TeSys Model U Controller

User’s Manual

10/2004
1743233
2
 Table of Contents

Safety Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
About the Book . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Chapter 1 Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Setting up the TeSys model U controller. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
General presentation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Presentation of the TeSys Model U controller. . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Presentation of the power unit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Assembly of the TeSys model U controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Starting up the TeSys model U controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

Chapter 2 Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Operation of the TeSys model U controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Fault management and reset mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

Chapter 3 Technical characteristics. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

Technical characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

Glossary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57

3
4
 Safety Information
§

Important Information

NOTICE Read these instructions carefully, and look at the equipment to become familiar with
the device before trying to install, operate, or maintain it. The following special
messages may appear throughout this documentation or on the equipment to warn
of potential hazards or to call attention to information that clarifies or simplifies a
procedure.
The addition of this symbol to a Danger or Warning safety label indicates
that an electrical hazard exists, which will result in personal injury if the
instructions are not followed.
This is the safety alert symbol. It is used to alert you to potential personal
injury hazards. Obey all safety messages that follow this symbol to avoid
possible injury or death.

DANGER
DANGER indicates an imminently hazardous situation, which, if not avoided, will
result in death, serious injury, or equipment damage.

WARNING
WARNING indicates a potentially hazardous situation, which, if not avoided, can result
in death, serious injury, or equipment damage.

CAUTION
CAUTION indicates a potentially hazardous situation, which, if not avoided, can result
in injury or equipment damage.

October 2004 5
Safety Information

PLEASE NOTE Electrical equipment should be serviced only by qualified personnel. No responsi-
bility is assumed by Schneider Electric for any consequences arising out of the use
of this material. This document is not intended as an instruction manual for untrained
persons.
© 2004 Schneider Electric. All Rights Reserved.

6 October 2004
 About the Book

At a Glance

Document Scope This manual describes the setup, functions and operation of the TeSys model U
controller.

Area of application: Installers, design office, maintenance staff.

Validity Note The data and illustrations in this manual are not contractual. We reserve the right to
modify our products in line with our policy of continuous development. The
information given in this document may be modified without notice and must not be
interpreted as binding on the part of Schneider Electric

Revision History
Rev. No. Changes
1 Initial version.

Related
Documents
Title of Documentation Reference Number
LUTM• Tesys model U Controller Quick Reference Guide W9 1743236
LUC• Control Units Quick Reference Guide W9 1629990
LUF•/ASILUF•/LUL•/LU9• Quick Reference Guide W9 1629995
LULC032 Modbus Communication Module User’s Manual 1743234
LUCMT1BL Multifunction Control Unit User’s Manual 1743237
Internal Communication Variables User’s Manual 1743240

Product Related Schneider Electric is in no way liable for any errors in this document. Please contact
Warnings us if you have any suggestions for improvements or modifications, or if you find any
errors in this publication.

October 2004 7
About the Book

No part of this document may be reproduced in any form or by any means

whatsoever (electronic, mechanical or photocopying) without the prior authorization
of Schneider Electric.
All relevant local safety regulations must be followed when installing and using this
product. For safety reasons and to ensure conformity with the documented system
data, only the manufacturer is authorized to repair the components.

User Comments We welcome your comments about this document. You can reach us by e-mail at
techpub@schneider-electric.com

8 October 2004
 Setup

1
Setting up the TeSys model U controller

Foreword In view of the size of the document, this chapter is divided into a number of topics:
z Presentation
z Assembly
z Connection
z Startup

WARNING
Danger
These devices must only be installed, configured and used by qualified
personnel.
Users must observe the requirements of all applicable instructions,
standards and regulations.
Check the function settings before starting the motor.
Do not downgrade or modify these devices.
Failure to follow this precaution can result in death, serious injury,
or equipment damage.

WARNING
Improper setup
Data relating to motor-starter states and load current values must not
be used to control safety devices and emergency stops.
Check the function settings before starting the motor.
Failure to follow this precaution can result in death, serious injury,
or equipment damage.

October 2004 9
Setup

What's in this This chapter contains the following topics:

Chapter?
Topic Page
General presentation 11
Presentation of the TeSys Model U controller 12
Presentation of the power unit 18
Assembly of the TeSys model U controller 20
Connection 21
Starting up the TeSys model U controller 26

10 October 2004
 Setup

General presentation

Aim of the When used with a short-circuit protection device and a contactor, the TeSys model
product U controller creates a motor starter that provides protection against overloads and
permits control of motor starter functions. Functions include:
z Direct control via its output relays of the coils of reversing and non-reversing
contactors up to 250 kW (F500)
z Control of the coils of reversing and non-reversing contactors above 250 kW
using an interface relay between the controller output relays and the contactor
coils
z Monitoring and protection of nominal currents up to 800 A

Note: In an installation containing TeSys model U controller-starters and

controllers, motor-starter management is identical from the point of view of the
PLC, whatever the TeSys product.

Conditions of Irrespective of the nominal current value of the motor it is supposed to control, the
use TeSys model U controller is always used with external current transformers in which:
z The secondary is at 1 A nominal.
z The primary is selected according to the motor nominal current.

Typical Typical composition of a motor-starter unit

composition

– Q6

A TeSys model U controller

B C
B Power unit
A
– KM1
C Current transformers

M
3

October 2004 11
Setup

Presentation of the TeSys Model U controller

Description The TeSys model U controller consists of:

z A controller base
z An advanced or multifunction control unit
z and, if required, a function or communication module.

LUCBT1BL or LUCDT1BL LUCMT1BL multifunction

LUTM••BL controller base
advanced control unit control unit

Module (optional)

z Function module:
zLUFW10 thermal overload alarm
zLUFV2 motor load indication
z LULC• communication module

2 configurations There are two main configurations:

z Controller without communication module
Protection of a motor > 32A, stand-alone operation
z Controller with communication module
Control and protection of a motor in a control panel

12 October 2004
 Setup

Composition of a Five possible combinations.

Controller
LUTM••BL controller base
Without
Communication Control unit Control unit
Advanced
Multifunction Multifunction
LUCBT1BL/ Advanced LUCBT1BL/LUCDT1BL
LUCMT1BL LUCMT1BL
LUCDT1BL

--- Function module (optional)

--- --- LUFW10 LUFV2

October 2004 13
Setup

Composition of a Two possible combinations.

Controller With
LUTM••BL controller base
Communication
Control unit
Advanced LUCBT1BL/LUCDT1BL Multifunction LUCMT1BL

Function module
LULC• communication module

LUTM••BL There are two controller bases depending on the model of contactor to be controlled:
controller base LUTM10BL and LUTM20BL.
Table of LUTM/contactor combinations.
LUTM10BL LUTM20BL
Voltage Contactor Voltage Contactor
24 <=> 250 V TeSys model d 110 <=> 250 V TeSys model f
24 V TeSys model d
09 <=> 95

14 October 2004
 Setup

Composition of Components in the controller base.

the LUTM••BL
Reset button and LEDs
controller base
1

RESET

2 1 Fixed terminals: Connection of the current-transformer

secondaries
2 Slot for control unit
3 Slot for module (optional)
3
4 Removable terminals: Connection of the power supply and the
inputs
4
5 Removable terminals: Connection of the outputs
5

LEDs on the Description of the various states of the LEDs on the controller base.
LUTM••BL
Light-emitting diodes
controller base Comment
Green "24V " LED Red "FAULT" LED
On Off Normal operation
Off Fault condition
On
See State of the LEDs on the
Flashing or off
controller base, p. 43

Light-emitting diodes Comment

On Contact for output "13" "closed"
Green "13" LED
Off Possible fault
See State of the LEDs on the
Off
Green "23" LED controller base, p. 43
On Contact for output "23" "closed"

October 2004 15
Setup

LUC•T advanced Functions performed by the advanced control unit.

control unit
z Protection:
z Against overloads, class 10 (LUCBT1BL) or 20 (LUCDT1BL)
z Against loss of phase and phase imbalance
z Against insulation faults (equipment protection only)
z Current setting on front panel
z Thermal trip test
z Reset:
z manual
z remote or automatic in conjunction with a function module or a
communication module
z Display (motor load) with a function module or a communication
module
z Alarm: With a function module (e.g., LUFW10)
Setting the advanced control Unit, p. 26

LUCMT Functions performed by the multifunction control unit.

multifunction
z Protection
control unit
z Alarm
z Diagnostics
These three functions can be configured and monitored.
z Reset:
z manual
z remote or automatic
Refer to the documentation for this product.

LUFW10 function Functions performed by the "Alarm on thermal overload" function module.
module
z Determination of the motor thermal state
z Alarm signaling for:
z improving the performance of the controlled motor
z anticipating a complete stop due to a thermal overload
z Avoiding, by load shedding, interruptions in operation due to
tripping on overloads
All the data processed by this module can be accessed on the discrete
contacts.

Note: Can only be used with the advanced control unit.

16 October 2004
 Setup

LUFV2 function Functions performed by the "Indication of the motor load (analog)" function module.
module
z Determination of the state of the motor load (I mean/FLA)
z I mean = mean value of the rms currents in all 3 phases
z FLA = value of the setting current
It delivers an analog signal of 4 to 20 mA (0% to 200%) proportional to
the motor load.

Note: Can be used with an advanced or multifunction control unit.

LULC• Functions performed by the communication module.

communication
z TeSys model U controller line connection
module
z Alarm
z Diagnostics
Once it has been processed, data is exchanged via the serial link.
Setting the LULC032 communication-module parameters, p. 28.
Refer to the documentation for this product.

The protection and control data available depend on the control unit with which the
communication module is used.
Control unit
Data - Commands Advanced Multifunction
LUCBT/CDT1BL LUCMT1BL
Start and stop commands X X
Status (ready, running, fault condition) X X
Alarm X X
Automatic reset and remote reset via the bus X X
Indication of the motor load X X
Differentiation of faults X
Remote parameter setting and viewing of all
X
functions
"Log" function X
"Monitoring" function X

October 2004 17
Setup

Presentation of the power unit

Description The power unit consists of:

z Three current transformers (see Transformer characteristics, p. 22):
z Telemecanique supplier ==> LUTC••01
z Other suppliers ==> characteristics to be adhered to
z A contactor
z A short-circuit protection device

Note: In combination with LUTC••01 current transformers, the LUTM••BL controller

base must only be used with motors from 0.75 kW up to 450 kW/800 A nominal.

Current Product reference (Telemecanique) for the current transformers and contactor.
transformer and
Current transformers 3 * LUTC••01
contactor
Contactor Non-reversing LC1•••• Reversing LC2••••

Protection Protection against short-circuits is provided by one of the following:

against short- z Magnetic circuit-breaker
circuits z Fuses

WARNING
Validity of thermal protection
Thermal-magnetic motor circuit-breakers are prohibited since they
incorporate an overload protection function, which would duplicate that
in the modules and interfere with the control-unit analysis.
Failure to follow this precaution can result in death, serious injury,
or equipment damage.

18 October 2004
 Setup

Protection via a Magnetic circuit-breaker

magnetic circuit-
Power (1) Circuit-breaker
breaker
P (kW) Ie (A) Product Rating (A) FLAm (A) (2)
reference
0.75 to 400 2 to 710 NS•••H 2.5 to 800 25 to 8000
0.75 to 15 2 to 32 GV2-L2• 2 to 32 33 to 420

(1) Standard power ratings for 50/60 Hz 400/415 V 3-phase motors

(2) FLAm = Magnetic circuit-breaker setting current

Protection with Fuses with disconnect switch.

fuses
Disconnect
Power (1) aM fuse
switch
P (kW) Ie (A) Size Rating (A) Product
reference
GS1-DD
0.75 to 315 2 to 555 10.3x38 to T3 4 to 630
to GS1-S

Fuses with holder.

Power (1) aM fuse Holder
P (kW) Ie (A) Size Rating (A) Product
reference
0.75 to 15 2 to 32 10.3x38 4 to 32 LS1•
0.75 to 55 2 to 105 14x51 to 22x58 4 to 125 GK1•

(1) Standard power ratings for 50/60 Hz 400/415 V 3-phase motors

October 2004 19
Setup

Assembly of the TeSys model U controller

Principle The module (optional) is installed in the controller base beneath the control unit,
which locks it in position.

Installation You must proceed as follows when assembling the controller:

Step Action
1 (optional) Install the module:
z Function module:
z LUFW10 thermal-overload alarm
z LUFV2 motor-load indication
z LULC• communication module

2 Install the control unit:

z Advanced LUCBT1BL/LUCDT1BL
z Multifunction LUCMT1BL

Location of the components.

LUTM10BL LUCBT1BL
LUTM20BL LUCDT1BL LUCMT1BL

LUFW10 LUFV2 LULC•

20 October 2004
 Setup

Connection

Connecting the
transformers
WARNING
Loss of thermal protection
Switch off the power supply before disconnecting the current
transformers.
Do not disconnect the current transformers during operation.
Failure to follow this precaution can result in death, serious injury,
or equipment damage.

Disconnecting them during use will disable controller protection.

The three current transformers are connected to the fixed terminals.

L1
L2
L3

L1 L2 L3

S1 S2

These terminals can be used to measure the current in all three phases.
z 2 x 3 terminals for connecting the current transformer secondaries placed in each
of the 3 power phases: L1 - L2 - L3
z One ground terminal for connecting the center point

Note: Use of the ground terminal is not compulsory.

October 2004 21
Setup

Transformers to In order to operate correctly, the TeSys model U controller requires an accurate
be used current value received from the current-transformer secondary up to 10 times the
nominal current (5P10) minimum.
It is therefore essential to use transformers, which accept up to 10 times the
nominal current with accuracy of at least 5%. For most purchased CTs it is essential
to use motor protection type transformers to achieve these accuracy
requirements.

Note: Typical "measurement" type transformers are prohibited as their

operating range is too limited and therefore they are not sufficiently accurate.

Transformer If the transformer supplier is Telemecanique: Product references to be ordered.

characteristics
Motor In Primary (A) Secondary (A) No. of pass(es) Product
reference
3.5 to 10.5 30 1 3 LUTC0301
5.2 to 16 30 1 2 LUTC0301
10.5 to 32 30 1 1 LUTC0301
17.5 to 53 50 1 1 LUTC0501
35 to 105 100 1 1 LUTC1001
70 to 210 200 1 1 LUTC2001
140 to 420 400 1 1 LUTC4001
280 to 840 800 1 1 LUTC8001

Illustration showing how current transformers are set up.

1 pass 2 passes

Ip Ip

The three TIs must be connected in the same way in order to ensure an identical
relative polarity:
z The cable must be routed in the same direction for the three current transformers
(entering via the side marked P1-K-H1).

22 October 2004
 Setup

Connecting the In order to operate, the TeSys model U controller must be powered by a 24 V
power supply source.
and the control
inputs
I.1 I.2 I.3 I.4 24V

I.5 I.6 I.7 I.8 I.9 I.10

Both these terminal blocks are removable.

z 2 terminals for 24 V power supply
z 1 terminal for the power-supply connection to the inputs
z 10 terminals for the control inputs

Note: The TeSys model U controller is rated IP20 or higher. However, for best
protection from electric shock and consistent product performance, do not touch
the connections during product operation.

The 24 V is distributed internally in order to supply power directly (without

additional customer wiring) to:
z The advanced (LUCBT or LUCDT) or multifunction (LUCMT) control unit
z The LULC• communication module

Note: Power is supplied to the control unit, the function module and the
communication module automatically once they are installed in the controller base.

October 2004 23
Setup

Particular feature In "remote via the bus" or "mixed" mode.

of the LULC•
communication The use of outputs OA1, OA3 and LO1
module on a communication module requires a
24 V power supply connected to the
controller.
Inputs LI1 and LI2 do not require an
external power supply.
Use a cable shorter than 5 cm to connect
the LUTM controller’s 24 V(-) to the
LULC032 communication module’s 24
V(-).
Do not connect the LULC032
communication module’s AUX 24 V (+)
when the module is mounted on the
LUTM controller.

Connecting the Relay outputs - 24 V or 24 V to 250 V .

outputs

Note: The contacts (95 - 96) and (97 - 98) are represented with the controller
powered up, input I.6 at 1 and in the absence of any fault condition.

These terminals are removable.

z 2 NO contacts (13 and 23) for controlling the contactors
z 1 NO contact (95 - 96) and NC contact (97 - 98): "Any fault" relay
z 1 NC contact (05 - 06): "Control-unit fault" relay.

24 October 2004
 Setup

State of the Before power-up.

output relays
Output Relay State
"Control-unit
05 - 06 Closed
fault"
95 - 96 Open
"Any fault"
97 - 98 Closed

After power-up (24 V ) with input I.6 at 1 and in the absence of any fault condition.
Output Relay State
"Control-unit
05 - 06 Closed
fault"
95 - 96 Closed
"Any fault"
97 - 98 Open

Note: Fault management and reset mode, p. 42.

Connection Table showing conductor cross-sections to be used.

capacities
6, 7 and 8-pin connectors -
Connection Possibilities pitch: 5 Starter command
and control
z Solid conductor z 0.2 to 2.5 mm2
z Stranded conductor z 0.2 to 2.5 mm2
z Size of conductor z AWG 24 to AWG 12
1 conductor
z Stranded conductor with cable end: z -
z Non-insulated z 0.25 to 2.5 mm2
z Insulated z 0.25 to 2.5 mm2
z 2 solid conductors z 0.2 to 1 mm2
z 2 stranded conductors z 0.2 to 1 mm2

2 conductors z 2 stranded conductors with cable end: z -

(same cross- z Non-insulated z 0.25 to 1 mm2
section) z 2 stranded conductors with TWIN cable z -
end: z 0.5 to 1 mm2
z Insulated

Tightening torque 0.5/0.6 N.m. (5lb.in)

Flat screwdriver 3.5 mm (0.125 in)

October 2004 25
Setup

Starting up the TeSys model U controller

Principle Certain settings must be made before starting up the controller.

Current Before attempting to start up the controller, the characteristics of the current
transformers transformers used must be specified for each control unit.

WARNING
Inadequate thermal protection
The transformer ratio must be set in order to:
z Indicate the characteristics of the current transformers used
z Determine the default value of the adjustment range for the current
threshold required for setting the thermal protection
z Connect the current transformers to the LUTM prior to starting the
TeSys model U controller
Failure to follow this precaution can result in death, serious injury,
or equipment damage.

Setting the The characteristic of the current transformers used must be indicated before
advanced any attempt to power up the controller, by setting the thermal protection on the
control Unit front panel of the advanced control unit: range 35% to 105%.
A set of 8 self-adhesive
labels is supplied with each
TeSys model U controller,
enabling the user to set the
current value directly in
Amps. Example
.........................>

Method of calculating the percentage to be applied:

Equivalent CT I primary of CT (Current Transformer)

=
transformer ratio I secondary of CT x No. of pass(es) in the primary
Motor In
% setting = x 100
Equivalent CT transformer ratio

26 October 2004
 Setup

Example 1 (I secondary = 1A in all cases):

3 kW motor at 400 V motor In of 6.5 A Motor In Primary No. of*
(A) passes

Current transformer (CT) selected from one of the 2 3.5 to 30 3

options (see Transformer characteristics, p. 22): 10.5
CT = 30:1 Number of passes = 2 5.2 to 16 30 2
Calculation to be performed to determine the percentage to be applied in order to set the
thermal protection
z Equivalent CT transformer current = 30/(1 x 2) = 15
z % setting = (6.5 x 100)/15 = 43%

Example 2:
90 kW motor at 400 V motor In of 165 A Motor In Primary No. of*
(A) passes

Current transformer (CT) selected from one of the 2 70 to 210 200 1

options (see Transformer characteristics, p. 22): 140 to
400 1
CT = 200:1 Number of passes = 1 420
Calculation to be performed to determine the percentage to be applied in order to set the
thermal protection
z Equivalent CT transformer ratio = 200/(1 x 1) = 200
z % setting = (165 x 100)/200 = 83%

No. of passes = Number of pass(es) in the current transformer primary.

Setting the The characteristic of the current transformers used is selected when the
LUCMT controller is first powered up in the "CT_Ratio" function of the "Configure"
multifunction menu.
control unit The protection, alarm and diagnostic functions can be configured and monitored:
z Locally via the built-in keypad and display unit
z Remotely via the Modbus RS 485 RJ-45 communication port, using:
z A PC equipped with PowerSuite software (VW3A8104)
z A PDA equipped with PowerSuite software (VW3A8104)
z An XBT NU 400 operator dialog terminal mounted on a cabinet door

Refer to the documentation for this product.

October 2004 27
Setup

Setting the The communication-module parameters are set in order to determine:

LULC032 z The operating mode
communication- z The reset mode
module z The correspondence between the communication module outputs and the
parameters controller inputs.

Refer to the specific documentation for this product.

Parameter-setting registers (Modbus protocol) accessible in read/write mode

(factory setting).
Topic Register Factory Meaning
setting
Selection of the
control-unit fault- 602.0 1 Default selection of "manual" mode
reset mode
Enable When forced to 0 (zero), this bit inhibits
communication communication between the LUCM
602.4 1
between LUCM and multifunction control unit and the LULC032
LULC032 Modbus communication module
Fallback mode on
loss of 682 2 Forced stop (OA1 and OA3 at 0)
communication
Local operating
mode or via the bus Mode for controlling the LUTM controller
683 1
with the LUTM and outputs remotely via the bus
LULC032
Adjustment of:
- Output 13 687 LSB 12 13 is the image of control bit 704.0
- Output 23 687 MSB 13 23 is the image of control bit 704.1

Note: For more information, refer to the "Internal Communication Variables" User’s
Manual (1743240).

Status registers (Modbus protocol) accessible in read mode only

Topic Register Value Parameter settings
This 16-bit register concentrates the data, so
that the operating or fault status of the TeSys
General status 455 0 model U controller can be ascertained.
The control unit installed determines the
available data.

28 October 2004
 Setup

Topic Register Value Parameter settings

Control registers (status) of inputs I.1 to I.10.
State of inputs 459.0 to 9 1
Data written by the communication module.
459.12 Output 13 (1 = closed)
459.13 Output 23 (1 = closed)
State of outputs 459.14 0 Outputs 95-96 and 97-98
(1= 95-96 closed and 97-98 open)
459.15 Outputs 05-06 (1 = closed)

Anticipating loss Register 682 (accessible in read/write mode) is used to configure the fallback mode
of in the event of loss of communication with the PLC.
communication
with the PLC Refer to the documentation for the LULC032 communication module.
(fallback mode)

October 2004 29
Setup

30 October 2004
 Operation

2
Operation of the TeSys model U controller

Foreword Operation describes the operating modes in each of the two configurations: with or
without the communication module and inputs used.

Operation also covers the management of faults and the various reset modes.

In view of the size of the document, the technical characteristics of the TeSys model
U controller are incorporated in this chapter.

What's in this This chapter contains the following topics:

Chapter?
Topic Page
Operation 32
Fault management and reset mode 42

October 2004 31
Operation

Operation

Operating mode Operating modes and inputs used for each configuration.
Configuration Operation Inputs used
Without
communication "Local" mode I.1, I.2, I.6 + I.5
module
"Local" mode "Mixed" mode I.1, I.2, I.3, I.4, I.6 + I.10 + I.5
With (by default) (if I.10 = 0) I.7, I.8 and I.9
communication
"Remote via the "Mixed" mode I.1, I.2, I.3, I.4, I.6 + I.10 + I.5
module
bus" mode (if I.10 = 1) I.7, I.8 and I.9

Note: The operating mode ("local", "remote via the bus" or "mixed") must be
configured in the communication module (see Setting the LULC032
communication-module parameters, p. 28).

In the PLC, the user can read the register reflecting the state of the I/O at any time.

32 October 2004
 Operation

Inputs used 4 inputs are used in a configuration without a communication module.

WITHOUT a
Input Function Output Comment
communication
module I.1 Each input controls the 13 = state of the input.
I.2 output relay. 23 = state of the input.
Note: If the voltage is too low, the output opens.
An external fault or control unit fault has no effect on the state of these relays.
This input is dedicated.
It is used for remote
I.5 RST Using a reset button on the front of
"manual" reset of the ---
(ReSeT) the rack or control panel
controller following a control
unit fault.
This input is dedicated.
It is used to feed back trip
data from an additional
protection device to the Example: Receipt of the data
I.6 SF controller. provided by the "Trip" NC contact:
(System This input must be --- => For a circuit-breaker, a sensor
Fault) connected to 24 V(+) to relay, a voltage relay
enable LUTM controller => For a string of these contacts
operation in the absence of a
data signal from an
additional protection device.

Note: Inputs I.3, I.4and I.7 to I.10 are only used in a configuration with a
communication module.

October 2004 33
Operation

Application Machines with manual local control.

examples 2-wire control by the controller I/O (non-reversing)

1 Channel 1
2 Channel 2

1 2 3 4 3 Any fault
4 Control unit
fault

2-wire control by the controller I/O (reversing)

3
1 Channel 1
2 Channel 2
3 Any fault
1 2 3 4
4 Control unit
fault

5 External fault
5

3-wire control by the controller I/O (reversing)

3
1 Channel 1
2 Channel 2
3 Any fault
1 2 3 4
4 Control unit
fault

5 External fault
5

34 October 2004
 Operation

Inputs used 7 inputs are used in a configuration with a communication module.

WITH a
Input Function Output Comment
communication
module I.1 In "local" mode: Each input controls 13 = state of the input.
I.2 the output relay. 23 = state of the input.
I.1 In "remote via the bus" mode: 13 = state of the register.
These inputs are available for
sending back external data via the
I.2 communication bus (writing to a 23 = state of the register.
register).
Note: If the voltage is too low, the output opens.
An external fault or control unit fault has no effect on the state of these relays.
With a multifunction
These inputs are dedicated to
control unit, increments
feeding back the state of the
I.3 or I.4 --- register 76: number of
contactor controlled by the output
operating hours and
relay.
number of starts.
This input is dedicated.
Using a reset button on the
I.5 RST It is used for remote "manual" reset
--- front of the rack or control
(ReSeT) of the controller following a control
panel
unit fault.
Example: Receipt of the
data provided by the "Trip"
This input is dedicated. NC contact:
I.6 SF
It is used to feed back trip data from => For a circuit-breaker, a
(System ---
an additional protection device to the sensor relay, a voltage
Fault)
controller. relay
=> For a string of these
contacts
In "local" or "remote via the bus" mode
This input is used to send back external data via the communication bus
(writing to a register).
In "local" mode. Output = state of the input.
In "remote via the bus" mode. Output = state of the register

I.10
In "mixed" mode.
This input feeds back the "local" or "remote via the bus" data and enables
the controller to manage the command priorities.
If I.10 = 0 then: "local" mode. Output = state of the input.
If I.10 = 1 then: "remote via the bus"
Output = state of the register
mode.

October 2004 35
Operation

Additional inputs 3 inputs can be used in addition to those already mentioned during operation with
a communication module.
Input Function Comment
This input is dedicated.
It is used to communicate the system Example: Receipt of the
I.7 SR
availability via the bus. data provided by the
(System
However, if the mapping "Ready" bit is not circuit-breaker "Ready"
Ready)
used, I.7 is available for feeding back any other NO contact.
data item.
Example: "Emergency
I.8
This input is used to send back external data via stop button status".
the communication bus (writing to a register). Example: In the case of a
I.9 It has no effect on controller operation. control panel with "rack in
test position".

Control of Control of outputs 13 and 23 of the LUTM controller depends on the selected
outputs 13 and operating mode (see Setting the LULC032 communication-module parameters,
23 p. 28).
Operation Comment
Outputs 13 and 23 are only controlled by inputs I.1 and I.2 .
"Local" mode
Commands via the bus are not taken into account.
"Remote via the Outputs 13 and 23 are only controlled by the bus.
bus" mode The state of inputs I.1 and I.2 does not affect outputs 13 and 23.
Outputs 13 and 23 are only controlled
by inputs I.1 and I.2.
"Local" mode if I.10 = 1
"Mixed" mode Commands via the bus are not taken
(input I.10 into account.
manages the Outputs 13 and 23 are only controlled
priorities) "Remote via the bus" mode if by the bus, via the PLC.
I.10 = 0 The state of inputs I.1 and I.2 does not
affect outputs 13 and 23.

Note: Commands transmitted during communication are passed directly to the

output relays, without wiring between the communication module outputs and
inputs I.1 and I.2.

36 October 2004
 Operation

Note: Even when there is a control unit fault or external fault condition, outputs 13
and 23 can still be controlled. Their state is not necessarily "open", even if the
communication module is in fault condition.

Application Control with "remote via the bus" operating mode.

examples

6 7

1 2 3 4

1 Channel 1 4 Control unit fault 7 Communication module

2 Channel 2 5 External fault

3 Any fault 6 Network connection

Note: To feed back external data via the communication bus (write to a register)
using inputs I.1 and I.2, operation must be configured in "remote via the bus"
mode (see Setting the LULC032 communication-module parameters, p. 28).

October 2004 37
Operation

3-wire control with "local" or "remote via the bus" operating mode and data
feedback (pushbutton voltage: 24 V ).

6 7

1 2 3 4

8
5

1 Channel 1 4 Control unit fault 7 Communication module

2 Channel 2 5 External fault 8 "Local"/"remote via the bus"

3 Any fault 6 Network connection

38 October 2004
 Operation

3-wire control with local operation, "remote via the bus" operating mode and data
feedback (voltage local control > 24 V).

3 8

6 7

1 2 3 4

9 9 8
5

1 Channel 1 4 Control unit fault 7 Communication module

2 Channel 2 5 External fault 8 "Local"/"remote via the bus"
3 Any fault 6 Network connection 9 Free

Note: To feed back external data via the communication bus (write to a register)
using inputs I.1 and I.2, operation must be configured in "remote via the bus"
mode (see Setting the LULC032 communication-module parameters, p. 28).

October 2004 39
Operation

3 Examples of Safety of operation.

fault
management
3
1 Channel 1
2 Channel 2
1 2 3 4 3 Any fault

4 Control unit
fault

Motors stop in the event of:

z The control unit tripping
z Internal fault (see Glossary, p. 55)
z External fault (see Glossary, p. 55)

Motors only stop if the control unit trips.

1 Channel 1
2 Channel 2

3 Any fault
4 Control unit
1 2 3 4
fault

40 October 2004
 Operation

Continuity of service.

DANGER
Loss of overload protection and protection against other faults
monitored.
If the controller base is connected in "continuity of service" mode, the
motor will not stop in the event of a thermal overload or any other type
of fault.
Failure to follow this precaution will result in death, serious injury,
or equipment damage.

1 Channel 1
2 Channel 2

3 Any fault
4 Control unit
1 2 3 4
fault

There is no longer a fault contact in series with the contactor coils.

The motors will not stop in the event of the control unit tripping or an external fault.
The controller simply tells the PLC why it is taking the necessary measures:
z Branch circuit
z Starting up the fans

October 2004 41
Operation

Fault management and reset mode

Presence of a The presence of a fault is indicated by:

fault z The state of the LEDs on the controller base
z The state of the LEDs on the communication module (see specific
documentation)
z The alarm on the multifunction control unit (see specific documentation)
z The display of a message on the multifunction control unit screen
z The alarm on the advanced control unit used with a function module
z The state of the output relays on the controller base

Fault reset Following a control unit fault, the reset mode selected (and, for the multifunction
control unit, the type of fault) determines how the fault can be reset. The operating
mode (e.g., "local" or "remote via the bus") has no effect on the method selected.

Configuration with advanced control unit:

Presence of a Can be reset using the following methods
Reset
communication LUTM Remote via the
(acknowledgement) Input I.5 Automatic
module pushbutton bus
Manual NO YES YES - -
Manual YES YES YES NO NO
Remote YES AFTER DELAY AFTER DELAY AFTER DELAY NO
Automatic YES NO NO NO AFTER DELAY

Configuration with multifunction control unit (with or without LULC032

communication module).
Specifically for thermal overload faults:
Reset Can be reset using the following methods
(acknowledgement) LUTM pushbutton Input I.5 Remote via the bus Automatic
Manual YES YES NO NO
Remote AFTER DELAY AFTER DELAY AFTER DELAY NO
Automatic NO NO NO AFTER DELAY

42 October 2004
 Operation

Other faults (e.g., jam, underload, ground fault):

Reset Can be reset using the following methods
(acknowledgement) LUTM pushbutton Input I.5 Remote via the bus Automatic
Manual YES YES NO NO
Remote YES YES YES NO
Automatic NO NO NO NO

Note: The reset mode ("manual", "remote" or "automatic") must be configured

beforehand in the multifunction control unit or communication module (see Setting
the LULC032 communication-module parameters, p. 28).

State of the LEDs Measures to be taken according to the state of the "24 V " and "FAULT" LEDs.
on the controller
State Cause The reset occurs
base
Red Measure to be
Green "24 taken
"FAULT" Controller status
V " LED
LED
Connect the
No 24 V
Off controller to 24 V
Voltage too low

Internal fault in the

multifunction control On power-up (if no
Off unit Power down the
faults are present)
controller base
On Communication fault
and power it up
between the module
again
and the controller
Internal controller fault

Disconnect the
controller from
the power
supply then On power-up (if the
z No control unit
Flashing install the control control unit is
On z Control unit not
(500 ms) unit or check that installed and locked
locked
the handle is correctly)
locked before
reconnecting the
controller.

October 2004 43
Operation

State Cause The reset occurs

Red Measure to be
Green "24 taken
"FAULT" Controller status
V " LED
LED
Reset the
As soon as the
Control unit waiting for control unit (see
On power poles close
manual reset Fault reset,
after the reset
p. 42)
Reset the
After the reset
Control unit waiting for control unit (see
command is
reset via the bus Fault reset,
accepted
p. 42)
On
All the controller
Flashing output relays are in
Wait for After the reset time
(500 ms) fault mode
automatic reset out
Control unit waiting for
automatic reset
As soon as the
External fault Nothing external fault has
disappeared

Note: A fault requiring a manual reset cannot be reset by powering down and then
powering up the controller.

Measures to be taken according to the state of the LEDs on the output relay (13-23).
State Cause Measure to be taken
Green LED (13) Off
No run command Issue a run command
(relay "13" "open")
Contactor "closed" Trouble-free operation
Green LED (13) On
(relay "13" "closed") Contactor "open" and red See State of the LEDs on the
"FAULT" LED on controller base, p. 43
Green LED (23) Off
No run command Issue a run command
(relay "23" "open")
Contactor "closed" Trouble-free operation
Green LED (23) On
Contactor "open" and red See State of the LEDs on the
(relay "23" "closed")
"FAULT" LED on controller base, p. 43

44 October 2004
 Operation

Fault according After tripping, a control unit fault is declared if the state of the output relays is as
to the state of the follows:
output relays on
Output Relay State Comment Measure to be taken
the controller
base "Control unit Only on tripping of the
05 - 06 Open
fault" control unit Reset control unit fault (see
95 - 96 Open All faults detected by Fault reset, p. 42)
"Any fault"
97 - 98 Closed the controller

Activation of I.5 (Reset) clears faults from the control unit.

After tripping, an internal fault is declared if the state of the output relays is as
follows:
Output Relay State Comment Measure to be taken
"Control unit Switch off the 24 V
05 - 06 Closed Not affected
fault" controller power supply by:
95 - 96 Open z Unplugging the 24 V
If a signal is present connector
"Any fault"
97 - 98 Closed on I.6 z Disconnecting the control
circuit

After tripping, an external fault is declared if the state of the output relays is as
follows:
Output Relay State Comment Measure to be taken
"Control unit Reset the product
05 - 06 Closed Not affected
fault" concerned after
95 - 96 Open identification
If a signal is missing (it is not necessary to reset
"Any fault"
97 - 98 Closed onI.6 the controller)

Note: An external fault can come from a sensor relay, a protection module (e.g.,
voltage)

October 2004 45
Operation

Acknowledgment List of possible application faults.

of application
faults
Registers LULC032 LUCM• LUTM
451 452
Fault Fault bit Fault
Application faults number acknowledgment

"ERR" (line 2) "FAULT"

According to the
reset mode
Thermal overload fault 4 _.3 = 1 Off Overload -
configured in register
602
Application fault in the LUCM• 3, and 5 to Refer to the user’s manual
multifunction control unit 12 for the LUCM••BL or LUCMT1BL multifunction control unit

Registers LULC032 LUCM• LUTM

451 453
Fault Fault bit Fault
Application faults number acknowledgment

"ERR" (line 2) "FAULT"

Flashing

LUTM external fault indicated Automatic with I.6

201 _.0 = 1 - -
by I.6 changing to 0 returning to 1

46 October 2004
 Operation

Acknowledgment List of possible internal faults.

of internal faults
Registers LULC032 LUCM• LUTM
451 452
Fault Fault bit Fault
Internal faults number acknowledgment

"ERR" (line 2) "FAULT"

Fault in the LULC032 Modbus
14 - M14 -
communication module
LULC032 Modbus Power down and
communication module not then power up the
15 - Off M15 -
installed or not supplied with LULC032 and the
power LUCM•
Internal fault in the LUC••
54 _.11 = 1 M54 -
control unit
Fault in the LUCM• 51 to 53, Refer to the user’s manual
multifunction control unit 55 to 63 for the LUCM••BL or LUCMT1BL multifunction control unit
Power down and
Write to EEPROM fault 100 _.13 = 1 On M100 - then power up the
LULC032
Communication fault with the Power down and
LUCM• multifunction control 101 _. = 1 On M101 then power up the
unit LULC032
Flashing

Checksum fault in EEPROM 102 _.13 = 1 On M102 Write: 704.3=1

EEPROM configuration fault 104 _.13 = 1 On M104 Write: 704.3=1
Power down and
Communication fault with the
105 _.13 = 1 On - then power up the
LUTM controller base
LULC032

Identification of the LUC••

Flashing

control unit by the LULC032

110 - Off -
Modbus communication
module

October 2004 47
Operation

Registers LULC032 LUCM• LUTM

451 452
Fault Fault bit Fault
Internal faults number acknowledgment

"ERR" (line 2) "FAULT"

Power down and
(not
LUTM internal fault 200 - See State then power up the
applicable)
of the LUTM
LUTM internal fault: LEDs on Power down and
Communication fault with the 205 _.13 = 1 - - the then power up the
LULC032 module controller LUTM
base, Power down and
LUTM internal fault: p. 43
206 _.13 = 1 - then power up the
No control unit
LUTM

Alarm List of possible alarms.

acknowledgment
Registers LULC032 LUCM• LUTM
460 461
Alarm Alarm bit Fault
Alarms number acknowledgment

"ERR" (line 1) "FAULT"

Thermal overload alarm
Automatic when the
Overload
3 _.3 = 1 - - overload is less than
alarm
85%

Loss of communication with

Flashing

Flashing

(not
the LULC032 Modbus 109 Comm Loss Write: 703.3=1
applicable)
communication module alarm

LUCM• multifunction control Refer to the user’s manual

2, 4 to 13
unit alarm for the LUCM••BL or LUCMT1BL multifunction control unit

48 October 2004
 Operation

Restart following After acknowledgment by setting bit 703.3 to 1, restart according to the states of
loss of control bits 704.0 and 704.1.
communication

October 2004 49
Operation

50 October 2004
 Technical characteristics

3
Technical characteristics

Environment Table of the TeSys model U controller technical characteristics.

Certification UL, CSA
Compliance with
IEC/EN 60947-4-1, UL 508, CSA C22-2 No. 14
standards

marking. Satisfies the essential requirements of the low

European community
voltage (LV) machinery and electromagnetic compatibility (EMC)
directives
directives.
According to IEC/EN 60947-1,
overvoltage category III, degree V 250
Rated insulation of pollution: 3
voltage (Ui)
According to UL508, CSA C22-2
V 250
no. 14
Rated impulse
withstand voltage According to IEC/EN 60947-4-1 kV 4
(Uimp)
Degree of protection Front panel (outside connection
IP 40
according to IEC/EN zone)
60947-1 (protection Front panel and wired terminals IP 20
against direct finger
contact) Other sides IP 20

According to IEC/EN 60068 "TH"

Protective treatment According to IEC/EN 60068-2-30 Cycles 12
According to IEC/EN 60068-2-11 hr 48

October 2004 51
Technical characteristics

Storage °C - 40+ 85
- 25 +70 (LUCBT/
DT/LUTM)
°C
Ambient air -13 +160 (LUCBT/
temperature around F°
DT/LUTM)
the device Operation
- 25 +60 (LUCMT,
°C
LULC032)
°F
-13 +140 (LUCMT,
LULC032)
m 2000
Maximum operating height
ft 6560
According to UL 94 V2
960
°C 1760
Fire resistance °F (parts supporting
According to IEC/EN 60695-2-1 live components)
°C 650
°F 1200
Half-sine mechanical According to IEC/EN60068-2-27
15 gn
shock pulse = 11 ms (1)
Resistance to According to IEC/EN 60068-2-6
4 gn
vibration 5...300 Hz (1)
Withstand to kV In the air: 8 - Level 3
electrostatic According to IEC/EN 61000-4-2 On contact: 8 - Level
kV
discharge 4
Immunity to radiated
According to IEC/EN 61000-4-3 V/m 10 - Level 3
fields
Current-transformer
According to IEC/EN 61000-4-4 kV inputs and outputs: 4
Immunity to fast
- Level 4
transients
Inputs and power
According to IEC/EN 61000-4-4 kV
supply: 2 - Level 3
Immunity to radio-
According to IEC/EN 61000-4-6 V 10
electric fields

(1) Without modifying the state of the contacts in the least favorable direction.

52 October 2004
 Technical characteristics

Controller base and control unit relays.

According to IEC/EN 61000-4-5 Common Differential
(Uc = 24 Vcc) mode mode
Surge immunity Output relay kV 4 2
Inputs kV 2 1
Serial communication kV 2 -

Characteristics Table of the TeSys model U controller technical characteristics.

of the control
Supply voltage V 24
power supply
Power consumed According to IEC/EN 60947-1 W 2
Power-supply voltage
According to IEC/EN 60947-1 V 20 to 29
range
Overcurrent protection 24 V fuse 0.5 A gG
Compatible with
Resistance to
ms Phaseo power
microbreaks
supply
Resistance to voltage 70% of UC min. for
According to IEC/EN 61000-4-11
dips 500 ms

Input Table of the TeSys model U controller technical characteristics.

characteristics
24 V (positive
Voltage V
Nominal input values logic)
Current mA 7
Voltage V 16
At state 1
Current mA 6
Input limit values
Voltage V 5
At state 0
Current mA 2
Change to state 1 ms 10 +/-30%
Response time
Change to state 0 ms 10 +/-30%
IEC 1131-2 conformity A Type 1
Lead-In Type Resistive

October 2004 53
Technical characteristics

Characteristics Table of the TeSys model U controller technical characteristics.

of discrete
Type Double break volt free contacts
outputs
C 300 (LUTM10BL)
Alternating current
Load B 300 (LUTM20BL)
Direct current 24 V/5 A
Maximum power in AC-15 180 (LUTM10BL)
VA
(for 500,000 operating cycles) 500 (LUTM20BL)
Maximum power in DC-13 30 (LUTM10BL)
W
(for 500,000 operating cycles) 30 (LUTM20BL)
Protection against output overcurrents 0.5 A gG

z 500,000 operating cycles on F500 contactors

z Ue AC max: 250 V
z Ue DC max: 30 V

54 October 2004
 Glossary

Any fault "Any fault" relay:

This relay has 2 contacts: NO 95-96 and NC 97-98.
For optimum protection, contact 95-96 should be wired in series with the contactor
coils.
Contact 97-98 is a signaling contact.
The relay is energized (95-96 closed and 97-98 open) if and only if:
z The controller is powered with 24 VDC
z The controller "external fault" input I.6 is at 1
z There is no control unit, base or module fault

Control unit fault "Control unit fault" relay:

This relay has 1 NC contact (05-06).
The relay is energized (05-06 open) when the control unit trips on a thermal
overload, phase loss, phase imbalance or ground fault.

Note: In addition, for the multifunction control unit, also in the event of underload,
overtorque, prolonged start, overcurrent.

October 2004 55
Glossary

External fault The tripping of a protection device on the motor starter, other than the controller, is
known as an "external fault".
For example: Tripping of the circuit-breaker in the event of a short-circuit, tripping of
a PTC sensor relay in the event of a winding or bearing overheating.
This data can be fed back to the controller by connecting the fault contacts on the
devices in question to input I.6 on the controller. In this case, a product trip will cause
contact 95-96 to open and contact 97-98 to close. The states of these contacts will
change back automatically as soon as the tripped product has been reset.

Internal fault Any malfunction of the controller/control unit/module assembly, other than
application problems, is known as an "internal fault".
For example: Internal fault in the base, the control unit or the communication
module, or communication fault between the base and the module

Local Operation in "local" mode:

The contactors are controlled by pushbuttons.

Remote via the Operation in "remote via the bus" mode:

bus Contactors controlled via the communication bus, by changing the values of the
command registers.

56 October 2004
 Index
B
AC
A L
Acknowledgment, 46 LEDs, 15
Alarm, 48 Light-emitting diodes, 15
Application fault, 46 Loss of communication, 29
Assembly, 20 LULC032, 28

C O
Characteristics, 22, 51 Operating modes, 32
Circuit-breaker, 19
Communication module, 28
Composition of a controller with P
communication, 14 Parameter setting, 28
Composition of a controller without Power, 18
communication, 13 Protection, 18
Conditions of use, 11
Conductor, 25
Connection, 21 R
Controller bases, 14 Resets, 42
CT_Ratio, 27 Restart, 49

F S
Fault, 45 Secondary, 11
Fault management, 42 Setting, 26, 27
Fuses, 19 Startup, 26
State of relays, 25
State of the LEDs, 43
I
Inputs, 33, 35, 36
Internal fault, 47

October 2004 57
Index

T
Terminal block, 23
Terminals, 21, 24
Transformer ratio, 26
Transformers, 18, 22, 26

58 October 2004