Remote Keypad User Guide

Remote Keypad User Guide
User Guide
Remote Keypad
Digistart CS
0477-0011-01
www.controltechniques.com
English
General Information
The manufacturer accepts no liability for any consequences resulting from inappropriate, negligent or incorrect installation or adjustment
of the optional parameters of the equipment or from mismatching the starter with the motor.
The contents of this guide are believed to be correct at the time of printing. In the interests of commitment to a policy of continuous
development and improvement, the manufacturer reserves the right to change the specification of the product or its performance, or the
content of the guide without notice.
All rights reserved. No parts of this guide may be reproduced or transmitted in any form or by any means, electrical or mechanical
including, photocopying, recording or by an information storage or retrieval system, without permission in writing from the publisher.
Copyright: © October 2009 Control Techniques Ltd
Issue: 1
Product Version 13
Contents
1.
Introduction .......................................................................................................................................................4
2.
Installation .........................................................................................................................................................4
2.1
2.2
Mechanical installation ...........................................................................................................................................................4
Connection.............................................................................................................................................................................6
3.
Operation ...........................................................................................................................................................7
3.1
3.2
Operation ...............................................................................................................................................................................7
Trip codes ..............................................................................................................................................................................7
4.
4-20 mA Analog Output ....................................................................................................................................8
4.1
4.2
4.3
Overview................................................................................................................................................................................8
Calibration .............................................................................................................................................................................8
Programming .........................................................................................................................................................................8
5.
Troubleshooting................................................................................................................................................9
6.
Specifications....................................................................................................................................................9
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1.
Introduction
Observe all necessary safety precautions when controlling the soft starter remotely. Alert personnel that machinery may
start without warning.
WARNING
It is the installer's responsibility to follow all instructions in this manual and to follow correct electrical practice.
Use all internationally recognised standard practice for RS485 communications when installing and using this equipment.
General description
The Remote Keypad allows remote operation of Digistart CS soft starters, and offers the following functionality:
•
•
•
•
•
•
Operational control (Start, Stop, Reset, Quick Stop)
Starter status monitoring (Ready, Starting, Running, Stopping, Tripped)
Performance monitoring (motor current, motor temperature)
Trip code display
4-20 mA analog output (motor current)
Optional RS485 network connection 1
1
The Remote Keypad can act as a gateway device for connection to an RS485 serial communications network, allowing remote control
of a motor using Modbus RTU or standard AP ASCII communications protocol. For further information, please refer to the Modbus
Module Instructions.
2.
Installation
This section describes how to install the Remote Keypad for basic control and monitoring of a soft starter. The Remote Keypad is
pre-configured to control a soft starter once control supply power is applied to both devices. For basic operation, no parameter
adjustments are required on the Remote Keypad or the soft starter.
In order to use the Remote Keypad's 4-20 mA analog output to monitor motor current, follow the instructions in the section 4-20 mA
Analog Output on page 8.
Remove mains and control voltage from the soft starter before attaching or removing accessories.
WARNING
2.1
Mechanical installation
2.1.1
For use with Digistart CS
In order to use the Remote Keypad with Digistart CS soft starters, a Remote Keypad Module must first be installed to the starter using
the following steps:
Figure 2-1 Attach the module to the starter
Remove control power and mains supply from the soft starter.
Attach the module to the soft starter as illustrated.
08627. A
1.
2.
2.1.2
Mounting
The Remote Keypad is rated IP54 or NEMA 12 1 when mounted correctly in accordance with these instructions. It is intended for use on
the flat surface of a panel, with all external wiring connected from behind the panel.
The Remote Keypad is supplied with a mounting bracket and four fasteners. The built-in gasket seal guarantees protection from outside
the panel.
Select the panel location of the Remote Keypad. The required panel cutout is 92 mm x 92 mm. Place the Remote Keypad through the
cutout and locate the mounting bracket at the rear of the panel onto the four studs. Use the four fasteners to tighten the mounting
bracket up to the rear of the panel.
1
For use on a flat surface of a NEMA 1 or NEMA 12 enclosure.
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Remote Keypad User Guide
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Figure 2-2 Mounting
Fasteners (x4)
Mounting bracket
1
Universal panel cutout (92 mm x 92 mm)
2
Remote Keypad
3
4
2.1.3
Dimensions
Figure 2-3 Unit dimensions
7.0 (0.28)
AMPS
TEMP
CODE
START
START
RUN
STOP
+
TRIP
RESET
-
RS485
DATA
PROG
120 (4.72)
37.5 (1.48)
mm (in)
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2.2
Connection
The Remote Keypad requires a minimum of three electrical connections - the external power supply, the chassis earth and the RS485
Starter port. All external wiring, except the chassis earth (M4 stud provided), is connected to spring operated clamp connector terminals
with a maximum wire size of 2.5 mm2. No special tools are required.
Once the Remote Keypad Module has been installed, wire between the Remote Keypad and the module.
Figure 2-4 Remote Keypad connections
1
3
2
Digistart CS
Remote Keypad Module - RS485 serial port
Remote Keypad
B10, B11: 4-20 mA analog output (motor current)
B1, B2, B3: RS485 connection to starter/module
B6, B7, B8: RS485 connection to network
1, 2: power supply (18 to 30 Vac/dc)
For the Remote Keypad to accept serial commands, a link must be fitted across terminals CSL-DI2 on Digistart CS starters.
2.2.1
Grounding and shielding
Twisted pair data cable with earth shield is recommended. The cable shield should be connected to the GND device terminal at both
ends and one point of the site protective earth.
2.2.2
Termination resistors
In long cable runs prone to excessive noise interference, termination resistors should be installed between the data lines at both ends of
the RS485 cable. This resistance should match the cable impedance (typically 120 Ω). Do not use wire wound resistors.
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3.
Operation
3.1
Operation
The Remote Keypad performs all soft starter functions except programming of the soft starter. The Remote Keypad can only be used to
program its own parameters.
Figure 3-1 Keypad and display
Display: Indicates the value of the selected data.
1
AMPS
Display mode indicator: Indicates the data type shown on the display.
2
Status LEDs: Indicates the status of the starter and the communication link.
TEMP
CODE
START
RUN
TRIP
RS485
Start (green): soft starter is starting, running or stopping
3
Run (green): soft starter is providing full voltage to the motor
STOP
RESET
DATA
+
-
PROG
03206.B
START
Trip (red): soft starter has tripped
RS485 ON: the serial link between the Remote Keypad and the starter is
healthy
RS485 FLASHING: communication between the Remote Keypad and the
starter has been lost
Control buttons
4
Start: Starts the motor
Stop: Stops the motor 1
Reset: Resets the starter 1
Data/Prog: Selects the data type to be shown on the display (motor current
or motor temperature), or accesses Programming Mode.
1
Simultaneously pressing the STOP and RESET buttons initiates a quick stop, which immediately removes voltage from the motor,
ignoring any soft stop time set on the starter.
3.2
Trip codes
If the soft starter trips, the CODE and TRIP LEDs illuminate and the relevant trip code is reported on the Remote Keypad display.
Table 3-1 Trip codes
Code
1-1
1-2
1-3
1-4
1-5
1-6
1-8
1-b
1-C
1-H
Description
Excess start time
Motor overload
Motor thermistor
Current imbalance
Frequency
Phase sequence
Power circuit
Bypass overload
Communications failure between module and starter
Forced communications trip from the network master
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4.
4-20 mA Analog Output
4.1
Overview
The Remote Keypad has a 4-20 mA analog output for monitoring motor current. The 4-20 mA output is available on terminals B10, B11.
The analog output signal spans from 4 mA when the motor current is zero (when the soft starter is not running) to 20 mA when the
motor current is 125% of the Motor FLC setting in the Remote Keypad (Pr 6).
4.2
Calibration
The Remote Keypad Motor FLC parameter (Pr 6) must be adjusted to match the Motor FLC setting in the soft starter.
The lower end of the analog output signal can be calibrated using the Remote Keypad Analog Output 4 mA Offset parameter (Pr 7).
This is set to give a 4 mA output signal when the motor current is zero.
The 4-20 mA analog output has an accuracy of ±10%. It is not designed for process signal control and should only be used for motor
current monitoring and metering.
4.3
Programming
When the 4-20 mA output is being used, the Remote Keypad's Motor FLC and Analog Output 4 mA Offset parameters (Pr 6 and 7) must
be set appropriately (see Calibration). Programming can only be carried out while the soft starter is not running.
4.3.1
Programming procedure
1. To enter Programming Mode, hold down the Data/Prog pushbutton for four seconds. The default value of the first parameter will
be displayed.
2. Use the Data/Prog pushbutton to advance to the next parameter.
3. Use the Stop and Reset pushbuttons to adjust parameter values.
Programming Mode closes when the Data/Prog pushbutton is pressed after Pr 9.
There is a 20 second timeout when the Remote Keypad is in Programming Mode. Programming Mode will automatically
close if no input is registered for 20 seconds. Any changes already made will be saved.
NOTE
4.3.2
Programmable parameters
Table 4-1 Programmable parameters
Parameter
Number
Description
Default
Setting
1
2
3
4
5
6
7
RS485 Network Baud Rate 1
RS485 Network Satellite Address 1
RS485 Network Timeout 1
RS485 Network Protocol 1
Modbus Protocol Parity 1
Motor FLC (A)
Analog Output
4 mA Offset (%)
Start, Stop, Quick Stop function
disable
4
20
0
1
0
10
100
8
9
0
Current ÷ 10
0
Adjustable Range
1 to 2868
80 to 120
0 = Remote Keypad start, stop, quick stop function enabled.
1 = Remote Keypad start, stop, quick stop function enabled.
2 = Remote Keypad start, stop, quick stop function disabled. 2
3 = Remote Keypad start, stop, quick stop function disabled. 2
0 = off (required for Digistart CS)
1 = on (not suitable for Digistart CS)
1
Pr 1 to 5 only apply when the Remote Keypad is being used as a Modbus or AP ASCII network gateway. See the Modbus Module
User Guide for details.
2
Remote Keypad Reset pushbutton is always enabled.
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5.
Troubleshooting
Table 5-1 General faults
Display Indication
Problem
No display
AMPS or TEMP
LED flashing
Four dashes on display and
RS485 LED flashing
No control voltage
Soft starter in restart delay mode
-
Incorrect or no 4-20 mA analog output
signal
-
The motor cannot be started
6.
The Remote Keypad has detected a
loss of communication on the RS485
link to the soft starter
Possible Solution
Check that correct voltage is present at terminals 1, 2.
Wait for the restart delay (programmed in the soft starter)
to elapse.
Verify and solve the cause for loss of communication.
If communication is restored before the soft starter trips,
the display will return to active status and the RS485 LED
will illuminate. If communication is restored after the soft
starter has tripped, the display will indicate the trip code.
Use the Reset button to reset the soft starter fault.
Check the correct voltage is present at terminals 1, 2.
Check that correct polarity is used at terminals B10, B11.
Check that the Motor FLC, Analog Output 4 mA Offset and
Current ÷ 10 parameters are set correctly.
Check that control voltage is connected to the starter.
•
If connected to a Digistart CS, check that terminals
CSL-DI2 on the starter are linked.
Pr 8 on the Remote Keypad must be set to 0 or 1.
Specifications
Enclosure
Front Panel Height ............................................................................................................................................................... 120 mm
Front Panel Width ................................................................................................................................................................ 120 mm
Inside Panel Depth (when mounted) .............................................................................................................................. 30 mm (max)
Panel Cutout ............................................................................................................................................................................92 mm2
Weight ....................................................................................................................................................................................... 450 g
Power Suply
Voltage ..................................................................................................................................................... 18 - 30 Vdc/Vac (50/60 Hz)
Consumption ........................................................................................................................................ 100 mA (max - steady state)
Connection (Terminals 1, 2) ................................................................................................. 2 pole spring clamp connector terminals
RS485 serial network port (optional)
RS485 Network Interface .......................................................................................... AP ASCII or Modbus RTU protocol (selectable)
Connection (Terminals B6, B7, B8) ...................................................................................... 3 pole spring clamp connector terminals
RS485 serial starter port (soft starter connection)
RS485 Soft Starter Interface............................................................................................................... AP ASCII protocol as standard
Connection (Terminals B1, B2, B3) ...................................................................................... 3 pole spring clamp connector terminals
Analog output
Motor Current Monitoring Interface ....................................................................................................... 4-20 mA (max burden 200 Ω)
Connection (Terminals B10, B11) ......................................................................................... 2 pole spring clamp connector terminals
Sundry
Enclosure Rating ..................................................................................................... IP54 or NEMA 12 when correctly panel mounted
Pollution Degree .................................................................................................................................................. Pollution Degree 3
Operating Temperature .............................................................................................................................................. - 5 oC / + 60 oC
Relative Humidity ............................................................................................................................ 5 to 95% (max non-condensing)
This product has been designed as Class A equipment. Use of this product in domestic environments may cause radio interference, in
which case the user may be required to employ additional mitigation methods.
Approvals
CE ............................................................................................................................................................................IEC 60947-4-2
UL and C-UL .......................................................................................................................................................................... UL 508
C ............................................................................................................................................................................ IEC 60947-4-2
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