replace the mainboard, see 7.1 on page 66.

• Clock Read failure Failure while reading clock IC. Replace the mainboard, see 7.1 on page 66.

• Clock Write failure Failure while writing clock IC. Replace the mainboard, see 7.1 on page 66.

• Safety circuit failure The expected status of the digital out-put does not match the actual status of the digital output.

Replace the mainboard, see 7.1 on page 66.

• EEPROM Read failure Failure while reading the EEPROM. Replace the interface board, see 7.2 on page 66.

• EEPROM Write failure Failure while writing data to the EEP-ROM.

Replace the interface board, see 7.2 on page 66.

• RAM failure Failure while selftesting the RAM. Replace the mainboard, see 7.1 on page 66.

• FLASH failure Failure while selftesting the FLASH. Replace the mainboard, see 7.1 on page 66.

• Crystal failure Frequency of the crystal is not correct. Replace the mainboard, see 7.1 on page 66.





• Invalid serial number The SCU has an invalid serial number. Replace the mainboard, see 7.1 on page 66.

• EEPROM CRC (Cyclic Redundancy Check) failure

The calculated CRC over the contents of the EEPROM does not match the stored CRC.

Replace the interface board, see 7.2 on page 66.

• Thermal input failure The thermal input is wrong because current is detected while the status of contactor is OPEN.

Check wiring and contactor.





7 MAINTENANCE SCU

The Starter Control Unit consists of a multi-layer withdrawable main board and fixed mounted interface board.The interface board contains an EEPROM and the DeviceNet™ connectors. The EEPROM contains all theSCU-specific motor data. A jumper setting on the main board determines whether the print functions as aStarter or Feeder Control Unit. The main board and the interface board can be replaced while the systemremains operative. The Starter Control Unit is maintenanced on print level. A faulty SCU or interface board is replaced by a newone.

• To replace a main board see 7.1 on page 66• To replace an interface board see 7.2 on page 66

WarningWhile replacing an interface board of an SCU the associated feeder can not be controlled viaDeviceNet. Therefore the replacement should always be reported according to local safetyprocedures.

WarningClink II components contain Electrostatic Discharge sensitive parts and assemblies. Static controlprecautions are required when installing, testing, servicing, or repairing an assembly. Componentdamage (including degradation or malfunctioning of the performance) may result if ESD controlprocedures are not followed.

7.1 Replacement of the main board

1 Before replacement of a main board the actual data of the main board have to be saved in the EEPROM of the interface board.

• In order to store the actual data in EEPROM reset the main board either via the Reset Common Service of the Identity Object. The type of reset to be used is 0, see the appendix DeviceNet Interface of the SCU orwith the Hyper terminal, see 7.3 on page 67.

2 Replace the main board:• Take the main board out of the cassette.• Check the correct jumper setting of the new main board.• Place the new main board in the cassette.

3 Verify whether the main board is operational (status Module LED should light solid green, see also 6.2 on page 58).

7.2 Replacement of the interface board

1 Before replacement of an interface board the actual data of the main board have to be saved in the EEP-ROM of the interface board and then the data must be saved to file.

• In order to store the actual data in EEPROM reset the main board either via the Reset Common Service of the Identity Object. The type of reset to be used is 0, see the appendix DeviceNet Interface of the SCU orwith the Hyper terminal, see 7.3 on page 67.

• Save the EEPROM data to file by using RSNetWorx™ or store the data in LCU-5. Select LCU-5 System Manager - Unit Upload.

2 Replace the interface board:• Take the main board out of the cassette.• Take away the side plates of the cassette.

maintenance scu version 5.0 66


• Replace the interface board.• Mount the side plates of the cassette.• Place the main board back in the cassette.

3 Commission the node of the new interface board via RSNetWorx™, see Use of Hyper Terminal in 7.3 on page 67 (the default node of a new interface board is 63).

4 Download the saved settings from file to device. Select LCU-5 System Manager - Unit Download.5 Verify whether the main board is operational (Module LED should light solid green, see also 6.2 on page

58).

7.3 Use of Hyper Terminal

The program Hyper Terminal can be used as a practical tool for commissioning and maintenance of the ClinkII units. In the embedded software of the SCU a monitor program is included. The Hyper Terminal can be usedto communicate with this monitor program.

WarningThe Hyper Terminal may only be used by authorized personnel. Via Hyper Terminal direct access tothe embedded software is possible. Changes made to the software may result is malfunctioning ofthe Clink II system at the risk of e.g. stopping or starting motors or in changing of the protectionparameters.

To connect the PC with Hyper Terminal to the Clink II unit a so called Reset box (Holec part number 1307 223)is necessary.

To communicate via Hyper Terminal the settings of the serial port of the PC are:bits per second: :9600databits: 8parity: nonestopbits: 1datatransport: noneUnder Properties the emulation type should be auto detection.

With the command < h > an overview of the available commands can be seen.To assign a new node number to a Starter Control Unit, type < MAC xx >, where xx is the node number.

To adjust the baud rate on DeviceNet level to 500 kBaud type < MAC 500 >.

To give a reset command type 0, use the command RST. All data present in the RAM memory on the mainboard is written in the EEPROM on the interface board.

maintenance scu version 5.0 67


8 TECHNICAL SPECIFICATIONS SCU

8.1 Technical specifications main board and interface board

8.2 SCU print

The Starter Control Unit is a microprocessor controlled system provided with digital and analog I/O functionsand a serial bus for communication with DeviceNet.

The hardware is distributed over two prints:• Main board• Interface board

In order to comply with the EMC requirements (IEC 1000-4), the main board is designed as a 4 layer multi-layer(Printed Circuit Boards). All inputs and outputs are adequately high-frequency decoupled against interferencesignals. A combination of SMD components and conventional components is used for the main board. The interface board includes varistors for the DeviceNet buses.

8.3 Connections

8.3.1 Connectors on the front of the SCU

Reserved for future development.

Table 61: Type and part numbers

Component Holec Partnumber(with CFCU functionality)

Holec Partnumber(without CFCU functionality)

(C)FCU main board 1307222 1307200

Interface board 1307221 1307201

Table 62: Environmental conditions

Item Specification Unit

Power supply 24 - 30 V /100 mA

Ambient temperature operating 0 to 55 0C

storage -5 to 70

Relative Humidity 0 to 95 % Note: non-condens-ing

Vibration (operating) 1.0 G

Vibration (non-operating) 1.0 G

technical specifications scu version 5.0 68


8.3.2 Motor starter tray connections of the interface board

Interface board connectionsSee figure 23, figure 24 and table 63 for a description of the connections between the interface board andcomponents in the motor starter tray.

Figure 23: Connectors of the interface board and SCU

Table 63: Connectors of the interface board and the SCU

Connector Description

X1 SCU-interface board connector

X2 Vertical connections Devicenet and GPS (Network A)

X3 Vertical connections Devicenet and GPS (Network B)

X4 Interface board to tray connector

X3

X2

X1 X4

1

1

MODULE

NETWORK A

NETWORK B

RS 232

ELCO's

Jumper SCU/FCUSF

X1

Jumper EarthLeakage Range

H = 0.3 - 6 AL = 0.03 - 0.6 A

LH



Figure 24: Interface board motor tray connections (X4)

Table 64: Pin description main board and interface board connections

Motor starter tray connector number SCU connector (X1) Interface board

connector (X4) Interface board label

A1 DI_0 21 DI_0

A2 DI_1 22 DI_1

A3 DI_2 23 DI_2

A4 DI_3 24 DI_3

A5 DI_4 25 DI_4

A6 DI_5 26 DI_5

A7 DI_6 27 DI_6

A8 DI_7 28 DI_7

Inte

rface

boar

d

A

C

B

D

E

Differential Transformer

Analog Input

Digital Output

Digital Input

LPS

30

15

Analog Output

MIU

A10

V+_Tray

B1,B2

C9,C10

C1 t/mC8

B1 t/mB10

C4,C5

A1 t/mA9



Vertical connections for DeviceNet and the General Power Supply.The vertical connections for DeviceNet and the General Power Supply consist of six wires:

Droplines used for power supply of DeviceNet:• V-• V+

Droplines used for DeviceNet data communication:• CAN_H• CAN_L

Droplines from the GPS trunking used for General Power Supply:• 24V+• 24V-

A9 V+_Tray 29 V+_Tray

A10 GND 30 GND

B1 AO_0 11 AO_0

B2 V+_Tray 12 V+_Tray

B3 DO_0 13 DO_0

B4 DO_1 14 DO_1

B5 DO_2 15 DO_2

B6 DO_3 16 DO_3

B7 DO_4 17 DO_4

B8 DO_5 18 DO_5

B9 DO_6 19 DO_6

B10 DO_7 20 DO_7

C1 I1 1 SI_0

C2 I2 2 SI_1

C3 I3 3 SI_2

C4 4 SI_3

C5 AGND 5 AGND

C6 U 6 SI_4

C7 -- 7 SI_5

C8 -- 8 SI_6

C9 9 SI_7

C10 AGND 10 AGND

Table 64: Pin description main board and interface board connections

Motor starter tray connector number SCU connector (X1) Interface board

connector (X4) Interface board label

I n∆



NoteThe cable shield of the DeviceNet cable is connected to the cassette.

see figure 23 on page 69 and table 65 for the lay-out of the interface aboard. X2 (network A) and X3 (networkB when applicable) are the connectors to the vertical connections.

8.4 Inputs and outputs

8.4.1 Digital inputs

The digital inputs are used for reading of contact and push button statuses. For information regarding thefunction of digital inputs see table 5.3.1 on page 25.

Technical specification digital inputs

8.4.2 Analog inputs

The analog inputs are used for measurement of phase currents, phase voltages and earth leakage currents.The SCU has 5 analog inputs. For a description see table 67.

Table 65: Connector description vertical connections DeviceNet™ and GPS

Pin number Description X2 Description X3

1 24V+A 24V+B

2 24V-A 24V-B

3 V+A V+B

4 CAN_HA CAN_HB

5 CAN_LA CAN_LB

6 V-A V-B

Table 66: Technical specification digital inputs

Name Specification Unit

Nominal input voltage 24 Vdc

Max. input voltage 30 Vdc

Input resistance 2300 - 2500 Ohm

Threshold voltage high > 17 Vdc

Threshold voltage low < 13 Vdc

Transient 150 Vmsec

Vmax = 150 V



Technical specifications analog inputs

8.4.3 Digital outputs

The SCU has 8 digital outputs which are used for operating contactors and general purposes. For informationregarding the function of digital outputs see table 19 on page 26 and table 21 on page 28.

Technical specifications digital outputs

Table 67: Description of analog inputs

Input Description

U Phase voltage L1 or phase to phase voltage L1-L2

I1 Phase current L1

I2 Phase current L2

I3 Phase current L3

Earth leakage current

Table 68: Technical specification analog inputs

Name Specification Unit Note

Nominal voltage range• voltage input• current input

0 .. 0.0180 .. 0.044

VacVac

4 kHz

Input filter bandwidth 0 ..4 kHz

Transient• voltage input• current input

830

VmsecVmsec

Vmax = 150 V

Input resistance (Ri)• Voltage input• Current input

2.7535.7

OhmOhm

Table 69: Technical specifications digital outputs


Nominal voltage 24 Vdc

Maximum voltage 30 Vdc

Output resistance 31 - 38 Ohm

Max. sink current 100 mA

I∆n



8.4.4 Analog output

The SCU has 1 unipolar analog output, with description A0_0. For information regarding the function of theanalog output see table 22 on page 29.

Technical specifications

Transient 150 Vmsec

Vmax = 150 V

Overload Short circuit proof from -30 V.. +30 V with respect to Gnd

Vdc

Table 70: Technical specifications analog outputs

Name Specification Unit Note

Type Current, unipolar

Burden resistance 0-900 Ohm

Nominal burden resistance 500 Ohm

Nominal supply voltage 24 Vdc

Max. supply voltage 30 Vdc

Min. supply voltage - 0.6 Vdc

Output voltage 0-10 Vdc at 0-20 mAdc(Rb = 500 Ohm).

Transient 150 Vmsec

Vmax = 150 V

Table 69: Technical specifications digital outputs




9 ELECTRIC CIRCUIT DIAGRAMS SCU

9.1 Single line and auxiliary circuit diagrams

9.1.1 Direct On Line starter

Figure 25: Single line diagram Direct On Line starter

NoteIn figure 25 auxiliary current transformers are applied for current measurement. This is necessary formeasurement of nominal currents > 64 A. Nominal currents up to 64 A run directly through the MIU.

T1

X1

T2, T3

K1

X2: U-V-W

L1-N

MIU

F1

F2 SCU

auxiliary circuit

K1

T1: core balance transformerT2, T3: current transformersF1: fuse main circuitF2: fuse auxiliary circuitMIU: Measurement Interface UnitSCU: Starter Control UnitK1: Main ContactorK10: off contact SCUK11: on contact SCUX1: incoming busbarX2: outgoing cabling motorLPS: Local Power Supply

L1, L2, L3, N

K11K10

LPS

electric circuit diagrams scu version 5.0 75


Figure 26: Auxiliary circuit diagram Direct On Line starter

Note• The main circuit contains fuse F1, isolator Q1 and contactor K1. To determine the status (OFF,ON) of the

main circuit, the status of K1 (see figure 26) is read in by the Starter Control Unit via digital input DI_1. The status of the isolator is read in through digital input DI_0. Digital inputs are used for manual control (S10 and S11). The auxiliary relays K10 and K11 are activated with outputs DO_0 and DO_1.

• Direct switch on and off via auxiliary circuit is possible with S1 and S2.

F2

OFF

K11 ON

K1

MAINS

S1

K10

K10OFF

K11ON

DI_1

DI_2DI_3DI_4DI_5DI_6DI_7

DO_0

DO_1

DO_2DO_3DO_4DO_5DO_6DO_7

V+_Tray

DI_0

K1S2

S10S11

K1

Q1



9.1.2 Star-Delta starter

Figure 27: Single line diagram Star Delta starter


T1

X1

T2, T3

K2

X2: U1-V1-W1

L1-N

MIU

F1

F2 SCU

auxiliary circuit

K1

T1: core balance transformerT2, T3: current transformersF1: fuse main circuitF2: fuse auxiliary circuitMIU: Measurement Interface UnitSCU: Starter Control UnitK1: Star or Low ContactorK2: Delta or High ContactorK3: Main ContactorK10: off contact SCUK11: on1 contact SCUK12: on2 contact SCUX1: incoming busbarX2: outgoing cabling motorLPS: Local Power Supply

L1, L2, L3, N

K11K10 K12

K3

X2: U2-V2-W2

K1

K2 K3 LPS



Figure 28: Auxiliary circuit Star Delta starter

Note• The main circuit contains fuse F1, isolator Q1 and contactors K1, K2 and K3. To be able to determine the

status (OFF, STAR, DELTA) of the main circuit, the status of K1 (see figure 28) and K2 is read in by the Starter Control Unit through the digital inputs DI_1 and DI_2. The status of the isolator is read in through digital input DI_0. Digital Inputs are used for manual control (S10, S11 and S12). The auxiliary relays K10, K11 and K12 are activated with the digital outputs DO_0, DO_1 and DO_2.

• Direct switch off via auxiliary circuit is possible with S1.

F2

OFF

K12

K11 K1

K1

STAR

S1

K2

K2

DELTA

K3

MAINS

K1

K12K2

K11

K10

K10OFF

K11STAR

K12DELTA

Q1

K1

K2DI_1

DI_2DI_3DI_4DI_5DI_6DI_7

DO_0

DO_1


V+_Tray

DI_0

K1 K2 K3

S10S11S12



9.1.3 Forward Reverse starter

.

Figure 29: Single line diagram Forward Reverse starter


T1

X1

T2, T3

K1

X2: U1-V1-W1

L1-N

MIU

F1

F2 SCU

auxiliary circuit

K1

T1: core balance transformerT2, T3: current transformersF1: fuse main circuitF2: fuse auxiliary circuitMIU: Measurement Interface UnitSCU: Starter Control UnitK1: Left or Low ContactorK2: Right or High ContactorK10: off contact SCUK11: on1 contact SCUK12: on2 contact SCUX1: incoming busbarX2: outgoing cabling motorLPS: Local Power Supply

L1, L2, L3, N

K11K10 K12

K2

X2: U2-V2-W2

K2 LPS



Figure 30: Auxiliary circuit Forward / Reverse starter

Note• The main circuit contains fuse F1, isolator Q1 and contactors K1, K2. To be able to determine the status

(OFF, LEFT, RIGHT) of the main circuit, the status of K1 (figure 30) and K2 is read in by the Starter Control Unit through the digital inputs DI_1 and DI_2. The status of the isolator is read in through digital input DI_0. Digital inputs are used for manual control (S10, S11 and S12). The auxiliary relays K10, K11 and K12 are activated with the outputs DO_0, DO_1 and DO_2.


F2

OFF

K12

K11 K1

K1

LEFT

S1

K2

K2

RIGHT

K1

K12 K2

K11

K10

K10OFF

K11LEFT

K12RIGHT

Q1

DI_1DI_2DI_3DI_4DI_5DI_6DI_7

DO_0

DO_1


V+_Tray

DI_0K1K2S10S11S12



9.1.4 Dual Speed starter

Figure 31: Single line diagram Dual Speed (Dahlander) starter


T1

X1

T2, T3

K2

X2: U1-V1-W1

L1-N

MIU

F1

F2 SCU

auxiliary circuit

K1

T1: core balance transformerT2, T3: current transformersF1: fuse main circuitF2: fuse auxiliary circuitMIU: Measurement Interface UnitSCU: Starter Control UnitK1: Star or Low ContactorK2: Delta or High ContactorK3: Main ContactorK10: off contact SCUK11: on1 contact SCUK12: on2 contact SCUX1: incoming busbarX2: outgoing cabling motorLPS: Local Power Supply

L1, L2, L3, N

K11K10 K12

K3

X2: U2-V2-W2

K1

K2 K3 LPS



Figure 32: Auxiliary circuit Dual / Speed starter (Dahlander connection)

Figure 33: Auxiliary circuit Dual Speed starter (separated windings)

F2

OFF

K12

K11 K1

K3

K1

LOW

S1

K2

K2

HIGH

K3

MAINS

K1

K12 K2

K11

K10

K10OFF

K11LOW

K12HIGH

Q1


DO_0

DO_1


V+_Tray

DI_0K1K2S10S11S12

F2

OFF

K12

K11 K1

K1

LOW

S1

K2

K2

HIGH

K1

K12 K2

K11

K10

K10OFF

K11LOW

K12HIGH

Q1


DO_0

DO_1


V+_Tray

DI_0K1K2S10S11S12



Note• The main circuit contains fuse F1, isolator Q1 and contactors K1, K2 and K3. To be able to determine the

status (OFF, LOW, HIGH) of the main circuit, the status of K1 and K2 is read in by the Starter Control Unit through the digital inputs DI_1 and DI_2 (see figure 32 and figure 33). The status of the isolator is read in through digital input DI_0. Digital inputs are used for manual control (S10, S11 and S12). The auxiliary relays K10, K11 and K12 are activated with the digital outputs DO_0, DO_1 and DO_2.


9.2 Mains configurations SCU

9.2.1 Single phase supply (L-N) I < 64A

Figure 34: Single phase supply (L-N)

Note• Current measurement must be connected to the analog input I1 to enable correct Power Factor measure-

ment. Select the phase that has to be measured by using the setpoint Voltage Measurement Mode (see 5.2.1 on page 15).

• The contactor must be connected between the same phase and neutral as used for voltage measurement by the SCU to enable Automatic Restart Function.

• Both MIU 21-16 and MIU 21-64 can be applied. For information regarding the MIU see the System Over-view manual. Connection points are the same.

Lx N

SCU

AGND

I1

I∆N

U

I2

I3

CT1

CT2

s1-1000

s1-250

s1-1000

s1-250s2

p1

p2

p1

p2

VT1

s1

s2

p1

p2R2

R1

1

2

3

4

5

6

8

10

9

s2

s2

7

12

11

MIU 21-16



9.2.2 Three phase supply without neutral. I < 64 A

Figure 35: Three phase supply without neutral. I < 64 A

Note• Voltage measurement between phase L1 and L2 to enable power factor measurement.• The contactor must be connected between the same phases as used for voltage measurement by the

SCU to enable the Automatic Restart Function.• Both MIU 21-16 and MIU 21-64 can be applied. For information regarding the MIU see the System Over-

view manual. Connection points are the same.

CT1

CT2

s1-1000

s1-250

s1-1000

s1-250s2

p1

p2

p1

p2

VT1

s1

s2

p1

p2R2

R1

1

2

3

4

5

6

8

10

9

s2

s2

7

12

11

MIU 21-16

L1 L2 L3

SCU

AGND

I1

I∆N

U

I2

I3



9.2.3 Three phase supply without neutral. I > 64 A

Figure 36: Three phase supply without neutral. I > 64 A

Note• Voltage measurement between phase L1 and phase L2 to enable power factor measurement.• The contactor must be connected between the same phases as used for voltage measurement by the

SCU to enable the Automatic Restart Function.

CT1

CT2

s1-1000

s1-250

s1-1000

s1-250s2

p1

p2

p1

p2

VT1

s1

s2

p1

p2R2

R1

1

2

3

4

5

6

8

10

9

s2

s2

7

12

11

MIU 21-16

L1 L2 L3

SCU

AGND

I1

I∆N

U

I2

I3



9.2.4 Three phase supply with neutral. I < 64 A

Figure 37: Three phase supply with neutral. I < 64 A

Note• Voltage measurement between phase L1 and neutral to enable power factor measurement.• The contactor must be connected between the same phase and neutral as used for voltage measurement

by the SCU to enable the Automatic Restart Function.• Both MIU 21-16 and MIU 21-64 can be applied. For information regarding the MIU see the System Over-

view manual. Connection points are the same.

CT1

CT2

s1-1000

s1-250

s1-1000

s1-250s2

p1

p2

p1

p2

VT1

s1

s2

p1

p2R2

R1

1

2

3

4

5

6

8

10

9

s2

s2

7

12

11

MIU 21-16

L1 L2 L3

SCU

AGND

I1

I∆N

U

I2

I3

N



9.2.5 Three phase supply with neutral. I > 64 A

Figure 38: Three phase supply with neutral. I > 64 A

Note• Voltage measurement between phase L1 and neutral to enable power factor measurement.• The contactor must be connected between the same phase and neutral as used for voltage measurement

by the SCU to enable the Automatic Restart Function.

CT1

CT2

s1-1000

s1-250

s1-1000

s1-250s2

p1

p2

p1

p2

VT1

s1

s2

p1

p2R2

R1

1

2

3

4

5

6

8

10

9

s2

s2

7

12

11

MIU 21-16

L1 L2 L3

SCU

AGND

I1

I∆N

U

I2

I3

N



10 GLOSSARY

CANControl Area Network

CFCUContactor Feeder Control Unit

CIUCentral Interface Unit

DCSDistributed Control System

EDSElectronic Data Sheet, a file on disk that contains configuration data for specific device types.

ESDElectrostatic Discharge

EWSEngineering Work Station

FCUFeeder Control Unit

GPS

General Power Supply

LCU-5Local Control Unit

LPSLocal Power Supply

MIUMeasurement Interface Unit

NPSNetwork Power Supply

Process controllerA higher level control system, e.g. PLC, DCS or SCADA.

SCADASupervisory Control and Data Acquisition

SCUStarter Control Unit

glossary version 5.0 88


11. INDEX

AAcknowledge command 47Acknowledge Protection

setpoint 47Acknowledge Trip

setpoint 48Acknowledge Warning

setpoint 48Active Energy Export

parameter 25Active Energy Import

parameter 25Active Power 23Active power

calculation 24measurement 23

Analog Output Rangesetpoint 29

Analog Output Sourcesetpoint 29

Analogue inputs 72Analogue outputs 29Automatic restart 40

cancel 44during starting 44mains failure 41

Auxiliary CT ratioexplanation 23setpoint 21

Auxiliary Relay K10digital output 27



CCancel automatic restart 44Capitole 10Change Over Current Level 33Change Over Time Level 34Command After Communication Failure40

setpoint 40Communication failure 40Connections 68

DeviceNet and General Power Sup-ply 71

interface board 70motor tray 69

Connectorsdescription

Connectionmotor tray 70

Contactor failure detection 41Contactor K1 Operations

during last hour parameter 55parameter 55

Contactor K2 Operationsduring last hour parameter 55parameter 55

Contactor operationsduring last hour 55parameters 55

Contactor status 41Cooling ratio 20

explanation 23setpoint 21

DData monitoring 54Delayed restart 43Delayed Restart Time-out 44Device Self Testing Mode 59Digital Input

Invert 26Digital inputs 25, 72

configuring 25Digital Output

Invert 28Digital Output Function x

setpoint 28Digital outputs 26, 73

configuring 26Direct on Line 35Direct On Line starter

circuit diagrams 75Drive type

setpoint 32Dual Speed 37Dual Speed starter

circuit diagrams 81EEarth leakage

acknowledge commands 47setpoints 51

index version 5.0 89


Trip Level setpoint 51Trip Time setpoint 51Warning Level setpoint 51

Earth leakage currentcalculation 17measurement 17parameter 17

Energy 24Energy Value Export

parameter 25Energy Value Import

parameter 25External protection 53

acknowledge commands 47connections 53

FFault messages 61FCU

transitions operational modes 60Forward Reverse 36Forward Reverse starter

circuit diagrams 79Functions

overview 15GGeneral power supply

configuration 12General Purpose Output

digital output 27General Purpose Output Status 28Glossary 88IImmediate restart 42Immediate Restart Time-out 44Inputs 25

analogue 72digital 72

Inputs and outputs 72Interface board

connections 69, 70connectors 69

Interlock 1 Timesetpoint 31

Interlock 2 Timesetpoint 31

Introduction to the manual 6JJumper settings

controlling 12

LLocal power supply

configuration 13Lock

setpoint 32MMains failure detection 40Mains voltage

calculation 15measurement 15parameter 15

Mains voltage drop 40Maintenance 66Major Recoverable Fault 60, 62Major Unrecoverable Fault 60, 63Maximum Temperature Rise


Minor Recoverable Fault 63Minor Unrecoverable Fault 63Modes 59Module LED 14Module Status LED 60Monitoring

diagnostic and maintenance data 54Motor

nominal temperature rise 23trip times 49

Motor control 29levels 30

Motor currentcalculation 17measurement 16parameters 16setpoints 16

Motor Current Lx parameter 16Motor data

parameters 21Motor overload

acknowledge commands 47Overload 49

Motor stall 48acknowledge commands 47

Motor Stall Trip Ack. command 48Motor Stall Trip Level setpoint 48Motor temperature

parameters 21Motor temperature Cu 21Motor Temperature Cu setpoint 48



Motor temperature Fe 21Motor temperature rise

cold start, nominal load 19measurement 18overload 20

Motor trayconnections 70

Motor weightexplantion 22setpoint 21

NNetwork configurations 83Network power supply

configuration 12Network Status LED 61No restart 44Nominal Cos Phi 1

setpoint 22Nominal Cos Phi 1 and 2

explanation 23Nominal Cos Phi 2

setpoint 22Nominal Current 1

setpoint 22Nominal Current 1 and 2

explanation 23Nominal Current 2

setpoint 22Nominal Power 1

setpoint 21Nominal Power 1 and 2

explanation 23Nominal Power 2

setpoint 21Nominal temperature rise

insulation category 23Nominal Voltage


Non existing mode 59OOperating Hours

parameter 54Operational mode 59Operational modes 59Outputs 26

analogue 29digital 26, 73

Over Voltage Protection 53

Overload Currentexplanation 22setpoint 21

PPhase unbalance 50

acknowledge commands 47calculation 50

Phase Unbalance Trip Levelsetpoint 51

Phase Unbalance Trip Timesetpoint 51

Phase Unbalance Warning Levelsetpoint 51

Powerpower factor 24

Power Factor 24Power factor

calculation 24measurement 24

Power Factor parameter 24Power supply configuration

setting the 12Powering the SCU 13Process Overload 52

acknowledge commands 47Interlock Time setpoint 52Trip Level setpoint 52Trip Time setpoint 52Warning Level setpoint 52

Process Underload 51acknowledge commands 47Interlock Time setpoint 52, 53, 54Settings 52, 53, 54Trip Level setpoint 52, 53, 54Trip Time setpoint 52, 53, 54Warning Level setpoint 52, 53, 54

Protectionexternal 53external connections 53trip current 46

Protection and or status messageconfirming 47

Protection functionscharacteristics 45

Protection states 45RReset maintenance command

setpoint 57Restart



delayed 43immediate 42no restart 44

Restart Delay Timesetpoint 44

Restart time out 41RSNetWorx™ 6SSafety

Capitole 11Clink II 11

SCUconnector description 70description 10design and layout 10electrical circuit diagrams 75function 10inputs and outputs 72interface board connector 69location 10mainboard layout 10maintenance 66network configurations 83operational modes 14placing 12print 68putting into operation 13technical specifications 68

SCU connections 68Self test 59Stall Current 1 and 2

explanation 22Stall Current1

setpoint 21Stall Current2

setpoint 21Stall Time 1

setpoint 21Stall Time 1 and 2

explanation 22Stall Time 2

setpoint 21Stall Time Condition

setpoint 21Standby mode 59Star-Delta 35Star-Delta starter

circuit diagrams 77Start 1 command 40

Start 2 command 40Starter logic 32

Direct on Line 35Forward-Reverse 36parameter 34starting 33

Starter logic Dual-Speed 37Starter logic Star-Delta 35Starting 33Starting current 55Starting K1 Current parameter 55Starting K1 Time parameter 56Starting K2 Current parameter 55Starting K2 Time

parameter 56Starting time 56States of the SCU 58Status and or protection message

confirming 47Stop command 40Stop/start

commands 39Symbols

use in manual 6System configuration

setpoint NPS 12TTechnical specifications 68Temperature Rise Interlock Level 57


Thermal model 18initial temperature 20parameters 18

Time To Resetparameter 57

Time To Trip parameter 57Trademarks 6Tray in test state 32Trip Acknowledge Status

parameter 45Trip and warning level

setpoints 51Trip and warning signals

acknowledge command 47description 46read-out 45

Trip current 46Trip Current Lx



parameters 56Trip current Lx

parameter 46Trip Or Warning Signal

digital output 27Trip Or Warning Status

digital output 27Trip Signal

digital output 27Trip Status

digital output 27parameter 45

Trip Time At 1.5 Inexplanation 22setpoint 21

Trip timestable 49

Trouble shootingcorrective actions 63

Troubleshooting guide 58UUnder Current Protection 54Under Voltage Protection 53Unlock

setpoint 32User categories 8VVoltage Measurement Mode

setpoint 15WWarning Acknowledge Status

parameter 46Warning and trip level

setpoints 51Warning and trip signals

description 46read-out 45

Warning Signaldigital output 27

Warning Statusdigital output 27parameter 46

Warning Temperature Riseexplanation 23setpoint 21

Windows™ 6


version 5.0

Eaton Electric N.V.Eaton Holec Low Voltage SystemsP.O. Box 237550 AA HengeloThe NetherlandsPhone +31 74 246 9111Fax +31 74 246 3444www.holec.com

© 2003 Eaton Electric N.V.

Partly or complete publication ofcontents is allowed with writtenpermission of Eaton Electric N.V.

Manual Clink II SCU ManagerVersion 5.0October 2003

ClinkII Starter Control - User Manual (en)

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Transcript of ClinkII Starter Control - User Manual (en)