SOFTSTART USER`S MANUAL - ug
Contents
1. M Three phase Asynchronous Motor 2 3 4 Description of Control Circuit Terminals 1 Cautions forControl Circuit Wiring The connecting wire of the control circuit shallbe shielded wire or twisted pair wire which must be wired separately from the main circuit andthe power circuit If the connecting wire ofthe control circuitmust crosscut themain circuit they shallintersect at anangle of 90 9 Chapter 2 Installation and Wiring The length of the wire shall be asshort as possible exceed 30m generally because the controlcircuit is easilyinfluenced by externalinterference The recommended wire size ofthe control circuitconnecting wire is0 75mm When external terminals are selected togive control overstart and stop functions of the soft starter please set the code P9 to External Control Enabled If there isa request fornon local control the two wire control modeis suggested 2 Diagram of Control Terminals 01 02 03 04 05 06 07 08 09 10 11 12 ooet r J i Bypass Delayed Failure Analog Output Output Output Output ee Start gt Sto ommon Por aT HB i Terminal vermin Functional Description Switch on 01 and 02 after soft starter 15 completely started control bypass contactor 01 02 0 L1 E Output r 02 Al 03 and 04 indicate programmable relay2. to start or stop the soft starter monitor the operation state of the soft starter and modify its functional parameters For details of this communication please refer to RS485 Operating Manual By using RS485 COM of the soft starter remote operation can be realized via acomputer suchas input of runcommand management on operation state and one step writing of functional codes for multiple soft starters to realize simplified operation while inputting functional codes Main Functions of RS485 COM Inputting start or stop command Monitoring operation status Real time tracing 1 table display of running information Once step reading and writing of functional codes and saving to the file A separate agreement shall be signed between the two parties ofus for communication software
3. arecursive way If entering setting mode in none soft start stop mode you may gettips Press thenpress og to readtips Press Enter orStop key inthe state ofhelp you may exit the help mode Chapter 4 Operation 4 1 Check before operation The following steps should be inspectedand confirmed before the soft starteris put into operation Be sure thatthe application ambientand the input power supply complywith the requirements in this manual Be sure thatthe main circuitis properly wired The input powersupply must be connected to theterminals R Sand theoutput terminals U V and W mustbe connected to the motor the bypass electromagnetic contactor isinstalled and properly connected the groundterminal is reliably and properly grounded sure thereis no shortcutting or shortto ground ofall terminals andelectrified parts Allterminals connectors andscrews are tightly fastened 4 2 Operation Now start atrial operation afterall the inspectionsteps in 4 1 have been done While in trial operation itis suggested thatthe motor has vacant load Ifeverything is OK then perform on load running Be careful toselect an optimummode of operationin accordance withspecific operational requirements See the detail below The factory defaultsetting of the product operation modeis operation panel control The value ofrated power current PC should beset to the same as the one on the motor s specificat
4. Functional description Maximum working current refersto maximum current performing sustainable operation whose value isreckoned on the basis of the set value in the functional code PC If the currentexceeds the max value there willbe an inverse time thermal reliefprotection Note Modification willbe valid ifthe code P7is set to 0 Functional Code P5 Undervoltage Protection SettingRange 60 90 DefaultSetting 80 Functional description Whenthe actual working voltage is lowerthan the set value then protection for motor softstarter is disabledand the LED display F09 Functional Code P6 Overvoltage Protection Setting Range 100 130 DefaultSetting 120 Functional description Whenthe actual working voltage is higherthan the set value then protection for the motorsoft starter isdisabled and the LED display F10 Functional Code P7 Starting Mode SettingRange 00 05 DefaultSetting 01 1 Current limiting Start If the code P7 is setto 0 indicating current limiting then current starting mode is selected The figure belowis a currentchange waveform ofa motor inthe mode of current limiting start 11 inthe figure refers to the setvalue of starting current limiting When themotor starts the output voltage willrise rapidly tillthe motor current reaches the set current limiting value 11 and Chapter 5 Description of Function Parameters will not goup any more Then with gradualraise of outputvalue the motorwill accelerate
5. 3PH380V 12 x 50Hz i L1 1 Full Voltage Output N B54 Delay Output Programmable Failure Output Chapter 2 Installation and Wiring 2 3 2 Description of Main Circuit Terminals Terminal Mark TerminalName Functional Description Rs S Main Circuit Input Terminal Sieh to three phase input power W Main Circuit OutputTerminal Connect to three phase electric motor 121 L22 123 Bypass Connection Connect to bypass contactor G Ground Terminal Soft starter cabinetground terminal 1 Input Terminals R S T Three phase input power supply shouldbe connected tothe input terminals R S and T of the motorsoft starter afterit goes throughthe circuit breaker Three phase power supply doesnot differon phase sequenceand can bearbitrarily connected While wiring DOconnect three phase input power supply tothe terminals R S and T Otherwise itmay result insevere damage tothe motor softstarter It is recommended not to shutdown the machine by disconnecting the main circuit power supply orinstall an electromagneticcontactor between theinput terminals R S Tand the powersupply to runor stop the motor soft starter Do selectRUN or STOP keys on the operation panel or external control terminals torun or stop the motor soft starter 2 Output Terminals U V W The output terminals U Vand W shouldbe connected tothe three phase motor If the mot
6. eenn rania E 7 12 2 4 Selection of Peripheral 13 Chapter 3 Operation Panel and 14 3 1 Operation Panel amp amp 14 3 2 aes 14 15 3 3 Panel Display 16 Chapter 4 17 4 1 Inspection before 17 4 2 0 aE aaaea 17 Chapter 5 Description of Function 18 5 1 Schedule of Function 18 5 2 Detailed Description of Function Parameters 19 26 Chapter 6 Trouble Protection amp 27 6 1 Schedule of Protection 27 6 2 Trouble Diagnosis and Troubleshooting 28 Chapter 7 Structure and SIZES eiennenn enin N 29 30 Chapter 8 Quality Waranty sissie N 31 ne E EEE 32 Chapter 1 1 1 Safety Instructions The installation and wiring of motor soft starter should be operated only by professional technicians who should read this manual in detail before installing and wiring Do not perform wiring
7. then currentramp start modeis selected The figure belowis a waveform of output currentin the mode of current rampstart 11 in this figure stands for current limiting value set bythe code P3 and T1 stands for time set by thecode P1 Current ramp startmode is applicableto bipolar motorowing to its strong accelerating capacity This mode canalso shorten the starting period oftime within a certain range Chapter 5 Description of Function Parameters 5 Voltage and Current limiting Double closed Loop Start When the codeP7 is setto 5 doubleclosed loop then this start mode is selected Voltage and current limiting double closed loop startmode with adoption of voltageramp and current limiting double closed loop control is a kind of comprehensive start mode that bothsteady start andstrict current limiting are required It usesa pre reckoning method for estimating the working state ofthe motor The waveform ofoutput voltage inthis mode always fluctuates according to different conditions ofthe motor and loads Functional Code P8 Protective Class SettingRange 00 04 Factory Default Setting 04 To adaptto different applications this motor softstarter provides 5 protection classes namely 0 primary class 1 light load 2 standard 3 heavy load 4 advanced which are set bythe code P8 Primary protection disabling the function ofexternal instantaneous terminals and only remaining overheat protection shortcut p
8. Functional Code P1 Soft Starting Time Setting Range 2 60S Factory Default Setting 16S Functional description This function is used to set the time spent bythe motor frominception voltage to rated voltage Note Voltage ramp modeis enabled Setthe code P7to 1 the value can be modified Functional Code P2 Soft Stop Time Setting Range 0 60S Factory DefaultSetting 00 Functional description This function is usedto set thetime spent bythe motor from being just stoppedat rated speedto full stop Set this valueto 0 thereis a freestop Note There aretwo stop modes for motor softstarter soft stop and free stop If the machine has anone to multi system thenset the valueto 0 1 Soft Stop If the code P2 is notset to 0 then soft stopmode is selected The figure belowis the output current waveform inthe mode ofsoft stop Underthis condition the motor is powered by athyristor shifted froma bypass contactorto a softstarter the output voltage of this soft starter gradually decreasedfrom full voltage till it stops completely thus the motordecelerates smoothly and mechanicaloscillation can beavoided The output cut off voltage of soft stopis equal tothe Inception Voltage In the mode of soft stop surf of water pump loads canbe reduced oreven removed and large currentimpulse caused by soft stop canbe reduced Thecurrent limitation value of softstop is apercentage reckoned on thestarting current limiting value Ue gt T 1
9. Level 2 0 5 I le 1 05 2 00 3 00 4 00 5 00 Motor Thermal ProtectionTrip Time Curve Heat State Chapter 6 Trouble Protection amp Treatment 6 1 Schedule of Protection Operating Protective functions enabled with an immediate tripping once anomaly of the soft starter occurs Referto the descriptions below for warnings and relevant contents displayed on LED Panel Display Warnings Actions amp Treatment Faults such asundervoltage overvoltage overcurrent instantaneous terminal openetc have beeneliminated 0 Fault cleared Everything turns tonormal and nowthe LED ready lights up indicating the motor can be started after reset F01 Paternal ia Check the connectionbetween terminal 07and terminal 10 terminals open or check break contacts of other protective devices F02 Soft starter Check if startingis too frequently operated or the motor 5 overheat power doesn t match the soft starter Starting time Check if improperly set the load F 03 too lon is too heavy or the power capacity is insufficient F g Check if three phase power supply issolidly connected the Fo4 Input open phase bypass contactor ischucked on the closed position the SCR is shortcut andthe ground wire G is properly connected Output Check if connecting wires of outputloop and the motor is F05 utput open firm the bypass contactor is chucked on the closed position phase the SCR isshortcut and the groun
10. While pressingany of thesekeys the beeperinside the softstarter will give out abeep tone Enter into functional selection mode ofthe code P9 The range ofsetting can bemodified when colon flashes The data modifiedhas been saved The action is escaped to the default state and REAdy is displayed Display Display 4 Display Display Power On Display Display 15 Chapter 3 Operation Panel 3 3 Description of Panel Display Codes Displayed Description This indicates the power is ON This indicates the motor soft starteris getting ready and the readiness pa Paga REAdY LED turns on X XXX This indicates the motor is inthe state of getting started V VVV This indicates the motor is inthe running state and the running indicator turns on X XXX This indicates the motor is inthe state ofsoft stop This indicates athree figure voltmeter usedto detect the voltage of three phase AC power supply The specification ofthis soft starteris 22K W 380V This indicates the last failure tip F 04 indicates aninput open phase occurs This indicates no failure This presents the software version ofthe product is Ver3 0 This indicates totaltimes of successful starting This indicates the duration of the last soft starting regardless of successor failure Note H1 H9 referto save 9recently occurred failuretips
11. current limiting 01 voltage ramp 02 kick current limiting P7 Starting Modes 03 kick voltage ramp 04 01 current ramp 05 voltage and current limiting double closed loop 00 primary 01 light load 02 P8 Protection Classes standard 03 heavyload 04 04 advanced 00 operation panel control 01 operation panel external control 02 external control 03 external control COM control Control Modes 04 operation panel external 01 control 05 operation panel COM control 06 COM control 07 start stop disabled i 00 parameter modification disabled PA Parameter Protection o parameter modification enabled 01 Pb Programming Output ii as in Page24 Functional 07 Pc Rated Cur 11 1200 Set according to specifications Pd Motor Protection 00 90 00 Notes 1 Idle keys for over 2 minutes the machine will escape fromthe setting state automatically 2 Do notset parameters duringsoft start orsoft stop Setthem in otherstates 18 Chapter 5 Description of Function Parameters 5 2 Detailed Description of Function Parameters Functional Code PO Inception Voltage Setting Range 30 70 Factory Default Setting 30 Functional description This function is used to set the voltage value ofmotor soft starter when it is being started Note Voltage ramp modeis enabled Setthe code P7to 1 the value can bemodified Set P7to 0 the inception voltage will be40
12. 1200 Factory Default Setting Set according tothe specifications Function Description This parameter should beset in conformity with rated current value displayed on specifications label ofthe motor Otherwise it may cause big deviation between starting current and protectivecurrent The motorrated current set by PCshould not be 20 lower thanthe nominal currentof soft starter The flexibility tolerance ofprotective trip action will increase ifthere is less motor rated current set by PC Functional Code Pd Motor Protection Setting Range 00 90 Factory Default Setting 00 1 Descriptions of Protective Functions This motor softstarter has perfect protective functions to guarantee safety whileusing soft starter andmotor Whilein use DOset proper protectionclasses and protection parameters according to different circumstances Soft Starter Overheat Protection Overheat protectionenabled when temperature rises to 90 5 C and disabled when temperature falls to60 C lowest Input open phase protection lag time lt 3S Output open phase protection lag time lt 35 Three phase Unbalance Protection Time lt 3S Based on therule that all phases of current deviation is larger than 50 10 when load current is 30 lower than the nominal rated valueof softer starter the decisiondatum deviation willbe enhanced Overcurrent Starting ProtectionTime Thisrefers to the protection time thatis successively 5 times longer than themaximum working currentset
13. gradually When the motorspeed reaches therated speed ofrotation the bypass contactor willattract kick on and the outputcurrent will godown rapidly tothe motor rated current le or below Thus thestarting process is finished Even if the motor has alight load or the set value of current limiting is big there is still the possibility that the maximum current of the motor during startcan not reach set value ofcurrent limiting Current limiting startmode is usually applied on the occasion where strict limitation of currentis required 0 T 2 Voltage Ramp Start When the code P7 isset to 1 voltage then voltage start mode isselected The figure below is awaveform of output voltage during voltage limiting ramp start U1 in the figure is the starting inception voltage When the motor is started and its current does notexcess 400 of itsrated value the output voltage ofsoft starter willjump up to U1 then the output voltage will rise gradually as the set starting parameter and the motor will accelerate with voltage rise When the voltage reaches the rated voltage Ue the motor will runat rated rotation speed andthe bypass contactor will pickup thus start up procedure will be completed Starting Time isthe control parameter derived by standardload under standard experimental conditions basedon which the soft starter isable to accelerate the motor smoothly to complete starting process throughthe control overoutput
14. ofthe terminals andset parameters of P9 properly External control starting is disabled Check if the code P9 is set to external control If open circuits occur among theterminals 07 08 and 10 check external wiring of terminals set parameters of P9 properly Be sure external control has been set The motor rotates but its speed cannot be raised Check if thereis too heavy load Lighten the loads Modify parameters increase the inception voltage or starting current Starting time is too long Check if thereis too heavy load Be sureparameter settings of the soft starter are proper and themotor model is correct Lighten the loads Set PO inception voltage P3 starting limitation current and P1 softstart time properly Check model descriptions ofsoft starter andits specifications label Starting time is too short Check if thereis light load or too short starting time When there isa light load the starting time is generally shorterthan the setvalue It will be normal ifthere is abalanced start Setthe starting time ofP1 current modeinvalid Sudden shutdown occurs during operation Check external input terminals Check if thereis any loosenconnection between the terminal 07and 10 Ifthere is an external protector checkif the break contact works Check ifthere is loosenconnecting wire of external stop button Chapter 7 Structure and Sizes 7 1
15. output whose Operation functions are set by the code Pb If they are set to be the 03 04 Output make contacts normally open and output voltage of the soft starter is enabled to start the motor then 03 04 Delayed will be switched on Contact capacity AC 250V 3A Failure 05 06 indicate programmable failure relay output which 05 06 will be closed switched on if there is faiure of the softer Output starter or power and open switched off when energizd If 07 isdisconnected from10 orconnected to the break 07 rre normally closed of any other protectors the motor will stop immediately 08 Soft Stop Input When 08 and 10 are switchedoff the motorwill perform decelerated soft stopor free stop 09 10 Start Input Common Port Close 09 and 10 the motor begins starting andrunning 10 indicates terminal of the contact input signal 11 12indicate AC 0 20mA analog output usedto monitor operating current of themotor Whenthe value is 20mA which means the output currentis 4 times asnominal current capacity 11 12 Analog Output of the motor an external DC ammeter 0 20mA can be connected and the maximum valueof output load resistance will be 3000 DBO RS485 COM RS485 COM input outputterminal used toconnect multiple soft starters Chapter 2 Installation and Wiring 2 3 5 External Control Wiring Modes Thee phase Control Mode ZJI 11 Instantaneous S
16. while the motor soft starter is POWER ON Be sureto perform this step only after the power 15 disconnected Otherwise there is the danger of electric shock Be sure the motor chosen should be matched with the motor soft starter Do follow this manual while perform installing and wiring While wiring the three phase input power supply should be connected tothe terminals R Sand T The output wire of the motor should be connected tothe terminals U Vand W Otherwise it may cause severe damage tothe motor soft starter Do notinstall any capacitor between the output terminals U V and W and the motor Otherwise it may cause damage to the motor soft starter The electronic elements inside the motor soft starter are very sensitive to static Do not touch the appliances on the circuit board by hand before anti static measures are taken The ground terminal G should be properly solidly and separately grounded Once the motor soft starter is installed please cover pigtails in the input and output ports with insulated sheath or tape When the motor soft starter is under remote control do lock the keyboard control to avoid accidence due to error operation Do cut off the power supply when the motor starter is in maintenance to guarantee safety l Introduction to Product Chapter 1 Introduction to Product 1 2 Inspection upon Arrival This product is guaranteed a highlevel of quality with strict outgoing inspection crushpr
17. 21 L22 L23 Input Terminals of Power Supply R S T Circuit Board Cabinet Operation Panel Base Control Terminal Connect to the motor U V W Chapter 1 Introduction to Product 1 5 Models Specifications Schedule of Models amp Specifications Product Model Input Voltage Rated Weight of Power kw V A Type Z Kg ZJR1 3055 5 5 380 11 3 5 ZJR1 3075 7 5 380 15 3 5 ZJR1 3110 11 380 22 3 5 ZJR1 3150 15 380 30 3 5 ZJR1 3185 380 37 3 5 ZJR1 3220 380 43 3 5 ZJR1 3300 380 60 3 5 ZJR1 3370 380 75 3 5 ZJR1 3450 380 90 3 5 ZJR1 3550 380 3 5 ZJR1 3750 380 25 ZJR1 3900 380 25 ZJR1 31100 380 25 ZJR1 31320 380 25 ZJR1 31600 380 25 ZJR1 32000 380 25 ZJR1 32500 380 35 ZJR1 32800 380 35 ZJR1 33150 380 35 ZJR1 34000 380 40 ZJR1 35000 380 45 Chapter 1 Introduction to Product 1 6 Technical Indications Item Item Description Input Input Voltage Three phase 380V 15 415 10 Power Supply Frequency 50 60Hz Adaptive Motor Squirrel cage three phase asynchronous motor Starting Times It is recommended not to exceed 20 times perhour Chapter 2 Installation and Wiring Control Modes Start Modes 1 Operation panel control 2 Operation panel external control 3 External control 4 Externalcontrol COM control 5 Operation panel
18. 63 63 16 ZJR1 3300 30 60 80 63 25 ZJR1 3370 37 75 100 100 25 ZJR1 3450 45 90 125 100 25 ZJR1 3550 55 110 160 160 35 ZJR1 3750 15 150 180 160 50 ZJR1 3900 90 180 225 250 70 ZJR1 31100 110 220 315 250 70 ZJR1 31320 132 264 315 400 50X2 ZJR1 31600 160 370 350 400 50X2 ZJR1 32000 200 400 500 400 70X2 ZJR1 32500 250 500 630 630 95X2 ZJR1 32800 280 560 560 630 95X2 ZJR1 33150 315 630 700 630 95X2 ZJR1 34000 400 800 800 630 120X2 ZJR1 35000 500 1000 1000 1000 120X2 Options in the above table are for reference only 13 Chapter 3 Operation Panel 3 1 Description of Operation Panel 1 Outline Drawing of Operation Panel Functional Code Data Code Unit Indicator Failure Add Substract Key Start Key Stop Key Programming Key Confirm Key Operation Panel Key Set Description Symbols Key Set Name Functional Description When REAdy is displayed press this key tobegin starting the Run Key machine and the startingstate XXXX will be displayed 1 Whenthe machine is in normal operation press this key to stop and Stop Key XXXX will be displayed once the machine stops completely 2 This key also performs the function of failure state resetting Programmin When REAdy is displayed press this keyto set the manual When Ke 9 9 P0030 is displayed repress this key When flashes pressQ y to modify parameters 1 After parameters are modified in programming
19. 9 Chapter 5 Description of Function Parameters 2 Free Stop If the code P2 is setto 0 then free stop modeis selected In this stopmode once stopcommand is received the soft starter will disconnect the bypass contactor and disable voltage output of the thyristor Then the motor will gradually shutdown dueto load inertia Toavoid open phase error report P2 should be set to this mode if the soft starter adopts one to multi wiring method Toextend the service life of softstarter free stop mode is generally preferred ifthere is no need to adopt softstop mode Infree stop mode instantaneous output is completely disabled thus instantaneous impulse ofheavy current canbe avoided ZJR1 series of softstarters provide 6 working modes applicableto various kinds of motors and loads Sousers should choosea proper oneaccording to different applications Functional Code P3 Starting Limitation Current Setting Range 50 500 Default Setting 400 Functional description This function is usedto set the peak output currentvalue of a motor soft starter when it is starting The formulais set value X motor rated current Function PC peak current unit A that is limited by amotor softer starterto be output Note Current limiting mode enabled Ifthe code P7is set to 0 the modification will be valid If P7is set to 1 the current limiting value willbe 400 Functional Code P4 Max Working Current SettingRange 50 200 DefaultSetting 100
20. CHZIRI SOFTSTART USER S MANUAL ZJR1 SERIES ZIRI ELECTRICAL TECHNOLOGY Co LTD Foreword E Thank you for your purchaseof ZJR1 seriesof motor softstarter produced by Ziri Electrical Technology Co Ltd hereinafter referredto as ZIRICompany E This manualintroduces the installation operation function setting trouble shooting and etc of ZJR1 motorsoft starter E Incorrect installation oruse may resultin damage orother accidents E Do read allinstructions in detail before installing andfollow this manual strictly during installing wiring and operating E Please keep this manual handy for quick reference inthe future E f there areany doubts orquestions please contactthe Technical Service Center of ZIRICompany Table of Contents Chapter 1 Introductionto the 1 1 1 Safety Instructions is tiene nee 1 1 2 Product Inspection upon Arrival 2 1 3 Demonstration ofthe Specifications Labeland Model 2 1 4 Outline ofthe PTOdUCt sosna essan 3 1 5 Models and 4 1 6 Technical 5 Chapter 2 Installation and 6 2 1 Operating 6 22 6 259 WINN
21. Outline Sizes amp Install Sizes d Install a screw Rated Rated Outline Sizes Install Sizes Net Models Power KW Current A w1 w2 d oe 130 M6 lt 3 5 ZJR1 3055 5 5 11 270 145 ZJR1 3075 7 5 15 270 145 130 M6 lt 3 5 ZJR1 3110 11 22 270 145 130 M6 lt 3 5 ZJR1 3150 15 30 270 145 130 M6 lt 3 5 ZJR1 3185 18 5 37 270 145 130 M6 lt 3 5 ZJR1 3220 22 44 270 145 130 M6 lt 3 5 ZJR1 3300 30 60 270 145 130 M6 lt 3 5 ZJR1 3370 37 75 270 145 130 M6 lt 3 5 ZJR1 3450 45 90 270 145 130 M6 lt 3 5 ZJR1 3550 55 110 270 145 130 M6 lt 3 5 Notes The rated powerand rated currentin the tableabove are the maximum values ofa soft starter Generally ratedcurrent matching the motor that hassame power shouldnot excess therated current values listedin this table If outline sizes differ from the values above pleaserefer to actual sizes Chapter 7 Structure and Sizes Install Sizes Net Weight w2 d kg Rated Rated Outline Sizes Models Power KW Current A H4 ZJR1 3750 75 150 ZJR1 3900 ZJR1 31100 ZJR1 31300 ZJR1 31600 ZJR1 32000 ZJR1 32500 ZJR1 32800 290 245 460 ZJR1 33150 260 M8 lt 35 ZJR1 34000 M8 lt 40 Mad
22. by thecode P4 See protection Time Table in Page 23 Overload Running Protection Time Thisrefers to the inverse time thermal relief protection based onthe maximum working current set bythe code P4 See the curveof trip protection timein the figureon page 26 Power Supply Undervoltage Protection Lag Time When powersupply voltage is40 lower than limit value the protectiontime will beless than 0 5 second when the power supply voltageis lower thanthe set value the protection time will be lessthan 3 seconds Power Supply Overvoltage Protection Lag Time When powersupply voltage is 130 higher than limitvalue the protectiontime will beless than 0 5 second when the power supply voltageis higher thanthe set value the protection time will be less than 3 seconds Load Shortcut Protection Retarding Time lt 01 second Ifthe current 15 10 times more as nominalrated current ofthe soft starter than afuse or shortcutdevice shall be used The above time parameters are set for the period from valid signals detected to trip protection command is given They arefor reference only If protective functions of this softstarter do notcomply with users needs then special protective devices shall be usedto insure safety Chapter 5 Description of Function Parameters 2 Protective Trip Curve T S 10000 1000 100 Level 20 10 Level 10
23. d wire G is properly connected Three phases Check if thereis anomaly ofinput three phase power supply F 06 unbalanced or the load motor FO7 Starting Check if the load is too heavy or the motor power doesn t overcurrent match the softstarter 08 Operating overload Check if thereis any tooheavy load orimproper parameter protection set by thecode P4 andPC F09 Power supply Check if thereis error input power supply voltage or voltage below level improper parameter setby the code P5 F10 Power supply Check if thereis error inputpower supply voltage or voltage too high improper parameter setby the code P6 Modify settings orpress to restoreto the F11 setting error default settings ofsoft starter whenit is energized Check the loador the motor check if the SCR is shortcut F12 Load shortcut loaded F13 Auto restart Check the external control start andstop terminals ifthey wiring error are in two wirecontrol mode External control stop When external control mode is enabled external control F14 wiring error Stop terminals willopen which leadto failure startof the motor Notes 1 Some faults are correlative i e if there isa report of F02 soft starter overheat thismay be concerned with starting overcurrentor load shortcut Therefore full considerations shouldbe taken to have anexact judge on faultsduring troubleshooting 2 When the soft starterstarts the motor the operation LED inthe mi
24. ddle of thepanel lights up which indicates the machineis in thestate of bypass operation If bypass contactor failsto pickup at this time which results in stopof the motor check if there isany error or badcontact of the bypass contactor andrelevant connecting wires 3 If any protective actionoccurs press STOP RESET key to remove failurestate after troubleshooting then restart themachine Chapter 6 Trouble Protection amp Treatment 6 2 Trouble Diagnosis and Troubleshooting Anomalies Items to Check Solutions Check Perform correct wiring Cut off power wiring Be surethat power lines are c nnectedio supply and then perform rewiring terminals R S T The motor Check if bypass contactor Check the connectionof bypass contactor can t rotate works Be sureterminals 01 02 have signals Check the controland connection ofthe coil loop of bypass contactor Check if thereis abnormal display on the operation panel Refer to page27 Schedule ofProtection Operating Check if the motor is locked or there istoo heavy load Unlock the motoror lighten the loads Keyboard starting is disabled Check if thereis error tipon the operation panel Be sure that the terminals 07 10 open and settings of the code P9 iscorrect If no errortip is displayed check the input power supply If error tipis displayed checkif the terminals 07 08 and 10 are open check external wiring
25. e to Order m ZJR1 35000 500 1000 M8 lt 45 Notes The rated powerand rated currentin the tableabove are the maximum values ofa soft starter Generally ratedcurrent matching the motor that hassame power shouldnot excess therated current values listedin this table If outline sizes differ from the values above pleaserefer to actual sizes Chapter 8 Quality Warranty 1 Warranty Period Under Normal Conditions 0 We provide guarantees for repair replacement and return of the purchase in 1 month from the date ofuse We provide guarantees for repair and replacement in 3 months from the date ofuse 3 We provide guarantee for repair in 12 months from the date of use or 18 months from the date of ex factory 2 The purchaser enjoys life long paid service whenever and wherever he uses a motor soft starter made in our company 3 Service in the following cases even within the warranty period shall be charged tothe purchaser Problems caused by mal operation in violation of this manual or caused by unauthorized repair or renovation Problems caused by improper use of soft starter that is off standard and requirement 3 Malfunction or damage caused by improper transit or storage after purchase Induced failure or aging of the device due to poor ambient Malfunction or damage caused by fire flood thunder earthquake abnormal voltage or other natural disasters Unid
26. entifiable nameplate mark andORD number due to intentional spoilage Delayed or unsatisfied payment in violation of purchase appointment Fail to give an objective description on the use of installation wiring operation maintenance or else 4 Defective products should be sent to us for repair replacement and return which can be proceeded only after verifying the burden of liability 5 Incase there is any quality problem or accident we merely promise to bear the above mentioned responsibilities Ifa user needs more guarantees for liabilities please assure onthe insurance company voluntarily Appendix 1 Varieties of ApplicationLoads This soft startcan meet therequirements of mostheavy loads Thetable below is for reference only Varieties of Start Ramp Stop Ramp Inception VoltageStart C umen Application Loads Time 5 Time S Voltage imiine Value gears Centrifugal Pump 16 20 40 4 2 5 Ball Grinder 20 6 60 4 3 5 Fan 26 4 30 4 3 5 Compresior 16 4 40 4 3 Light Load Motor 16 2 30 4 3 EM eet a 6 10 60 4 3 5 Mixer 16 2 50 4 3 Crusher 16 10 50 4 3 5 Screw Compressor 16 2 40 4 Spiral Conveyor 20 10 40 4 2 Leather Belt Conveyes 20 10 40 4 2 5 Heat Pump 16 20 40 4 3 2 RS485 Communication This soft starter can be connected to PC PLC or other hosts through a built in RS485 standard interface to perform serial communication COM The host can give
27. external COM control 6 Operation panel COM control 7 COM control 8 start or stop operation 1 Current limiting start 2 Voltage ramp start 3 Kick start current limiting start 4 Kickstart voltage ramp start 5 Current ramp start 6 Voltage current limiting double closed loop start Stop Modes 1 Soft stop 2 Free stop Protective Functions 1 Open loop protection for external instantaneous stop terminals 2 Over heat protection for soft starter 3 Protection fortoo long starting time 4 Input open phase protection 5 Output open phase protection 6 Unbalanced three phase protection 7 starting overcurrent protection 8 Running overload protection 9 Undervoltage protection for power voltage 10 Overvoltage protection for power voltage 11 Protection for faultparameter setting 12 Load shortcircuit protection 13 Autorestart or incorrect wiring protection 14 Incorrect wiring protection of external control stop terminals JUSIQUIY Place to be used Indoor location with good ventilation free from corrosive gas and conductive dust Altitude Below 1 000M Derating should be performed before use if the altitudeis higher than 1 000M Ambient Temperature 10 40 C Ambient Humidity lt 90 RH without dewcondensation Vibration lt 0 5G Structure Protection Class IP20 Cooling Pattern Natural wind cooling 2 1 Operating Co
28. ft starter receives start command atthis moment thenthe relay will be disconnected Programmable sequential output mode takesthe whole process of startas its control cycle If the motor is restarted the previous programming output will automatically be interrupted and this procedure shall be preceded again If Pb isset to 5 9 the programmable output working and state output mode andthe set working state output will beshown in the table below Valuesset by Pb 5 15 6 16 7 17 8 18 9 19 Moment of Programmable Output Fault State Operation Hold State Starting State Bypass State State Programmable state output is used to indicate the working state ofsoft starter The factory default setting value of Pb is 7 which indicates holdmode of softerstarter In this state the motor can bestarted When programmable output isin fault state it indicates motor failure F05 F06 F07 08 F12 which is different from the function of failure output terminals Operation state refersto non hold ornon fault state including suchthree procedures as start bypass andsoft stop If Pb gt 9 thereset state ofprogrammable output external terminals changes from open toclose that is reversed phase output Flexible use ofprogrammable relay output functions cansimplify external control logic circuit Chapter 5 Description of Function Parameters Functional Code PC Motor Rated Current Setting Range 11
29. ions label Press to startthe motor andpress to endit Be sure the motor has asmooth running without whistler or vibration If the motorstarting is not good enough justchange settings ofthe basic functions of Pl If the motor s starting torque isnot powerful enough just change the inception voltage code 0 indicating voltage mode enabled or the current limiting value code P3 indicating currentmode enabled toraise the torque Be sure the motor rotates inthe correct direction Only after making sure there isno anomaly can the motorbe put into formal operation Notes 1 If thereis any anomaly of the softstarter or the motor orthere is adisplay of the fault code F XX juststop operation immediately and deal withit in accordance with the protective requirements in Chapter 6 2 If the on spot ambient temperatureis lower than 10 C please restartthe machine more than 30 minutes lather afterit is energizedand preheated 17 Chapter 5 Description of Function Parameters 5 1 Schedule of Function Parameters Function Default Function Name Setting Range MEMO Code 2 Value PO Inception Voltage 30 70 30 P1 Period of Starting 2 60S 16 P2 Period of SoftStop 0 60S 00 P3 Starting limitation Current 5 0 500 400 P4 Max WorkingCurrent 50 200 100 P5 Undervoltage Protection 60 90 80 Overvoltage Protection 100 130 120 00
30. nditions Use the motorsoft starter in the following environmental conditions Altitude Maximum 1000m above sea level Derating should be performed before use ifthe altitude ishigher than 1 000M Ambient Temperature 10 40 C Ambient Humidity 90 RH Non condensing Place to beused Indoor places free from directexposure to sunlight dust corrosive gas flammable gas oil mist steam drip andsalt Vibration lt 0 5G Starting Times 20 times perhour 2 2 Installation The motor softstarter shall beinstalled vertically DO NOT turnupside down lay diagonally or horizontally whileinstalling Be surethe base is fixed solidly andevenly To get better coolingeffect and forthe convenience ofmaintenance the motor softstarter shall beinstalled with enoughspace left referto the figure below Unit in the Figure mm Air Outlet gt 100 gt 50 gt 100 SS Air Inlet Chapter 2 Installation and Wiring The wiring ofmotor soft starter should be operated only by professionals experienced in highand low voltageelectric circuit andshould read this manual in detail before wiring 2 3 1 Standard Wiring Diagram Basic Wiring Diagram rene Main Circuib Bypass Magnetic Contactor i 5 6 1 1 Circuit Breaker MCCB or Leakage Circuit Breaker g ELCB M lwo q gt N je i 1
31. oof andshockproof packaging Butthere is the possibility of damage in transit bycarelessness So itis necessary to unpack the packageupon receipt ofthe product and perform the following steps Check the motorsoft starter whetherthere is any damage caused during transit Check the specifications label of the motor soft starterand make sureit matches the productpart number you ve ordered Check whether the items in the package are inreadiness or not which include 1 motorsoft starter 1 user manualand 1 conformity certificate In case thereis any problem with the above mentioned contents damage or deficiency please contact yourdealer or ZiriCompany immediately 1 3 Demonstration of the Specifications Label and Model 1 3 1 Demonstration of the Specifications Label Name of Product SOFTSTART Model MODEL ZJR1 3370 Power POWER 37KW Input Power Supply INPUT 3PH 380V 50Hz Rated Electric Current ELECTRIC 75A Production Ordinal ORDINAL 1 3 2 Demonstration of the Model Z R 1 3 370 Adaptive 370 37KW Motor Power 1600 160KW Indicated Voltage Design Serial Number Motor Soft Starter Biz Code Chapter 1 Introduction to Product 1 4 Outline ofthe Product Input Terminals of Power Supply R S T Connect to the bypass contactor L21 L22 L23 Nameplate Operation Panel Base Circuit Board Cabinet Control Terminal Connect to the motor U V W Connect to the bypass contactor L
32. or counterrotates reverses justchange arbitrarily two phases of U V and W Do not installa capacitor orsurge absorber betweenthe output terminals U V W and the three phase motor Otherwise it may resultin failure ofthe motor soft starter or damageto the devices Too long connecting line between the motor and the motor soft starter may result in overcurrent trip increase of cutoff current lowaccuracy of currentdisplay of the motor soft starter So itis suggested touse a linenot exceeding 50m 3 Bypass Connection L21 L22 L23 The bypass connectionterminals L21 L22 and L23 shouldbe connected tothe electromagnetic contactor No wrong connectionor incorrect phase sequence When the starting of the softstarter is finished the main loop power device SCR will log outand the bypass electromagnetic contactor willrun simultaneously Atthis time the motoris brought intonormal service 4 Ground Terminal The ground terminalof motor softstarter should be properly connected tothe ground to avoidelectric shock orfire The ground wire cannot share aground point with any otherstrong current load They mustbe connected respectively and the ground wire isthe shorter the better 8 Chapter 2 Installation and Wiring 2 3 3 Main Circuit Connection Diagram Power Supply AC380V 50 60HZ Circuit Breaker orLeakage Circuit Breaker MCCB or ELCB CHZIRI Soft Starter ZJR1 AC Contactor KM
33. press this key to save If there is the indication of good with 2 sounds this indicates the data has been saved Repress this key or press the stop key to exit Confirm Key 2 Press this key when the machine is in operation the voltage of input power supply will be displayed 3 When the power is on press this key and the parameters you ve set will be restored to the factory default value Add K 1 When entering intomanual setting press thiskey to modify parameters ey When the colon doesnot flicker thiskey is used tomodify the functional code when the colon flickers this key is usedto modify the datavalue 2 When the machineis in operation pressthis key to keepan eye on the Substract Key display of current A power P and overloadheat balance H OO When the lastdecimal behind the three figure data gt 999 is lightened then 0 shall be added behind the mantissa The tone beeps while pressing any of these keys Otherwise this actionis invalid Chapter 3 Operation Panel 3 2 Panel Operation Parameter Modification Example Eg If the control mode ischanged to externalterminal control justset the code P9to 02 9 Action Display Description 1 Power Getting started 2 Press Enter into the state of programming 3 Pressa for 9 times 4 Press 5 Twice 02 indicates externalterminal control 6 Press re Note
34. rotection and input open phase protection while starting isapplied to some emergency occasions i e fire pump etc Light load standardand heavy load protection classes have full protection functions Their distinguish liesin different timecurves of motor s overload heat protection Refer to thetable below andthe figure inpage 26 tosee time parameters for motor heat protection The protection standard for advanced protectionis even stricter Functional parameters for the rest protection classes areset the sameas the standard protection See thetable below for different protection classes andheat protection setby the code P8 P8 Setting 0 Primary 1 Light 2 3 Heavy 4 Class Load Standard Load Advanced Pescuphion Overload In accordance Running Class2 Class 10 Class 20 Class 10 with Protection 1 60947 4 2 Classes standard Overcurrent Based on that Starting 38 158 308 1367 Protection than 5 times the Time set value Current Overload Multiple 4 5 4 5 4 5 4 5 Numerical Running 1 values in Trip Time this table Lists are typical Trip 5 4 5 2 3 1 5 23 12 7 5 46 23 15 23 12 7 5 ones Functional Code P9 Control Modes SettingRange 00 07 Factory Default Setting 01 00 operation panel control 01 operation panel external control 02 external control 03 external control COM control 04 operation panel external COM con
35. top 7 Stop 1 Start 09 oO Control Terminal Lead 0 75 1 5 Two wire Control Mode ZJR11 7777 Instantaneous Stop Stop 08 o K eal Start i 09 1 Switch on motor starts switchK off motor stops 11 Chapter 2 Installation and Wiring 2 3 6 Relay amp Non local Control Wiring Diagram Relay Control Mode TEARC nstantaneous Stop 1 07 1 1 Stop 08 1 i Start KA 09 1 10 1 1 1 1 1 Pi Ia Sat Seems pe Monae 1 i CSS eS Se Relay Control Mode instantaneous Stop 1 Stop 1 Start 1 08 Por q 1 1 1 1 1 1 09 q 1 1 1 1 1 1 is connected to the breakcontact normally protector i e athermal protector The factory defaultsetting of Kis shorted 1 2 Chapter 2 Installation and Wiring 2 4 Selection List of Peripheral Appliances Option list ofthe motor softstarter peripheral breakers electromagnetic contactors and cables shownas below ee eee ZJR1 3055 5 5 11 16 16 4 ZJR1 3075 7 5 15 20 16 6 ZJR1 3110 11 22 32 25 6 ZJR1 3150 15 30 40 40 10 ZJR1 3185 18 5 37 50 40 16 ZJR1 3220 22 44
36. trol 05 operation panel COM control 06 control 07 start stop disabled Chapter 5 Description of Function Parameters Functional Code PA ParameterProtection Setting Range 00 01 Factory DefaultSetting 01 Functional Description This function is usedto set whetherthe internal parameters of the motorsoft starter are allowed to be modified 00 Parameter modification disabled 01 Parameter modification enabled Functional Code Pb Programmable Output Setting Range 00 19 Factory Default Setting 07 Code Pb isused to setthe action time for operation outputrelay The output functionof programmable relay provides 2 working modes programmable sequential outputand programmable status output When Pb isset to 0 4 10 14 programmable output works in the mode of time output0 The setstarting moment ofthis output is seen in thetable below Values set by Pb 0 10 1 11 2 12 3 13 4 14 Moment of When ordering When bein When ordering When Programmable the command started 8 hog bypass the command of shutdown is Output of start stop completed This working mode is usedin an immediate state and therelay acts atthe moment when the stateset by Pbjust begins The reset momentof this output will be completed 1 second slater afterthis state endsup Eg The factory defaultsetting value of Pb 15 7 which means thesoft starter isina hold mode when energized and therelay attracts at the sametime If the so
37. voltage butnot through the mechanical control over time t regardless of whether the motoris accelerated steadily Therefore if thereis a lightload the starting time will tendto be lessthan the set starting time Itis normal ifthe machine canbe started smoothly Generally speaking voltage ramp start mode is applicableto the occasion where there isno strict requirementon starting current buta high requirementon the stability of starting Chapter 5 Description of Function Parameters 3 Kick Start When the code P7 isset to 2 kick current limiting or 3 kick voltage then kick start modeis selected The figure belowis the change waveform of output in kick start mode This start modecan be selectedin case thereis a failure start of the motor due to influence of the machine s static friction force on the occasion of heavy loads While the machineis just started DO feed afixed higher voltage to the motor and keep it for ashort period oftime so asto smooth away static friction force of motorloads and enable the motorrotate and thenselect a startmode of current limiting or voltage ramp Before selecting this mode itis strongly recommended to startthe motor bynon kick starting Then select thismode ONLY AFTER the motor failed to start DO keep clear of kickstart as possibleto reduce unnecessary impulse ofstrong current Un100 0 1 00 T 4 Current Ramp Start When the code P7 is setto 4 currentramp
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