1639576EN–01

Quick Start Guide

Overview of the Application Example

Introduction

The Quick Start Guide uses an application example to illustrate each step in the process of installing, configuring and using TeSys T.

The application example uses the LTM R controller to protect and control a motor and its driven load, in this case, a pump.

This application example is intended to:

  • show you how to configure the LTM R controller in a few steps,

  • provide an example you can modify to develop your own configuration,

  • serve as a starting point for the development of more complex configurations, incorporating such additional features as HMI or network control.

Functions Performed

When the LTM R controller has been configured in order to protect and control the motor and pump, it will perform the following functions:

  • thermal overload protection

  • motor temperature sensor protection

  • voltage protection / undervoltage

  • external ground current trip protection

  • initial system configuration during commissioning using PC and PowerSuite software

Operating Conditions

The operating conditions used in the application example are:

  • motor power: 4 kW

  • line-to-line voltage: 400 Vac

  • current: 9 A

  • control circuit voltage: 230 Vac

  • 3-wire control

  • motor trip class 10

  • start button

  • stop button

  • reset button on enclosure door

  • trip light

  • alarm light

  • full voltage, non-reversing starter (direct over the line starter)

  • 24 Vdc power supply in the motor control center or control station for future use with LTM E expansion module inputs

Network Conditions

The network conditions for the example are:

  • protocol: Modbus/TCP

  • address: 1

Components Used

The application example uses the following components:

Item

Component Description

Reference Number

1

LTM R 100-240 Vac Modbus/TCP motor management controller (1.35...27 A FLC)

LTMR27EFM

2

LTM E 24 Vdc expansion module

LTMEV40BD

3

LTM R to LTM E RJ45 connection cable

LTMCC004

4

PowerSuite cable kit

VW3A8106

5

PowerSuite software on CD-ROM, version ≥ 2.5

PowerSuite

6

External ground current sensor

TA30

7

External PTC binary motor temperature sensor

User supplied

Presentation of the TeSys T Motor Management System

System Overview

The TeSys T Motor Management System offers protection, control, and monitoring capabilities for single-phase and 3-phase AC induction motors.

The system offers diagnostic and statistics functions and configurable alarms and trips, allowing better prediction of component maintenance, and provides data to continuously improve the entire system.

The 2 main hardware components of the system are:

  • the LTM R controller, and

  • the LTM E expansion module.

System Presentation

The following tables describe the main components of the TeSys T Motor Management System.

LTM R Controller

Functional Description

Reference Number

  • current sensing 0.4...100 A

  • single-phase or 3-phase current inputs

  • 6 discrete logic inputs

  • 4 relay outputs: 3 SPST, 1 DPST

  • connections for a ground current sensor

  • connection for a motor temperature sensor

  • connection for network

  • connection for HMI device or expansion module

  • current protection, metering and monitoring functions

  • motor control functions

  • power indicator

  • trip and alarm LED indicators

  • network communication and alarm indicators

  • HMI communication LED indicator

  • test and reset function

LTMR08EBD (24 Vdc, 0.4...8 A FLC)

LTMR27EBD (24 Vdc, 1.35...27 A FLC)

LTMR100EBD (24 Vdc, 5...100 A FLC)

LTMR08EFM (100...240 Vac, 0.4...8 A FLC)

LTMR27EFM (100...240 Vac, 1.35...27 A FLC)

LTMR100EFM (100...240 Vac, 5...100 A FLC)

LTM E Expansion Module

Functional Description

Reference Number

  • voltage sensing 110...690 Vac

  • 3-phase voltage inputs

  • 4 additional discrete logic inputs

  • additional voltage protection, metering and monitoring functions

  • power LED indicator

  • logic input status LED indicators

Additional components required for an optional expansion module:

  • LTM R controller to LTM E connection cable

LTMEV40BD (24 Vdc logic inputs)

LTMEV40FM (100...240 Vac logic inputs)

PowerSuite Software

Functional Description

Reference Number

  • configure the system through menu entries

  • display parameters, alarms, and trips

  • control the motor

Additional components required for PowerSuite software:

  • a PC

  • separate power source

  • LTM R/LTM E to PC communication cable

PowerSuite ≥ v 2.5

VW3A8106

(PowerSuite cable kit)

LTM CU Control Operator Unit

Functional Description

Reference Number

  • configure the system through menu entries

  • display parameters, alarms, and trips

  • control the motor

Additional components required for an optional HMI device:

  • LTM R/LTM E to HMI communication cable

  • HMI to PC communication cable

LTM CU

VW3A1104R.0

(HMI communication cable)

VW3A8106

(PowerSuite cable kit)

LTM9KCU

Kit for portable LTM CU

LTM R and LTM E Description

The following diagrams show the features of the LTM R controller and LTM E expansion module:

LTM R Controller

LTM E Expansion Module

1 Test / Reset button

2 LTM E / HMI port with RJ45 connector connecting the LTM R controller to an HMI, PC, or LTM E expansion module

3 Ethernet port number 1 with RJ45 connector connecting the LTM R controller to a Modbus/TCP network

4 Ethernet port number 2 with RJ45 connector connecting the LTM R controller to a Modbus/TCP network

5 LTM R status-indicating LEDs

6 Plug-in terminal: control power, logic inputs and commons

7 Plug-in terminal: double pole/single throw (DPST) output relay

8 Plug-in terminal: output relay

9 Plug-in terminal: ground current trip input and temperature sensor input

10 Rotary switches (Tens and Ones) for IP addressing

11 Ethernet port link and activity LEDs

12 MAC address

1 Port with RJ45 connector to HMI or PC

2 Port with RJ45 connector to LTM R controller

3 Status-indicating LEDs

4 Plug-in terminal: voltage inputs

5 Plug-in terminal: logic inputs and common

Installation

Overview

The following procedure describes how to install and physically configure the TeSys T system, according to the operating conditions used in the application example. The same procedure is used for other configurations.

The full installation procedure is shown on the Instruction sheets provided with the LTM R controller and the LTM E expansion module. It is also described in detail in the Installation chapter of the User Manual.

DANGER
HAZARD OF ELECTRIC SHOCK, EXPLOSION OR ARC FLASH
Turn off all power supplying this equipment before working on it.
Apply appropriate personal protective equipment (PPE) and follow safe electrical work practises.
Failure to follow these instructions will result in death or serious injury.

The following diagrams show the physical dimensions of the LTM R controller and the LTM E expansion module:

LTM R

LTM E

Mount LTM R and LTM E

Mount the LTM R controller and the LTM E expansion module, respecting clearance zones and operating position.

The diagrams below show how to mount the LTM R and LTM E on a DIN rail, solid mounting plate, or Telequick plate:

This diagram shows the operating positions possible:

Connect LTM R to LTM E

Connect the LTM R controller and the LTM E expansion module using the RJ45 cable.

Connecting to a TeSys T LTM CU HMI Device (Optional)

The diagrams below show the TeSys T LTM CU HMI device connected to the LTM R controller, with and without the LTM E expansion module:

1 LTM CU Control Operator Unit

2 RJ45 cable (VW3 A1 104R30, in this example)

3 LTM R controller

4 LTM E expansion module

Wire Current Transformers

Wire the current transformers according to the operating conditions:

  • Product range → 1.35...27 A

  • Nominal motor current → 9 A

1 pass through the CT windows is sufficient in this case, although 2 passes are possible:

Wire Ground Current Sensor

Wire the ground current sensor:

Wire LTM R

  • Wire the power supply and the I/O.

  • Wire the temperature sensors.

NOTICE
RISK OF DESTROYING THE INPUTS
Connect the LTM R controller's inputs using the 3 Common (C) terminals connected to the A1 control voltage via an internal filter.
Failure to follow these instructions can result in equipment damage.

Wire LTM E

Wire the voltage transformers and the I/O on the LTM E expansion module.

LTM R Controller Wiring

The diagram below illustrates the main power circuit and the 3-wire (impulse) local control with network control selectable, corresponding to the application example.

1 Contactor

2 Ground current sensor

3 PTC binary thermistor

4 Alarm indication

5 Trip indication

L Local control

O Off

N Network control

Configuration

Overview

After the wiring connections are made, the next step is to configure parameters using PowerSuite software (see the PowerSuite chapter of the User Manual).

WARNING
UNINTENDED EQUIPMENT OPERATION
The application of this product requires expertise in the design and programming of control systems. Only persons with such expertise should be allowed to program and apply this product.
Follow all local and national safety codes and standards.
Failure to follow these instructions can result in death, serious injury, or equipment damage.

Install Software

Step

Description

1

Place the installation disk into your PC’s CD/DVD drive.

2

Navigate to and click on the setup.exe file. The setup wizard begins.

3

Follow the instructions in the setup wizard.

Connect to PowerSuite Software

In the application example:

1 PC running PowerSuite software

2 PowerSuite cable kit VW3 A8 106

3 LTM R controller

4 LTM E expansion module

If you are not using the expansion module, the HMI connects directly to the controller:

1 PC running PowerSuite software

2 PowerSuite cable kit VW3 A8 106

3 LTM R controller

Set Parameters

Step

Description

1

Start up the PowerSuite software.

2

In the Load Configuration screen, select and open a configuration file with factory default settings.

3

Open the Device Information branch of the tree control and set the Operating parameter settings.

4

Open the Settings branch of the tree control.

5

Locate and set the Operating parameter settings in the Motor and Control sub-branch.

6

Repeat step 5 for all other setting item sub-branches.

7

Save a copy of the completed configuration settings to a new configuration file.

Parameter settings for the application example:

Device Information Branch

Sub-branch

Parameter

Setting

Device information

Current range

1.35-27 A

Network

Modbus/TCP

Control voltage

100-240 Vac

Settings Branch

Sub-branch

Parameter

Setting

Motor and Control Settings

Motor operating mode

Nominal voltage

400 V

Nominal power

4 kW

Operating mode

3 wire independent

Contactor rating

9 A

Phase

3 phase

Motor temperature sensor

Sensor type

PTC binary

Trip enable

Enable

Trip level

According to motor

Alarm level

According to motor

Load CT

Load CT ratio

Internal

Load CT passes

1 (1)

Ground current sensor

Ground current sensor ratio

1000:1

Control mode

Local control

Terminal trip

Thermal Settings

Thermal overload

Trip type

Inverse thermal

Trip class

10

FLC1 (1)

50 %

See FLC (Full Load Current) Settings.

* (equivalent to 9 A)

Trip enable

Enable

Alarm enable

Enable

Current Settings

Ground Current Mode

Trip enable

Enable

Trip level

1 A

Trip timeout

0.5 s

Alarm enable

Enable

Alarm level

200 mA

Voltage Settings

Undervoltage

Trip enable

Enable

Trip level

85 %

Trip timeout

3 s

Alarm enable

Enable

Alarm level

90 %

Transfer the Configuration File

Step

Description

1

Open the configuration file to be transferred.

  • Be sure the file is in the Main window

2

Connect your PC to the LTM R controller.

  • Check the task bar to see whether your PC is connected to the LTM R controller.

3

Transfer the configuration file:

  • Select PC to Device, in either the Link > File Transfer sub-menu or the icon bar.

  • In the Upload Configuration dialog, click Continue. A progress bar briefly appears.

  • To confirm the success of the transfer, check the results in the Output window, which opens automatically at the bottom of the Main window.

Result: The product is now ready to use.

FLC (Full Load Current) Settings

FLC Basics

NOTE: Before setting the FLC, you must first set the Contactor rating and Load CT ratio.

Load CT ratio = Load CT primary / (Load CT secondary * Passes)

Current sensor max = Current range max * Load CT ratio

Current range max is determined by the LTM R controller commercial reference. It is stored in units of 0.1 A and has one of the following values: 8.0, 27.0, or 100.0 A.

Contactor rating is stored in units of 0.1 A and is set by the user between 1.0 and 1000.0 A.

FLCmax is defined as the lower of the Current sensor max and the Contactor rating values.

FLCmin = Current sensor max / 20 (rounded to the nearest 0.01 A.). FLCmin is stored internally in units of 0.01 A.

NOTE: Do not set the FLC below the FLCmin.

Conversion of Amperes to FLC Settings

FLC values are stored as a percentage of FLCmax

FLC (in %) = FLC (in A) / FLCmax

NOTE: FLC values must be expressed as a percentage of FLCmax (resolution of 1 %). If you enter an unauthorized value, the LTM R will round it up to the nearest authorized value. For example, on a 0.4-8 A unit, the step between FLCs is 0.08 A. If you try to set an FLC of 0.43 A, the LTM R will round it up to 0.4 A.

Example (No External CTs)

Data:

  • FLC (in A) = 9 A

  • Current range max = 27.0 A

  • Load CT primary = 1

  • Load CT secondary = 1

  • Passes = 1or 2

  • Contactor rating = 18.0 A

Calculated parameters with 1 pass:

  • Load CT ratio = Load CT primary / (Load CT secondary * passes) = 1 / (1 * 1) = 1.0

  • Current sensor max = Current range max * Load CT ratio = 27.0 * 1.0 = 27.0 A

  • FLCmax = min (Current sensor max, Contactor rating) = min (27.0, 18.0) = 18.0 A

  • FLCmin = Current sensor max / 20 = 27.0 / 20 = 1.35 A

  • FLC (in %) = FLC (in A) / FLCmax = 9.0 / 18.0 = 50 %

Calculated parameters with 2 passes:

  • Load CT ratio = 1 / (1 * 2) = 0.5

  • Current sensor max = 27.0 * 0.5 = 13.5 A

  • FLCmax = min (13.5, 18.0) = 13.5 A

  • FLCmin = Current sensor max / 20 = 13.5 / 20 = 0.67 A

  • FLC (in %) = FLC (in A) / FLCmax = 9.0 / 13.5 = 66 %

Diagnostic

LTM R and LTM E LEDs

As the application example uses the LTM R and LTM E, you must check the LEDs on both components:

LEDs

Use the 7 LEDs on the face of the LTM R controller to monitor its state, as follows:

LTM R LED

Color

Describes

Indicates

HMI Comm

Yellow

Communication activity between LTM R controller and LTM E expansion module

  • On = communication

  • Off = no communication

Power

Green

LTM R controller power or internal trip condition

  • Solid green = power on, no internal trips, and motor off

  • Flashing green = power on, no internal trips, and motor on

  • Off = power off, or internal trips exist

Alarm

Red

Protection trip or alarm, or internal trip condition

  • Solid red = internal or protection trip

  • Flashing red (2 x per second) = alarm

  • Flashing red (5 x per second) = load shed or rapid cycle condition

  • Off = no trips, alarms, load shed or rapid cycle (when power is On)

Fallback

Red

Communication connection between LTM R controller and network module

  • Solid red = in fallback

  • Off = not in fallback (no power)

STS

Green

These LEDs together indicate network communication: connection, speed and activity

If the green STS LED and the green LK/ACT LED are solid ON:

  • Connection is established

  • Speed = 100 Mbits/s

LK/ACT

Green

If the green STS LED is solid ON and the green LK/ACT LED is solid OFF:

  • Connection is established

  • Speed = 10 Mbits/s

If the green STS LED is solid ON and the green LK/ACT LED is blinking: there is an activity

Use the 5 LEDs on the face of the LTM E expansion module to monitor its state:

LTM E LED

Color

Describes

Indicates

Power

Green or red

Module power or internal trip condition

  • Solid green = power on with no internal trips

  • Solid red = power on with internal trips

  • Off = power off

Digital Inputs I.7, I.8, I.9 and I.10

Yellow

State of input

  • On = input activated

  • Off = input not activated

Use with TeSys T LTM CU Control Operator Unit

Available Functions

Once connected to the LTM R, the LTM CU can be used to:

  • configure parameters for the LTM R controller,

  • display information about the LTM R controller configuration and operation,

  • monitor trips and alarms generated by the controller,

  • control the motor locally using the local control interface.

LTM CU Front Face

The LTM CU front face is shown below:

1 LCD display

2 Contextual navigation keys

3 Front face RJ45 port for PC connection (covered)

4 Local control interface, including 5 control keys and 4 LEDs

Navigation Keys

The LTM CU navigation keys are contextual, that is, their function depends on the associated icons shown on the LCD display. These icons change for different displays, so the navigation key functions also change.

The navigation keys can be used to:

  • navigate menus and sub-menus,

  • scroll within a value list,

  • select a setting in a value list,

  • exit a value list without making a selection,

  • return to the main (first-level) menu,

  • switch between manual and automatic presentation mode in Quick View display.

The diagram below shows an example of the different functions of each of the navigation keys associated with an icon on the LCD display:

1 Information area of the LCD display

2 Contextual navigation icons area of the LCD display

3 Move up to the next higher-level menu

4 Move down to the next item in the menu

5 Select an item

6 Move up to the previous item in the menu

7 Return to the main menu

LCD Displays

The LTM CU presents 3 different LCD displays:

LCD display

Functionality

Menu

  • Displaying and editing the configuration settings required for configuring the LTM R (metering, protection, control and services settings)

  • Displaying diagnostic and history data

Quick View

  • Displaying real-time metering of pre-selected parameters by automatic or manual scrolling

Trips and alarms

  • Displaying the most recent detected trip or alarm

Contextual Navigation Icons

The following table describes the icons used with the contextual navigation buttons on the LTM CU:

Icon

Description

Icon

Description

Enables access to the main menu from a sub-menu or from Quick View

Enables access to Quick View from the main menu or a sub-menu

Scroll down

Enables access to manual scroll mode (when Quick View is in automatic scroll mode)

Scroll up

Enables access to automatic scroll mode (when Quick View is in manual scroll mode)

Validates a setting or value and enables access to a sub-menu when a menu is selected

Used to increment a setting in menu mode

Move up to the next higher-level menu

Used to decrement a setting in menu mode

When a menu item is password-protected, this icon enables access to the Enter Password screen

   

Information Icons

The following table describes the icons provided as information in the information area of the LCD display. They indicate, among others, the selected menu or parameter:

Icon

Description

Icon

Description

Main menu

Indicates that the present display is Quick View

Metering setting menu

Indicates that an alarm has occurred

Protection setting menu

Indicates that a detected error has occurred

Control setting menu

Information

Services menu

Check box selected

Language selection menu

Check box unselected

Radio button selected

Item has been selected (for inclusion in Quick View display)

Radio button unselected

LTM R in Configuration mode

Example of an HMI Display

Here is an example of HMI LCD displaying an average current of 0.39 A in local control, run mode:

1 Quick View display icon

2 Name of the setting currently displayed

3 Motor state

4 Short key to main menu

5 Manual scroll mode icon; pressing the associated contextual navigation key switches to manual scroll mode

6 Value of the setting currently displayed

Network Communication on Modbus/TCP

Wire the Communication Port

This procedure is shown on the Instruction sheets provided with the LTM R and the LTM E, and described in Installation chapter of the User Manual:

1 Premium PLC with an Ethernet coupler

2 Straight or crossed shielded twisted pair connection cable (490NT•000•••)

3 ConneXium switch

4 TeSys T LTM R Modbus/TCP controller

Parameters Used in the Application Example

For the application example, the following parameters are used:

LTM R Modbus/TCP Controller

IP address

Served through DHCP

Device name

TeSysT001

Behavior on communication loss

Trip and motor stop after 5 seconds

Configuration mode

Via network

Fast device replacement

  • Enabled

  • With auto backup enabled every 2 minutes

PLC Ethernet Coupler

Primary IP address

192.168.2.3

Sub-network mask

255.255.255.0

Gateway address

192.168.2.200

Address server

Use of DHCP to associate:

  • Device name TeSysT001

  • IP address 192.168.2.100

I/O scanning

  • Inputs: Registers 2502 to 2505 (= 455 to 458)

  • Outputs: Register 2507 (= 704)

Set Up the LTM R Communication

Set up the LTM R communication with rotary switches and PowerSuite step by step:

Step

Description

Tool

1

Configure Device Name

With rotary switches

2

Configure communication loss parameters

With PowerSuite

3

Select configuration mode and configure FDR function

4

Download configuration from PC to LTM R controller

5

Power cycle the LTM R controller to take into account the new communication parameters

Device Name Configuration

To configure TeSysT001 device name, set the rotary switches on the LTM R front face as follows:

Communication Loss Configuration

In PowerSuite, configure the communication loss as follows:

Select Configuration Mode and Configure FDR Function

Using PowerSuite, select the configuration mode and Fast Device Replacement (FDR) functions as follows:

Download Configuration from PC to LTM R

Transfer the configuration file from PC to LTM R controller as follows:

Power cycle the LTM R controller to take into account the new parameters.

Set up the PLC Communication

Set up the communication between a PLC and the LTM R controller:

Step

Description

1

Declare the Ethernet network in the PLC.

2

Configure the IP address of the Ethernet coupler.

3

Configure the address server function of the Ethernet coupler.

4

Configure the I/O scanning function.

5

Validate the overall configuration.

6

Associate the Ethernet configuration with the Ethernet module.

7

Compile, save and transfer the project to the PLC.

8

Test the communication via the debug screen.

9

Via an animation table, check that the motor management controller is properly working.

10

Using PowerSuite, transfer the parameter file from LTM R controller to PLC parameter file server.

The example below describes how to configure the communication between a Premium PLC running Unity software and an LTM R controller.

Step 1

Declare the Ethernet network in the PLC.

  • In the Project Browser window, right-click Communication > Network sub-menu and select New Network. The following window appears:

  • Select Ethernet among the list of available networks.

    Ethernet_1 is the default network name:

  • Click OK to validate your choice.

    Ethernet_1 network appears in Communication > Network sub-menu.

Step 2

Configure the Ethernet_1 coupler IP address.

  • In the Project Browser window, double-click Ethernet_1 network.

    The coupler configuration window appears.

  • Select IP Configuration tab and enter the coupler IP address as shown below:

Step 3

Configure the address server function of the Ethernet coupler.

  • Validate the address server function in the Module Utilities area on top of the configuration window:

  • Select Address Server tab and configure the address server table as shown below:

Step 4

Configure the IO Scanning function.

  • Validate the IO Scanning function in the Module Utilities area on top of the configuration window:

  • Select IO Scanning tab and configure the IO Scanning function as shown below:

Step 5

  • Validate the global Ethernet configuration through the Edit menu.

  • When the Modification Authorization box pops up, click Yes to confirm the edit.

Step 6

Associate the Ethernet configuration with the Ethernet module.

  • In the Project Browser window, Configuration menu, double-click the reference corresponding to the Ethernet port. The Configuration window appears:

  • Associate Ethernet_1 configuration to the coupler via the Net Link scrolling list:

Step 7

  • Compile, save and transfer the project to the PLC.

  • Connect the PC to the PLC.

Step 8

Check that the communication is working via the setting screen:

  • In the Project Browser window, Configuration menu, double-click the reference corresponding to the Ethernet port.

  • Select the Debug tab. The Debug window opens, including the following areas:

    Check that a green square appears in the IO Scanning area and that it corresponds to equipment number 1.

Step 9

Via an animation table, check that the motor management controller is properly working.

  • In the Project Browser window, right-click Animation Tables sub-menu and select New Animation Table item.

  • In the Properties window which opens, select a name and click OK.

  • Select one by one the words corresponding to the IO Scanning table:

    • %MW0 to %MW3 for the input variables (LTM R status),

    • %MW10 for the output variable (LTM R control).

The animation table enables you to check LTM R global status and to control the motor:

Step 10

Using PowerSuite transfer configuration from LTM R controller to PLC parameter file server:

  • Connect the PC to the LTM R controller.

  • In the Link > File Transfer menu, select LTMR to parameter server to transfer the configuration file from LTM R controller to PLC parameter file server, as shown below:

In case of a Fast Device Replacement, the file will automatically be downloaded from PLC parameter file server to the new LTM R controller.

See the User Manual for more details.

Registers for Simplified Operation

Basic setup information using configuration, control and monitoring registers applies to all applications:

QR Code is a registered trademark of DENSO WAVE INCORPORATED in Japan and other countries.

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