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SS6000 Soft Starter User Manual

1. Motor Off Brief message as motor defluxes or Pending motor loss trip Tripped System has tripped Not seen in Auto retart Cooling Starter too hot to start or during Minimum off time Shut down PSU under voltage detected SMARTSTART shutting down Brownout Sustained PSU under voltage condition supply problem fault AR Pending System tripped but waiting for auto restart AR Lockout Final trip after all AR attempts exhausted Technical Manual Smartstart 6000 Warnings Alarms and Messages The Smartstart 6000 has been designed to provide the user with a comprehensive display of its operating status Messages in plain English are flashed across the screen if enabled to alert the user of its current status any warnings trips or pending actions The code will have a prefix of T trip W Warning or Interlock Example 1 If auto restart is selected it will flash AR PENDING the number of restarts and time before a restart Example 2 If the motor or starter has reached a thermal state where cannot restart it will flash PENDING 130 MTR OVERLOAD FLASH ALERTS Top Line of Display The Smartstart 6000 can be configured to Flash Warning amp Alarm messages irrespective of the DASHBOARD screen currently active See DO5 Warning alarms on page 21 These alert include PENDING WARNING TRIPPED OVERRIDE AR 12 in
2. Range 5 3600 seconds Default 10 seconds ENTER To save changes ESC To exit without saving a R13 AR Clear Time Enter time period the soft starter must run for to reset the R11 AR attempt log to 0 Range 10 7200 seconds Default 1200 seconds ENTER To save changes ESC To exit without saving a Setup Menu 6 Inputs For more detailed description of Digital input functions refer to table 3 page 33 X10 Dieln 1 Mode Activates digital input 1 Range Enable Invert Disable Default Enable ENTER To save changes ESC To exit without saving a Technical Manual Smartstart 6000 IMIO042 rev H Page 26 Programming X11 Digin 1 Variable Set the functionality of digital input 1 Refer to page 33 for more details Pa Range Trip Reset Start Stop Coast Local Lv ESO Default Reset ESC To save changes To exit without saving X12 Digin 1 Delay Set the delay that the digital input needs to be active for the Soft starter to respond Range 0 0 300 0 seconds Default 0 0 ENTER To save changes ESC To exit without saving a 0 X20 DigIn 2 Mode Activates digital input 2 Range Enable Invert Disable Default Disable ENTER To save changes ESC To exit without saving ap 0 X21 Digln 2 Variable Set the functionality of digital input 2 Refer to page 33 for more details Range Trip Reset Start Stop Coast Local ESO Default Trip To save changes To exi
3. SCR PIV SCR configuration Dv dt suppression Over Voltage Rated Insulation EMC Current Feedback Standards Compliance lEC60947 4 2 Environment Enclosure protection Operating Temp Cooling Maximum Altitude Operating position Pollution All Models All Models 6R15 30 60 80 Only i 3 wire amp 6 wire ii Bypass or Continuous 6R15 to 6R80 have integral Bypass Contactor 300 for 15 secs 10start hr 300 for 40secs 10start hr 400 for 10 secs 10start hr 450 for 20 secs 5start hr 300 for 60 secs 5start hr Minimum 1400V 6R series Minimum 3600V 6V series Full wave RC snubber networks MOV 2Kv 6R series Class A to AS61800 C tick Current transformer in circuit at all times Torque controlled Ramp or voltage ramp with current limit override AS31800 C tick AS3947 4 2 IPOO IP20 Oto 55 C derate by 1 C gt 40 C Temperature controlled forced ventilated 1000m without derating Vertical Degree 3 conforming to IEC947 4 2 Technical Manual Smartstart 6000 Inputs Digital Inputs Function Thermistor Outputs Digital Output Contact Rating Analogue Output Signal Communications Protection Motor Overload SCR Over temp SCR protection Under Current Over Current Under Torque Over Torque Motor Stalled Current limit Starter Overload O P Short Circuit Voltage imbalance Current Imbalance Bypass failure SCR fault Acc over tim
4. Range 1 90 seconds Default 10s To save changes To exit without saving a ENTER ESC IMIO042 rev H Programming P50 Overcurrent P50 Overcurrent Trip 110 2s ENTER To enter submenu to modify To exit sub menu P51 Overcurrent Alarm Provide protection against over current This protection is not active during the accel amp decel period Range off trip warn Default off ENTER To save changes ESC To exit without saving ap Trip The soft starter trips stops the motor and indicates an over current trip The Trip relay will change state if selected Warn The soft starter does not trip or stop the motor See DOS amp DO6 for more information regarding warning alarms P52 Overcurrent Level Adjust to the desired trip threshold as a percentage of the Motor Amps Range 80 250 Default 10096 ENTER To save changes ESC To exit without saving a P53 Overcurrent Delay Adjust to set the time period that the current must exceed the threshold before a trip occurs Range 0 30 seconds Default 10s ENTER To save changes ESC To exit without saving a P60 Under Torque P60 Under Torque Trip 10 10s ENTER To enter submenu to modify ESC To exit sub menu Technical Manual Smartstart 6000 P61 Under torque Alarm Provide protection against under torque This protection is not active during the accel amp decel period Range off trip
5. 430h 248w 232d 430h 248w 232d 670h 375w 285d 670h 375w 285d 670h 375w 285d IMIO042 rev H Unit ratings 220 460V 6 Wire Continuous Inside Delta Connection Light Duty Standard Duty Severe Duty 8 y y y Model Chassis Amps Amps Amps 173 152 128 6R10000 A2 308 270 224 6R19000 A2 350 310 255 6R22000 A2 590 520 442 6R36000 A3 920 815 687 6R58000 A3 1378 1225 1042 6R83000 A3 600V 1000V 3 Wire Bypass Light Duty Standard Duty Severe Dutv 6 y y y Model Chassis Amps Amps Amps 90 79 67 6V09000 A2 214 187 156 6V20000 A3 368 322 265 6V40000 A3 571 499 401 6V60000 A3 600V 1000V 3 Wire Continuous Light Duty Standard Duty Severe Duty 8 y y y Model Chassis Amps Amps Amps 86 76 65 6 09000 A2 196 173 146 6V20000 A3 343 303 253 6V40000 A3 514 457 375 6V60000 A3 Note Dimensions mm 430h 248w 232d 430h 248w 232d 430h 248w 232d 670h 375w 285d 670h 375w 285d 670h 375w 285d Dimensions mm 430h 305w 244d 670h 375w 305d 670h 375w 305d 670h 435w 285d Dimensions mm 430h 305w 244d 670h 375w 305d 670h 375w 305d 670h 435w 305d 1 The above ratings are based on a 40Degree Ambient Ratings up to 60degC are available 2 The bypass contactor is not included unless stated otherwise Shipping Packaging Details Sarena Dimensions Weight mm kg 6RO15B2 380 x 220 x 248 5 6RO30B2 380 x 220 x 248 5 6RO60B2 488 x 220 x 248 6 6RO80B2 488 x 220 x 248 7 6R10000 480 x 305 x 290 18 6
6. CA Ti Ea 1 Optional Fast Acting Semiconductor Fuses selected to suit SCR Devices used 2 Line Contactor controlled by the Soft Starter see Control Wiring Page 14 amp Application Drawings Page 36 38 Refer to page 13 For Control Wiring Refer to page 12 For details on correctly installing external C T s IMIO042 rev H Installation Povver VViring 100A model and above Relocating the Internal Current Transformers for 6 wire operation The Smartstart 6000 comes standard vvith internal Current Transformers C T s for monitoring the current during acceleration deceleration and vvhen in bypass It is important that the Smartstart 6000 be vviredin a manner to ensure the C T s are alvvays monitoring the motor current For this reason 9 terminals are provided This is important to ensure continual protection of the soft starter the motor and the load The correct installation of the C T s is crucial for optimum performance of the torque control system In some situations such as 6 wire operation it may be necessary to relocate the C T s external to the starter For 6 wire operation the C T s are to be installed on the incoming line supply cables so that the line current is monitored not the phase currents The Smartstart 6000 can be purchased with C T s external by ordering prepared for 6 wire Part no Description TF60015 Prepare for 6 wire 6R100 220 TF60016 Prepare for 6
7. STOP SEMICONDUCTOR Ji Pi _j _ 1 up to 240VAC E 4 H m 2 TEST 1 65 OFF HI Oo wt TT x AUTO wa C9 1 36 59 7 9 n BO y 14 L3 8 a a A WM Bi B2 B3 NENEN i cx pa 3 BC Ee g g 8 2 BYPASS SMARTSTART 6000 OB a E ad E 5 CONTACTOR pa lt t 1 T3 2 amp H ze Ba o K e 8 e DG ia D Optional lt 2 TO PLC OR ee TO PLC OR perator CONTROL CCT RLY A RUN Defaut Console RLY 4 TRIP Default TH TH MOTOR VDC B J TH 1 Optional Fast Acting Semiconductor Fuses selected to suit SCR Devices used 2 Relay Contacts are rated for 5A 240VAC 30VDC inductive An intemediate relay may be required where peak currents may exceeds this rating 3 Models 6R15 to 6R80 include an integral Bypass Contactor With these models an external Bypass Contactor Is not required Technical Manual Smartstart 6000 IMIO042 rev H Page 45 Appendix B Application Diagrams Irrigation Pump POWER CIRCUIT 415V 3 PHASE SUPPLY 24VDC LC LINE ISOLATION CONTACTOR CIRCUIT Ke o DEA CONTROL CIRCUIT j i 5 timer GUTPUT 1 OPTIONAL fil T RUN STOP SEMICONDUCTOR a FUSES Contactor Supply 4 F H VE up to 240VAC 2 i X TEST E V ner ao O E YT JET Li z E L3 a a 5 81818 amp CA d 3 BC Er SY SY B SY ek SMARTSTART 6000 8 E JEJ NTACTOR CONTACTO T2 T3 THE
8. in the motor to measure its temperature can be connected to the thermistor input terminals This input has a trip resistance of 30000hms and a resistance of 20ohms or less will be detected as a short circuit Alternatively a normally closed thermal switch may be used which open circuits at a specific temperature Technical Manual Smartstart 6000 Motor thermal Protection Cold Curves Trip Time s 10000 000 SS6000 Motor Thermal Overload Curves Cold 1000 000 100 000 e Class 30 Cold m Class 20 Cold a Class 10 Cold gi Class 10A Cold x Class 2 Cold 10 000 1 000 0 2 3 4 7 8 X FLC Hot Curves SS6000 Motor Thermal Overload Curves Warm 1000 000 I li 100 000 i i Class 30 Warm a ma Class 20 Warm E 10 000 k Class 10 Warm 2 Class 10A Warm F Class 2 Warm 1 000 0 100 2 3 4 7 8 XFLC IMIO042 rev H Page 37 Unit ratings The following tables provide the maximum motor FLC that should be used on each model for specific starting amp operating duties 15A 80A vvith Integral Bypass Contactor 380 415V Light Duty Amps 15 30
9. 60 80 Standard Duty Amps 15 25 54 70 220 460V 3 Wire Bypass Light Duty Amps 105 193 221 367 586 830 Standard Duty Amps 92 170 193 321 513 806 220 460V 3 VVire Continuous Light Duty Amps 100 178 203 341 534 196 Standard Duty Amps 88 157 179 302 473 710 Severe Duty Amps 15 20 44 56 Severe Duty Amps 77 139 157 271 427 647 Severe Duty Amps 75 131 149 258 401 608 220 460V 6 Wire Bypass inside Delta Connection Light Duty Amps 180 330 380 635 1015 1435 Standard Duty Amps 159 290 330 555 888 1395 Technical Manual Smartstart 6000 Severe Duty Amps 130 238 269 478 731 1108 Model 6RO15B2 6RO30B2 6RO60B2 6RO80B2 Model 6R10000 6R19000 6R22000 6R36000 6R58000 6R83000 Model 6R10000 6R19000 6R22000 6R36000 6R58000 6R83000 Model 6R10000 6R19000 6R22000 6R36000 6R58000 6R83000 Page 38 Chassis B2 B2 B3 B3 Chassis A2 A2 A2 A3 A3 A3 Chassis A2 A2 A2 A3 A3 A3 Chassis A2 A2 A2 A3 A3 A3 Dimensions mm 335h 162w 174d 335h 162w 174d 440h 162w 174d 440h 162w 174d Dimensions mm 430h 248w 232d 430h 248w 232d 430h 248w 232d 670h 375w 285d 670h 375w 285d 670h 375w 285d Dimensions mm 430h 248w 232d 430h 248w 232d 430h 248w 232d 670h 375w 285d 670h 375w 285d 670h 375w 285d Dimensions mm 430h 248w 232d
10. Default Setup ENTER To save changes To exit without saving If the menu access is disabled a user access code is required to access the menu The access code is 1470 MENU ACCESS Read Only Press lt Enter gt for 3 seconds LOGI N CODE gt 1470 DO2 Default Screen The default screen is the dashboard screen that the Soft Starter will return to on power up exit or time out from the menu pa Selection Overview Thermal Electrical Power BK Volt imbal Curr imbal Counters meters clock net Default Overview ENTER To save changes To exit without saving DO3 Bargraph Var Sets the bargraph variable to monitor 8 Display Selection Mtr current Mtr Torque w Mtr Thermal SCR Thermal Active Power Power Factor Defqult Mtr Current To save changes To exit without sqving DO4 Bargraph FS Adjust the full scale of the bar graph meter as a percentage Selection 100 120 150 200 300 400 600 we Default 300 ENTER To save changes To exit without saving IMIO042 rev H Page 20 Programming DOS Flash Warnings Alarms General inclusion of warning alarms to be flashed over the current dashboard screen Refer to table 4 p34 for alarm message explanation a Selection All Alarms Disabled Trips only Fit Warnings Major Warnings Default All Alarms ENTER To save changes ESC To exit without saving DO6 Alm over Bar The default screen will
11. Input qt ENTER Setup Menu 7 Output ESC n gt Setup Menu ENTER 8 Network lt ENTER DO Menu Access DO2 Default Screen DO3 Bargraph Variable D04 Bargraph FS DOS Warning Alarms D06 Alm over Bar D10 Time D20 Date MOT Motor Amps MO2 Motor Volts M03 Motor PF M04 Motor Wiring C01 Run Mode gt C02 Current Limit C10 Accel Ramp C11 Accel Time C12 Start Torque C13 Final Torque C20 Decel Ramp C21 Decel Time C22 Release Torque gt p ESC R01 Manual Reset RO2 Power Reset R03 Start Reset R10 Auto Restart R11 AR Attempts R12 AR Min Delay R13 AR Clr time X11 Digln 1 Variable X12 Digln 1 Delay X20 Digin 2 Mode X21 Digln 2 Variable XI22 Digln 2 Delay n p e NOT Net protocol NO2 Net Control NO3 Net Timeout N10 RS485 Addr N11 RS485 Speed N12 RS485 Format N20 IP Address N25 IP Mask Bits Setup Menu gt 9 Advanced EC ENTER Setup Menu 10 Command ESC ENTER Y Setup Menu 11 Starter Diag ESC ENTER Setup Menu 12 Network Diag ESC 1 Reset Trips 2 Clear Trip Log 3 Clear mtr OL 4 Clear Counters 5 Clear meters 6 Reset Configuration General Diagnostics Network Diagnostics Page 19 P01 Motor Overload PO2 Motor Over Temp PO3 Phase Rotation P10 Accel OverTime P20 Voltage Imbalance Alarm P21 Volt Imbal Alarm P22 Volt Imbal Level P23 Volt Imbal Delay P30 Current Imbalance Alarm P31 Current Imbal Alarm P32 Current Imbal Level P33 Curren
12. N24 IP Address 4 Ethernet Only A20 Accel Method A20 Accel Method Squared Range 0 255 Default 0 ENTER To save changes To exit without saving Torque a Accel Profile N25 IP Mask Bits Ethernet Only Accel Control amp Range 2 30 The acceleration method allows adjustment of the we Default 24 aceleration profile and acceleration control This To save changes provides advanced control of the motor during the ESC To exit without saving ramp time to better match the type of load or application See Appendix A on Page 42 for more details Setup Menu To enter submenu to modify ESC To exit sub menu 9 Advanced A21 Accel Profile A10 Kick Start A10 Kick Start Select the type of acceleration profile to match the type of load or application 0 2s 70 Example Pump Fan Squared Kick Time Range Linear Squared Default Squared ENTER To save changes Set to provide a kick during starting This provides an Esc To exit without saving adjustable torque boost to the motor when a start is initiated This will also result in a higher start current during the kick duration Kick Level a A22 Accel Control Select the type of Acceleration control to suit the When a kick time of 0 0 seconds is selected Disabled load or application Torque Control will provide will be displayed greater control of motor acceleration Range Torque Voltage To enter submenu to modify Def
13. Overtime Alarm Protection against the start time exceeding the preset acceleration or ramp time Range off trip warn Default off ENTER To save changes ESC To exit without saving a P12 Overtime Del The time exceeding the set ramp time before a trip on Accel overtime occurs Range 5 300 secs Default 1205 ENTER To save changes ESC To exit without saving a P20 Volt Imbal P20 Volt I mbal Trip 25 5s Status Level Delay ENTER To enter submenu to modify To exit sub menu P21 Volt Imbal Alarm Provide protection against a supply voltage imbalance Range off trip warn Default trip ENTER To save changes ESC To exit vvithout saving a IMIO042 rev H Page 23 Programming P22 Volt Imbal Level Adjust to set the voltage imbalance threshold as a percentage of the average phase voltage Range 5 2590 Default 25 To save changes To exit without saving ENTER ESC ap P23 Volt Imbal Delay Adjust to set a delay for the voltage imbalance trip Range 0 5 seconds Default 55 To save changes To exit vvithout saving ap ENTER ESC P30 Curr Imbal P30 Curr I mbal 25 Trip 10s Status Level Delay To enter submenu to modify ESC To exit sub menu P31 Curr Imbal Alarm Protection against a current imbalance Range off trip warn Default trip To save changes To exit vvithout saving ap ENTER ESC P32 Curr Imbal
14. Page 15 A 120 Ohm za B Com 0009SS YANAZ e line polarization 450 650 Ohms pull up and pull down is also recommended typically in near the master device e Avoid laying communications cables adjacent to power cables e f possible communications cables should cross power cables at right angle to each other e Up to 64 nodes equipment may be connected to the same network without an RS485 repeater Modbus Ethernet TCP An Ethernet option card is available which provides an Ethernet socket When the Ethernet card is fitted the RS485 connection will not operate PLC Computer gnH LANYAHLSA OOO9SS YANAZ OOO9SS HiNIZ IMIO042 rev H Programming Local Control Panel Remote Console The local control panel consists of 5 push buttons anda plain English display to simplify programming Increase the value or change selection Navigate up through menu submenus Decrease the value or change selection Navigate down through menu submenus Allovvs access to menu submenus 8 saves ENTER the parameter entered EP Escapes from current menu position vvithout saving ESC RESET Manual reset of a trip if enabled This also takes you direct to the trip log The DASHBOARD The Smartstart 6000 provides a comprehensive display of operating variables status and alarms The screens can be scrolled through usi
15. changes ESC To exit without saving Ki A41 Motor Mtr OL Reset Enter the level for the Motor over load protection to allow a reset Range 10 100 Default 75 ENTER To save changes ESC To exit without saving a A42 Str OT Reset Enter the level for the Starter over temperature protection to allow a reset Range 40 90 C Default 60 C ENTER To save changes ESC To exit without saving Ki A43 Warning Level Set the threshold level for warning alarms with protection based on level only Eg Thermal trips such as Motor Overload Enter as a Range 50 100 Default 90 ENTER To save changes ESC To exit without saving ap Technical Manual Smartstart 6000 time function Eg Overcurrent Enter as a of the trip delay time Range 25 100 Default 50 ENTER To save changes ESC To exit without saving ap Notes 1 If the soft starter is configured to display warning alarms see DO5 amp DOG this sets the threshold point which a warning alert is displayed The screen will display WARNING followed by a code and description Eg W33 MTR OVERCURR 2 Ifa relay is configured for Warning then the relay will change state A51 Motor Stator Enter Details of the Motor Stator Range 1 5 5 0 Default 3 0 ENTER To save changes Esc To exit without saving ap A52 Min off time Adjust this parameter to provide a minimum off time before a start is permitted This will li
16. control to eliminate water hammer problems The SMARTSTART 6000 combines this superior torque control system with a robust design to suit all types of loads and applications All models include substantial heatsink mass with temperature controlled force ventilation to accommodate the more severe heavy duty applications IMIO042 rev H Page 42 Appendix A Indicative parameters for different load types 1 Pump 3 vviref Bypass with No Soft Stop 5 Conveyor 3 vvire Bypass Factory defaults are intended for general pumping fan application with no Soft Stop Enter motor parameters Factory defaults are preset for a variable torque load as per motor nameplate The Torque settings will need to be adjusted for a constant torque type load Enter motor parameters as per motor nameplate 2 Submersible Pump 3 wire Bypass with No Soft Stop Ref Page Parameter Setting factory Default 8 C13 130 A21 Linear Squared 01 Factory defaults are intended for general pumping application with no Soft Stop The acceleration time needs to be reduced to 3secs or as per pump motor Class 20 10 manufacturers recommendations Enter motor Nameplate Motor FLC parameters as per motor nameplate Motor Volts Nameplate Motor Volts MO3 Motor PF Nameplate Motor PF C p cil Gel ad E ypase Factory defaults are preset for a variable torque load The Torque settings will need to be adjusted for a constant
17. more details on overload class curves Select the overload protection class suitable for the motor amp load combination This protection is type R1 thus will not reset the thermal capacity when power is removed or motor is stopped This prevents the motor from restarting if the motor is too hot dh kange 2 100 10 15 20 25 30 disabled Ed Default 10 To save changes To exit without saving The overload setting must be selected according to the motor manufacturers recommendations PO2 Mtr OverTemp Provides overload protection of the motor by monitoring the actual motor temperature A thermistor PTC Type only or NC switch can be connected directly to terminals 20 and 21 This will operate in conjunction with PO2 Mtr Therm OL a Range Thermistor PTC only NC switch disabled Default Disabled ENTER To save changes esc To exit without saving i PTC type i Trip resistance 3000 Q li Reset 16500 ili Thermistor Fault lt 20 Q PO3 Ph Rotation Selectable phase sequence protection to inhibit motor operation if a prohibited phase sequence is detected ie reverse operation Ideal for pumping applications dh J Range Ignore 1 2 3 3 2 1 Default Ignore ENTER To save changes esc To exit without saving i Technical Manual Smartstart 6000 P10 Acc Overtime P10 Accel OverTime Trip 120s Trip off Over Time Delay ENTER To enter submenu to modify ESC To exit sub menu P11
18. more wiring configuration Refer to pages 26 27 for selection of digital inputs and also page 33 for description of the digital input variables A61 Try Tiny Motor Allows a test of the starter using a small test motor or motor smaller than the starter is rated Range Enable Disable Default Disable ENTER To save changes ESC To exit without saving a The Smartstart 6000 will trip on motor loss if motor current falls below 15 of the entered FLC This creates a problem for workshop testing or fault finding If Try Tiny Motor is enabled a start is allowed which ignores this protection When the control supply is removed this automatically resets to disabled Setup Menu 10 Commands To clear reset any of the following a confirmation code is required 1 Reset Trip 2 ClrTrip Log 3 Clr Mtr OL 4 Clr Counters 5 Clr Meters 6 Restore Defaults The Confirmation Code is 1470 Technical Manual Smartstart 6000 Setup Menu 11 Starter Diag This menu provides indication of inputs and wiring checks Digital EN D1 D2 Inputs o 0 0 Digital In Enable Input Digital 1 Input Digital 2 Input 0 No control signal present 1 Control signal present Thermistor In Displays thermistor resistance in Kohms The trip resistance is 3000 Ohms and a short circuit is detected when lt 20 Ohms Ambient temperature is also display when a data logger option is fitted Relay Status Displ
19. positioned over the gate leads 3x connectors located at the top end of the control board Technical Manual Smartstart 6000 Page 49 IMIO042 rev H DESIGNATOR Menu Map Set up Record Sheet Software Revision Main menu Sub menu Level 1 1 Display __ Default Setting D05 Warning Alarms DO6 Alarm over bar 2 Motor MO MO2 Motor Volts MO3 Motor PF C20 Decel Ramp 4 Protection tr Overl C21 Decel Time nl C22 Release Torque 20 _____ i j P02 Mtr Over Temp Disabled TT TT TT P03 Ph Rotation P20 Volt Imbal Alarm P30 Curr Imbal Alarm P40 Undercurrent Alarm P41 Undercurrent Alarm of o _P42 Undercurrent level 10 o P43 Undercurrent Delay 108 o P50 Overcurrent Alarm P51 Overcurrent Alarm lot o P52 Overcurrent Level 100 ________ P53 Overcurrent Delay dos P60 Under Torque Alarm P61 Under Torque Alarm jot _P62 Under Torque Level 106 _P63 Under Torque Delay 10 o _P71 Over Torque Alarm off _P72 Over Torque Level Im P73 Over Torque Delay 109 Disabled Enabed Disabled i m soqoqqe Zi eo P70 Over Torque Alarm Reset Restarts RO1 Manual Reset RO2 Power Reset RO3 Start Reset R10 Auto Restarts Disabled R11 AR Attempts o oo R12 AR Min Delay mm R13 AR Clr time km Technical Manual Smartstart 6000 IMIO042 rev H Page 50 DESIGNATOR Menu Map Se
20. warn Default off ENTER To save changes ESC To exit without saving ap Trip The soft starter trips stops the motor and indicates an Under Torque trip The Trip relay will change state if selected Warn The soft starter does not trip or stop the motor See DOS amp DO6 for more information regarding warning alarms P62 Under Torque Level Adjust to the desired trip threshold as a percentage of nominal torque Range 10 100 Default 10 ENTER To save changes ESC To exit without saving A P63 Under Torque Delay Adjust to set the time period that the torque must fall below the threshold before a trip occurs Range 1 90 seconds Default 10s ENTER To save changes ESC To exit without saving a P70 Over Torque Electronic Shear Pin P70 Over Torque Trip 100 5s Status Level Delay Electronic Shear Pin or protection against over torque This protection is not active during the accel amp decel period ENTER To enter submenu to modify ESC To exit sub menu IMIO042 rev H Page 25 Programming P71 Over Torque Alarm Provide protection against excess torque This protection is not active during the accel amp decel period Range off trip vvarn Default off ENTER To save changes ESC To exit vvithout saving a Trip The soft starter trips stops the motor and indicates an Over Torque trip The Trip relay will change state if se
21. 10s Motor Overload Class 10 Class 20 10 Motor Amps Nameplate Motor FLC Motor Volts Nameplate Motor Volts Motor PF Nameplate Motor PF Technical Manual Smartstart 6000 IMIO042 rev H Page 43 Appendix B Application Diagrams General Purpose POVVER CIRCUIT 415V 3 PHASE SUPPLY CIRCUIT HI BEER KA CONTROL CIRCUIT 24VDC LC LINE ISOLATION CONTACTOR rh r q 1 OPTIONAL II SEMICONDUCTOR 1 Ji FUSES Contactor Supply a V 4 up to 240VAC EI 0 RUNISTOP 24VDC 3 951 51518 3 BC Ee 2 9 A S 9 BYPASS SMARTSTART 6000 et a p K g 5 5 CONTACTOR e E T T3 menm _ BR keen S 20 21 25 4 6 B 10 Be We Optional Remote Operator Console TH l TH MOTOR A J No TH 1 Optional Fast Acting Semiconductor Fuses selected to suit SCR Devices used 2 Relay Contacts are rated for 5A 240VAC 30VDC inductive An intemediate relay may be required where peak currents may exceeds this rating 3 Models 6R15 to 6R80 include an integral Bypass Contactor With these models an external Bypass Contactor Is not required Technical Manual Smartstart 6000 IM10042 rev H Page 44 Appendix B Application Diagrams Typical Water amp Sevverage Pumping POVVER CIRCUIT 415V 3 PHASE SUPPLY CIRCUIT A e CONTROL CIRCUIT 24VDC LC LINE ISOLATION i CONTACTOR SEW 7 r 1 OPTIONAL ity RUN
22. 1234s AR 12 Anytime LOCKOUT Refer to table 4 on page 34 for explanation of each ALARMS and interlock Messages The Smartstart 6000 can be configured to Display the Trip code and Description over the bar graph on the default screen Interlock messages can also be displayed See D06 Alm over bar on page 21 Interlock Messages When this feature is enabled ie DOG All Alarms interlock messages are displayed on the 2 line Refer to DO6 Warning Alarms for more information Interlock messages have an T prefix Eg 170 Enable OFF These messages provide more information about the current status of the starter and provide diagnostics to why the motor may not be operating Refer to table 5 on page 34 for explanation of these messages IMIO042 rev H Page 17 Programming Trip Log The trip log is accessed from the Trip status screen The Trip status screen is the last DASHBOARD screen or press the reset button The Trip status screen displays the last trip To access the trip log press ENTER Trip status screen ENTER T60 MOTOR FAULT Trip Log Trip Log 1 screen 04 Jan 2014 A gt T60 ESC L01 Accel T60 MOTOR FAULT L01 00 12 17 L10 00 08 17 01 Jan 2014 A gt T60 If no trips have occurred Trip Log ENTER No Alarms For all trip codes and descriptions refer to page 35 Technical Manual Smartstart 6000 Alternate Trip Log s
23. 6000 if any obvious damage exists or suspect damage has occurred After the initial inspection the Smartstart 6000 can be repacked and stored in a clean dry location until it is required for use Handling amp Storage To ensure the starter is protected before installation handle and store the equipment in its packaging DO NOT store this equipment in an area where the ambient temperature will fall below 202C or rise above 702C DO NOT store this equipment in areas that are subject to condensation or corrosive atmosphere Proper storage is necessary to ensure satisfactory startup and performance Handling on Installation A Use handling points where provided to lift The Smartstart 6000 range comprises 5 sizes with various larger units weights and dimensions An appropriate handling device must be used with large starters Handling points have been provided to aid lifting Software The precautions described below must be followed This manual applies to the Smartstart 6000 series software NER revision V1 20 The Software revision can be viewed on the VAN Dash Board Display of the Starter M DO NOT handle the starter by the power A terminals busbar Technical Manual Smartstart 6000 IMIO042 rev H Page 2 The Smartstart 6000 Basic Soft Starter Operation The Zener Smartstart 6000 is a reduced voltage controller designed for starting standard 3 Phase induction motors The unit is solid state usin
24. 60021 TF20080 6RO60B2 Semiconductor Fuse Kit to suit 6R60 TQ60022 TF20125 6RO80B2 Semiconductor Fuse Kit to suit 6R80 TQ60023 TF20160 6R15 6R80 Semiconductor Fuse Kit Cover TQ60024 Replacement Fuse 6RO15B2 Semiconductor Fuse Kit to suit 6R15 TQ60120 TF20063 6RO30B2 Semiconductor Fuse Kit to suit 6R30 TQ60121 TF20081 6RO60B2 Semiconductor Fuse Kit to suit 6R60 TQ60122 TF20161 Semiconductor Fuse Kits Busbar Mount Technical Manual Smartstart 6000 Page 41 SS6000 Model Description Part Number Replacement Fuse 6R10000 Semiconductor Fuse Kit to suit 6R100 TQ60025 TF22400 6R19000 Semiconductor Fuse Kit to suit 6R190 6R220 TQ60026 TF22400 6R22000 Semiconductor Fuse Kit to suit 6R190 6R220 TQ60027 TF22400 6R36000 Semiconductor Fuse Kit to suit 6R360 TQ60028 TF23630 6R58000 Semiconductor Fuse Kit to suit 6R580 TQ60029 TF23500 2 per phase 6R83000 Semiconductor Fuse Kit to suit 6R830 TQ60030 TF23700 2 per phase IMIO042 rev H Appendix A ZENER SMART TORQ Torque Control System There are several methods available to soft start a motor The more traditional methods are Direct on line Star Delta Auto transformer and Primary resistance starters The more sophisticated methods also provide a soft stop and include Soft Starters and Variable Speed drives VSD s VSD s can provide a better soft start with significantly lovver starting currents and many other benefits including energy savings Hovvever a Soft Starter may provide
25. IMIO042 rev H Page 13 Technical Manual Smartstart 6000 Control VViring Default Standard Control 1 Standard Povver up Start no Soft stop DIGIn 2 16 DIGIn 1 15 ENABLE 14 24VDC 12 13 Control Supply 2 Standard Run stop using enable input Soft Start Soft stop or coast C20 Decel Ramp 0 0 for coast Adjust for soft stop gt 0 If enable is left on povver up start vvill be supported DIGIn 2 16 DIGIn 1 15 RUN STOP ENABLE 14 24VDC 12 13 Control Supply 3 Network Communications with local over ride X10 Dig In 1 inverted X11 Dig In 1 Variable Local X11 Dig In 1 Delay 0 0sec 1 N C contact to switch to local to force starter in local with broken wire 2 Use enable to start and stop Technical Manual Smartstart 6000 Page 14 Alternative configuration available 1 3 vvire starti stop A53 Start Logic edge sensed X10 Dig In 1 Enabled X11 Dig In 1 Variable Start latching X11 Dig In 1 Delay 0 0sec Use enable or DIG in2 for stop X20 Dig In 2 Invert X21 Dig In 2 Variable Stop X22 Dig In 2 Delay 0 Osec C20 Decel Ramp 0 0 for coast Adjust for soft stop gt 0 START DIG In 2 16 T DIG In 1 15 ENABLE 14 24VDC 12 13 Control Supply 2 Delayed softstart softstop Multiple pump control systems or prestart warning A X10 Dig In 1 Enabled X11 Dig In 1 Variable Start latching X11 Dig In 1 Delay Adjust to s
26. Level Set the current imbalance threshold as a percentage of the average phase current Range 5 2590 Default 25 a To save changes To exit without saving ENTER ESC P33 Curr Imbal Delay Set a delay for the current imbalance trip Range 0 10 seconds Default 10s To save changes To exit without saving a ENTER ESC Technical Manual Smartstart 6000 Page 24 P40 Undercurrent ESC P40 Undercurrent Trip 5 5s To enter submenu to modify To exit sub menu P41 Undercurrent Alarm Protection against under current This protection is not active during accel amp decel period Active when motor is up to speed Range off trip warn Default off To save changes To exit without saving ENTER ESC ap Ideal for detecting loss of load or low load conditions such as belt breakages or blocked water pipes Trip The soft starter trips stops the motor and indicates an undercurrent trip The Trip relay will change state if selected Warn The soft starter does not trip or stop the motor See DOS amp DO6 for more information regarding warning alarms P42 Undercurrent Level Adjust to the desired trip threshold as a percentage of the Motor Amps Range 10 100 Default 10 To save changes To exit without saving ENTER ESC Aa P43 Undercurrent Delay Adjust to set the time period that the current must fall below the threshold before a trip occurs
27. Manual Smartstart 6000 Page 5 Depth 172 172 172 172 Depth 232 232 232 244 285 285 285 305 305 305 B a i ZENER P E IDEEDE CS 1 D ist FC N m i2 SMARTSTART i m __ RA see SS E L DL 8 MM D TD I A IMIO042 rev H Installation Povver VViring Povver VViring The Zener Smartstart 6000 is installed between the mains and cable to the motor Ifa mains or isolation contactor is used itis best controlled by the starters Line relay MOT START e err 3Wire 6vvire The standard connection of an electronic soft starter is 3 wire An alternative connection is 6 wire or inside delta connection This is commonly used when replacing a star delta type motor starter Bypass Continuous The Smartstart 6000 can operate with or without a bypass contactor Some models include an integral bypass contactor The bypass contactor reduces the heat dissipation of the soft starter as the semiconductors are bypassed after the ramp time Select cables amp install in compliance with local regulations Technical Manual Smartstart 6000 Page 6 Motor Protection The Smartstart 6000 provides advanced motor protection with user selectable overload classes over amp under current protection phase imbalance and thermistor protection It is important that the power wiring is followed correctly to ensure proper protection and
28. QLOG txt 1 Single storage TXT File 0 Multiple storage TXT Files Secure Digital storage device E File Edit View Favorites Tools Help 3 A Search KC Folders E Address A E wrt CONFIG Ext SEQLOG txt File and Folder Tasks y Text Document E z Document e J ike e J 86KB Other Places A 4 My Computer Installation KL Secure Digital storage device E File Edit View Favorites Tools Help i2 Search E Folders E Address J El enz CONFIG txt LOGO1038 txt File and Folder Tasks y Text Document Text Done e e i KB Other Places A g zm LOG01040 txt E d My Computer D xt Document LoGo1041 txt io My Documents SA My Network Places 1 Remove the top cover There are 4x hex type screws holding the top cover in place LOG01039 tx Text Docume TE iske 2 The Option Board plugs into the control board into the socket marked OPTION located on the right hand side of the control Board 3 There are 2 nylon spacers and 4x 2 5mm screws supplied to secure the option card in place The Control Board will need to be carefully removed to access the underside to fit the nylon spacers 4 Carefully cut out the label marked SD Card ra En i KK Lem ann nj Kuel ETHERNET CONSOLE PORT 5 Return the control board ensuring all connectors plugs are secure and screws in place An insulation piece should be
29. R19000 480 x 305 x 290 18 6R22000 480 x 305 x 290 18 6R36000 770 x 470 x 430 68 6R58000 770 x 470 x 430 68 6R83000 770 x 470 x 430 68 6V200 6V400 770 x 470 x 430 70 6V90 480 x 305 x 290 20 Technical Manual Smartstart 6000 Page 39 IMI0042 rev H 556000 Options Control Supply Options Part Number Description Comments TF60013 415VAC Internal Control Supply 6R15 30 fitted Control powered from 3phase 415V supply internally TF60014 415VAC Internal Control Supply 6R60 80 fitted Control powered from 3phase 415V supply internally TF60031 18VAC Control Supply 6R60 80 fitted TF60032 18VAC Control Supply 6R15 30 fitted TF60033 18VAC Control Supply 6R100 fitted All models from 6R100 to 6R830 TF60034 240VAC Control Supply 6R15 30 TF60035 240VAC Control Supply 6R60 80 TF60036 240VAC Control Supply 6R100 All models from 6R100 to 6R830 24vdc Power Supplies Part Number Description Comments TQ60001 24Vdc Power Supply 36W 1 5 Amps Power Supply to suit 6R15 to 6R30 TQ60002 24Vdc Power Supply 48W 2 0 Amps Power Supply to suit 6R60 to 6R80 TQ60003 24Vdc Power Supply 72W 3 0 Amps Power Supply to suit 6R100 to 6R220 TQ60004 24Vdc Power Supply 96W 4 0 Amps Power Supply to suit 6R360 to 6R830 amp 6V series Option Boards SS6000 Model Description Part Number All Option Card data logger with SD card TQ60005 All Option Card data logger with SD card fitted TF60005 All Communications Option Ethernet Modbus TCP Data Log
30. RM e f XI IX S Y RT Ang gt Dei a Optional TH d l TH MOTOR Oe 1 Optional Fast Acting Semiconductor Fuses selected to suit SCR Devices used 2 Relay Contacts are rated for 5A 240VAC 30VDC inductive An intemediate relay may be required where peak currents may exceeds this rating 3 Models 6R15 to 6R80 include an integral Bypass Contactor With these models an external Bypass Contactor Is not required Technical Manual Smartstart 6000 IMIO042 rev H Page 46 Appendix C Remote Console Description The remote console kit provides the user remote access to perform the following e Scroll and display the Dashboard Variables a display of the following Operating status Motor Amps 3 Supply Voltage 3 Povver Torque Current imbalance Voltage imbalance Trip kVVhrs Run Hrs No of starts No of trips e Program any user configurable parameter e Reseta trip e Use the diagnostic menu and display I O status Note There is a 30 second delay between using the local or remote operator panels Specification IP Rating IP66 when installed as per instructions Panel Thickness 1 2to5mm Cable Type Cat 5 Maximum Cable length 30m unscreened Standard cable lengths 1m 2m 3m 5m rv Za Za Wm sees mm Installation ETHERNET CONSOLE The kit contains the remote console assembly and a plug in module board to provide connection at the Smartstart 6000 The plug in module p
31. User Manual SMARTSTART 6000 Series Models 6R15 6R830 6V90 6V630 ZENER Electronic Controls for motors AN General Warning Read amp familiarise yourself with the warnings detailed on Page 1 of the manual before proceeding High Voltage Warning Read all operating instructions before installing wiring operating servicing or inspecting the Smartstart Ensure that the instruction manual is made available to the final user of the product as well as all personnel involved in any aspect of installation adjustment or maintenance This symbol identifies the essential parameters for quick setup Technical Manual Smartstart 6000 Contents Introduction Receiving Handling amp Storage Handling on Installation Software The Smartstart 6000 Soft Starter Operation SMART TORQ Torque Control Installation Mechanical Installation Heat Dissipation amp ventilation Mechanical Dimensions Power Wiring General Semiconductor Fuses Power Wiring 15A 80A Power Terminals 100A and above Power Terminals 6 wire amp CT relocation Control Wiring Communications Programming Local Control Panel Display Trip Log Resetting Menu Map 1 Setup menu Display DO1 D20 2 Setup menu Motor M01 M04 3 Setup menu Control C01 C22 4 Setup menu Protection PO1 P73 5 Setup menu Reset RO1 R13 6 Setup menu Input X10 X22 7 Setup menu Outpu
32. a more economical solution to motor starting over the life of the motor Soft Starters provide the following benefits 1 Reduced stresses and wear on the mechanics of the system Reduced starting currents Minimise voltage dips on the supply Lowered Peak demand charges Eliminate belt slippage on fans Smooth acceleration of motor load DURUN The conventional voltage ramp Soft Starter is a reduced voltage starter and is similar to the traditional methods mentioned above The problem with voltage ramp soft starters is a non linear acceleration of the motor This is very noticeable on a pump type load where there is much higher acceleration torque available at the beginning of the start The diagram below shows the variation in acceleration torque available for both a Direct on line full voltage and the voltage ramp type soft start DOL full Voltage Torque LRT Acceleration Load Torque FLT Torque 100 Voltage Ramp Torque A 100 Speed SMART TORQ is a Torque Control System developed by Zener to overcome this problem with greater control over the acceleration torque in the motor The torque is controlled in a manner which suits the type of load to achieve a linear acceleration in motor shaft speed This control system is also active during the deceleration phase providing a soft stop where the motor decelerates at a constant rate This can be used to overcome water hammer problems associated with the closing or sl
33. amming of check valves ZENER SMART TORQ Key Benefits 1 A true linear acceleration of the load and motor for variable amp constant torque loads 2 Reduced stresses and wear on the mechanics of the system 3 Ramp profiling to better match type of load such as variable torque loads Better control of pumps and fans 4 Torque Control available in Accel amp Decel Modes and 3wire or 6wire motor configuration 5 Eliminate water hammer problems 6 Reduced peak current draw especially at motor pull in pull out operating points 7 Reduced heating in motor at low speeds 8 No instability due to changing power factor Closed loop system to monitor and react to changing power factor 9 No instability due to slot ripple in 3 wire and 6 wire operation 10 Better control of deceleration through closed loop torque control system 11 No external speed sensor required to produce superior performance The rate of acceleration is dependent on the additional torque Acceleration Torque available in the motor Thus we can achieve a constant or linear rate of Acceleration by providing Constant acceleration torque to the motor Technical Manual Smartstart 6000 Torque Torque Since the torque required by the load may not be linear the torque delivered by the soft starter must match that of the load To achieve this the torque developed in the motor must be the sum of the acceleration torque and the load torque at a spec
34. art time AR Lockout Restarts exhausted starter tripped ESO Proof In ESO and current detected sense may be used Initiates a motor stop vvith the configured decel profile A delay may be incorporated Forces a free wheel stop from any operating state Optional delay Forces local control and disables network control Curr Imbal Current imbalance trip active Essential Services Override This feature is designed for systems that must operate in the event of an emergency eg Fire Mode ESO overrides most protection and input conditions to run the motor Technical Manual Smartstart 6000 IMIO042 rev H Page 33 Programming Table 4 Flash Alerts Messages PENDING TRIPPED OVERRIDE AR 12 in 1234s AR 12 Anytime Soft Starter or Motor Cooling LOCKOUT Start is delayed postponed by an active interlock alarm There is an active warning alarm The alarm is identified by W displayed on 2 line The Soft starter has not tripped Refer to DO5 Warning Alarms for selection and adjustment The SMARTSTART has tripped on a fault condition The alarm is identified by THH displayed on 2 line Refer to page 30 for more detail on trip alarms Essential Services Over ride ESO requested Starter has tripped and automatic restart is pending Includes AR counter value and delay to reset restart attempt with T alarm displayed Starter has tripped and automatic restart is pe
35. arter see Control Wiring Page 14 amp Application Drawings Page 36 38 3 Models 6R15 to 6R80 include an integral Bypass Contactor Refer to Page 40 for replacement fuses With these models an external Bypass Contactor is not required Refer to page 13 For Control Wiring Technical Manual Smartstart 6000 IMIO042 rev H Page 7 Installation Povver Terminals 100A model and above Chassis AZ TOP Povver Terminations Model Chassis Busbar Hole Bolt Size Earth Stud O BYPASS BYPASS BYPASS 6R10000 A2 1x 8 5mm M8 M8 B1 B2 8 B3 9 6R19000 A2 1x 10 4mm M10 M8 6R22000 A2 1x 10 4mm M10 M8 LINE LINE LINE 6V09000 A2 1x 8 5mm M8 M8 L1 1 L2 3 L3 5 6R36000 A3 2x 10 4mm M10 M8 6R58000 A3 2x 10 4mm M10 M8 6V20000 A3 2x 10 4mm M10 M8 6V40000 A3 2x 10 4mm M10 M8 MOTOR MOTOR MOTOR All soft starters include a bolt kit O O O Semiconductor Fuse kit Optional Model Description Part No 6R10000 Fuse Kit to suit 6R100 TQ60025 Chassis A3 6R19000 Fuse Kit to suit 6R190 TQ60026 TOP 6R22000 Fuse Kit to suit 6R220 TQ60027 6R36000 Fuse Kit to suit 6R360 TQ60028 O O O O O O 6R58000 Fuse Kit to suit 6R580 TQ60029 BYPASS BYPASS BYPASS 6R83000 Fuse Kit to suit 6R830 TQ60030 Semiconductor Fuse Replacement LINE LINE LINE i L1 1 L2 3 L3 5 Model Description Part No Qty per Starter BOTTOM 6R10000 Semiconductor Fuse 200A TF22200 3 6R19000 Semiconductor Fuse 400A TF22400 3 MOTOR MOTOR MOTOR 6R22000 Semico
36. ault Torque ap To exit sub menu ENTER 0 Save changes ESC To exit without saving A11 Kick Time Set to the time of the kick A30 Decel Method Range 0 0 2 0 seconds Default 0 0 Disabled ENTER To save changes ESC To exit without saving A30 Decel Method Linear a Torque Decel Profile A12 Kick Level Set the level of kick as a percentage of Locked Rotor Current The deceleration method allows adjustment of the deceleration profile and acceleration control of the Range 50 100 Soft Starter This provides advanced control of the Default 70 motor during the ramp down time to better match the ENTER To save changes type of load or application This is especially useful in Bee n BEER resolving water hammer related problems Decel Control ap Technical Manual Smartstart 6000 IMIO042 rev H Page 29 Programming ENTER To save changes To exit vvithout saving A44 VVarning Delay Set the vvarning threshold for protection based on a A31 Decel Profile Select the type of deceleration profile to match the type of load or application Range Linear Squared Default Linear ENTER To save changes ESC To exit vvithout saving a A32 Decel Control Select the type of deceleration control to suit the load or application Torque control will provide greater control over the deceleration stopping of a motor under load Range Torque Voltage Default Torque ENTER To save
37. ays relay status of internal relays for Fan Bypass and Programmable Relays 1 2 3 and 4 Chk Motor Wiring Displays detected motor wiring Example Correct Mtr 3 wire Chk CT1 CT2 Displays detected CT connection Example Correct L1 L3 IMIO042 rev H Page 31 Programming Setup Menu 12 Network Diag This menu provides a diagnostic for Network Communications Netvvork Status ldle Diag Flgs 0x0000 CO ReqsAoK 0 C1 BusMsgs 0 C2 BusErrs 0 No Comms errors C3 Reqs Bad 0 No Exceptions C4 Reqs Rxd 0 No Requests C5 ReqsCast 0 C6 RspNaks 0 C7 RspBusy 0 C8 OvrRuns 0 Network status amp event wheel Network Diagnostic Flags in hex Count of requests processed normally Count of error free bus messages Count of bus messages with a communication error Count of bad requests received Shows no or recent exception Count of requests received with or without exceptions Count of broadcast requests received Count of exception responses sent Count of busy responses sent Count of messages detected with a character over run For more comprehensive instructions and mapping 17 25 45 Net 14 APR 2013 RxOK The network status summary is also shown on the clock date dashboard screen Refer to the corresponding SS6000 networking guide for more information Technical Manual Smartstart 6000 Page 32 IMIO042 rev H Programming Table 1 Outpu
38. cal that the C T s be installed in the correct phase and in the correct direction Page 12 provides instructions as to where the C T s are to be located Refer to page 12 For details on correctly installing external IMIO042 rev H Installation Povver VViring 100A model and above Standard 6 vvire Bypass POVVER CIRCUIT 415V 3 PHASE SUPPLY CIRCUIT BREAKER r Ga 2 LC LINE ISOLATION CONTACTOR bi ce To 556000 S2 PE SET To S 6000 5S1 far L 24 ti intemal C Ts relocated externally see Page 12 for more details 1 B2 B3 SMARTSTART 6000 T2 T3 3 BC BYPASS CONTACTOR TI 1 Optional Fast Actng Semiconductor Fuses selected to suit SCR Devices used 2 Line Contactor controlled by the Soft Starter see Control Wiring Paqe 13 amp Application Drawings Page 36 38 3 Bypass Contactor controlled by the Soft Starter see Control Wiring Page 13 amp Application Drawings Page 36 38 Keter to page 13 For Control Wiring Refer to page 12 For details on correctly installing external C T s Technical Manual Smartstart 6000 Page 11 Standard 6 wire Continuous POWER CIRCUIT 415V 3 PHASE SUPPLY CIRCUIT BREAKER VVT ME Me Visi LINE ISOLATION A i CONTACTOR bij 3 aj o To 856000 51 relocated externally see Paqe 12 for more details G ai O Q Bi B2 B3 To 556000 52 SMARTSTART 6000 T2 T
39. creen 1 gt The Trip Log Message Log Number TRIP Code 04 Jan 2014 A gt T60 NAN Gr LO1 Accel 1 gt T60 MOTOR FAULT L01 00 12 17 Operating state at time on Code of ramp time Each trip log shows 1 Log Number LO1 most recent to L10 Oldest 2 Date amp Time of trip 3 The Trip code and description See trip codes 4 Op Code Indicates the operating state when the trip occurred A Accel Accel Ramp up with ramp timer progress B Run Bypass Bypass contactor closed C Run Cont D Decel with ramp timer progress K Kick Start U Atspd Motor up to speed with ramp timer progress How to Reset after a trip To reset the starter press the reset button for 3 seconds The display will countdown 3 2 1 Resetting fault The trip will be logged into the fault log The reset function can be configured multiple ways Refer to 5 Reset Restart Menu and page 26 for more information IMIO042 rev H Page 18 Programming Menu Map Overvievv The Dash Board ENTER SMARTSTART 6000 6RO30 V1 13X ESC Technical Manual Smartstart 6000 Set Up Menu ENTER Setup Menu 1 Display ESC ENTER Setup Menu gt 2 Motor EC ENTER Setup Menu 3 Control Q ___ ENTER Setup Menu 4 Protection ENTER Setup Menu a 5 Reset Restarts ESC ENTER Setup Menu 6
40. ction Thermal protection of the soft starter is provided by a temperature sensor located on the heatsink and by calculating the temperature of the thyristor junction with sophisticated modeling of the specific devices used Fans are powered by 24VDC supply and thermally controlled when the heatsink temperature exceeds 40 C and whist the motor is ramping Motor thermal Protection The Smartstart 6000 provides thermal protection of the motor by providing a thermistor input and also a programmable motor overload protection feature The starter continuously monitors the current and calculates the temperature rise of the motor based on the motor data provided The standard IEC60947 4 2 defines the protection classes giving the starting capacities of the motor warm or cold without thermal trips The thermal protection displayed by the starter corresponds to the thermal time constant e An overload trip will occur and stop the motor if the motor exceeds the critical temperature rise threshold of 125 e This feature has a memory function based on the thermal capacity and may not allow a start if the temperature rise is too high e The thermal state continues to calculate even when the starter is off and powered down Simply by turning power off and back on will not reset the thermal state Motor thermistor Protection The Smartstart 6000 provides an input for a thermistor or normally closed switch Thermistor PTC probes integrated
41. dent safety equipment must be installed if the application is such that failure of the product may result in personal injury or property damage Ensure the Smartstart 6000 is applied in a manner that does not adversely affect the proper operation of other equipment or systems particularly those that have a safety function Install emergency stop circuitry that removes power from the Smartstart 6000 and does not depend on any feature of the product for proper and safe operation The Smartstart 6000 has features that may be used to cause an automatic restart in certain circumstances The overall application machine etc must be designed such that automatic restart is not hazardous Do not install this equipment in locations where mechanical damage to the enclosure is possible In particular consider vehicles vandalism and attack by insects or animals Severe equipment damage and safety hazards may result The Smartstart 6000 offers an Essential Services Overide ESO mode of operation This mode of operation intentionally ignores some motor and starter protection As a result the equipment may operate outside its thermal rating and void any warranty Technical Manual Smartstart 6000 IMIO042 rev H Page 1 Introduction Receiving Inspect the Smartstart 6000 for any shipping damage If any damage is found report it to the carrier immediately Remove cover of starter and visually check for damage Do not attempt to operate the Smartstart
42. display when a trip has occurred with details of the type of trip in the trip log The Smartstart 6000 may be configured to display the trip or alarm warning on the default screen over the bar graph The highest priority active alarm is displayed in place of the bar graph only when the motor is off Refer to table 5 p34 for alarm message explanation a Selection All Alarms Disabled Trips only Fit Warnings Major Warnings Default All Alarms ENTER To save changes ESC To exit without saving Level Option Description 1 Trips Only Only displays trip Alarms T Incl Tripped AR amp Lockout alerts 2 FIt Warnings Include fault warning alarms vvo2 22 15 14 11 05 07 32 08 06 3 Major Warnings Include major warning alarms vvo2 04 13 23 21 20 31 30 24 25 26 4 All Warnings Include remaining minor alarms W37 38 41 33 35 34 36 5 All Alarms Include interlock warning alarms see T message alarms on page 34 D10 Time Set the time of real time clock Pa Adjust the value of time ENTER To save changes To exit vvithout saving D20 Date Set the date of real time clock Pa Adjust the value of time ENTER To save changes To exit without saving Technical Manual Smartstart 6000 Setup Menu 2 Motor M01 Motor Amps indicated on the motor rating plate even if connected in 6 wire inside delta Adjust to the value of motor full load current FLC Pa Ran
43. e Phase reversal Motor Loss CT fault Line Freq Phase Network Timeout Remote Input 24V dc logic 2x Programmable inputs 1x Enable Input Thermistor or NC switch PTC type Trip Resistance 30000hms lt 20ohms detected as Short Circuit 4 Programmable Relays 5A 250Vac 5A 30VDC 1x Programmable Output 0 10V 0 5V 4 20mA Modbus RS485 Standard Ethernet Modbus Option Adjustable Class 10 10A 20 25 30 type R1 total memory function Heat sink temperature Currrent amp thermal modelling Adjustable level and trip time Adjustable level and trip time Adjustable level and trip time Adjustable level and trip time 300 for 3 seconds run mode only Adjustable Current amp thermal modelling Semiconductor fuses optional Input voltage imbalance Input amp output current imbalance No bypass after ramp time or during run mode Open or Short circuit SCR Accel time exceeds set time Phase rotation inhibit Motor or output open cct Fault with CT s Problem with supply Network Fault Forced trip from external source Human Interface Module HIM Type Display Menu Menu Protected Cable type Local or remote mountable IP66 Backlit LCD Blue English Coded amp English Selectable user access code Ribbon or Cat 5 Essential Services Over ride ESO Selectable Digital input with 24Vdc logic Battery Type Page 36 CR1220 IMIO042 rev H Thermal Protection Starter Thermal Prote
44. er hour When installing the Smartstart 6000 in an enclosure or switch board it is necessary to consider the heat dissipated and then the ventilation required The following formula s will assist in determining whether ventilation is required and how much Ventilated Enclosure V 3 1xP T Where V Airflow required in m3 hour P Power dissipated in Watts T Temperature differential in C inside outside Non Ventilated Enclosure A P Txk Where A Exposed surface area of cabinet inm2 P Power dissipated in Watts T Temperature differential in C inside outside k Heat transmission constant 5 for Painted metal IMIO042 rev H Installation Mechanical Dimensions All Dimensions in mm Model Chassis A B C D 6RO15B2 B2 335 162 315 111 6RO30B2 B2 335 162 315 111 6RO60B2 B3 440 162 420 111 6RO80B2 B3 440 162 420 111 Mounting Holes Top Bottom 6 0 mm 6 0 mm Q 12 0 mm Model Chassis A B C D 6R10000 A2 430 248 400 216 6R19000 A2 430 248 400 216 6R22000 A2 430 248 400 216 6V09000 A2 430 248 55 400 216 Mounting Holes Top Bottom 8 0 mm 8 0 mm 100mm SEN a F K E JE r T 16 0 mm Model Chassis A B C D 6R36000 A3 670 375 640 159 6R58000 A3 670 375 640 159 6R83000 A3 670 375 640 159 6V20000 A3 670 375 640 159 6V40000 A3 670 375 640 159 6V60000 A4 670 375 70 640 159 Mounting Holes Top Bottom 120mm 12 0 mm 24 0 mm Technical
45. g a microprocessor to control inverse parallel back to back pairs of SCR s An SCR thyristor is a semiconductor device that latches when triggered Once triggered it allows current to flow in one direction only and turns off at zero current The firing angle of the SCR s are controlled to achieve the desired acceleration of the motor M3 yai Soft Starters provide the following benefits 1 Reduced stresses and wear on the mechanics of the system Reduced starting currents Minimise voltage dips on the supply Lowered Peak demand charges Eliminate belt slippage on fans Smooth acceleration of motor load a ee Technical Manual Smartstart 6000 Page 3 SMART TORQ Torque Control Feature The Zener Smartstart 6000 incorporates a closed loop torque control system to provide better control over starting amp stopping 3 phase induction motors Conventional voltage ramp control systems typically produce low torque at low speeds When starting amp stopping variable torque loads e g Pumps this can results in a very rapid acceleration or deceleration with a non linear change in motor speed The Smartstart 6000 series overcomes these issues by regulating the torque in the motor to match the load type during the acceleration amp deceleration This essentially allows a constant torque to be produced in the motor The continual monitoring of the motor characteristics during the ramp al
46. ge 40 of Nom unit rating to max rating Default Nom rating of unit ENTER To save changes SC To exit without saving Nom unit rating 3vvire bypass light duty KEN M02 Motor Volts Adjust the value to the motor nameplate voltage a Range 199 481V 480 1160V Default 415V 1000V ENTER To save changes ESC To exit without saving M03 Motor PF Adjust to the value to the motor Power Factor as indicated on the motor rating plate Range 0 60 0 98 Default 0 90 ENTER To save changes Esc To exit without saving M04 Motor Wiring excl 6R15 6R80 Select the wiring configuration of the soft starter 3 Wire Std 6 Wire Alt 6 Wire 3 Wire ENTER To save changes To exit vvithout saving Setup Menu 3 Control C01 Run Mode Set to the configuration of the Smartstart 6000 Aa Range Bypass Continuous Iw Default Bypass ENTER To save changes To exit vvithout saving IMIO042 rev H Page 21 Programming CO2 Current Limit a The current limit is expressed as a percentage of the entered motor Amps FLC This current limit setting operates during the ramp time only and will over ride the torque settings Reducing the current limit will limit the torque available to the motor and load If set too low it may prevent the motor from accelerating or reaching full speed Range 100 to 450 FLC Default 450 ENTER To save changes ESC To ex
47. ger TQ60040 All Communications Option Ethernet Modbus TCP Data Logger Fitted TF60040 Remote SMART Console Option H I M Cat 5 Cable Part Number Description Comments TQ60011 SMART Console IP66 loose Available for all models TF60011 SMART Console IP66 fitted Available for all models TQ60012 Cable SMART Console per m Max length of 30m TQ60050 Cable SMART Console 1m TQ60051 Cable SMART Console 2m TQ60052 Cable SMART Console 3m TQ60053 Cable SMART Console 5m Note The Smartstart 6000 will operate with the local console and a remote console connected A connection port is provided when fitted There is a 30second delay between operating either the local or remote keypad before the alternate keypad can be used REMOTE ETHERNET CONSOLE PORT Technical Manual Smartstart 6000 IMIO042 rev H Page 40 556000 Options Other Options SS6000 Model Description Part Number 6R100 6R220 Prepared for 6 vvire TF60015 6R360 6R830 Prepared for 6 vvire TF60016 For 6 vvire operation the Current transformers supplied integral to the Smartstart 6000 must be relocated to L1 amp L3 of the Line circuit not the Phase circuit Semiconductor Fuse Kits IPOO Replacement SS6000 Model Semiconductor Fuse Kits IP20 Enclosed Description Part Number SS6000 Model Description Part Number Fuse 6RO15B2 Semiconductor Fuse Kit to suit 6R15 TQ60020 TF20032 6RO30B2 Semiconductor Fuse Kit to suit 6R30 TQ
48. icient start T63 T3 PHASE FLT Current not detected in single settings Ambient temperature rating exceeded or Starter rating exceeded T24 MOTOR STALL Motor Stalled current after start gt 300 for 3 seconds Check motor load and Starter settings See P20 page 23 Check supply P30 page 24 Check supply and motor T30 MTR OVERLOAD Motor thermal overload trip as per user setting See page 20 Incorrect overload class amp starter rating Motor or load problem Excessive starts per hour for overload class selected Insufficient start torque and or current limit too low check settings T31 MTR OVERTEMP Motor over temperature from the thermistor input See PO2 page 23 Check Motor and Load Technical Manual Smartstart 6000 IMIO042 rev H Page 36 Specification Input Voltage 6R series 6V series Input Frequency Control Supply 220 to 460Vac 6R15 80 380Vac to 415Vac 600 to 1000V 10 50 60Hz 3Hz Auto detecting 24Vdc 15 15 24VDC Power Supply min requirements Power Supply O P 24VDC Regulated Peak power requirements 6R15 30 6R60 80 6R100 220 6V90 6R300 880 6V200 630 1 5 Amps 36W 2 Amps 48W 3 0Amps 72W 4 0 Amps 96W 4 0 Amps 96W These ratings allovv for peak current requirements of internal fans AC Control Supply Options Available 240VAC 18VAC 415VAC Self Powered Configurations Duty Light Duty Standard Duty Severe Duty
49. ific speed Below illustrates the constant acceleration torque applied for different load types 1 Constant Torque type Load eg Conveyor Total Torque Acceleration Torque Load Torque Speed 100 2 Variable Torque type Load eg Pump Fan Total Torque Load Torque 100 How is this achieved The SMARTSTART 6000 continually monitors start variables such as motor current voltage and power factor to determine the input electrical power From the motor parameters the IR amp magnetic losses are used to calculate the Air Gap Power ie the power transmitted to the motor shaft With an instantaneous value of shaft power the instantaneous torque can be determined With this information we can vary the thyristor conduction to achieve the desired torque The torque is varied to follow a specific curve based on the initial torque setting the final torque setting and the profile selected The end result is equal acceleration torque over the ramp period to provide a linear acceleration in motor shaft speed The profile is user adjustable allowing for non linear torques if required to other or unusual types of loads Summary The SMART TORQ Torque Control System provides smoother starting amp stopping allowing ramp profiling to produce a linear acceleration and deceleration of the motor speed There are many benefits with variable torque loads such a pumps A linear acceleration and deceleration provides better
50. ired Included is a simple application that extracts and reports basic operating variables Compatibility SMARTSTART 6000 firmware revision 0 96X or later is required SD Cards Accepted Standard SD Card 1G 2G Micro SD Card with Adapter If the SD card has a write protect tab ensure it is not in the lock Samisk 4 oi position 2 0 S Operation e With the control power to the soft starter off Insert the SD card e Power up the control circuit The Data Logger is now operational The soft starter will create 2 files onto the data card i txt file config txt which logs the Baud Rate and Data Format ii txt file This is where the data will be stored A new text file will be created each time the control supply is cycled or can save data to the one text file see over page on instructions on how to modify this e The text file may be deleted on a computer at any stage and a new file will be created e The text files may be removed copied and or sent via email to Zener for analysis should a problem exist Technical Manual Smartstart 6000 IMIO042 rev H Page 48 Appendix D Data Logger Option Board Modifying the config txt file To change the logging behavior vvrite over the last digit and save the changes a CONFIG txt Notepad File Edit Format View Help 115200 6 3 0 This last digit sets the logging behavior as follovvs O Creates a new data file when power is cycled 1 Saves data is same file SE
51. it without saving Appendix A Page 42 provides a guide to starting parameters for various load types C10 Accel Ramp C10 Accel Ramp 10s 30 100 Accel Time Start Torque Final Torque ENTER Toenter submenu to modify ESC L YI To exit sub menu C11 Accel Time Adjust this to vary the time taken to ramp the voltage to full supply voltage or the torque to reach the finish torque The accel time will affect the actual current during starting the faster the rate of acceleration the higher the start current Range 1 to 60 seconds Default 10s ENTER To save changes ESC To exit without saving C12 Start Torque The initial torque provided when a start is initiated Adjust to the lowest setting which allows the motor to turn on a start command This is entered as a percentage of nominal Torque FLT This setting will be dependent on the torque required by the load Range 0 to 200 Default 30 C13 Final Torque torque control only This sets the torque provided at the end of the acceleration period This is entered as a percentage of nominal Torque FLT Range 15 to 200 Default 100 ENTER To save changes To exit without saving C20 Decel Ramp C20 Decel Ramp 10s 20 DECEL Time Release Torque To enter submenu to modify To exit sub menu C21 Decel Time The time taken to decelerate the motor from 100 to 0 V or FLT actual time dependant o
52. l via network is enabled and online TRIP LOG ENTER T00 NO TRIP ALM This symbol identifies the parameters for quick setup IMIO042 rev H Page 16 Programming Operating Status Indication of Accelor Actual Current Decel time Current status ACCEL 50 250A O 300 Current as of motor Bar Graph displaying FLC Programmable current Off The Smartstart 6000 has control power applied but not enabled and no line supply Standby The Smartstart 6000 has been enabled to start and the run relay energized to bring in the line contactor if installed The Smartstart 6000 will initiate a start immediately 3 phase supply is applied Ready Line supply on but nor enabled ACCEL The Smartstart 6000 is accelerating the motor Ramp time completed amp Motor Current A displayed At Speed The motor is at full speed the accel time period may not be complete Ramp time completed amp Motor Current A is displayed Run Bypass or Run Cont The ramp time is complete and the bypass contactor operated or SCR s are in full conduction Motor Current A is displayed DECEL The Smartstart 6000 is decelerating the motor Ramp time completed amp Motor Current A displayed Start Req Enabled but start delayed postponed due to cooling or start timer delay Kick Start Kick start is active
53. lected Warn The soft starter does not trip or stop the motor See DOS amp DO6 for more information regarding warning alarms P72 Over Torque Level Adjust to the desired trip threshold as a percentage of nominal torque Range 80 250 Default 10094 ENTER To save changes ESC To exit vvithout saving a P73 Over Torque Delay Adjust to set the time period that the torque must exceed the threshold before a trip occurs Range 0 30 seconds Default 10s ENTER To save changes Esc To exit without saving At Setup Menu 5 Reset Restarts RO1 Manual Reset Activate or de activate the manual reset ie The reset on the local console Range Enable Disable Default Enable ENTER To save changes ESC To exit without saving a RO2 Power Reset Activate or de activate reset on removal of control supply Pa Range Enable Disable ww Defqult Enable ENTER To save changes ESC To exit vvithout saving RO3 Start Reset Activate or de activate reset on a start command Range Enable Disable Default Disabled ENTER To save changes ESC To exit without saving a R10 Auto Restart P70 Over Torque 5 10s 1200s No of Attempts 4 AR Min Delay AR Clear time R11 AR Attempts Enter number of restart attempts Range 0 15 Default Oz Disabled ENTER To save changes To exit without saving a m 0 O R12 AR Min Delay Enter Minimum delay before restart attempt
54. mit the amount of starts per hour and allow the soft starter or Motor to cool before a restart The motor may restart after time lapsed if enabled Range 0 600mins Default 0 0 ENTER To save changes Esc To exit without saving ap A53 Start logic This parameter sets the operation of a start signal whether it senses level or an edge of a start signal Range Edge sense Level sense Default Level sense ENTER 70 save changes ESC To exit without saving a The enable input is generally used as the level sensed run input for the soft starter IMIO042 rev H Page 30 Programming An optional Start function is also selectable as a digital input This is a latching input which is unlatched by a stop control input deactivating the enable input or a trip Level Sense The default setting when using the enable input to run the soft starter For power up start with line supply to function level sense must be selected Also used for 2 wire run stop control using the digital input Start and enable input may be used in conjunction with the stop or coast input The start signal must be present until motor commences start Edge Sense Will only start with an edge trigger This is the recommended setting for 3 wire start stop control May also be used to prevent an unexpected start if stop coast is restored and enable start input signal remains active Refer to page 14
55. n torque settings Pa Range 0 to 120 seconds Default Os To save changes To exit without saving C22 Release Torq The Smartstart 6000 will decelerate the motor at the decel time rate until the torque reaches the release torque value entered This is entered as a percentage of nominal Torque FLT a Range 0 to 100 v Default 20 To save changes To exit without saving In pump applications the deceleration provided by the Smartstart 6000 will reduce problems with water hammer with greater control of the motor torque amp speed The Smartstart 6000 has advanced settings to customise the control of the motor during acceleration and deceleration Refer to Menu Advanced Controls on page 29 for more details ap ENTER To save changes ESC To exit without saving Technical Manual Smartstart 6000 IMIO042 rev H Page 22 Programming Setup Menu 4 Protection Some protection may be set for trip or vvarn A Trip vvill cause the soft starter to stop vvithout a soft stop based on the parameters configured A Warning is based on the configuration of A43 warning level or A44 Warning delay and will not cause the soft starter to trip or motor to stop P01 Mtr Overload The Smartstart 6000 continuously monitors the motor current even in bypass and calculates the temperature rise of the motor The tripping curves are based on the protection classes as defined by lEC60947 4 2 Refer to page 37 for
56. n which it is installed open Do not touch the terminals of the Smartstart 6000 or any associated motor and wiring when it is energised even if the Smartstart 6000 and motor are stopped Electric shock may result Do not modify this equipment electrically mechanically or otherwise Modification may create safety hazards as well as voiding the UL listing of models so listed The Smartstart 6000 is designed to drive an appropriately rated and otherwise suitable 3 phase induction motor It is not suitable for single phase motors or other types of motor or non motor load Use with inappropriate load types may create a safety hazard Where the Smartstart 6000 is used as a component part of another product it is the purchaser s responsibility to ensure that the final product meets all of the necessary safety EMC regulatory operational and other requirements for that product Requirements for the purchaser s final product may be substantially different to the requirements for stand alone inverters The Smartstart 6000 is intended for use only in fixed wiring applications It is not intended for use on a flexible supply cable Mount the Smartstart 6000 on a vertical incombustible surface such as metal or masonry Do not place combustible or flammable material near the Smartstart 6000 Failure to observe these precautions may create a fire hazard The Smartstart 6000 is manufactured under strict quality control arrangements however additional and indepen
57. nding Includes AR counter value and delay to reset restart attempt with THH alarm displayed The actual restart time is dependent on thermal reset level and cooling rate Flashed after all Auto restart attempts exhausted Technical Manual Smartstart 6000 121 STR OVERTEMP I30 MTR OVERLOAD I31 MTR OVERTEMP 151 Min Off Time I52 Prestart Dly I53 No Supply 170 Enable OFF 171 Coast ON 172 Stop ON 173 Start OFF 174 Net Enbl OFF 175 Net coast ON 176 Net Strt OFF Page 34 Table 5 Interlock Messages Starter too hot to start Waiting for heatsink to cool Motor is too hot to start Motor TOL reset threshold not reached Motor thermistor is too hot to start Waiting for min off timer to expire Waiting for start input D1 D2 timer to expire Line relay on but no supply detected Local Enable digital input is off Local coast input is on D1 D2 Local stop input is on D1 D2 Local start input is off D1 D2 Network enable command flag is off Network coast command flag is on Network Coast command flag is off IMIO042 rev H Programming Technical Manual Smartstart 6000 IMIO042 rev H Page 35 Programming Trip VVarning codes amp messages A warning message will have a W in place of the T for the following messages CODE Message CODE Message TOO NO TRIP ALM No fault or trip has occurred T32 MTR TEMP FLT Motor thermistor sensor fault TOL PSU LOW VOLT Contr
58. nductor Fuse 400A TF22400 3 T1 2 T2 4 T3 6 6R36000 Semiconductor Fuse 630A TF23630 3 O O O O O O 6R58000 Semiconductor Fuse 500A TF23500 6 6R83000 Semiconductor Fuse 700A TF23700 6 Technical Manual Smartstart 6000 IMI0042 rev H Page 8 Installation Povver VViring 100A model and above 3 VVire Bypass POVVER CIRCUIT 415V 3 PHASE SUPPLY CIRCUIT BREAKER 2 LC LINE ISOLATION A A CONTACTOR 1 OPTIONAL SEMICONDUCTOR FUSES Bi KA Vo 3 BC BYPASS CONTACTOR T3 MOTOR j 1 Optional Fast Acting Semiconductor Fuses selected to suit SCR Devices used 2 Line Contactor controlled by the Soft Starter see Control Wiring Page 14 amp Application Drawings Page 36 38 3 Bypass Contactor controlled by the Soft Starter see Control Wiring Page 14 amp Application Drawings Page 36 38 Refer to page 13 For Control Wiring Technical Manual Smartstart 6000 Page 9 3 Wire Continuous Without Bypass Contactor NOTE The SS6000 must have the appropriate rating to operate without a bypass contactor POWER CIRCUIT 415V 3 PHASE SUPPLY CIRCUIT BREAKER 2 LC LINE ISOLATION CONTACTOR i 1 OPTIONAL SEMICONDUCTOR FUSES Lb a J B1 B2 B3 gt SMARTSTART 6000 T1 T2 T3 06 ew Ka fe 1 Optional Fast Acting Semiconductor Fuses selected to suit SCR Devices used 2 Line Contactor controlled by the Soft S
59. ng the UP DOWN push buttons These DASHBOARD screens are also accessible even when the menu lockout is enabled Any of these screens may also be configured as the default screen on povver up Default Screen Status displayed in Plai nede A Supply Voltage or English S 17 f e u ES ai Motor Current more details x Bar Graph to provide visual Bar Graph Value indication See DO4 Page 20 Default Motor current See DO3 Page 20 Technical Manual Smartstart 6000 The Dash Board SMARTSTART 6000 6R030 VI 2X 11 44 43 Net 19 AUG 2013 Idle ENTER MER Ready 100A Note 1 The defqult screen can be Li E 80 changed See menu item DO2 TS I Ce Default Screen Note 2 Thermal 100 STR The bargraph Variable can be Capacity 100 MTR changed See menu item Bargraph Var Note 3 415v 50Hz 100A User Access to the menu may 1 2 3 56kW be resticted See menu item D01 Menu Access Pwr T Network Status Indication The time amp Clock screen also e displays the network status Volt Imbal 0 415 415 415V Net Indicates rate of Network transactions CAT I Ce Off Network is disabled Idle No Activity Curia 0 Down Network Down 100 100 100A Live Network is qctive but not receiving Ca v ERR Communication error message corrupt 0 Starts BAD Invalid request 0 Trip RxOK Request processed normally 0 8 Hrs 400 kWh Ctrl Contro
60. nical Mechanical Installation The Smartstart 6000 should be installed by qualified electrical personnel only The following should be considered when installing the Smartstart Mount in a vibration free environment Mount vertically and away from heat radiating sources Do not mount in direct sunlight or on hot surfaces Mount in a suitable enclosure for the environment in which it is to operate the total heat dissipation must be considered Do not drill holes into the Smartstart 6000 enclosure Do not allow metal shavings or any other conductive material to enter the enclosure or damage may result gt 75mm gt 75mm gt 75mm Models 6R15 30 60 80 Only Below illustrates the clearances to allow access to Ports if fitted i Remote Console RJ Connection ii SD Card Slot iii Ethernet Port Technical Manual Smartstart 6000 Page 4 Heat Dissipation The Smartstart 6000 is cooled by temperature controlled internal fans Installing a bypass contactor will reduce the heat dissipated and the ventilation required Soft Starters generally dissipate approximately 4 5watts per Amp when operated without a bypass contactor The heat dissipated can be calculated by Continuous Duty P FLCx 4 5 Bypass Duty P FLCxSCx4 5xtxN 3600 Where P Power dissipated in Watts FLC Nameplate FLC of Motor SC Average starting current expressed per unit of FLC t Starting time N Number of starts p
61. ol supply voltage low Check control Se mon voltage i T33 MTR OVERCURR Over current trip as per user TO3 LINE PH FLT 3 Phase supply problem one phase open T34 MTR UNDERCURR Ee ei SS Check L1 L2 L3 i T04 PHS ROTATION Line Phase sequence in wrong direction 135 MTR OVERTORQ SAN A i d ad User selectable See PO3 page 23 Ura 8 e TO5 MTR 3 6 WIRE Wiring detected different to motor wiring T36 MTR UNDERTORQ S Ee eg setting Check motor vviring To edir pag eem TO6 NET T O Loss of communications while network 137 D1 INPUT ALM controlling motor connected to Digital input 1 T38 D2 INPUT ALM Trip initiated from external source motor current Check correct installation of E external CT s 6 wire only Check CT T41 ACC OVERTIME Acceleration time has exceeded phasing under the diagnostics menu to bey UME aS Pel USET SEINE 266 check or help identify the error Gen 23 Ne load e ore T11 MTR STUCK ON Unexpected motor current detected vvhile Ne and or current limit too low off Check wiring relay configuration and check settings bypass contactor T42 ESO MODE Warning Message when Essential DR unexpectedly T50 MTR AMPS CFG Motor Amps configuration Error unexpectedly 3 Phase pole fault and or motor wiring T61 TI PHASE FLT Current not detected in single El T23 STR OVERLOAD Starter thermal overload Motor or load T62 T2 PHASE FLT Current not detected in single Excessive starts per hour Insuff
62. rk control timeout a Range Disabled Stop On T O Trip On T O iw Default Disable ENTER To save changes ESC To exit without saving Technical Manual Smartstart 6000 NO3 Net Timeout RS485 8 Ethernet Adjust for the time delay for the timeout function Range 0 1 60secs Default 2 0sec ENTER To save changes ESC To exit without saving a N10 RS485 Addr RS485 only Adjust to the desired network address value for the soft starter Each device on the bus must have a unique address Range 0 247 Default 0 ENTER To save changes ESC To exit without sqving a N11 RS485 Speed RS485 only Adjust to the required baud rate Range 4800 9600 19k2 38k4 Default 19k2 ENTER To save changes ESC To exit without saving a N12 RS485 Format RS485 only Select the correct protocol format Range 801 8n1 8n2 8e1 Default 8e1 ENTER To save changes ESC To exit without sqving a N20 IP Address Ethernet Only Enter the IP address in format shown N20 IP Address 000 000 000 000 N21 IP Address 1 Ethernet Only Range 0 255 Defqult 0 ENTER To save changes To exit without sqving N22 IP Address 2 Ethernet Only a Range 0 255 YI Default 0 ENTER To save changes To exit without sqving N23 IP Address 3 Ethernet Only ap Range 0 255 Defqult 0 ENTER To save changes ESC To exit vvithout saving ap IMIO042 rev H Page 28 Programming
63. rovides a socket for the remote console as shown Remote Console Mounting Mark up you panel using the dimensions below Ensure there is sufficient space to connect the cable s 1 Cut out the panel 2 Install as shown Ensure the display modules has the black rubber seal fitted to ensure an IP66 rating is achieved 3 Connect the connecting cable Cat 5 to the module and the SMARTSTART 6000 54 mm Cut out Dimensions FRONT VIEW 108 0 mm Tr 720mm 3 0 mm XA VETE Tere II 1250 mm Technical Manual Smartstart 6000 IMIO042 rev H Page 47 Appendix D Data Logger Option Board Description e The Data Logger Option Card provides a SD Card slot to record the soft starter s parameters and operating data 1 Operating data is logged at the following rates i A rate of 1 10second during acceleration and Deceleration ii Every 10 seconds during running iii Every 10seconds when in idle mode ie control supply ON but starter not running 2 The Soft Starter parameters are logged onto the data card when the unit is powered and if any parameters are changed e The data is stored as a text file txt on to the SD card inserted The SD card should not be removed while running or a short period after as recent data may be lost e The data may be read using Notepad or other application capable of reading text files or use of a custom designed application to extract and report the data requ
64. so allows instantaneous adjustment of the starter output to allow for changes in load conditions The SMART TORQ control system provides smooth starting amp stopping allowing ramp profiling to produce a linear acceleration and deceleration of the motor speed There are many benefits with variable torque loads such a pumps and fans by achieving a linear ramp profile and greater control over deceleration With pump applications this provides better control to minimise water hammer problems SMART TORQ Benefits include 1 A true linear acceleration of the load and motor for all load types 2 Reduced peak inrush starting currents 3 Reduced stresses and wear on the mechanics of the system 4 Ramp profiling to better match type of load such as variable torque loads Better control of pumps and fans without rapid initial ramp but linear ramp 5 Reduced heating in motor at low speeds 6 No instability due to changing power factor Closed loop system to monitor and react to changing power factor 7 No instability due to slot ripple in 3 wire and 6 wire operation 8 Better control of deceleration through closed loop torque control system The Smartstart 6000 also offers user access to ramp profiling parameters to fine tune the Torque Control System to achieve more application specific performance requirements See Page 41 for more information IMIO042 rev H gt bomm gt lt gt gt 20mm Installation Mecha
65. starter performance Refer to page 23 26 and 37 for more details regarding motor protection Semiconductor Fuses Semiconductor fuses are recommended for all electronic soft starters to provide protection of the thyristors in the event of an output short circuit Semiconductor fuses are strongly recommended for applications such as submersible pumps Semiconductor fuses are optional with all models e For smaller models 15 80Amp fuse kits are available e For larger models semiconductor fuse kits are available which mount to the Line Busbar e Refer to page 40 for more details on semi conductor fuses IMIO042 rev H Installation Povver Terminals up to 80Amp 3 Wire with integral Bypass POWER CIRCUIT Only Models 6RO15B2 Af 6RO30B2 SUPPLY 6ROGOB2 6ROSOB2 Povver Terminations BREAKER TT Model Max cable size Tightening Torque LC 6RO15B2 6 mm 1 5 1 8 Nm ioe 6RO30B2 6 mm 1 5 1 8Nm 6ROGOB2 35mm 3 2 3 7Nm 1 OPTIONAL 5 SEMICONDUCTOR 6RO80B2 35mm 3 2 3 7Nm FUSES Earth M6 stud _____ eeeeeee es22220 eeeeeeel L1 L2 L3 eae 2 222 _ LINE r MOTOR mmm SMARTSTART 6000 1 L1 3L2 5 L3 2 T1 41T2 61T3 DD Oo T1 T2 T3 Semiconductor Fuse kit Optional Le N MOTOR Refer to Page 40 for selection N Bi 1 Optional Fast Acting Semiconductor Fuses selected to suit Semiconductor Fuse Replacement SCR Devices used 2 Line Contactor controlled by the Soft St
66. t Y10 Y52 8 Setup menu Network NO1 N20 9 Setup menu Advanced A10 A61 10 Setup menu Commands 11 Setup menu Starter Diag 12 Setup menu Network Diag Alarm amp Trip Messages Fault Diagnosis Specifications Thermal Protection Unit ratings Shipping Packaging Details Options Appendix A Smart Torque Typical start parameters B Application Diagrams C Remote Console Instructions D Data Logger Option Board Set up Record Sheet NNN N NH VI VI W CON On SN HH gt kA 3 nwo 16 16 18 19 20 21 21 23 26 26 21 28 29 31 31 32 33 35 36 37 38 38 39 41 43 46 47 49 IMIO042 rev H IMPORTANT Read this first Read all operating instructions before installing vviring operating servicing or inspecting the Smartstart 6000 Ensure that the instruction manual is made available to the final user of the product as vvell as all personnel involved in any aspect of installation adjustment or maintenance Your Smartstart 6000 must be applied and installed by a suitably qualified and experienced electrical tradesperson in accordance vvith this manual good engineering practice and all local rules and regulations There are hazardous voltages inside the Smartstart 6000 whenever it is connected to an electrical supply The Smartstart 6000 contains high energy circuits that may be hazardous Do not operate with the covers removed or the doors of the enclosure i
67. t Imbal Delay P40 Undercurrent alarm P41 Under Current Alarm P42 Under Current Level P43 Under Current Delay P50 Over Current Alarm P51 Over Current Alarm P52 Over Current Level P53 Over Current Delay P60 UnderTorque Alarm P61 Under Torque Alarm P62 Under Torque Level P63 Under Torque Delay P70 OverTorque Alarm P71 Over Torque Alarm P72 Over Torque Level P73 Over Torque Delay Y10 Relay 1 Mode Y11 Relay 1 Variable Y20 Relay 2 Mode Y21 Relay 2 Variable Y30 Relay 3 Mode Y31 Relay 3 Variable Y40 Relay 4 Mode Y41 Relay 4 Variable Y50 AN Out 1 Mode Y51 AN Out 1 Variable Y52 AN Out 1 FS A10 Kick Start A11 Kick Time A12 Lick Level A20 Accel method A21 Accel Profile A22 Accel Control A30 Decel method A30 Decel Profile A31 Decel Control A41 Motor OL Reset A42 Str OT Reset A43 Warning level A44 Warning Delay A51 Motor Stator A52 Min off time A53 Start Logic A61 Try Tiny Motor IMIO042 rev H Programming Menu Navigation o N Dashboard screen 1 of 11 0 Setup Menu 1 Display Refer to Page 20 Setup Menu 2 Motor Refer to Page 21 Setup Menu Refer to Page 23 Refer to Page 26 Refer to Page 26 Refer to Page 27 UPT Refer to Page 28 amp E the SS6000 Network rs JZAaS89RZNP Guide Setup Menu Setup Menu Setup Menu Setup Menu Technical Manual Smartstart 6000 Setup Menu 1 Display DO1 Menu Access Sets the desired user access to menu a Selection Disabled Setup Read only
68. t Relay Functionality Table 2 Analogue Output Functionality Relay Function Selection pm Line Ctrl Control for Line Contactor Bypass Ctrl Control for Bypass Contactor Accel Ramp Starter in acceleration ramp mode LEN Open circul motor Mtr Current Motor Current isolate 5 Trip Alarm A trip alarm is active I T Supply frequency range exceeded Wi i i Table 3 Digital Input Functionality Bypass contactor failed STROL Trip Starter reached overload level Motor reached overload level Mtr OT Trip Motor thermistor switch trip active Dig In Trip Digital input trip active Analogue Output eme oest Estimated torque produced in motor Estimated Motor temperature of Mtr Thermal H over load STR thermal Soft Starter temperature Power consumed kW Digital Input Attempts to reset a Smartstart trip fault condition Motor may start immediately on successful reset A delay can also be configured Ph Rotation Rotation trip active Volt Imbal Voltage Imbalance trip active Trips the Smartstart after a configurable delay Ideal for external pressure flow switch Enable this function where 3 wire start stop control is required The start request is latched once the motor starts Use the enable or stop input to a N C stop button to unlatch Edge or level TOL VVarni Se anne Motor Overload warning alarm Alarm Soft starter is operating in Regen Mode R ka Ha regeneration mode AR Pending Waiting for rest
69. t up Record Sheet Software Revision Main menu Sub menu Level 1 Sub menu Level 2 Default Setting 6 Inputs X10 Digln 1 Mode O neble X20 Digin 2 Mode N Deche O X21 Digin 2 Variable 1 X22 Digin 2 Delay a 7 Outputs Y10 Relay 1 Mode Enable ____ Y11 Relay 1 Variable Y20 Relay 2 Mode Enable Y21 Relay 2 Variable Bypass Ctl Y30 Relay 3 Mode Y31 Relay 3 Variable Motor On Y40 Relay 4 Mode O Ce Y31 Relay 4 Variable Im _ Y50 An Out 1 Mode ON Disabled Y51 An Out 1 Variable Y52 An Out 1 FS 200 8 Networks NO1 Net Protocol NO2 Net Control Disable O mc xw KeKK cen NO3 Net Timeout J 2 0 N10 RS485 Addr F Y y ND NA EBYEW cEEE _N 1 RS485 Speed E a N20 IP Address n _ _ _ _ ooo j I T 7 pea peg pn2sipMask oo N 24 t _ 9 Advanced MO Kick Start Au Kick ne oo A12 Kick level mm A20 Accel Method A21 Accel Profile Square LA22 Accel Control Torre _ __ o o A30 Decel Method A31 Decel profile Linear A32 Decel Control Torque o o ETEN E E E QI Ai s r OT Reset I codec A43 Warning Level 7 804 A44 Warning Delay ps A51 Motor Stator eg 1 A52MinoffTime oo A53 Start Logic EE Level sense Technical Manual Smartstart 6000 IMIO042 rev H Page 51
70. t vvithout saving ENTER ESC a X22 Digin 2 Delay Set the delay that the digital input needs to be active for the Soft starter to respond Range 0 0 300 0 seconds Default ENTER To save changes ESC To exit without saving ap Setup Menu 7 Outputs Y10 Relay 1 Mode Activates Relay 1 Range Enable Invert Disable Default Enable ENTER To save changes ESC To exit without saving a Technical Manual Smartstart 6000 Y11 Relay 1 Variable Set the functionality of Relay 1 Range See table on page 33 Default Line Ctrl ENTER To save changes Esc To exit without saving a Y20 Relay 2 Mode Activates Relay 2 Range Enable Invert Disable Default Enable ENTER To save changes ESC To exit without saving a Y21 Relay 2 Variable Set the functionality of Relay 2 Range See table on page 33 Default Bypass Ctrl ENTER To save changes ESC To exit without saving ap Y30 Relay 3 Mode Activates Relay 3 Range Enable Invert Disable Default Enable To save changes To exit without saving a ENTER m 0 O Y31 Relay 3 Variable Set the functionality of Relay 3 Range See table on page 33 Default Motor On To save changes To exit without saving Ki ENTER m 0 O Y40 Relay 4 Mode Activates Relay 4 Range Enable Invert Disable Default Enable To save changes To exit without saving ENTER a m 0 O Y41 Relay 4 Variable Set the func
71. tarter see Control Wiring Page 14 amp Application Drawings Page 36 38 Refer to page 13 For Control Wiring IMIO042 rev H Installation Povver VViring 100A model and above Using 6 vvire Configuration The Smartstart 6000 can be configured to operate in 6 vvire mode 6 vvire mode may be the preferred method due to 1 Possible reduction in the size of starter required saving on space and Jor cost 2 Wiring may already be present if a start delta type starter vvas previously used 3 Reduced motor cable size The major advantage is that the current in the SCR is 58 less than it would be for the same motor connected in 3 wire The diagram below illustrates how the motor is connected in 6 wire also known as inside delta Supply L2 Technical Manual Smartstart 6000 Page 10 The following illustrates the difference between 3 wire amp 6 wire connection 3 Wire Connection aa ail 1 GA ks uppl lt ZENER 556000 Typical Motor Terminals LINKS FOR DELTA CONNECTED 6 Wire Connection Supply ZENER SS6000 Typical Motor Terminals u VIC wit wO uO vO NO LINKS FITTED Current Monitoring amp Torque Control For the torque control to operate correctly the C T s need to monitor the line current and not the Phase currents For this reason the C T s normally supplied internally need to be relocated external to the soft starter It is criti
72. tionality of Relay 4 Range See table on page 33 Default Trip Alarm ENTER To save changes ESC To exit without saving a IMIO042 rev H Page 27 Programming Y50 An Out 1 Mode Activate and set the signal type for Analogue Output 1 Range Disabled 0 10v 0 5v 0 20mA 4 20mA Default Disabled ENTER To save changes ESC To exit without saving ap Y51 An Out 1 Variable Set the functionality of Analogue Output 1 Range See table on page 33 Default Current ENTER 70 save changes ESC To exit vvithout saving a Y52 An Out 1 FS Full Scale Set the full scale of the Analogue output signal Range 50 500 Default 200 ENTER To save changes ESC To exit without saving a On a 0 120A meter scale amp 40Amp Motor FLC Scaling 120 40 x 100 300 Therefore 20mA 300 to display 120A Example Setup Menu 8 Network Below are the menu parameters that may require adjustment to allow communication to take place with other devices The Communication setup must be completed and checked before communications can begin For more comprehensive instructions and mapping details refer to the corresponding SS6000 Networking guide NO1 Net protocol Select enable the desired Communications protocol Range Disable Modbus RS485 Modbus TCP Default Disable ENTER To save changes ESC To exit without saving a NO2 Net Control RS485 amp Ethernet Select desired operation on a netwo
73. torque type load Enter motor parameters as per motor nameplate 3 Pump 3 wire Bypass with Soft Stop Factory defaults are intended for general pumping application with no Soft Stop Enter motor parameters Ref Page Parameter Setting factory Default as per motor nameplate Adjust the Release Torque C12 60 30 and Decel time to achieve the required soft stop er rne GRU n 13020 Setting factory Default C21 15sec 0s C22 Release Torque 2 2 Motor Amps Nameplate Motor FLC Motor Volts Nameplate Motor Volts Motor PF Nameplate Motor PF 7 Suggested Protection Settings Below are suggested settings to provide additional 4 Fan 3 wire Bypass protection of the motor and load These are general settings and should be further tuned to suit the Factory defaults are intended for general pumping application and load conditions application which is similar to that required for a fan However the Accel time may need to be increased to allow for longer ramp times of high inertia fans The Ref Page Parameter Setting factory Default Motor Overload Class 10a 10 20 10 Motor Overload Class may also need to be increased i oe i Motor O Temp Thermistor Disabled with the extended ramp of high inertia fans Enter 1 2 3 Disabled motor parameters as per motor nameplate Accel O Time Trip 5s Disabled P41 Da e a zz IS AU Setting factory Default C11 15
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75. uit 0 300seconds X20 Dig In 2 Invert X21 Dig In 2 Variable Stop X22 Dig In 2 Delay Adjust to suit 0 300seconds Adjust Accel and Decel to suit application STOP DIGIn2 16 DIGIn1 15 ENABLE 14 2AVDC 12 13 Control Supply IMIO042 rev H Network Connections Modbus RS485 The Smartstart 6000 comes standard with Modbus RS485 serial Communications Typical wiring for RS485 shown below N PLC B E Computer or m RS232 485 converter 3 Z m JJ Lg E N CO z E Com lo The following precautions will help minimize the risk of netvvork failure e Use twisted pair shielded communications cable e Each length of cable should have its shield connected to ground at one end only recommended at the computer or controller end e tis recommended to use two twisted pairs one pair for circuit common and another pair for balanced data lines GE e The common circuit must be connected to all devices on the bus and connected directly to protective ground at one point only typically near the master device Screen terminal provides a local protective ground Eg For cable shield e To reduce network noise place a line terminator near each of the two ends of the bus A 120 Ohm resistor is recommended for both line terminators A capacitor inf in series with the resistor may also improve performance Technical Manual Smartstart 6000
76. wire 6R360 830 Installation of external C T s When relocating the C T s external to the soft starter it is important to ensure the following 1 C T s are installed on L1 8 L3 2 C T s are installed in correct direction P1 label line side 3 C T s are terminated with correct phasing S1 Red S2 Black The C T s supplied with the Smartstart 6000 has a label which shows the correct phase and direction If the C T s are not installed correctly the starter will display a fault or a C T Phase error Technical Manual Smartstart 6000 Page 12 Supply Supply Supply TE ZC 13 ji SS6000 QA SS6000 1651 182 Tu 558000 S1182 ZENER SS6000 Las an xn xo xn cn an an La ave se ma eng vg ee pn n Motor Programming Program the starter for 3wire or 6 wire operation The selection available for 6 wire is Standard 6 wire or alternate 6 wire depending on the wiring configuration used The wiring in this manual is drawn for Standard 6 wire Refer to page 21 parameter M04 Motor Wiring Check for correct installation If a CT phase error occurs the problem may be identify under the menu Starter Diagnosis L1 L3 should be displayed gt If L2 is displayed move the CT from L2 phase U U gt If a is displayed the direction of the corresponding CT needs to be reversed IMIO042 rev H iring Typical Configuration of Con

SS6000 Soft Starter User Manual

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