Setra CSC Operating Manual

2.56 (65)

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CONTACTOR

CONTROL POWER 120 V A

FAN OR PUMP

24 V AC/DC

Relay Coil

Troubleshooting

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Table 1: Troubleshooting

Symptom Action

CSS solid state output does not function Verify the maximum amperage range has not been exceeded.

Setpoint screw keeps turning The setpoint screw has a slip clutch to prevent damage at either

Motor is turned on and switch does not close Insufﬁcient current to the load leads ( for example, a motor or

Voltages or currents above the rated levels may damage the CSS.

end. To return the LED to the original setting, turn the setpoint screw 20 full turns counterclockwise and start the calibration procedure again.

heater) to reach the setpoint threshold. To turn the switch on, wrap the cable multiple times through the sensing hole (see Figure 3.)

Technical Speciﬁcations

Model CSSGA2100R1

Amperage Range 1.0 to 135 A

Continuous Operating Current 135 A, 600V AC

Switch Setpoint Adjustable

Output Relay Single Pole, Single Throw (SPST), Normally Open (NO), 10 A @ 260V AC, 5 A @ 30 DC

Actuation Coil 32.5 mA maximum

Switch LED Indication Yes

Relay LED Indication Yes

Current Switching Mode Over/U nder current sensing

Trip Setpoint Value 1.0 to 135 A

Sensor Supply Voltage Induced from power conductor cable.

Status Output Switch normally open

Switch Load Capacity 30V AC/ DC max. 1 A max.

Isolation Voltage 600 V AC rms

Temperature Range -15 to 60°C (5 to 140°F)

Frequency Range 50/60 Hz

Humidity Range 0 to 95% non-condensing

Dimensions 65 x 65 x 40 mm (2.56 x 2.56 x 1.56 in.)

Aperture (Sensing Hole) Size 18 mm Dia. (0.71 in. Dia)

Compliance United States: UL Listed, File E317719 CCN NRNT, Under UL 508, Industrial Control Equip-

For all CE technical questions, contact Setra Systems, USA. EU customers may contact our EU representative Hengstler GmbH, Uhlandstr 49, 78554 Aldingen, Germany (Tel: +49-7424-890; Fax: +49-7424-89500).

The performance speciﬁcations are nominal and conform to acceptable industry standards. For application of conditions beyond these speciﬁcations, consult your local Setra representative. Setra Systems, Inc. shall not be liable for damages from misapplication or misuse of its products.

159 Swanson Road, Boxborough, MA 01719/800-257-3872;

4 CSS Series - Current Switch Solid w/Relay Installation Instructions

Fax: 978-264-0292; Email: sales@setra.com/Web: www. setra.com

ment

Canada: UL Listed. File E317719, CCN NRNT7, Under CAN/CAS C22.2 No. 14-05, Industrial Control Equipment

Europe: CE Mark LVD 2006/95/EC, EMC Directive 2004/108/EC

Model CSSGA2100R1

Installation Instructions

Introduction

The Current Switch Solid (CSS) Series of digital output switches are noninvasive devices designed to detect low current ﬂowing through a cable or wire. A cost effective solution for monitoring on and off status or proof of operation, these units are ideal for monitoring small current loads on motors driving fans and blowers, and for sensing the status of heating coils and lighting.

These units provide a universal solid state output. Excitation is magnetically induced from current carrying conductor (wire or cable), making these units completely self-powered.

The factory installed snap-on power relay facilitates the remote startup and stopping of the motor. It requires a

separate 24 V AC/DC supply.

IMPORTANT: The Current Switch Device (CSS) Series Current Devices are intended to provide an input to equipment under normal operating conditions. Where failure or malfunction of the CSS could lead to personal injury or property damage to the controlled equipment or other property, additional precautions must be designed into the control system. Incorporate and maintain other devices such as supervisory or alarm systems or safety or limit controls intended to warn of, or protect against, failure or malfunction of the CSS.

Installation

Dimensions

SSCSS-R REV. C 09/17/09

CSS Series - Current Switch Solid w/Relay

WARNING, Risk of Electric Shock

Disconnect power supply before making electrical connections. Contact with components carrying hazardous voltage can cause electric shock and may result in severe personal injury or death.

65 (2.56)

Figure 1: CSS Dimensions mm. (in.)

CSS Series - Current Switch Solid w/Relay Installation Instructions 1

40 (1.56)

Mounting

1. Using the two screws (included), attach the mounti bracket to the back of the electrical enclosure.

2. Snap the CSS into place on the mounting bracket.

Wiring

1. Disconnect power to the conductor cable from the power source.

2. Slide the power conductor cable to be monitored through the sensing hole of the CSS.

3. Wire the CSS/Command Relay as shown in Figure 2.

Note: The switch contacts are solid state and work just like dry contacts When the switch is closed, less than 1 ohm is present; when the switch is open, more than 1 megohm is present.

4. Reconnect the power to the conductor cable (see

Figure 2).

5. Calibrate Model CSSGA2100RI (See the Setup and

Adjustments )

Figure 2: Model CSSGA2100R1

27 (1.08)

Status

Open Setpoint

Closed

Relay

Status

Open

Closed

Setpoint

Relay

If the measured current is too low to be detected or is higher

Status

Open

Closed

Setpoint

Relay

Status

Open Setpoint

Closed

Relay

than the maximum current rating of the CSS, use the following methods to increase or decrease current:

If Measured Current is Too Low to be Detected

Wrap the conductor (wire) through the sensing hole and

around the CSS body to produce multiple turns to increase the measured current

Measured current = actual current times the number of

turns (see Figure 3).

Setup and Adjustments

Calibration Model CSSGA2100R1

Position the CSS so that the status output panel faces you. Conﬁrm that the monitored load (for example a motor or heater) is running, and then use the following methods to calibrate the CSS.

Under current Status Condition (Belt Loss, Coupling Shear, Fan, and Pump Status)

1. Turn the setpoint screw clockwise until the Status Closed Light-Emitting Diode (LED) turns off and the Status Open LED turns on.

Figure 3: CSS Shown with Four Turns

IMPORTANT: Failure to derate the current capacity could result in

damage to the CSS when using multiple turns to increase measured current. Use the following formula to determine the new maximum current:

New Maximum Current = CSS Current Rating/number of turns (Example: Model CSSGA2100R1 with 4 turns = 135 A/4 = 33.8 A, new maximum current.)

To Monitor Currents Exceeding the Maximum Current

Rating of the CSS

For currents> 135 Amps: Use a 5 A Current Transformer (CT) to reduce the current passing

through the CSS as shown in Figure 4. Run the current transformer secondary wire through the sensing hole. Terminate the two secondary wires of the 5 A current transformer to each other, and then install the 5 A current transofrmer in the condutor being monitored.

Current > 135 A

2. Slowly turn the setpoint screw counterclockwise until the Status Closed LED turns on and the Status Open LED turns off.

3. Turn the setpoint screw an additional 1/4 turn counterclockwise to create a deadband to prevent hunting.

Figure 5: Status Open, LED On

Figure 6: Status Open, LED Off

The CSS is now calibrated to signal current ﬂows below normal full load amperes.

Output Status:

● Normal: Output Closed

● Alarm: Output Open

Figure 4: CSS with CT Transformer

2 CSS Series - Current Switch Solid w/Relay Installation Instructions

Over Current Status Condition (Locked Rotor, Seized Impeller)

1. Turn the setpoint screw counterclockwise until the Status Open LED turns off and the Status Closed LED turns on.

Note: This is the default factory setting.

Figure 7: Status Closed, LED On

2. Slowly turn the setpoint screw clockwise until the Status Closed LED turns off and the Status Open LED

turns on.

Figure 8: Status Open, LED On

3. Turn the setpoint screw an additional 1/4 turn clockwise to create a deadband to prevent hunting.

The CSS is now calibrated to signal current ﬂows below normal full load amperes.

Output Status:

● Normal: Output Open

● Alarm: Output Closed

CSS Series - Current Switch Solid w/Relay Installation Instructions 3

RETURNING PRODUCTS FOR REPAIR

Please contact a Setra application engineer (800-257-3872, 978263-1400) before returning unit for repair to review information relative to your application. Many times only minor ﬁeld adjustments may be necessary. When returning a product to Setra, the material

should be carefully packaged, and shipped to :

Setra Systems, Inc. 159 Swanson Road

Boxborough, MA 01719-1304

Attn: Repair Department

To assure prompt handling, returned unit(s) must be accompanied by Setra’s Return Order Form, completely ﬁlled out, found on Setra’s web site

at http://www.setra.com/tra/repairs/cal_rep.htm. Notes: Please remove any pressure ﬁttings and plumbing that you have installed and enclose any required mating electrical connectors and wiring diagrams.

Allow approximately 3 weeks after receipt at Setra for the repair and return of the unit.

Non-warranty repairs will not be made without customer approval and a purchase order to cover repair charges.

Setra maintains a complete calibration facility that is traceable to the National Institute of Standards & Technology (NIST). If you would like to recalibrate or recertify your Setra pressure transducers or transmitters, please call our Repair Department at 800-257-3872 (978-263-1400) for scheduling.

WARRANTY AND LIMITATION OF LIABILITY

ETRA warrants its products to be free from defects in materials and workmanship, subject to the following terms and conditions: Without charge, SETRA will repair or replace products found to be defective in materials or workmanship within the warranty period; provided that:

a) the product has not been subjected to abuse, neglect, accident, incorrect

wiring not our own, improper installation or servicing, or use in violation of instructions furnished by SETRA;

b) the product has not been repaired or altered by anyone except SETRA or its

authorized service agencies;

c) the serial number or date code has not been removed, defaced, or otherwise

changed; and

d) examination discloses, in the judgment of SETRA, the defect in materials or

workmanship developed under normal installation, use and service;

e) SETRA is notiﬁed in advance of and the product is returned to SETRA

transportation prepaid.

Unless otherwise speciﬁed in a manual or warranty card, or agreed to in writing and signed by a SETRA ofﬁcer, SETRA pressure and acceleration products shall be warranted for one year from date of sale.The foregoing warranty is in lieu of all warranties, express, implied or statutory, including but not limited to, any implied warranty of merchantability for a particular purpose.SETRA’s liability for breach of warranty is limited to repair or replacement, or if the goods cannot be repaired or replaced, to a refund of the purchase price. SETRA’s liability for all other breaches is limited to a refund of the purchase price. In no instance shall SETRA be liable for incidental or consequential damages arising from a breach of warranty, or from the use or installation of its products.

No representative or person is authorized to give any warranty other than as set out above or to assume for SETRA any other liability in connection with the sale of its products.

Calibration Services