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DS7 Soft Starters

1. DS7 34 SX mm Weight kg sac slopes 5 3 4 160 200 35mm 35mm 1 38 1 38 mm PE 0 59 ol sz t 9 E E E rm 28 A E NG 9999999 Seo gem pes eie drei Y B Y H PE 15jmm 0 591 52 5 mm 2 07 108 mm 4 25 ew 178 mm 7 01 gt Figure 64 Dimension drawing DS7 135 to 200 A DS7 Soft starter 07 10 MNO39010017 EN wwweaton com 89 7 Appendix 7 4 Technical data 90 DS7 Soft starter 07 10 MN03901001Z EN www eaton com Index A Acceleration time 00 0000 cee eee 73 Approvals aean e iD 77 B BYPASS enmaai 38 Bypass Connection seg Saa ra 38 Bypass contactor res serti RR a eee 38 C Cable protecilon_ cee eee 18 Cables R ovde etd nebat te eaves eet T ds 20 CEmarknNg sa sian sores rede 77 Change of rotation 0 0 0 0 0000 eee 35 Changing start commands 24 Circuit TY OO e iene sea Kio oe Lae qot cati Ks 21 Climatic proofing ca 14 GIOCKWISG ui ea toti e UE Po aaa Aasta ea 21 Clockwise rOtatiON ss sessi cede ae EA See ees 21 Commissioning PROCECUIE os o tete e t eur 67 Connecting MOtOTS br dr RS 11 Connection BICI 39 With soft stop ramp 29 Without soft stop ramp 26 COMMECTION types sadaa Ae e LR teu s 23 CONNGGUONS cose ee oes po bei ems 56 Conta
2. S 125A 175A 225A 275A 325A 375A 425A 475A 525A S 150A 175A 200A 225A 250A 275A 300A 325A 350A 150A 200A 250A 300A 350A 400A 450A 500A 550A DS7 34xSX160 DS7 34xSX200 30s 30s SX160 1 h SX200 1 h 255 SX160 10 h 255 SX200 10 h 5 X160 20 h 205 20s 5X200 20 h S S 150A 250A 350A 450A 550A 650A 200A 300A 400A 500A 600A 700A 800A 200A 300A 400A 500A 600A 250A 350A 450A 550A 650A 750A Figure 60 Conversion to other load cycles rated operational current from 41 A 82 DS7 Soft starter 07 10 MN03901001Z EN www eaton com 7 4 Technical data 7 4 1 General data 7 Appendix 7 4 Technical data The technical data is divided up into data applicable to all devices and data applicable to specific device series and device types General data General Standards IEC EN 60 947 4 2 Approvals Climatic proofing Damp heat constant according to DIN IEC 68 part 2 10 damp heat cyclical according to DIN IEC 68 part 2 3 Ambient temperature gE 5 40 up to 60 C at 1 derating per Kelvin temper ature rise Ambient temperature storage C 25 460 Installation altitude1 m 0 1000 above that 1 derating per 100 m max 2000 Mounting position Vertical Protection type2 IP20 Busba
3. Wait a minute for cooling and repeat step 1 gt 2 Optimize t Start set t Start as recommended in the previous setting Figure55 and allow 6 minutes for cooling gt 3 Carry out a complete start M 4 If the application runs up faster than the ramp time setting shorten this setting as much as is possible for the application p 5 If the application requires more time for the run up gt 125 96 than the set ramp time increase the value of t Start unless the load cycle of the soft starter is exceeded If the acceleration time is longer than the limits from step 4 or 5 let the soft starter cool down for 6 minutes increase the ramp time and proceed with step 3 D 6 Run up optimization completed gt 7 f a stop ramp is required the set time should be set longer than the run down time of the machine in order to achieve an effect As a soft stop produces a current increase observe the thermal output capacity load cycle of the soft starter A larger device must be selected if the required settings for an application cause the permissible load cycle of the soft starter to be exceeded DS7 Soft starter 07 10 MNO39010017 EN www eaton com 67 5 Operation 5 4 Starting a motor 5 4 Starting a motor Applying the start command High signal at terminal A1 will cause the motor to accelerate with the set values The actual acceleration time can differ from the set values depending on the load 5 5 Operation The soft
4. Intended use aana 14 Operating several motors 11 Output voltage 00 0 21 Selection criteria ooo ooooo o 11 Standard connection 25 Soft starters Fe tur s DSJ cu cest cep ee 9 SOME eis ende isdem e e p EA 69 SOM STO Ra o de Bor iere ici Cas te 24 Standard Connection 000 25 Standards A Eis 77 Star connection zuo ters ated pe NN each 21 Start datdr exc ia 48 Start time asc to en Be SS Eun e NU e 49 cio tos cast Cor et ah e my lr 21 47 49 Startibig tl ies Ses eke SS see aed tre ee 17 Startup current MAXIMUM srta fue ate x VII QR 17 SLO Pin e e Tett bier bo bees 69 SIOD Tal lp ende euro sonet aes Gr pui pa Ed 50 Storage deret uen ood ER ah 15 System overview eese 7 T Temperature monitoring 21 Terminal assignments nauan aana 50 Thermistor motor protection 21 Three phase asynchronous motor 9 lnc DE 53 Top OL RIME fotos eise rese trece ese e 50 TOP Of TANTO Sou a ccr whitey y oerte ite d cese Ai 73 PANS DOM 12st d R led IE ee 15 Stat des sosta ee n eer bn 49 TESTO Diese ad ore mer otia 50 TYDES pacos L esses ci R c aser fe 77 Type of coordination 00 00 0005 19 Voltage device internal Motor voltage n anaana aaan Start voltage 00 0 00005 DS7 Softstarter 07 10 MNO3901001Z DE www eaton com 93
5. Rotation direction reversal with ramp Figure 31 L01 L Q21 RUN 94 01 l CA y m FWD H 4 S REV K1 S K1 i K1 Q11 K2 Q12 Q12 011 EN Al K1L 1 K2 MEA Q11L 1 Q12L 1 LOO L FWD REV Figure 32 Control section Bidirectional operation CD with Soft stop 2 without Soft stop DS7 Soft starter 07 10 MNO39010017 EN www eaton com 37 2 Engineering 29 Connection types 2 9 9 Bypass connection Devices of the DS7 34 series are already equipped with inte grated bypass contacts An external bypass is therefore not required 2 9 10 Pump connection single direction of rotation When operating pumps one of the most frequent requirements is to be able to run emergency operations with the bypass contactor A service switch is used to select between soft starter operation and DOL starter operation via a bypass contactor In the latter setting the soft starter is fully bypassed But because the output circuit must not be opened during operation The interlocks ensure that a switchover is only possible after a stop Unlike simple bypass operation the bypass contactor in this case must be designed to utilization category AC 3 The recom mended mains contactor shown in the Appendix gt Page 87 can be used as a contactor L1 L3 e PE EEE Q2 FAA M1 7 Figure 33 Power section with bypass emergency operation pu
6. User Manual DS7 Soft Starters E T N Powering Business Worldwide Ha demo aa Rara SYSSS SS ff ETN Moruer DS7 3M0SX032NO N e L ma f CY ws B A TW 9 Ls w Te de AA 4 L E he ts 1 s AL See manuaitor dotas 2 A r eos Us Us 41 ao ww A a M YA 07 10 MNO3901001Z EN All brand and product names are trademarks or registered trademarks of the owner concerned Emergency On Call Service Please call your local representative http www eaton com moeller aftersales or Hotline After Sales Service 49 0 180 5 223822 de en AfterSalesEGBonn eaton com Original Operating Instructions The German language edition of this documentis the original operating manual Translation of the original operating manual All editions of this document other than those in German lan guage are translations of the original German manual 1st edition 2010 edition date 07 10 2010 by Eaton Industries GmbH 53105 Bonn Production Ren Wiegand Translation globaldocs GmbH All rights reserved including those of the translation No part of this manual may be reproduced in any form printed photocopy microfilm or any other process or processed duplicated or distributed by means of electronic systems without written permission of Eaton Industries GmbH Bonn Subject to alteration without notice Eaton Industries GmbH Safety instructions Danger A Dangerous electrical volta
7. K1 LOO Figure 38 Relay connection D Suppressor circuit with AC control voltage Suppressor circuit with DC control voltage The RUN relay closes together with the start command the ramp starts around 100 ms later This makes it possible to switch an optional mains con tactor on and off via the RUN relay If there is no voltage present at the power section by this time the DS7 soft starter switches off with the phase failure fault message DS7 Soft starter 07 10 MNO39010017 EN www eaton com 45 2 Engineering 2 13 Connecting the controller section 46 DS7 Soft starter 07 10 MN03901001Z EN www eaton com 3 Parameter setting 3 1 Operating principles 3 Parameter setting 3 1 Operating principles You can adapt the soft starter to your application by setting appropriate parameters The possible settings are defined in parameters The devices are assigned parameters either via the potentiometers on the front of the device or with DS7 soft starters of SmartWire DT version via the interface Only the standard versions DS7 340 and DS7 342 are described below The DS7 34D communication enabled version is described in a separate document 3 2 Factory settings of the basic device The soft starters of the DS7 series are factory set so that no settings are required for standard applications The following tables shows the most important settings Table 7 Factory settings DS7 terminal fun
8. 2 5 x 0 75 16 2 x 0 75 2 5 2 x 0 75 10 Stranded mm2 x 16 1x 25 70 1 x 4 185 2x16 2x 6 25 2x 4 70 Solid or stranded AWG 1x 18 10 x 14 8 1x 12 2 0 1x 12 2x 18 10 2x 14 8 350 mcm 2x 12 00 Flat conductor min mm 2x9x0 8 2x9x0 8 max mm 9x9x0 8 10x16 x 0 8 Tightening torque Nm 12 3 2 9 gt 10 mm 14 gt 10 mm 6 10 mm 5 s 10 mm Control cables Solid mm 1 x 0 75 4 1x 0 75 4 1x 0 75 4 1 x 0 75 4 2 x 0 75 2 5 2 x 0 75 1 5 2 x 0 75 1 5 2 x 0 75 1 5 Flexible with ferrule mm2 1 x 0 75 2 5 1 x 0 75 2 5 1 x 0 75 2 5 1 x 0 75 2 5 2 x 0 75 2 5 2 x 0 75 1 5 2 x 0 75 1 5 2 x 0 75 1 5 Stranded mm Solid or stranded AWG 1x 18 10 1x 18 14 1x 18 14 1x 18 14 2x 18 10 2x 18 16 2x 18 16 2x 18 16 Flat conductor mm Tightening torgue Nm 1 2 0 6 0 6 0 6 Screwdriver flat blade mm 0 6 x 3 5 0 6 x 3 5 0 6 x 3 5 0 6x 3 5 Control circuit Relay outputs Number 1 TOR 2 TOR Ready 2 TOR Ready 2 TOR Ready Voltage range V AC DC Us 250 250 250 Current range CSA 1 1 1 1 84 DS7 Soft starter 07 10 MNO3901001Z EN www eaton com 7 4 3 Non power supply dependent data 7 Appendix 7 4 Technical data Supply voltage Uc 24 V AC DC 110 230 V AC 424 V SmartWire DT General Radio interference level B A gro
9. IW IW IW Iw DS7 34xSX004N0 4 0 7 5 5 6 DS7 34xSX007NO J 0 7 6 5 7 DS7 34xSX009N0 y 0 7 6 5 7 DS7 34xSX012N0 12 0 7 7 5 8 DS7 34xSX016N0 16 0 7 7 5 8 DS7 34xSX024N0 24 0 7 9 5 0 DS7 34xSX032N0 32 07 2 5 3 DS7 34xSX041N0 41 0 7 8 5 9 DS7 34xSX055NO 55 0 7 0 5 0 DS7 34xSX070NO 70 07 2 5 2 DS7 34xSX081N0 81 0 7 3 5 4 DS7 34xSX100N0 100 0 7 7 5 8 DS7 34xSX135N0 135 07 24 5 25 DS7 34xSX160N0 160 0 7 31 5 31 DS7 34xSX200N0 200 0 7 43 5 44 The start produces currents above the rated operational current All enclo sure types in which the Soft starter is to be installed must have the required heat dissipation capacity Depending on the ramp time set and the current limitation this current can be present for several seconds The resulting heat dissipation must then be allowed for in the housing design DS7 Soft starter 07 10 MNO39010017 EN www eaton com 13 1 About the series 1 6 Intended use 1 5 6 Permissible environmental conditions The following shows the permissible values for the ambient influences on soft starters of the DS7 series Table 4 Permissible environmental conditions Property Value Protection type IP20 Installation altitude Up to 1000 m a s l higher than this up to 2000 m with a current reduction of 1 per 100 m Temperature Operation 5 up to 40 C without reduction up to 60 C with a reduction of 2 per degree Ke
10. Io IR 011 KEI LOO L Figure 22 Control section with mains contactor optional only if a stop without soft stop is required 32 DS7 Soft starter 07 10 MNO39010017 EN www eaton com 2 Engineering 29 Connection types 2 9 7 2 Construction size 2 16 A to 32 A L1 L2 L3 PE UHL TOR RUN Us Pr Us peur 14 E M K3 Us 24 V AC DC 110 230 V AC QU Figure 23 Standard connection with mains contactor Q11 Mains On Off K3 Start stop LO1 L v 01 p Q11 rr a sm 1 Soft Stop LOO L Figure 24 Control section with mains contactor D optional only if a stop without soft stop is required DS7 Soft starter 07 10 MNO39010017 EN www eaton com 33 2 Engineering 29 Connection types 2 9 7 3 Construction size 3 4 41 A to 200 A L1 Q21 Us 24V AC DC 110 230 V AC QU Figure 25 Standard connection with mains contactor Q11 Mains On Off K3 Start stop L01 L F2 7 ay pas KI 1 K1 021 l 24 o eem BE sa i ag Soft Stop al gal ED KIA Soft Start K3 eee eii 4 KICI K3 Q11 LOO L Figure 26 Control section with mains contactor CD optional only if a stop without soft stop is required 34 DS7 Soft starter 07 10 MNO39010017 EN www eaton com 2 9 8 Ro
11. Opera Ta 63 Recommended Sertings see 65 COMMISSIONING procedure ic ta 67 Starting a A A Sh gi ese EE 68 Operationen O M 68 A Pee a a ee eS 69 DiaQmOStics cuida 71 eel O1 lale Tse TTT 71 Motor not startrig TT 71 Motor stops immediately after start completed 71 Motor running UNeVeN TT 71 Motor consuming too much current 71 Connected Motor overheating viii ici 72 Error messages and rectification ooooooooccccnnnnooococnonccocnnnonnnononos 72 Error acknowledges nte eee 72 LED YINGICATORS lt xax c Lec tet oM EE 72 LED indication in the event of TautS eaaa eaaa eaaa eaaa rane 74 Monitoring messages 75 Fault messages OO Sta ve eel lees 75 Fault messages during Operation 76 DS7 Softstarter 07 10 MN03901001Z DE www eaton com 7 1 7 2 7 3 7 3 1 7 3 2 7 3 3 7 3 4 7 3 5 7 4 7 4 1 7 4 2 7 4 3 7 4 4 7 4 5 7 4 6 7 4 7 Contents Appendix ien ore rir er cid 77 StaladakdSs trece teet eL e Meet 77 Applicable product standards and approvals sssss 77 Control inputs and 0Utputs aaa rdiet eise Re tdi 78 Overload withstand capability aaa aaa eaaa eea eaaa 79 Overload capability load to ALC B291 eaaa eaaa aee en ea ee anane 79 Conversion of the overload capability to lower overcurrents 79 Different load cycles and start freguenciles aana nan anan anane 80 Conversion to othe
12. Soft starter 07 10 MN039010017 EN www eaton com 5 6 Stop 5 Operation 5 6 Stop If the drive is not isolated from the supply when stationary mains contactor main switch it may start up accidentally in the event of a malfunction Even if the motor is stationary the terminals are still energized leakage current across the thyristors uncontrolled phase DANGER A One phase to the motor is internally bridged which means that a supply phase is still directly present at the motor even when it is switched off Danger of fatal electric shock on contact After the start is completed the soft starter switches to the operating phase If the stop command low signal at terminal A1 is initiated the soft stop is triggered The drive then moves with the set stop time to the value of the stop voltage When this is reached the soft starter switches off the output If the motor still is still turning it will perform an uncontrolled stop from this point The soft stop time is factory set to O s in other words the motor performs an uncontrolled stop DS7 Soft starter 07 10 MNO39010017 EN www eaton com 69 5 Operation 5 6 Stop 70 DS7 Soft starter 07 10 MN03901001Z EN www eaton com 6 Diagnostics 6 1 Fault finding 6 Diagnostics The following information provides help in fault detection and troubleshoot ing DANGER A On no account should you open the device if the supply voltage is switched on Danger of fat
13. series 1 5 Selection criteria The soft starter is selected according to the rated motor current and the load type The load must have a quadratic speed torque characteristic Loads with a linear or constant speed torque characteristic cannot be started at full load with the DS7 soft starter e g piston pumps up to the completed run up only with bypass The rated output current of the soft starter must always be greater than equal to the rated motor current With machines with heavy starting characteristics the starter must be dimensioned accordingly higher in terms of its overload characteristics 1 5 1 Design with different load cycles The DS7 soft starter is designed for a standard load cycle When used in applications such as water pumps centrifugal pumps the DS7 must be selected with the assigned rated operational current If the switch frequency acceleration and or starting currents are different the design of the DS7 must take its thermal capacity into account The Appendix Page 79 provides overload curves for the different combinations of time current and starts per hour in order for the DS7 to be selected correctly for the application 1 52 Parallel connection of several motors to one soft starter If several motors are to be operated with one soft starter this must be designed on the basis of the sum of all rated motor currents It must be taken into account that an even run up of all motors cannot be ensured If moto
14. signals have the same potential and are supplied from the same voltage source 2 132 Internal device voltages The DS7 soft starters do not provide any internal voltage 2 13 3 Grounding the 0 V potential All control signal terminals of the DS7 soft starter are galvanically isolated from the power section Grounding is not required 44 DS7 Soft starter 07 10 MNO3901001Z EN www eaton com 2 13 4 Relay contacts 2 Engineering 2 13 Connecting the controller section The soft starters of the DS7 340 series are provided with one or two relays with an N O contact depending on the current range The signal assignment can be programmed via SmartWire DT otherwise this is pre programmed with the standard assignment The relay is galvanically isolated from the soft starter Table 6 Relay contacts Terminal Standard function Configuration Meaning Load carrying capacity 13 TOR Input K1 N O 250 V AC 1 A AC 1 o a ERE Or S AER Output K1 24 V AC DC 1 A AC or A2 with devices to 12A devices up to 12 Aat ee 24V supply voltage With devices from 16 A additionally 23 RUN Input K2 N O 250 V AC 1 A AC 1 24 Output K2 If you connect external contactors to a relay contact you can increase inter ference immunity by connecting in AC circuits the contactor coil parallel with an RC filter e by connecting in DC circuits the contactor coil in parallel with a free wheel diode 13 O L01 L gt K1
15. the start command is activated again the soft stop is aborted and a soft start is carried out from the current value of the output voltage a Figure 8 Changing start commands 2 9 3 Including the overload relay in the control system We recommend the use of an external overload relay instead of a motor pro tective circuit breaker with an integrated overload relay Only in this way can it be ensured that in the event of an overload the soft starter can be brought to a controlled stop WARNING A Overvoltages that can destroy the semiconductors in the soft starter may be present when the power cables are opened directly emergency stop during ramp operation Overload protection can be included in two ways e The overload relay s signalling contacts are incorporated in the On Off cir cuit In the event of a fault the soft starter decelerates for the set ramp time and stops e The signal contacts of the overload relay are evaluated in a higher level controller The control word is assigned accordingly via the SmartWire DT connection in order to switch off the output of the soft starter Enable signal immediately in the event of a fault The soft starter switches off but the mains contactor remains on In order to switch this off as well the Stop state must be detected and the contactor de energized sepa rately This is only possible with a SmartWire DT version of the DS7 soft starter 24 DS7 Soft starter 07 1
16. 0 MNO3901001Z EN wwweaton com 1 About the series 1 7 Storage transport and disposal The devices of the DS7 series are not devices for household use and are designed exclusively for use in commercial applications are not machines in the sense of the EC Machinery Safety Directive can be used in the described system configurations in the industrial envi ronment e comply in a typical drive configuration with the requirements of the EU EMC Directive the EU Low Voltage Directive as well as the specified standards The user of the equipment is responsible for ensuring that the machine use complies with the relevant EU Directives Any other usage constitutes improper use 1 7 Storage transport and disposal The DS7 soft starter is carefully packed and prepared for shipment It must only be transported in the original packaging with suitable means of transport see weight specifications in the Appendix under Dimensions Observe all printed labels and instructions on the packaging This also applies to the unpacked equipment On delivery please check whether e there is any external damage to the packaging e the specifications on the delivery note match those of your order Then open the packaging with a suitable tool or check whether e parts have been damaged during transport e the device matches the part no ordered e the installation instructions are provided with the device In the event of damage incomplete or in
17. 0 MNO3901001Z EN wwweaton com 2 Engineering 29 Connection types 2 9 4 Standard connection In standard operation the DS7 soft starter is connected in the motor feeder For mains isolation to EN 60947 1 subclause 7 1 6 or when working on the motor DIN EN 60204 1 VDE 0113 Part 1 subclause 5 3 stipulates the mandatory use of a central switching device contactor or main switch with an isolation function No contactors are required to operate individual motor feeders DS7 Soft starter 07 10 MNO39010017 EN www eaton com 25 2 Engineering 29 Connection types 2 9 5 Connection without soft stop ramp 2 9 5 1 Construction size 1 up to 12 A L1 L2 L3 PE EN Y Q21 Q1 M1 Us 24 V AC DC 110 230 V AC QU Figure 9 Standard connection without soft stop Uti 2 13 Q1 Uri Ta 134 dec E TOR 13 14 Figure 10 Logic sequence without soft stop 26 DS7 Soft starter 07 10 MNO39010017 EN www eaton com 29 Connection types 2 9 5 2 Construction size 2 16 A to 32 A L1 L2 L3 PE AAA TOR RUN 23 1 Us 24V AC DC 110 230 V AC QU Figure 11 Standard connection without soft stop Us Uri 2 13 Q1 Al RUN 23 24 Un 12 13 gt Ustart TOR 13 14 Figure 12 Logic seque
18. 24V AC DC 110 230 V AC QU Figure 17 Standard connection with Soft stop S3 Start stop KA Uri 2 13 Q1 3 Start Stop RUN 23 24 l Ut 12 73 H gt gt Y l Ustart TOR 13 14 t Start t Stop Figure 18 Logic sequence with soft stop 30 DS7 Soft starter 07 10 MNO3901001Z EN www eaton com 2 9 6 3 Construction size 3 4 41 A to 200 A L1 L2 L3 Q21 o QU Figure 19 Standard connection with Soft stop S3 Start stop Us T Uti 12 13 Q1 EN S3 Start Stop I RUN 23 24 Us 24V AC DC 110 230 V AC Uri 13 7 gt gt Ustartt f TOR 13 14 t Start t Stop Figure 20 Logic sequence with soft stop DS7 Soft starter 07 10 MN03901001Z EN www eaton com 2 Engineering 29 Connection types 31 2 Engineering 29 Connection types 2 9 7 Standard connection with upstream mains contactor and soft stop ramp 2 9 7 1 Construction size 1 up to 12 A L1 12 13 PE DUI TOR TU Ae il i Us 24 V AC DC 110 230 V AC e L U Figure 21 Standard connection with mains contactor Q11 Mains On Off K3 Start Stop LO1 L Q1 F2 7 Q11 Do l pS Soft Stop l l 1 I t I 3 Qn Soft Start G
19. 32 A 60 DS7 Soft starter 07 10 MNO3901001Z EN www eaton com 4 Mounting Installation 4 3 Connections 4 3 0 8 Fitting the motor plug gt To wire the motor plug see installation instructions AWA2100 2690 4 3 0 9 Fitting the overload relay The ZB12 or ZB32 overload relay can be fitted directly to a DS7 soft starter Figure 54 Mounting the overload relay with devices up to 32 A DS7 Soft starter 07 10 MNO39010017 EN www eaton com 61 4 Mounting Installation 4 3 Connections 62 DS7 Soft starter 07 10 MNO3901001Z EN www eaton com 5 Operation 5 1 Placing into operation 5 Operation 5 1 Placing into operation DS7 34 series soft starters are factory set so that you can operate a suit ably rated 4 pole standard motor in a typical soft starter application without any additional settings required CAUTION Before switching on the soft starter check whether the permis sible ambient conditions have not been exceeded and that there is no moisture inside the device Storing the soft starter in a cool place for example may cause moisture to occur If moisture has penetrated the device ensure that it is completely dried CAUTION The electrical installation and commissioning must only be car ried out by suitably qualified personnel The user is responsible for ensuring suitable grounding and cable protection for the incoming supply in accordance with local and national regulations The motor mu
20. 37 20 25 50 DS7 34x5X081N0 81 3 22 45 25 30 60 DS7 34xSX100N0 100 7 30 55 30 30 75 DS7 34xSX135N0 135 24 30 75 40 50 100 DS7 34xSX160N0 160 31 45 90 50 60 125 DS7 34xSX200N0 200 43 55 110 60 75 150 07 10 MNO3901001Z EN www eaton com 7 Appendix 7 4 Technical data 7 4 5 Protection short circuit strength Part no Type 1 coordination Type of coordination 2 Fuse holders in addition to fuses for type of coordination 1 DS7 34xSX004N0 PKZMO 4 CL PKZ0 3 x 50 179 06 16 3 x 51 060 04 DS7 34xSX007N0 PKZMO 10 CL PKZO 3 x 50 140 06 25 3 x 51 060 04 DS7 34xSX008NO PKZMO 10 CL PKZO 3 x 20 282 20 32 3x 21 189 0 DS7 34xSX012NO PKZMO 12 CL PKZO 3 x 20 282 20 32 3x 21 189 0 DS7 34xSX016N0 PKZMO 16 CL PKZO 3 x 50 140 06 50 3 x 51 060 04 DS7 34xSX024N0 PKZMO 25 CL PKZO 3 x 50 140 06 63 3 x 51 060 04 DS7 34xSX032N0 PKZMO 32 CL PKZO 3 x 50 140 06 80 3 x 51 060 04 DS7 34xSX041N0 NZMN1 M50 PKZM4 50 3 x 20 282 20 100 3 x 21 189 0 DS7 34xSX055NO NZMN1 M63 PKZM4 58 3 x 20 282 20 125 3x 21 189 0 DS7 34xSX070NO NZMN1 M80 3 x 20 610 32 200 3 x 21 313 02 DS7 34xSX081N0 NZMN1 M100 3 x 20 610 32 200 3 x 21 313 02 DS7 34xSX100N0
21. 7 Softstarter 07 10 MNO3901001Z DE www eaton com 91 L EED andicators eutanasia eem tee OY ws 72 OA conus een ete eem P bur 11 73 CapacitlV8 o tavern roses eee ei 14 Load 6ycle iia ns ve LR I be bees eee eS 17 Kerlean CIES en toto teil ok cae neta ae 80 Different 2 o ses tmp oS te dee 11 Load distribution 0 0 0020005 11 Low Voltage Directive a 14 77 M Machinery Safety Directive 14 Mains contactor Connection with upstream 32 Manual MNOS8902001Z EN co tt ds 17 Moments or inertia esses Le ee 17 Monitoring messages 75 Motor DODIIBOE consecr dotes euet Tra T T 11 Current consumption too high 71 Notstartlg ena detur EV RE da 71 OVEN CATING iss uem cett metes t le 72 Reversing rotation direction 22 OPS Saco temo es Go eds 71 Uneven TUNNING sax soo eee Se 71 Motor cables CONNECT che ainsi due iat ceret en amas 56 ONG i nec cene cose Ae onte ine odd GR dvd 22 Motor connection 2 05 18 21 Motor full load current_ aaa 11 Moto nd eR eei Dr E ep ES 17 Motor Powel ail deems se esee nee a p wa 12 Moto RATING a dm ep RES eh eet a NES 12 Motor rotation direction HOeVersiDg ridus Tefa g nao h uaa a ita BEIA 22 Motor supply cables SCE ening eme tpe s dd 56 Mounting on mounting plate 54 On top hat ral o oo ooo oo 54 Mounting positions 0 0 0 0
22. NZMN1 M100 3 x 20 610 32 200 3x 21 313 02 DS7 34xSX135N0 NZMN2 M160 3 x 20 610 32 350 3x 21 313 02 DS7 34xSX160N0 NZMN2 M200 3 x 20 610 32 400 3 x 21 313 02 DS7 34xSX200N0 NZMN2 M200 3 x 20 610 32 500 3 x 21 313 02 7 4 6 Protection overload relay optional mains contactor Partno Soft starter function with soft stop in case of overload Optionalmains contactor Cable protection Overload relays2 DS7 34xSX004N0 PKMO 4 CL PKZ0 ZB12 4 DILM7 DS7 34xSX007NO PKMO 10 CL PKZO 2812 10 DILM7 DS7 34xSX008NO PKMO 10 CL PKZO 2812 10 DILM9 DS7 34xSX012N0 PKMO 12 CL PKZO 2812 12 DILM12 DS7 34xSX016N0 PKMO 16 CL PKZO 2832 16 DILM17 DS7 34xSX024N0 PKMO 25 CL PKZO 2832 24 DILM25 DS7 34xSX032N0 PKMO 32 CL PKZO 2832 32 DILM32 DS7 34xSX041N0 NZMN1 M50 PKZM4 50 2865 40 ZB65 XEZ DILM50 DS7 34xSX055NO NZMN1 M63 PKZM4 58 ZB65 57 ZB65 XEZ DILM65 DS7 34xSX070NO NZMN1 M80 ZB150 70 KK DILM80 DS7 34xSX081N0 NZMN1 M100 28150 100 KK DILM95 DS7 34xSX100N0 NZMN1 M100 28150 100 KK DILM115 DS7 34xSX135N0 NZMN2 M160 2B150 150 KK DILM150 DS7 34xSX160N0 NZMN2 M200 25 160 FF250 DILM185 DS7 34xSX200N0 NZMN2 M200 25 220 FF250 DILM225 1 Used to specify the circuit breaker required for the specified load cycle For other switching cycles operating frequency overcurrent overcurrent time duty factor this value changes and must be modified accordingly 2 Used to specify the circui
23. Output voltage U2 three phase from an adjustable start voltage through a ramp function up to 100 supply voltage with a constant supply frequency lon 4 to 200 A at maximum ambient temperature of 40 C Motor shaft power Pa 1 5 to 110 kW at 400 V or 3 to 150 HP at 480 V 4 Controller card for controlling the power section This is used to initiate control commands and set the parameters SmartWire DT interface optional device series for modifying and storing parameters 1 3 Features of the soft starters DS7 series soft starters are provided with the following standard features Table 1 Features of the soft starters Feature Compact construction type PA Adjustable start voltage A Separately adjustable ramp times for start and stop J Digital inputs Y 1 BG1 2 BG2 4 Relay output V 1 BG1 2 BG2 4 Standard controller card and parameters over the entire performance range 4 Networkable DS7 34D D Y via SmartWire DT DS7 Soft starter 07 10 MN03901001Z EN www eaton com 9 1 About the series 1 4 Front View 1 4 Front View The following two devices are used as examples of the DS7 series DS7 34DSX012NO0 D and DS7 3405X032N0 N MA 32 m Us we 2000o eee LLLLSS gt 3 ETN Mor 0 OSA A gt o A SAA a Wwe E Y Nia 6 Y 274 472 6 13 m Figure 3 Front view DS7 Soft starter 10 DS7 Soft starter 07 10 MNO3901001Z EN www eaton com 1 5 Selection criteria 1 About the
24. S 36A 45A 12A 24A DS7 34xSX024 10 h th 20h 48A 60A 10 h th 20h 16A 32A DS7 34xSX032 305 255 205 64A 80A 24A 48A 10 h th 20 h 15s 10s 55 96A 120A S 32A 64A 96 A 128A 160A Figure 59 Conversion to other load cycles rated operational current up to 32 A DS7 Soft starter 07 10 MNO39010017 EN www eaton com 81 7 Appendix 7 3 Control inputs and outputs DS7 34xSX041 DS7 34xSX055 305 30 SKO41 1 h S X055 1 h 255 SX041 10 h 255 X055 10 h 5X041 20 h 205 205 SX055 20 h 15s 15s 10s 10s 5s 55 5 S 60A 80A 100A 120A 140A 80A 100A 120A 140A 160A 180A 200A 70A 90A 110A 130A 150A DS7 34xSX070 DS7 34xSX081 305 305 SX070 1 h SX081 1 h 25s SX070 10 h 255 SX081 10 h 205 SX070 20 h 20s 5X081 20 h 15s 15s 10s 10s 5s 5s S s 100A 125A 150A 175A 200A 225A 250A 100A 125A 150A 175A 200A 225A 250A 275A 300A DS7 34xSX100 DS7 34xSX135 30s 30s SX100 1 h SX135 1 h SX100 10 h 255 SX135 10 h 20s SX100 20 h 20s 5X135 20 h 25s 15s 105 5s
25. al injury 6 1 Fault finding Some possible faults are described below 6 1 1 Motor not starting Possible causes Start signal not present Supply voltage not present Regulator supply voltage not present Ramp too long Start voltage too low Error LED lit 6 1 2 Motor stops immediately after start completed Possible causes e Disconnection due to fault e g phase fault frequency fault 6 1 3 Motor running unevenly Possible causes Motor power too small lt lt 1 5 kW Low flywheel masses and no load on motor 6 1 4 Motor consuming too much current Possible causes Ramp time too long Start voltage too low Start voltage too high Motor overload DS7 Soft starter 07 10 MNO39010017 EN www eaton com 71 6 Diagnostics 6 2 Error messages and rectification 6 1 5 Connected motor overheating Possible causes are e Ramp time too long e Too many starts in succession e Heavy starting with this motor rating not or only not sufficiently allowed for when selected 6 2 Error messages and rectification 6 2 1 Error acknowledge If a fault message occurs a restart is only possible after an error acknowl edge has been carried out For this the soft start signal must be switched off With terminal control and a standard setting this is carried out with a Low signal on terminal A1 When the soft starter is controlled via the interface use the Error acknowledge bit in the control word to carry out the rese
26. al soft starters in parallel e feed in a supply voltage The power section should be protected according to the connection form used Cable and device protection on the supply side e Input AC via standard fuses for cable protection or motor protective cir cuit breaker e Fuses in UL compliant systems must be UL approved The rated voltages of the fuses must be suitable for the local supply volt age e No fuses are required on the motor side 18 DS7 Soft starter 07 10 MNO39010017 EN www eaton com 2 Engineering 2 5 Emergency switching off 2 5 Emergency switching off The soft starters of the DS7 series comply with safety category B in accor dance with EN 954 1 This means that some faults can remain undetected e g thyristor failed through overvoltage permanently conductive If the machine has more stringent requirements in accordance with EN 1050 Safety of machines additional external measures must be implemented in accordance with this standard 2 6 Protective element The devices are protected with fuse devices shown in the Appendix gt Page 87 Different fuse devices are used depending on the type of coor dination required 2 6 1 Type 1 coordination The protective switches or circuit breakers stated are used for cable protec tion and motor protection The soft starter may be damaged in the event of a short circuit 2 6 2 Type 2 coordination As well as the protective devices for type 1 c
27. and the start cycle switching frequency overcurrent When selecting the cable cross section take into account the voltage drop under load Compliance to further standards is the responsibility of the user DS7 Soft starter 07 10 MN03901001Z EN www eaton com 2 8 Motor connection 2 Engineering 2 8 Motor connection The soft starters of the DS7 series are intended for use with three phase asynchronous motors It is also possible to connect e pole changing three phase motors Dahlander motors as well as s rotor fed three phase motors slipring rotors With these motors both the application i e machine and the motor itself must permit this With pole changing motors the soft starter must first be disabled before the windings are changed over gt Full motor protection to VDE requirements is achieved with the use of an overcurrent relay and a temperature monitoring device PTC thermistors or thermostats with PTC characteristics are best suited for temperature monitoring The output voltage of the soft starter determines the torque of the motor At machine startup it must therefore be ensured that the selected starting voltage is not too low Otherwise this may cause the motor to overheat excessively before it starts up Three phase motors with different circuit types can be operated The circuit types depend on the rating of the motor concerned Ina 3 x 400 V supply network motors are operated e up to approx 4 kW m
28. ation direction reversal with soft stop ramp 29 97 Bypass eonneGctlon cete ete e cer vet Ed 2 9 10 Pump connection single direction of rotation 2 9 11 Delta CONNECT tee e da DS7 Softstarter 07 10 MNO3901001Z DE www eaton com Contents Contents 2 10 2 10 1 2 11 2 12 2 13 2 13 1 2 13 2 2 13 3 2 13 4 3 1 3 2 3 3 3 3 1 3 3 2 4 1 4 2 4 2 1 4 3 Starting several motors sequentially with a soft starter 40 Power section Construction size 3 4 41 A to 200 A 41 Pole changing motors Dahlander motors 43 Parallel switching of motors on one soft starter 43 Connecting the controller section 44 Regulator supply voltage rated control voltage Us 44 Internal device voltages see 44 Grounding the O V potential 44 Relay CONTACTS oco teet t prete Ce tes I UN pet eg Eo repe rer vean 45 Parameter SettiNg cid 47 CPS AUTO DOEIGIBIOS ia ana A an ENE AA ana AA Unai 47 Factory settings of the basic device 47 Parameterization of DS7 340 and DS7 342 oo 48 a o td aos pe a LK eis 48 Relay OULDULS TTT 50 Mounting Installation eese 51 COMO DI SUDDIV O Lu DEL MEL 51 Installation in switch cabinet 51 Possible mounting positi0ns aaa eaaa eaaa eaaa eaaa aaa eaaa aaa eaaa aaa 53 CONNECTIONS A itd ncaa e pen A tae 56 Operatioh aa eee er ack ee tet 63 Placingiinto
29. correct delivery please notify the responsible sales office immediately The soft starters of the DS7 series can be disposed of as electronic scrap in accordance with national regulations DS7 Soft starter 07 10 MNO39010017 EN www eaton com 15 1 About the series 1 7 Storage transport and disposal 16 DS7 Soft starter 07 10 MNO3901001Z EN www eaton com 2 Engineering 2 1 Selection of devices 2 2 EMC measures 2 Engineering 2 1 Selection of devices The DS7 soft starters can be designed for standard applications according to the technical specifications provided in the Appendix for standard motors A more precise design is required for drives with a high starting torque or high inertia The following information must be known for correct selection of device the overload cycle of the machine The startup time for DOL starting or for star delta starting the maximum starting current the load cycle as well as the load that the motor is required to drive The values of the moments of inertia must also be known for a more precise design These values enable you to select the most suitable soft starter The relevant procedure is described in the manual Soft Starter Design MN03902001Z EN previous description AWB8250 1346GB and applies generally to all Eaton soft starters The necessary key data of the DS7 soft starter series that is also required for this design rated operational current overload capacity root mean sq
30. ction Factory setting 1A Start stop Ramp times t Start 5 s t Stop 0s Start voltage 30 Relay K1 Top of Ramp Relay K2 for devices from 16 A RUN Publication Title 07 10 MNO3901001Z EN www eaton com 47 3 Parameter setting 3 3 Parameterization of DS7 3 40 and DS7 3 42 3 3 Parameterization of DS7 340 and DS7 342 The DS7 340 and DS7 342 soft starters are adapted to the application using the three potentiometers t Start U Start and t Stop No other set tings or entries are required apart from these potentiometer settings 3 3 1 Start data Table 8 Start data potentiometer settings Potentiometer Parameter Value Function Factory numbers setting U Start U StartPoti 30 92 Start voltage at which the ramp function 30 is started t Start t StartPoti 1 30s Time in which the voltage U Start is 5s increased to 100 by means of a linear voltage ramp t Stop t StopPoti 0 30 s Time in which the voltage 100 is Os reduced to U Start by means of a linear voltage ramp The start voltage determines the torque of the motor Low values produce soft starting and a higher thermal load of the motor If the voltage is too low the motor may not start immediately In this case the voltage should be set higher in order to avoid any unnecessary heating of the motor The ramp times likewise determine the startup behavior The longer the ramp times the greater the thermal load on the motors The ramp
31. dus network trial environment class A1 all devices Class B for use in public networks only for DS7 340 devices 24 V AC DC Insulation resistance Insulation resistance test to EN 60947 1 Appendix K Permissible pollution Pollution degree 2 to EN 60947 1 Permissible humidity rating Relative air humidity 85 96 non condensing 7 2 Applicable product standards and approvals Document type Name Product standard EN IEC 60947 4 2 Approvals UL UL 508 CSA CSA C22 2 No 14 05 CCC GB 14048 6 Gost Gost R Markings CE marking for LVD Low Voltage Directive and EMC Electromagnetic compatibility EMC Directive DS7 Soft starter 07 10 MN03901001Z EN www eaton com 77 7 Appendix 7 3 Control inputs and outputs 7 3 Control inputs and outputs Table 15 Control inputs control outputs Terminal Function Factory setting Current consumption load rating Digital inputs Al Control input Start stop Depending on variant DS7 34 24 V AC DC 1 6 mA 230 V AC 4 mA A2 Us 0 V reference point for A1 Us Supply voltage Depending on variant 24 V AC DC 150 mA 230 V AC 100 mA Relay outputs 13 N 0 contact K1 Top of Ramp 230 V AC 1 A AC 11 only 24 V AC DC with a D Scu devices up to 12 A and nos 24 V supply voltage From 16 A also 23 N 0 K2 RUN 230 V AC 1 A AC 11 24 Supply to K2 78 DS7 Soft starter 07 10 MN039010017 EN www eaton com The control inputs must only be operated with the same v
32. e from the rated value must not exceed the tolerance limits given in the specifications otherwise this may cause malfunction and dangerous operation Emergency stop devices complying with IEC EN 60204 1 must be effective in all operating modes of the automation devices Unlatching the emergency stop devices must not cause restart Devices that are designed for mounting in housings or control cabinets must only be operated and controlled after they have been installed with the housing closed Desktop or portable units must only be operated and controlled in enclosed housings e Measures should be taken to ensure the proper restart of programs interrupted after a voltage dip or failure This should not cause dangerous operating states even for a short time If necessary emergency stop devices should be implemented e Wherever faults in the automation system may cause damage to persons or property external measures must be implemented to ensure a safe operating state in the event of a fault or malfunction for example by means of separate limit switches mechanical interlocks etc Contents 0 About This Manuals esse sese 0 1 Additional device manuals 0 2 Target group nennen 0 3 Writing CONVENTIONS eret ea ree rt eve tede R 1 About the series cesses esec 1 1 System OVOFVIDV ds dati ium IS ats dim as Ls 1 1 1 Example key to part numbers aaa aaa aaa aaa aaa eaaa aaa eaaa 1 2 FUN CUM dos 1 3 Features of
33. eaton com 6 Diagnostics 6 2 Error messages and rectification 6 2 3 LED indication in the event of faults The LEDs also provide information about the device state and any detected 74 faults Message Operation Initialization Off Supply voltage connection without Enable Supply voltage connection with Enable In ramp TOR Warning Overtemperature for next start Start without enable Potentiometer not effective network operation Error Over under temperature heat sink Thyristor is defective Phase failure Bypass is defective Supply voltage faulty 1 only with sizes 3 and 4 b Figure 57 LED messages in the event of a fault DS7 Soft starter 07 10 MN03901001Z EN www eaton com 6 2 4 Monitoring messages 6 Diagnostics 6 2 Error messages and rectification The following events are detected as faults and cause the soft starter to switch off All events are indicated via the Error LED 6 2 5 Fault messages on start The following fault messages are possible at the start Table 12 Message Phase fault Fault messages on start Faults One phase missing on the mains side Possible causes e FUSE FAULT Wiring defective Remedy Change fuse C
34. ee 53 N Network configuration_ 17 0 ODOerati n s sex eee e ees 68 Ovgercurrentreldy eoe ener pereunte 21 Overheating oi eo eA E t s Rat 68 Overload Cycle ov vut eoe be bho SE CERA 17 Overload relays 00 00 00 eee 24 61 Overload withstand capability 79 P Parallel connection of multiple motors 11 Parameter setting 00 000 47 PE CONNECTION sieh urami PAN ee 56 Phasetault y cds a eases TE TIZYGS 75 Placing into operation oo 63 Pole changing motors aaa anaana 21 43 Potentiometer anrr 48 49 Product standards ni aan ka e aaa aa 77 Protection type eee 14 Protective element_ 18 19 PUIMO CONNECTION cna erecto 38 R Radio interference 000 0 e eae 17 Ramp anea evi al eer EO a 23 Rampitimes occ ers ese S e ae eee sy 47 48 Rated control voltage see regulator supply voltage Rated operational current 12 43 Rated output current 00 0000 11 Regulator supply voltage 44 Relay contacts S to fan kg Steet as 45 Relay outputs 0 00 00 eee 50 78 RUN Operation 72 92 DS7 Softstarter 07 10 MNO39010017 DE wwweaton com S Scope OPSUDDIV mr pena nm Ne ER ie 51 Selection criteria Laos eee hes Dar 11 Semiconductor fuse lessen 19 Shielding motor and control cables 56 Soft starter Connecting motors during operation 11 FUN CUO KL SN DEEP EE 9
35. empera Check filter and cooling ture too high of the control panel Under temperature e Heat up room or control panel A phase fault can only be detected in a specific situation e Motor in ramp After the top of ramp is reached TOR a phase fault can no longer be detected gt The supply frequency is not monitored in order not to prevent operation in difficult conditions e g unstable generator as sup ply Proper operation can only be ensured with the permissible limits of 50 60 Hz 5 96 76 DS7 Soft starter 07 10 MNO3901001Z EN www eaton com 7 Appendix 7 1 Standards 7 Appendix 7 1 Standards The relevant standards for the DS7 soft starters are listed below Table 14 Standards and EMC Standard type Standard Title Limit Values Type IP 20 to IEC EN 60947 EN 60529 Interference immunity IEC EN 61000 4 2 Electrostatic discharge 8 kV air discharge 4 kV Contactdischarge IEC EN 61000 4 3 Electromagnetic fields 10 V 1 m Frequency range 80 to 1000 MHz IEC EN 61000 4 6 High frequency field 140 dB pV Frequency range 0 15 to 80 MHz 80 amplitude modulated IEC EN 61000 4 4 Fast transients burst on power 2 kV 5 kHz terminals Burst on bus and control cables 2 kV 5 kHz IEC EN 61000 4 5 Surge voltage test supply cable 2 kV phase ground 1 kV phase phase Emitted interference IEC EN 60947 4 2 Radio interference housing and Class A for use in in
36. es 2 9 1 General enable immediate stop without ramp function e g with emergency stop When controlling a DS7 soft starter via terminals a stop can be implemented without a ramp function by using a soft stop ramp time of zero Alternatively with DS7 devices 2 41 A this can be achieved by disconnecting the EN Enable signal If the DS7 soft starter on the other hand is controlled via a SmartWire DT interface this stop can be executed via the control word irrespective of the ramp time set and device size In certain fault situations the DS7 soft starter also carries out a stop without a ramp function even when controlled via the terminals This is described in the chapter Diagnostics gt Page 71 Start Start U out i Uout lstop NE Motor NMotor Figure 7 Emergency switching off with and without soft stop D Terminal stop t Stop gt 0 s Stop with Enable with sizes 1 and 2 i e with devices up to 32A only with control via SmartWire DT or via terminal with t Stop 0 s DS7 Soft starter 07 10 MNO39010017 EN www eaton com 23 2 Engineering 29 Connection types 2 9 2 Changing start commands If the start command drops out during operation ramp or top of ramp the DS7 soft starter runs down from the current ramp value with the soft stop ramp If during the soft stop ramp
37. es the actual function of the soft starter The motor voltage is increased in the set time from the start value U Start to 100 96 thus accelerating the motor smoothly If the time is too long the motor and soft starter will be subject to higher temperature loads This can cause the protective devices to trip As short a time as possible should be selected ideally a time between 2 and 5 seconds With shorter start times more starts per hour are also possible than is stated in the load cycle Longer times mean accordingly fewer starts The start voltage U Start has a direct effect on the initial torque of the motor As this increases quadratically values lower than 30 96 are not useful corresponds to 9 96 of the starting torque of the motor in mains operation a star delta circuit supplies 30 96 The start voltage of the motor should be high enough for the motor to start turning immediately at the start in order to prevent any unnecessary temperature rise Publication Title 07 10 MNO3901001Z EN www eaton com 49 3 Parameter setting 3 3 Parameterization of DS7 340 and DS7 342 3 3 1 3 t Stop 3 3 2 Relay outputs A stop ramp is useful for pumps and conveyor belts in order for example to prevent the toppling of transported goods e g bottles on a conveyor belt or water hammer caused by valves shutting With all other applications the parameter t Stop can also be set to zero in order to prevent any unnecessary temperature rise in
38. es to the admissible operating frequency of the selected soft starter Otherwise select the soft starter so that the required times are achievable Setthe timing relay to 2 s off delay This ensures that the next motor branch is not connected when a soft starter is running Actuation motor cascade part 1 2 16 A N C contact S1 switches all motors off at the same time 53 53 Qn1 y Qn2 K3 Q22 Q22 K n 1 2 Qn2 Kn2 Q n 1 1 K4T Qn1 42 DS7 Soft starter gla el ls a Figure 37 Actuation motor cascade part 2 D Motor 1 Motor 2 Motorn The N C contact S3 is required if motors also have to be switched off individually 07 10 MNO3901001Z EN www eaton com 2 Engineering 2 11 Pole changing motors Dahlander motors 2 11 Pole changing motors Dahlander motors The DS7 soft starter is connected in the feeder cable before pole changing The start command must be present after a circuit is selected and a start command for the pole changing was set All pole changes are only executed at standstill Operation via the SmartWire DT interface is advantageous since this allows the downloading of different parameter sets In this way an optimum adap tion to the motor or the application is possible The actuation is similar to a cascade control apart from the fact that only the other winding is switched and not the next motor 2 12 Parallel switching of motors on one soft starter You can a
39. f heat in the proximity of the soft starter e Observe the mounting clearance above and below the soft starter as the temperature of the cooling air will otherwise reach impermissible values and the soft starter will switch off DS7 Soft starter 07 10 MNO39010017 EN www eaton com 51 4 Mounting Installation 4 2 Installation in switch cabinet A mounting clearance of 25 mm must be ensured at the front of DS7 series soft starters With devices up to 32 A a clearance of 75 mm is required above and below the device With higher currents 55 mm is sufficient to achieve the specified load cycle With smaller clearances derating is necessary or the optional fan can be used All types can be mounted directly next to each other Additional clearances must be observed when mounting together with the NZM circuit breaker Figure 40 Installation free areas to 32 A Figure 41 Installation free areas from 41 A When using a soft starter in a location that is continuously sub ject to vibration or shock the use of vibration dampers should be considered 52 DS7 Soft starter 07 10 MNO3901001Z EN www eaton com v 5 40 C 9 23 104 F Figure 42 Cooling air supply 4 Mounting Installation 4 2 Installation in switch cabinet gt The supplied cooling air must have a temperature between 5 and 40 C A derating is required for higher temperatures 4 2 1 Possible mou
40. f the possibility of hazardous situations that may possi bly cause slight injury DANGER A Warns of hazardous situations that result in serious injury or death gt Indicates useful tips For greater clarity the name of the current chapter and the name of the cur rent section are shown in the page header DS7 Soft starter 07 10 MN03901001Z EN www eaton com 5 O About This Manual 0 3 Writing conventions 6 DS7 Soft starter 07 10 MN03901001Z EN www eaton com 1 About the series 1 1 System overview 1 About the series 1 1 System overview The soft starters of the DS7 series are assigned part numbers according to the following type code DS7 3 4x SK yyy N 0 2z Explanation Options N no option P Pump option D SmartWire DT on board Protection type 0 IP00 or NEMA 0 or IP20 1 1P21 or NEMA 1 2 IP54 or NEMA 12 3 NEMA 3R RFI Filter N no filter Motor current Rated operational current le Device version 1st place S Standard soft starter H gating control regulators L Extended start ramp W Without keypad 2nd place M no internal bypass X Internal bypass Control voltage and Control signals D 24 V DC 0 2 24 V AC DC 2 120 230 V AC Mains supply voltage 1 120V 2 230V 4 480 V 400 V 480 V 5 575V 6 690 V Supply phases 1 single phase incoming unit 3 three phase incoming unit S
41. ge Before commencing the installation e Disconnect the power supply of the device e Ensure that devices cannot be accidentally restarted Verify isolation from the supply Earth and short circuit Cover or enclose neighbouring units that are live Follow the engineering instructions IL previously AWA of the device concerned Only suitably qualified personnel in accordance with EN 50110 1 2 VDE 0105 Part 100 may work on this device system Before installation and before touching the device ensure that you are free of electrostatic charge The functional earth FE must be connected to the protective earth PE or to the potential equalisation The system installer is responsible for implementing this connection Connecting cables and signal lines should be installed so that inductive or capacitive interference does not impair the automation functions Install automation devices and related operating elements in such a way that they are well protected against unintentional operation e Suitable safety hardware and software measures should be implemented for the I O interface so that a line or wire breakage on the signal side does not result in undefined states in the automation devices Ensure a reliable electrical isolation of the low voltage for the 24 volt supply Only use power supply units complying with IEC 60364 4 41 VDE 0100 Part 410 or HD 384 4 41 S2 Deviations of the mains voltag
42. heck wiring Over under temperature heat sink Heat sink too hot or environ ment too cold Device still overheated rom last start stop Wait for cooling time if necessary use fan option Under temperature F Check heating of room or control panel Thyristor is defective e Device was overloaded at ast stop Exchange device check dimensioning e Lightning Exchange device install lightning protection inthe installation Bypass is defective Bypass welded or not e Overload Exchange device check reacting e Short circuit in motor dimensioning Check motor Supply voltage faulty Too low voltage for the controller supply e Overload of the external power supply unit Supply voltage not avail able m Check dimensioning and overload of the power supply unit E Check control signals for Switching the power supply if necessary fit interlocks for the start command DS7 Soft starter 07 10 MN03901001Z EN www eaton com 75 6 Diagnostics 6 2 Error messages and rectification 6 2 6 Fault messages during operation The following fault messages are possible during operation Table 13 Fault messages during operation Message Faults Possible causes Remedy Over under temperature heat Heat sink too hot or environ e Device still overheated e Wait for cooling time if sink ment too cold from last start stop necessary use fan option e Control cabinet t
43. lso use soft starters to start several motors connected in parallel This does not however allow the behavior of the individual motors to be controlled Each motor is to be fitted with suitable overload protection The current consumption of all connected motors must not exceed the rated operational current le of the soft starter You must however protect each motor with thermistors and or overload relays If motors with large rating differences e g with 1 5 kW and 11 kW are con nected in parallel to the output of a soft starter problems may occur during the start In certain circumstances the motor with the lower motor power may not provide the required torque This is due to the relatively high resis tive load in the stator of the smaller motor In this case it requires a higher voltage than the higher rated motor during the start DS7 Soft starter 07 10 MNO39010017 EN www eaton com 43 2 Engineering 2 13 Connecting the controller section 2 13 Connecting the controller section 2 13 1 Regulator supply voltage rated control voltage Us The regulator supply voltage Us is fed externally via terminals Us Us 16 200 A and A2 4 12 A Depending on the device version 24 V AC DC or 110 230 V AC must be connected DS7 soft starters with a SmartWire DT connection can also be supplied via the SmartWire DT cable an additional connection to Us is unnecessary Ensure that the regulator supply voltage and the control
44. lvin Storage 25 up to 60 C continuous Transport 25 up to 60 C continuous Climatic proofing damp heat cyclic to DIN IEC Part 68 2 10 damp heat constant to DIN IEC 68 Part 2 3 1 6 Intended use The soft starters of the DS7 series are electrical apparatus for installation in the switch cabinets of electrical systems or machines They are designed as components for the soft starting of standard three phase asynchronous motors normal AC induction motor for installation in a machine or for assembly with other components of a machine or system When installing in machines the soft starters must not be commissioned until it is determined that the machine complies with the safety requirements of the Machinery Safety Directive 89 392 EC the EN 60204 standard must also be observed here Commissioning is only permitted if the requirements of the EMC Directive 89 336 EC have been observed The soft starters of the DS7 series meet the requirements of the Low Volt age Directive 73 23 EC they likewise comply with the product standard EN 60947 4 2 At the output of a DS7 soft starter terminals U V W you must not connect any capacitive load e g phase compensation capacitors connect several soft starters with each other on the output side Observe the technical specifications and the connection requirements These are shown on the rating plate of the soft starter as well as in this documentation 14 DS7 Soft starter 07 1
45. mination permissible 77 Control cables So cr 56 SGreenilig ss ese Eve cde ne Fa AGES 56 Control TUES mire Cop destra sco m yy te bs cd 78 Control G tputs cese sexe eer ER rv 78 control Section v Z R epu LER Es 44 SGE usta Corren 0 e bass LAH asc rt 53 CGSAN DE orat PLE MS ELI NS o Mid qs 77 D Deltaicireuit da a N eun see 21 DIAGNOSTICS cocina eter leen b A Eo 71 Digital INPUTS tat har ost ols tae ross ponia 78 Disposal 4 esee tede sd ll ER d 15 DS7 keat fesS N vee ane hein ve eed red 9 E Earn coke PIERDEN ID RE 44 EMC Directive sess 77 EMC rieasul es za cede tore Dens 17 Emergency switching off 19 Emitted interference 00000 77 Enable i results piae dot Date oye 23 Engineering eoo metu bre turre ER VEN 17 Environmental conditions aa aaa 14 Error EED3SIgnalss sam dirias 74 Error messages 2 o 75 Er TE e ANES mental ocn 72 F Factory Settings 47 Ean L th O 57 Fault finding a Da taa RE e 71 G OS A ios 77 H Heat dissipation oo 13 Humidity rating cee eee 77 A a tir A te Ae aa 9 Installation altitude_ aaua 14 Installation instructions a 55 Instructional leaflet 10390200937 oi leas Re 51 ILO3902004Z occ 51 IEOS9O 200 DZ ree ee See qo 51 Insulation resistance auauua 77 Interference immunity 05 77 K Key to part numbers 0 00000000 7 DS
46. mp operation Q1 Cable protection 011 mains contactor 021 Soft starter 031 Secondary contactor 022 Bypass contactor Emergency operation protection F2 semiconductor fuse for type 2 coordination in addition to 01 M1 Motor 38 DS7 Soft starter 07 10 MNO3901001Z EN www eaton com 2 Engineering 29 Connection types 23 13 K1 K3 K2 K3 K4 S5 XKR Y K5 Q21 RUN Q21 TOR K2 4 14 SAN K1 K4 Q31 EN M K1 Q2 K2 K3L 03157 Q11 KB LC Q21 J KA L Q22 Figure 34 Actuation with bypass emergency operation pump operation 2 16 A Enable Automatic Manual bypass operation 4 Soft start Soft stop Bypass contactor 2 9 11 Delta connection An In Delta connection is not possible with DS7 34 series soft starters DS7 Soft starter 07 10 MN03901001Z EN www eaton com 2 Engineering 2 10 Starting several motors sequentially with a soft starter 2 10 Starting several motors sequentially with a soft starter 40 When starting several motors one after the other using a soft starter keep to the following changeover sequence gt 1 Start using soft starter gt 2 Switch on bypass contactor 3 Block soft starter 4 Switch soft starter output to the next motor 5 Restart gt When starting several motors with one soft starter the thermal load of the soft starter start frequency current load must be taken into account If the starts occur closely in s
47. nce without soft stop DS7 Soft starter 07 10 MN03901001Z EN www eaton com 2 Engineering 27 2 Engineering 29 Connection types 2 9 5 3 Construction size 3 4 41 A to 200 A L1 L2 13 PE TOR RUN 021 Y Y 14 23 24 4 Us 24 V ACIDC 110 230 V AC QU Figure 13 Standard connection without soft stop Q1 lt Line protection 2 F3 Semiconductor fuse for type 2 coordination in addition to Q1 optional G 021 Soft starter M lt Motor Y Uu 12 13 01 Al RUN 23 24 Uri 12 13 TOR 13 14 Figure 14 Logic sequence without soft stop 28 DS7 Soft starter 07 10 MN03901001Z EN www eaton com 2 Engineering 29 Connection types 2 9 6 Connection with soft stop ramp 2 9 6 1 Construction size 1 up to 12 A L1 L2 00 0 PE 7 A 4 Us 24 V ACIDC 110 230 V AC QU Figure 15 Standard connection with Soft stop S3 Start stop U _ _ S gt K Uri 12 13 Q1 53 Start Stop Uri 12 T3 TOR 13 14 t Start Figure 16 Logic sequence with soft stop DS7 Soft starter 07 10 MNO39010017 EN www eaton com 29 2 Engineering 29 Connection types 2 9 6 2 Construction size 2 16 A to 32 A L1 L2 L3 PE Us
48. nstructional leaflet IL previous description AWA e L03902003Z previous description instructional leaflet 8250 2541 for devices in construction size 1 to 12 A device current e L03902004Z previous description instructional leaflet 8250 2542 for devices in construction size 2 to 32 A device current L03902005Z previous description instructional leaflet 8250 2543 for devices in construction size 3 or 4 to 200 A device current 42 Installation in switch cabinet The mounting should take into account the weight and dimensions of the soft starter For this use the necessary technical equipment lifting trolley or crane for large loads and tools Improper handling or use of the wrong tools may cause damage to the soft starter Soft starters are only designed for use as built in devices Take sufficient counter measures in the case of e contaminated cooling air such as dust fluff grease This can cause short circuits on the cards counter measures installation of filters separate ventilation circuit aggressive gases These can corrode circuit board conductors counter measures installation of filters separate ventilation circuit e contaminated filters These can cause overheating counter measure regular cleaning To prevent overheating observe the following points e Ensure the free flow of the cooling air both to and from the device e Do not install any devices that produce considerable amounts o
49. nting positions The maximum permissible angle of inclination for all soft starters of the DS7 series is 30 Figure 43 Mounting position DS7 Soft starter 07 10 MN03901001Z EN www eaton com 53 4 Mounting Installation 4 2 Installation in switch cabinet The soft starters are screwed onto the switch cabinet wall mounting plate The control signal terminals here point to the front 4 mm 0 16 Figure 44 Mounting on the mounting plate with devices up to 32 A Alternative Figure 45 Mounting on the top hat rail with devices up to 32 A 54 DS7 Soft starter 07 10 MNO3901001Z EN www eaton com 4 Mounting Installation 4 2 Installation in switch cabinet Figure 46 Mounting on the mounting plate with devices of 41 A and above Together with an NZM Eje Eo ur Figure 47 Mounting NZM DS7 from 41 A and above D Clearance of NZM to DS7 from 41 A and above with NZM1 25 mm with NZM2 2 35 mm The instructional leaflet is provided with the each soft starter DS7 Soft starter 07 10 MNO39010017 EN www eaton com 55 4 Mounting Installation 4 3 Connections 4 3 Connections Observe the following points for the connections CAUTION The devices contain components that are sensitive to electro static charges Before undertaking work near the terminals per sonnel must discharge themselves i e by to
50. oft starter series Drives motor starter Generation 7 Figure 1 Key to part numbers DS7 Soft starter 07 10 MN03901001Z EN www eaton com 7 1 About the series 1 1 System overview 1 1 1 Example key to part numbers An example of the key to part numbers is shown below DS7 3 42 SX 024 8 DS7 Soft starter 07 10 MN03901001Z EN www eaton com Explanation Options N no option Protection type 0 IP00 or NEMA 0 or IP20 RFI Filter N no filter Motor current lez 24A Device version 1st place S Standard soft starter 2nd place X Internal bypass Control voltage and Control signals 2 120 230 V AC Mains supply voltage 4 480 V 400 V 480 V Supply phases 3 three phase incoming unit Soft starter series Drives motor starter Generation 7 1 2 Function 1 About the series 1 2 Function DS7 soft starters control the voltage of the supply network from an adjust able start value up to 100 This considerably reduces the starting torque of a three phase asynchronous motor that is run on this supply system This enables the soft starting of asynchronous motors and the inrush current is also reduced Figure 2 Functional overview D Mains voltage Un 3 x 200 V to 3 x 480 V Antiparallel thyristors in two phases with asymmetrical trigger control for controlling the motor voltage 3
51. oltage stated as the supply voltage on the device 7 Appendix 7 3 Control inputs and outputs 7 3 1 Overload withstand capability The table below shows the overload capability of the soft starter in accor dance with the product standard IEC EN 60 947 4 2 7 3 2 Overload capability load to AC 53a The following values are shown X Value of basic overcurrent in multiples of the rated device current x Duration of the overcurrent X in seconds F Duty factor within the load cycle in S Number of permissible starts per hour Overcurrent Overcurrent time Duty factor Starts per hour Tx X F CSA DS7 34 3 5 75 10 7 3 3 Conversion of the overload capability to lower overcurrents The stated cycle can be converted for lower overcurrents but not for higher The following formula is used to calculate the new time X x Tx Tyneu X2new In which Xnew Required overcurrent must be less than the stated values Txnew New permissible time for the new overcurrent Xnew Example For X 23 Tx 5 s calculate Tx for X 2 5 32x 5s Txneu oS ot LS 2 52 Other overload cycles and switch frequen cies are available on request DS7 Soft starter 07 10 MNO39010017 EN www eaton com 79 7 Appendix 7 3 Control inputs and outputs 7 3 4 Different load cycles and start frequencies If load cycles or start frequencies are different the following graphs can be used for reading the possible time current combination f
52. oordination superfast semicon ductor fuses are also required These protect the soft starter from damage in the event of a short circuit The semiconductor fuses do not however provide any cable protective functions The semiconductor fuses must be mounted externally on DS7 soft starters The correct types are listed in the Appendix in page 87 CAUTION Protection against overvoltages in the supply network cannot be provided with superfast fuses DS7 Soft starter 07 10 MNO39010017 EN www eaton com 19 2 Engineering 2 7 Cables contactors line filters 2 1 Cables contactors line filters 20 The cables used must meet the requirements of locally applicable regula tions at the site of installation Large dimensioned cables and contactors are required when frequent start ups and high starting currents are expected The load capacity limits of the contactors are listed in the relevant documentation The appropriate assign ment of mains contactor for the selected starting cycle of the soft starters is provided in appendix under page 87 The fuses and cable cross sections to be selected for the incoming and out going cables are also listed there The specifications in the Appendix refer to e use in switch cabinets and machines e installation in the cable duct e amaximum ambient temperature of 40 C e normal switching frequency The fuses and cable cross sections depend on the rating of the soft starter
53. or devices over 41 A 55A AC 53a 3 5 75 10 CSA F 96 Tx s X le A LA 1 2 10 lune 7 r I 1 le d gt t Ty a tg tp tp S 1h F 10 h gt 1h 3600s gt Txy tg tp 360s Ty t gt F C y 100 Tyr tp 4 tp 5s 265s A x 100 75 5s 265s 90s ILRP X ie gt Itpp Xxle 3x55A 165A e DS7 34xSX055 30s X 55K 1 h 255 X v 55K 10jh 55K 20 h 20s 15s t Start s 10s 10 20 Pmotor 30 KW 55 F 10 h x 3 1 0 S 80A 100A 120A 140A 180A 200A l rp 165A DS7 34xSX100 100K 1 h 100K 10 h 100K 20 h UNI DS7 gt Poor NC Pua 30 KW F 10h x 5 4 325A 350A l rp 300 A Figure 58 Conversion to other load cycles use of graphs 80 DS7 Soft starter 07 10 MN03901001Z EN www eaton com 7 Appendix 7 3 Control inputs and outputs 7 3 5 Conversion to other load cycles DS7 34xSX004 305 DS7 34xSX007 30s 10 h th 25s 20h 10 h th 20h S 4A 8A DS7 34xSX009 30s 16A 20A TA 12A DS7 34xSX012 30s 10 h th 255 20h 28A 35A 10 h th 20h S 9A 18A DS7 34xSX016 305
54. otor Motor Motor Motor Motor tional current rating in rating in rated oper rating in rating in HPat200V kWat230V ational kWat400V HPat480V current in HP at 230 V A HP kw HP kw HP DS7 34xSX004NO 4 0 75 0 75 0 75 1 5 2 DS7 34xSX007NO 7 1 5 1 5 2 3 3 DS7 34xSX009N0 9 2 2 2 2 4 5 DS7 34xSX012NO 12 3 3 E Elo 115 DS7 34xSX016N0 16 3 4 5 ES 10 DS7 34xSX024N0 24 5 5 5 3185 11 15 DS7 MxSX0322NO 32 10 HE2 10 15 20 DS7 34xSX041N0 M 10 11 15 22 30 DS7 34xSX055NO 55 15 15 20 30 40 DS7 34xSX070NO 70 20 18 5 25 37 50 DS7 34xSX081NO 81 25 22 30 45 60 DS7 34xSX100N0 100 30 30 30 55 75 DS7 34xSX135N0 135 40 37 50 75 100 DS7 34xSX160N0 160 50 45 60 90 125 DS7 34xSX200N0 200 60 55 75 110 150 DS7 Soft starter 07 10 MN03901001Z EN www eaton com 1 About the series 1 5 Selection criteria 1 5 5 Heat dissipation Py The heat dissipation Py of the soft starter depends on the operating state of the connected motor The values in the following table refer to the rated operation of the motor sizes motor rating 4 pole three phase asynchronous motor at an ambient temperature of 40 C Table 3 Heat dissipation Part no DC versions AC versions Rated operational Heat dissipation Heat dissipation at Heat dissipation Heat dissipation at current standby rated load cycle standby rated load cycle A
55. otor power can be switched in a star connection 230 400 V e over 4 kW motor power in a delta connection 400 690 V ul vi Wi ul vi Wi S H al a A Figure 6 Possible motor circuit types Star connection and delta connection A standard connection produces a clockwise rotating field The clockwise rotation of the motor shaft is achieved by connecting the terminals of the motor and soft starter as follows Table 5 Connection of DS7 and motor Net Input DS7 Output DS7 Motor L1 1L1 271 U1 L2 312 4T2 VI L3 5L3 6T3 WI DS7 Soft starter 07 10 MNO39010017 EN www eaton com 21 2 Engineering 2 8 Motor connection The rotation direction of the motor can be reversed by changing over two phases on the motor by e permanently changing the connection Using a reversing starting combination or Using an electronic reversing contactor When reversing the rotation direction the output of the soft starter must be disabled before the reverse switching is carried out The rotating field direction at the input is always the same as that at the out put 2 8 1 Long motor supply cables DS7 soft starters can also be used with long motor cables i e 100 m However the voltage drop on the cable must be taken into account and a larger cross section must be laid if necessary 22 DS7 Soft starter 07 10 MN039010017 EN www eaton com 2 Engineering 29 Connection types 2 9 Connection typ
56. r load cycles ei eA 81 TECHNICAL MATa sic cette tete cem ds 83 General data tiene e Ee S RE EH eise 83 Terminal capacity control cables actuating circuit 84 Non power supply dependent data 85 A 86 Protection short circuit Strength 87 Protection overload relay optional mains contactor 87 DIMENSIONS e iier eese tate i eese 88 DS7 Softstarter 07 10 MNO3901001Z DE www eaton com 3 Contents 4 DS7 Softstarter 07 10 MN03901001Z DE www eaton com 0 About This Manual 0 1 Additional device manuals 0 About This Manual This manual provides special information required for connecting a soft starter correctly and setting its parameters to suit your requirements All information applies to the specified hardware and software versions The manual describes all sizes of the DS7 soft starter series Any differences and special features of the individual ratings and frame sizes are noted accord ingly 0 1 Additional device manuals Soft Starter Design MN03902001Z EN previous description AWB8250 1346GB 0 2 Target group The content of the manual is written for engineers and electricians A special ist knowledge of electrical engineering is needed for commissioning 0 3 Writing conventions Symbols used in this manual have the following meanings K indicates actions to be taken CAUTION Warns about the possibility of material damage WARNING A Warns o
57. r tag shroud Finger and back of hand proof Overvoltage category pollution degree 1 2 Mechanical shock resistance 8g 11 ms Vibration resistance to EN 60721 3 2 2M2 MTBF Main contacts Rated operational voltage VAC 200 480 Mains frequency Hz 50 60 Overload cycle to EN 60947 4 2 AC53a 3 5 75 10 Power section Rated impulse withstand voltage kV 4 Uimp 1 2 50 uis Rated insulation voltage Ui V 500 soft start functions Ramp times Acceleration S 1 30 Deceleration s 0 30 Start voltage switch off voltage 30 100 1 Higher installation heights on request 2 Protection type applies to the front and operator control and operating elements Protection type from all sides is IP00 DS7 Soft starter 07 10 MN03901001Z EN www eaton com 83 7 Appendix 7 4 Technical data 7 4 2 Terminal capacity control cables actuating circuit The following technical data depends on size Construction Construction Construction Construction size 1 size 2 size 3 size 4 4to12A 16 to 32A 41 to 100A 135 to 200 A General Dimensions W x H x D mm 45 x 130 x 95 45 x 150 x 118 93 x 175 x 139 108 x 215 x 178 Weight kg 0 35 0 4 18 37 Terminal capacity Cables box terminal Solid mm 1x 0 75 4 x 0 75 16 1x 25 70 1x 4 185 2x 0 75 2 5 2x 0 75 10 2x 6 25 2x 4 70 Flexible with ferrule mm2 1 x 0 75
58. rs are mechanically interconnected the load distribution is also uncer tain In this case the entire drive torque may only be supplied by a single motor which may cause this motor to overload In this type of application soft starters should be used for each single motor and the motors should be started with a current limiting function With a DS7 soft starter this can only be implemented in the SmartWire DT version in conjunction with the net workable PKE Alternatively a soft starter of the DMA series or its successor may be required 1 5 3 Connecting motors during soft starter operation If a motor is connected on the soft starter during operation a soft start is not executed for this motor The starter must then be able to supply the full start ing current approx 6 to 8 times the rated motor current and the current of the other motors Otherwise an overload will occur and the soft starter may be destroyed in the worst case DS7 Soft starter 07 10 MNO39010017 EN www eaton com 11 1 About the series 1 5 Selection criteria 1 5 4 Connectable motor power The motor power stated in Table 2 can be connected when using standard 12 motors and a normal load for so f t starters Figure 4 Permissible load connection shown for devices up to 32 A above this the phase L2 T2 must be connected instead of L3 T3 Table 2 connectable motor power Part no Rated opera M
59. st be protected from overloads gt Voltage breakdown tests must not be carried out on parts of the soft starter A suitable measuring instrument with an internal resistance of at least 10 per 1 V must be used for measuring signal volt ages gt Before switching on the soft starter check whether the regula tor supply voltage matches the supply voltage of the DS7 soft starters for this see the nameplate DS7 Soft starter 07 10 MNO39010017 EN www eaton com 63 5 Operation 5 1 Placing into operation When changing the parameters observe the following points e Never set the ramp time too long If the ramp time is too long the motor will only accelerate slowly This will cause the motor to operate with an increased current for an unnecessarily long time In extreme cases this can cause the device to switch off due to overtemperature e Never set too low a start voltage If the start voltage is set too low the motor cannot generate sufficient torque for the acceleration As a result the motor will only accelerate slowly or not at all If the motor does not move or does not accelerate quickly enough this can cause the device to switch off due to overtemperature If you wish to change parameters yourself refer to the values stated in the manual Soft Starter Design MN03902001Z EN previous description AWB8250 1346GB 64 DS7 Soft starter 07 10 MNO3901001Z EN www eaton com 5 Operation 5 2 Recommended set
60. starter heats up at the start To avoid overheating the required cooling times must be observed without fail If frequent starts are to be made in nor mal operation the soft starter must be overdimensioned in cer tain circumstances and or the optional fan must be used For this see the Appendix Technical data as well as the man ual Soft Starter Design MN03902001Z EN previous descrip tion AWB8250 1346GB Switching on the motor side is permissible for a safety disconnection emer gency switching off A DANGER On no account must you open the device if the supply voltage is switched on Danger A DANGER Soft starters are electrical apparatus for use in power installa tions in industrial applications During operation hazardous live parts and hot surfaces are pres ent on the soft starter These present a risk of serious injury DANGER The impermissible removal of the required cover improper installation or incorrect operation of the motor or soft starter can cause the failure of the device and serious injury and or material damage DANGER If the device displays a fault message this must be examined carefully If a hardware fault is indicated it is possible that not all phases of the soft starter have disconnected Before working on the device or motor they must be securely isolated beforehand from the mains supply without fail e g switch off circuit breaker 68 DS7
61. t If faults occur outside of the RUN state these are reset automatically as soon as the cause of the fault is no longer present Faults that occur in the RUN state are not automatically reset but must be acknowledged explicitly and reset 6 2 2 LED indicators Depending on the situation the LEDs have the following meaning normal operating states Table 11 LED indicators Red LED Green LED Function 0 Off Device is off 0 Flashing at 2 s intervals Device ready for operation supply OK but no Start signal present Flash with 2 s pulse 100 150 ms on 1900 1850 ms of 0 5 Hz ED 5 7 96 0 Flashing at 0 5 s interval Device in operation ramp is active soft start or soft stop flash with 0 5 s pulse 0 5 s on 0 5 s off 1 Hz DF 50 96 0 On Device in operation top of ramp reached 72 DS7 Soft starter 07 10 MN039010017 EN www eaton com 6 Diagnostics 6 2 Error messages and rectification EN Uri 12 73 TOR 13 14 Figure 56 Actuation signals and LED Initialization Ready 3 Acceleration phase Top of ramp reached TOR signal gt The top of ramp after the t Start time has elapsed and the actual run up of the motor can have different lengths The actual acceleration time depends on the load and the motor and even with the same setting of t Start can lead to different times if the loads change 73 DS7 Soft starter 07 10 MN03901001Z EN www
62. t breaker required for the specified load cycle For other switching cycles operating frequency over current overcurrent time duty factor this value changes and must be modified accordingly DS7 Soft starter 07 10 MNO39010017 EN www eaton com 87 7 Appendix 7 4 Technical data 7 4 7 Dimensions DS7 34 SX 003 04 005 007 09 The mounting should take into account the weight and dimen sions of the soft starter For this use the necessary technical equipment and tools Improper handling or use of the wrong tools may cause damage to the soft starter mm Weight kg 4 0 35 122 125 7 Figure 61 Dimension drawing DS7 to 12 A DS7 34 SX mm Weight kg 016 4 0 4 024 032 118 Figure 62 Dimension drawing DS7 16 to 32A 88 DS7 Soft starter 07 10 MNO39010017 EN www eaton com 7 Appendix 7 4 Technical data DS7 34 SX mm Weight kg 029p 4 1 8 041 22055 070 24 081 100 30mm 30mm 1 18 1 18 22 5 mm 4 0 89 i g L E E Ln nN 001 p PE 22 5 mm 0 89 35 mm 1 38 ER beu gt 93 mm 3 66 m 139 mm 5 47 Uu Figure 63 Dimension drawing DS7 41 to 100A
63. tation direction reversal with soft stop ramp 2 9 8 1 Construction size 1 up to 12 A L1 aif A2 Us T 9 LO U i 24V AC DC 110 230 V AC QU 2 Engineering 29 Connection types Figure 27 Rotation direction reversal with ramp L01 L4 1 01 KAT A STOP K1 K2 K1 11 K2 12 FWD I S REV i K2 Q Q K2 K1 Q12 Q11 A1 Bi A1 K1 K2 Q21 KAT Q11 Q12 A2 t gt tstop IZ LOO L FWD REV Figure 28 Control section Bidirectional operation K4T Simulated RUN signal DS7 Soft starter 07 10 MN03901001Z EN www eaton com 35 2 Engineering 29 Connection types 2 9 8 2 Construction size 2 16 A to 32 A L1 L2 gt 13 PE 7 ESR TORA aE ANA 1 Fe L O 191 E A Q21 Us 24 V ACIDC 110 230 V AC o Us Figure 29 Rotation direction reversal with ramp L01 L 02112 Q1 RUN Y stop FWD L LOO L FWD REV Figure 30 Control section Bidirectional operation 36 DS7 Soft starter 07 10 MNO3901001Z EN www eaton com 2 Engineering 29 Connection types 2 9 8 3 Construction size 3 4 41 A to 200 A L1 L2 L3 PE Q21 Us 24V AC DC 110 230 V AC 5
64. the motor A soft stop ramp has the same temperature characteristics as a start It also causes therefore the heating of the soft starter and motor and must be taken into account when determining the starting frequency The stop ramp is ended at the potentiometer setting of U Start A correct setting will cause the minimum torque to be generated at which the motor still turns With lower voltages torques the machine will remain at a standstill due to losses or friction Table 9 Relay outputs function Relays Designation Value Function K1 K1 Pointer TOR Top of ramp indicates operation with full voltage on the motor top of start ramp reached K2 K2 Pointer RUN This relay is closed while the soft starter is in operation The soft starter can be operating within a ramp or in the TOR state relay only provided with devices gt 12 A The relays are at the following terminals Table 10 Relay outputs terminal assignments Current range K1 Default Function K2 Default Function to12A 13 A2 TOR 16 32 A 13 14 TOR 23 24 RUN 41 200 A 13 14 TOR 23 24 RUN 50 Publication Title 07 10 MN03901001Z EN wwweaton com 4 Mounting Installation 4 1 Scope of supply 4 Mounting Installation 4 1 Scope of supply On receiving the soft starter check whether the delivery is complete and correct Contact your responsible sales office if anything is missing or faulty Equipment supplied e atype DS7 34 device ani
65. the rear of the soft starter Figure 48 Mounting a fan on soft starters up to 32 A basic principle For this break off the retaining strap carefully with a flat screwdriver insert the fan and then secure it with the previously removed strap To remove the fan carry out the same steps in reverse order Figure 49 Step 1 break off strap DS7 Soft starter 07 10 MNO39010017 EN www eaton com 57 4 Mounting Installation 4 3 Connections Figure 50 Step 2 insert fan Figure 51 Step 3 secure with strap The fan runs during the ramp time and continues running until the heat sink has cooled down The fan is then automatically switched off 58 DS7 Soft starter 07 10 MN03901001Z EN www eaton com 4 Mounting Installation 4 3 Connections 4 3 0 6 Construction size 1 with the PKZ PKE and mounting on the top hat or busbar rail Figure 52 Mounting on the top hat busbar rail with devices up to 12 A DS7 Soft starter 07 10 MNO39010017 EN www eaton com 59 4 Mounting Installation 4 3 Connections 4 3 0 7 Construction size 2 with the PKZ PKE and mounting on the top hat or busbar rail Mounting on the busbar adapter is carried out in the same way Figure 53 Mounting on the top hat busbar rail with devices up to
66. the soft Sta Tels usce edet eS 1 4 PONT VIE TT 1 5 Selectiotmettterias ie ei ote ee 1 5 1 Design with different load cycles anaa a eaaa eaaa 1 5 2 Parallel connection of several motors to one soft starter 1 5 3 Connecting motors during soft starter operation 1 5 4 Connectable motor power sce coo xb e eges 15 5 cHeat dissipation Ps sana kai aana eret rt ban eere ete edd 1 5 6 Permissible environmental conditions eee ani 1 6 Intended US Oe s ete a a 1 7 Storage transport and disposal 2 Engin ering nit 2 1 S lection OF deviDes ni 2 2 EM CcIMmeCASURGS ceso da till ica 2 3 Network configuration oerte eerta ren hie regen en 2 4 Power CONNECTION ia 2 5 Emergency switching OT 2 6 Protective Ten OT 2 6 1 Type 1 coordination eee 2 6 2 Type 2 CONAM MON otto 2 7 Cables contactors line filters ooo 2 8 MOtor COnNGCtiOn week eee ee es 2 8 1 Long motor supply cables eee 2 9 Connection ty OOS tence ees et eoe ide coa 2 9 1 General enable immediate stop without ramp function e g with emergency stop e 2 9 2 Changing start COMMMANGS s 2 9 38 Including the overload relay in the control system 2 094 Standard connection eost oeste nn bad ite a Head 2 9 5 Connection without soft stop amp 2 9 6 Connection with soft stop amp 2 9 7 Standard connection with upstream mains contactor and soft Stop Tapas nen een etes Era A EUN GU Pid ce RI DNA 2 9 8 Rot
67. times set should therefore only be long enough to meet the require ments of the machine example with conveyor belts select a time so that the transported goods do not topple with belt drives select a time so that the belts do not slip Some drives already reach the rated speed during the soft start ramp In this case it is not necessary to continue running a voltage ramp The setting t Start should then be adjusted to prevent unnecessary temperature rise During the ramps the DS7 soft starter uses a special process asymmetrical trigger control in order to suppress the otherwise normal imbalances in cur rent or torque characteristics for two phase controlled soft starters In this way DS7 soft starters can ensure the smooth running characteristics of a three phase controlled soft starter Any combination of start and stop time is possible 48 Publication Title 07 10 MNO3901001Z EN www eaton com 3 3 1 1 t Start 3 3 1 2 U Start 3 Parameter setting 3 3 Parameterization of DS7 340 and DS7 342 UA U Start gt t TOR RUN 13 14 23 24 13 14 J Top Of Ramp 23 24 a alle O Figure 39 Relationship between relay and ramp Current consumption at 35 mA Current consumption 65 mA operation With construction size 1 the RUN relay is omitted the terminal 14 is replaced by A2 The potentiometers have the following effects The start time t Start defin
68. tings 5 2 Recommended settings The following standard settings are recommended for an application t Start s U Start t Stop s 10 30 0 10 20 10 20 EX TEL J 0 1 30 30 100 0 20 25 30 30 10 E Y EX Tx 1 30 30 100 0 30 20 40 0 a lar o 1 30 30 100 0 20 10 30 20 TJI x A 1 30 30 100 0 30 15 40 0 Qu lar o 1 30 30 100 o 20 18 40 0 14 lar 1r 1 30 30 100 0 30 15 50 0 0 f 1r 1 30 30 00 0 30 gt DS7 gt PMotor DS7 Soft starter 07 10 MNO39010017 EN www eaton com 65 5 Operation 5 2 Recomm 66 ended settings t Start s U Start 96 tStop s t Start s U Start 96 t Stop s 10 60 0 10 20 10 20 1 30 30 100 0 30 10 60 0 O dl 9 20 G N all EE A L ES gt DS7 gt PMotor 1 30 30 100 0 30 E MDC Figure 55 Recommended settings per application DS7 Soft starter 07 10 MN03901001Z EN www eaton com 5 Operation 5 3 Commissioning procedure 5 3 Commissioning procedure Set the parameter U Start as recommended from the previous table also set t Start to maximum and t Stop to minimum 1 Start Switch off the start signal or at devices from 41 A the Enable signal after a maximum period of 1 second If the motor has turned proceed with point 2 If the motor has not started increase U Start by 10 or if the motor has started too abruptly with the current setting reduce U Start again by 5 96
69. uare current at nominal switching frequency is provided in the Appendix in the technical data EMC Electromagnetic Compatibility The European standard EN 60947 4 2 refers to the limit classes described in the EN 55011 standard No other measures are required for the limitation of interference emission in accordance with EN 55011 limit value class A industrial environment The devices of the DS7 340 24 V AC DC version series furthermore meet the requirements of limit value class B public environment without any other measures required 2 3 Network configuration DS7 soft starters can be used without restriction in the following network configurations e networks with a grounded or ungrounded star point e networks with an isolated star point IT networks e networks with a grounded phase conductor DS7 Soft starter 07 10 MNO39010017 EN www eaton com 17 2 Engineering 2 4 Power connection 2 4 Power connection The following diagram shows the basic connection of motor and power sec tion 312 5L3 E ZMA 4T2 613 p Figure 5 Power section and Motor connection D 01 Line protection motor protection F3 optional semiconductor fuse G Q21 Soft starter M lt Motor At the output of the soft starter terminals 2T1 4T2 6T3 you must not e connect any capacitive load e g phase compensation capacitors connect sever
70. uccession the soft starter must be dimensioned larger i e the soft starter must be designed with an accordingly higher load cycle Due to the thermal design of the DS7 soft starters we recom mend the use of an optional fan when using a DS7 series device for starting several motors DS7 Soft starter 07 10 MN03901001Z EN www eaton com 2 Engineering 2 10 Starting several motors sequentially with a soft starter 2 10 1 Power section Construction size 3 4 41 A to 200 A U L2 13 N PE e M1 M2 Mn Figure 35 Power section motor cascade Q1 Line protection Q2 Soft starters Qn1 Motor contactor n of soft starter Qn2 Supply bypass contactor for motor n F3 Semiconductor fuse for type 2 coordination in addition to 01 Mn Motor n DS7 Soft starter 07 10 MN03901001Z EN www eaton com Qn2 41 2 Engineering 2 10 Starting several motors sequentially with a soft starter 2 10 1 1 Actuation Construction size 3 4 41 A to 200 A 52 01 kf lb 012 K3 K1T K4 011 021 031 Qn1 13 23 Q2 f K32 Kn2 KAN Q2TOR Q2 RUN K4 K4 14 24 Figure 36 D Enable Q2 Soft start Soft stop G Starting frequency monitoring Set the timing relay so that the soft starter is not thermally overloaded The appropriate time relat
71. uching a PE mount ing screw or another grounded metal surface in the switch cabinet CAUTION The devices contain components that are sensitive to electro static charges Before undertaking work near the terminals per sonnel must discharge themselves i e by touching a PE mount ing screw or another grounded metal surface in the switch cabinet DANGER A The power section of the soft starter contains semiconductor components These do not have any isolation between the sup ply and the load Small leakage currents of a few milliamperes are always present An upstream disconnector must therefore be switched off before working on the starter or motor 4 3 0 1 Connecting the motor supply cable gt Lay all cables separately from the motor cable The conductor cross section apply to cables 1L1 3L2 5L3 N 2T1 412 and 6T3 A PE connection is not required with devices up to 32 A 4 3 0 2 Shielding motor cables Unlike with frequency inverters the shielding of the motor cables is not required 4 3 0 3 Connect control cables The cross sections suitable for the terminals are listed in the Appendix in the section Technical data 9 chapter 7 4 2 page 84 4 3 0 4 Shielding control cables The control cables do not have to be shielded 56 DS7 Soft starter 07 10 MNO3901001Z EN www eaton com 4 3 0 5 Installing a fan 4 Mounting Installation 4 3 Connections An optional fan can be installed on
72. up 1 p Control circuit Regulator supply voltage Us Voltage VDC 424V AC DC 120 15 to 24 V AC DC 10 15 230 10 VAC 10 15 Current consumption no load mA losses Current consumption operation mA 150 100 150 Current consumption peak perfor mA mance Bypass close Control voltage range AC DC operated 24 V AC DC 120 15 to 230 24 V DC 10 15 10 V AC 10 15 Electricity consumption mA 1 6 4 1 6 Pick up voltage DC operated VDC 17 3 to 27 17 3 to 27 AC operated VAC 17 3 to 27 120 15 to 230 10 VAC Drop out voltage DC operated VDC 0to43 0 to 3 AC operated VAC 0to3 Oto 28 Pick up time DC operated ms AC operated ms Drop out time DC operated ms AC operated ms DS7 Soft starter 07 10 MN03901001Z EN www eaton com 85 7 Appendix 7 4 Technical data 7 4 4 Power 86 DS7 Soft starter Part no Rated opera average heat Assigned motor power at tional current dissipation with nominal load cycle le Py 230 V 400 V 200 V 230 V 480 V A W kW kW HP HP HP DS7 34xSX004N0 4 5 0 75 1 5 0 75 0 75 2 DS7 34xSX007NO 7 6 1 5 3 1 5 2 3 DS7 34xSX009N0 9 6 2 2 4 2 2 5 DS7 34x5X012N0 12 Ji 9 SU 3 5 10 DS7 34x5X016N0 16 7 4 7 5 3 5 10 DS7 34xSX024N0 24 9 Bip 11 5 13 15 DS7 34xSX032N0 32 2 IS 15 10 10 25 DS7 34x5X041N0 41 8 11 22 10 15 30 DS7 34xSX055N0 55 0 15 30 15 20 40 DS7 34xSX070NO 70 2 15

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